TOLANI MARITME INSTITUTE

PREFACE

The aim of Practical Demonstration, fault diagnosis of various Hydraulics Circuits on

Advanced Hydraulic Trainer, is done to enhance the Practical Skill of cadets on
Hydraulics equipment and its components and also to inculcate safe working practice
by use of appropriate hand tools.

The cadets are to complete the necessary assignments and submit the same as
instructed by the faculty.

The faculty has to assess the assignments, carry out continuous assessment by
observing the cadet’s involvement, attitude and knowledge on the subject task and
provide Information for continuous improvement of the cadets.

This manual is meant solely for internal use of Tolani Maritime Institute. This
manual has been compiled from various books, manuals, websites etc. It is solely for
the purpose of educational use and not for any commercial purpose.
 TOLANI MARITME INSTITUTE

SAFETY GUIDELINES

1. Hydraulic circuits must only be setup under the supervision or direction of the
trainer.
2. Personal protective equipment (protective goggles, safety shoes) is mandatory
when setting up and operating equipment and when undertaking the project
exercises.
3. The maximum permissible hydraulic system pressure for Rexroth training
systems is 50 bar.
4. System-dependent, the temperature of some individual components can rise to
above 50 °C, which may cause burns or scalds.
5. Switching on the hydraulic power unit can lead to uncontrolled movement of
individual components (hydraulic cylinder, hydraulic motor).
6. The hydraulic components of the Rexroth training systems are equipped with self-
sealing quick couplings.
7. The following must be observed when carrying out a coupling operation:
a) Before dismantling after a project exercise the operating pressure must be
released.
b) Do not couple or uncouple under pressure! If connections are severed under
pressure, no reconnection will be possible. For components with coupling plug
pressure release is possible using a pressure release sleeve (accessory).
c) After each decoupling operation it must be ensured that the locking
mechanism of the coupling is closed.
 TOLANI MARITME INSTITUTE

INDEX

Module No. Title of the Experiments Page No.

MODULE NO. 1 Hydraulic Motor 1-10

MODULE NO. 2 4/3 Direction Control Valve 11-20

MODULE NO. 3 Non-Return Valve 21-30

MODULE NO. 4 Pilot Operated Non-Return Valve 31-40

MODULE NO. 5 Adjustable Throttle Valve 41-50

MODULE NO. 6 Throttle / Non-Return Valve 51-64

MODULE NO. 7 Flow Control Valve 65-76

MODULE NO. 8 Pressure Reducing Valve 77-86

MODULE NO. 9 Regenerative Circuit 87-98

MODULE NO. 10 Rapid Traverse / Creep Speed Circuit 99-110

MODULE NO. 11 Proportional Directional Control 111-124

Valve
MODULE NO. 12 Proportional Directional Control 125-135
Valve
MODULE NO. 13 Programmable Logic Controller ( PLC) 136-139
based Hydraulic System
 Bosch Rexroth AG I R901385283 Project 05: Hydraulic motor 1

Project 05: Hydraulic motor

Project definition
A winch is to be used for raising and lowering heavy loads at adjustable speeds. A hy-
draulic motor is suggested for driving the winch.

The customer requires documentation of the technical details in order to understand

the reasons for suggesting a hydraulic solution. In addition to the parts list and hy-
draulic circuit diagram this also includes the necessary measurement data at different 05
speeds. The customer also requires specifications defining the required drive power
and the output torque of the hydraulic motor at maximum speed.

Winch for lifting heavy loads

Project tasks
„ Check customer requirements; organize implementation

„ Acquire knowledge of the functional principles and uses of hydraulic motors

„ Determine the functional features of a hydraulic motor

„ Use a directional control valve and throttle vale for controlling a hydraulic motor

„ Understand the relationship between the supplied flow and displacement of the
hydraulic motor

„ Calculate the drive power and output torque

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 1
Distribution only for training purposes with indication of source.
 2 Project 05: Hydraulic motor Bosch Rexroth AG I R901385283

Project execution steps

„ Informing: - Accept and comprehend the task

- Check the design and condition of the workstation

05 „ Planning: - Plan and organize the project task

- Read and assess the circuit diagram
- Assess the parameters to be used for selecting the hydraulic
components required (including examination of the data
sheets)

Deciding:
„  - Select the components required
- Define the connections between the components
- Define the measuring points

„ Executing: - Setup of the hydraulic circuit on the workstation

- Connect the measuring points; close all inactive measuring
points
- Execute the project exercises using a hydraulic motor
- Influence the direction of rotation of a hydraulic motor
- Measure the rotational speed and use the measured values to
calculate the drive power and torque of a hydraulic motor
- Document the required measurements and perform any calcu-
lations if necessary

„ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

- Are there other possible solutions to achieve the require-
ments of the project task?
- Did any unexpected problems occur?

Notes

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 2
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 05: Hydraulic motor 3

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified 05
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard. WARNING
When starting the system, hydraulic fluid can escape from open ports in a narrow
stream at high pressure, which can cause serious injuries (cutting jet).

General notes on setup of the hydraulic circuit:

Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch-
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized.
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device.
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.

When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

Exercise caution when a system is pressurized and/or electrical voltage is present:

„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 3
Distribution only for training purposes with indication of source.
 4 Project 05: Hydraulic motor Bosch Rexroth AG I R901385283

Parts list for circuit diagram of project exercise 05

Quan- Rexroth
Item Description Type
tity material number
Hydraulic motor (planetary
1.10 1 EPMM-S8C R961008748
motor)
05 1.20 1 4/3 directional control valve 4WMM6E5X/F R961002551

1.30 1)
2 1)/1 Pressure relief valve DBDH6G1X/100 R961002520
1.31

1.40 1 Throttle valve DV06-1-1X/V R961002539

1.50 1 Hydraulic distributor 4 ports R961002485

1.60
1.61
4 Manometer 0 to 100 bar R961002715
1.62
1.63
1.70
1.71 Hose line 1000 mm with
4 ZN10031-08-W90MM-1000 R961004330
1.72 Minimess port
1.73
1.80 1)
1.81 3 1)/2 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
1.82
for WS290:
R961002564
2.5 l measuring glass
1.90 1
for WS200:
R961009485
1.6 l measuring glass
1)
... only required with the WS290 (DS4) workstation
Parts list of the hydraulic components for project exercise 05

Note:
This parts list represents the components and accessories required for executing this proj-
ect exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hose lines used correspond to the hose lines provided in
the associated Rexroth device set.

Measuring technology

1 Tachometer, visual R961008893

1 Stopwatch, digital R900061256
alternatively
1 Gear wheel flow sensor R961002508
with: 1 x measuring instrument set 3020 R913038909
1 x hose line 630 mm (item 1.83) R961002474
Recommended additional measuring instruments for project exercise 05

Note:
The methods for measuring flow are described in the “Flow measurement” section before
the descriptions of the project exercises.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 4
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 05: Hydraulic motor 5

Circuit diagram for project exercise 05

05

Circuit diagram for project exercise 05

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 5
Distribution only for training purposes with indication of source.
 6 Project 05: Hydraulic motor Bosch Rexroth AG I R901385283

Arrangement of components

1.70 1.62

V
D
1.31 1.50 1.10
05 1.73

1.90 1.83
1.71
1.61

1.72

1.20
1.82
1.63
T

1.80 1)
T

D 1.81
1.30 1)
P

D 1.40
P

1.60
MP

1) Component of the WS200 workstation, not in the exercise setup

D Connection between two hydraulic components without a hose
(components directly coupled to each other)
V Flow sensor (optional)
1.83 Hose line only required when using a flow sensor
1.71 Hose line only required when using a hydraulic motor with a leakage oil port (on units R961004259,
R961002811)
Recommended arrangement of the components for project exercise 05 (schematic representation)

Note:
The arrangement of the components (with item number as per the parts list) on a mount-
ing grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

Direction of rotation of the

motor shaft
L ... Left-hand rotation (counter-clockwise)

R ... Right-hand rotation (clockwise)

L
Note:
Here the direction of rotation of the hydrau- R
lic motor when looking at the output shaft.
This also applies to the description on the
type plate. Direction of rotation of the shaft of a hydraulic motor

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 6
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 05: Hydraulic motor 7

Project execution

Hang the required components and accessories in the workstation mounting grid
accor­ding to the table “Parts list of the hydraulic components for project exercise 05”
(see "Arrangement of components").

Project execution steps 05

1. Connect the hoses according to the circuit diagram for project exercise 05, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.

2. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage.
All manometers must show zero pressure (except for the operating pressure display
on a WS200; see notes on using this workstation)!

3. Set the operating pressure at the pressure relief valve to 50 bar.

Completely open the throttle valve (item 1.40).

4. Actuate the directional control valve (item 1.20) (move the lever to the right;
latches into place), connection P → A is established, the hydraulic motor starts
turning in a right-hand direction.
While the motor is running, use the pressure relief valve (item 1.31) to set the load
pressure at manometer M4 to 20 bar.

5. Completely close the throttle valve.

Use the throttle valve to adjust the speed of the hydraulic motor to the values
specified in the table below and make the required measurements:
- A tachometer is to be used for measuring and displaying the speed.
Note: When using the visual tachometer, the displayed value has to be divided by
the numer of reflective strips on the disc of the hydraulic motor (4 strips
when using the recommended planetary motor).
- The flow can be measured using a measuring glass and stopwatch or optionally
using a flow meter.
- Enter all measured values/calculations for right-hand rotation in the table.

Bring the directional control valve spool to the center position (P, T, A, B closed),
the hydraulic motor comes to a standstill.

6. Actuate the directional control valve again (move the lever to the left; latches into
place), connection P → B is established, the hydraulic motor turns in a left-hand
direction.

Repeat all measurements and enter the measured values for left-hand rotation in the
table.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 7
Distribution only for training purposes with indication of source.
 8 Project 05: Hydraulic motor Bosch Rexroth AG I R901385283

Measured
n M1 M2 M3 M4 qV M2 – M3
values Right-hand rotation
in min-1 p1 in bar p2 in bar p3 in bar p4 in bar in l/min | Δp in bar |

Throttle valve closed 0

1. Speed setting with

150
05 throttle valve

2. Speed setting with

270
throttle valve

3. Speed setting with

350
throttle valve

4. Speed setting with

440 1)
throttle valve

5. Speed setting with

600 1)
throttle valve
1)
... Speed only possible with WS290 (DS4) workstation

n M1 M2 M3 M4 qV M3 – M2
Left-hand rotation
in min-1 p1 in bar p2 in bar p3 in bar p4 in bar in l/min | Δp in bar |

Throttle valve closed 0

1. Speed setting with

150
throttle valve

2. Speed setting with

270
throttle valve

3. Speed setting with

350
throttle valve

4. Speed setting with

440 1)
throttle valve

5. Speed setting with

600 1)
throttle valve
1)
... Speed only possible with WS290 (DS4) workstation

Switch off the hydraulic power unit after finishing the practical work!
Screw the pressure relief valve back to the minimum pressure setting!
CAUTION
Completely open the throttle valve!
All manometers must show zero pressure!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 8
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 05: Hydraulic motor 9

Calculation of drive power and output torque at maximum speed using the hydraulic Additional task
motor EPMM-S8C (WS200 workstation) as an example

Technical data of the hydraulic motor (from the data sheet):

„ Geometric displacement volume Vg = 8 cm3/rev

Calculations: 05
„ Drive power
∆ p ⋅ qV 4 bar ⋅ 3 l/min
P = = = 0,02 kW
600 600

„ Output torque

∆p ⋅ Vg ⋅ ηmh 4 bar ⋅ 8 cm3 ⋅ 0, 9

Mab = = = 0, 46 Nm
20 ⋅ π 20 ⋅ π
P = Drive power(in kW)
Mab = Output torque (in Nm)
Δp = Pressure difference between the input/output of the hydraulic motor (measured value in bar, with
right-hand rotation at 350 min-1)
qV = Flow (measured value in l/min, with right-hand rotation at 350 min-1)
ηmh = Hydraulic-mechanical efficiency (0.9 to 0.95)

Assessment of work results

„ Hydraulic motors convert hydraulic energy into ........................ and ...........................

„ The ................................... of a hydraulic motor can be controlled using a directional

control valve.

„ The speed of a hydraulic motor depends on the supplied ..........................................

and ........................................ of the motor.

„ The torque of a hydraulic motor depends on the ................................................. and

..........................................

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 9
Distribution only for training purposes with indication of source.
 10 Project 05: Hydraulic motor Bosch Rexroth AG I R901385283

Notes

05

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 10
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 06: 4/3 directional control valve 11

Project 06: 4/3 directional control valve

Project definition
A differential cylinder is to horizontally move and position tools in a fixture. A 4/3 direc-
tional control valve is used for controlling the hydraulic cylinder.
The cylinder piston must not move when the hydraulic cylinder is in the specified
standstill state. The specified fixed displacement pump is to be used with a high de-
gree of energy efficiency.

The customer desires information on the advantages and disadvantages of different

4/3 directional control valve spool types, especially with regard to the pressureless cir-
culation and blocking in the center position. The customer requires documentation of 06
the technical details in order to understand the reasons for the suggested solution. In
addition to the parts list and hydraulic circuit diagram this also includes the necessary
measurement data for the different spool types.

4/3 directional control valve of size 6 with manual operation

Project tasks
„ Check customer requirements; organize implementation

„ Aquire knowledge of the functional principles and uses of directional control valves

„ Determine the functional features of directional control valves having different spool
types

„ Recognize the internal leakage of directional control valves

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 11
Distribution only for training purposes with indication of source.
 12 Project 06: 4/3 directional control valve Bosch Rexroth AG I R901385283

Project execution steps

„ Informing: - Accept and comprehend the task

- Check the design and condition of the workstation

„ Planning: - Plan and organize the project task

- Read and assess the circuit diagram

06 - Assess the parameters to be used for selecting the hydraulic

components required (including examination of the data
sheets; e.g. "RE 22280 – Directional spool valves")

Deciding:
„  - Select the components required
- Define the connections between the components
- Define the measuring points

„ Executing: - Setup of the hydraulic circuit on the workstation

- Connect the measuring points; close all inactive measuring
points
- Actuate a hydraulic cylinder via a directional control valve
- Recognize the system behavior with directional control valves
with different spool types; determine pressure differences
- Document the required measurements and perform any calcu-
lations if necessary

„ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

- Are there other possible solutions to achieve the require-
ments of the project task?
- Did any unexpected problems occur?

Notes

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 12
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 06: 4/3 directional control valve 13

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard.
When starting the system, hydraulic fluid can escape from open ports in a narrow
WARNING
06
stream at high pressure, which can cause serious injuries (cutting jet).

General notes on setup of the hydraulic circuit:

Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch-
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized.
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device.
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.

When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

Exercise caution when a system is pressurized and/or electrical voltage is present:

„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 13
Distribution only for training purposes with indication of source.
 14 Project 06: 4/3 directional control valve Bosch Rexroth AG I R901385283

Parts list for circuit diagram of project exercise 06

Quan- Rexroth
Item Description Type
tity material number

1.10 1 Differential cylinder CD70F25/16-200 R961009526

1.20 1 4/3 directional control valve 4WMM6G5X/F R961002550

06 1.30 1 4/3 directional control valve 4WMM6E5X/F R961002551

1.40 1) 1 1)/0 Pressure relief valve DBDH6G1X/100 R961002520

1.50
1.51 3 Manometer 0 to 100 bar R961002715
1.52
1.60 Hose line 1000 mm with
1.61 3 ZN10031-08-W90MM-1000 R961004330
1.62 Minimess port

1.70 1)
2 1)/1 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
1.71
for WS290:
R961002564
2.5 l measuring glass
1.80 1
for WS200:
R961009485
1.6 l measuring glass
1)
... only required with the WS290 (DS4) workstation
Parts list of the hydraulic components for project exercise 06

Note:
This parts list represents the components and accessories required for executing this proj-
ect exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hoses used correspond to the hoses provided in the as-
sociated Rexroth device set.

Measuring technology

1 Stopwatch, digital R900061256

alternatively
1 Gear wheel flow sensor R961002508
with: 1 x measuring instrument set 3020 R913038909
1 x hose line 630 mm (item 1.72) R961002474
Recommended additional measuring instruments for project exercise 06

Note:
The methods for measuring flow are described in the “Flow measurement” section before
the descriptions of the project exercises.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 14
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 06: 4/3 directional control valve 15

Circuit diagram for project exercise 06 – Task 1

06

Circuit diagram 1 for project exercise 06: Pressureless circulation with directional control valve in the center
position

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 15
Distribution only for training purposes with indication of source.
 16 Project 06: 4/3 directional control valve Bosch Rexroth AG I R901385283

Circuit diagram for project exercise 06 – Task 2

06

Circuit diagram 2 for project exercise 06: Blocking of all ports with directional control valve in the center position

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 16
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 06: 4/3 directional control valve 17

Arrangement of components

1.60
1.10

V
1.62 1.61

1.51 1.52
06
1.80

1.20/
1.30
T

1.70 1) 1.72
T

D
1.40 1)
P

1.71
P

1.50
MP

1) Component of the WS200 workstation, not in the exercise setup

D Connection between two hydraulic components without a hose
(components directly coupled to each other)
V Flow sensor (optional)

1.71 Hose line only required when using a flow sensor

Recommended arrangement of the components for project exercise 06 (schematic representation)

Note:
The arrangement of the components (with item number as per the parts list) on a mount-
ing grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 17
Distribution only for training purposes with indication of source.
 18 Project 06: 4/3 directional control valve Bosch Rexroth AG I R901385283

Project execution

Hang the required components and accessories in the workstation mounting grid
accor­ding to the table “Parts list of the hydraulic components for project exercise 06”
(see "Arrangement of components").

Project execution steps

06 Task 1 – Directional control valve with spool type G (pressureless circulation in the
center position):

1. Connect the hoses according to circuit diagram 1 for project exercise 06, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.

2. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage.
The initial position of the cylinder piston is the extended state.
All manometers must show zero pressure (except for the operating pressure display
on a WS200; see notes on using this workstation)!

3. Actuate the directional control valve (item 1.20) (hold the lever pressed to the right),
connection P → B is established, piston rod of the hydraulic cylinder retracts.
Record the measurements specified for the cylinder piston in the retracted end position.

4. Set an operating pressure at the pressure relief valve of 30 bar (manometer M1).

5. Stop actuating the directional control valve (center position), connection P → T is

established, the piston rod of the hydraulic cylinder does not move.
Record the measurements specified for the directional control valve in the center position.

6. Actuate the directional control valve (hold the lever pressed to the right), connec-
tion P → A is established, piston rod of the hydraulic cylinder extends.
Record the measurements specified for the cylinder piston in the extended end position.

Measured Directional control valve M1 M2 M3 qV

values Position
switching position p1 in bar p2 in bar p3 in bar in l/min

Piston rod retracted P→B

Piston rod extended P→A

Valve spool in center position 0

Switch off the hydraulic power unit before changing the setup for the sub­
sequent project steps!
CAUTION Screw the pressure relief valve back to the minimum pressure setting!
All manometers must show zero pressure!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 18
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 06: 4/3 directional control valve 19

Task 2 – Directional control valve with spool type E (all ports closed when in center position):

1. Replace the directional control valve in the exercise setup and connect the hoses
according to circuit diagram 2 of project exercise 06, while taking care to observe
the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.

2. Switch on the hydraulic power unit of the workstation and check the hydraulic 06
setup for any leakage.
The initial position of the cylinder piston is the retracted state.
All manometers must show zero pressure (except for the operating pressure display
on a WS200; see notes on using this workstation)!

Note: Compared to task 1, a directional control valve with a different spool type
is used, in which the connections are swapped for the respective valve
switching positions. In addition, the lever on this directional control valve
latches into each respective switching position.

3. Set the pressure relief valve to a pressure of 30 bar (manometer M1).

4. Actuate the directional control valve (item 1.30) (move the lever to the right,
latches into position), connection P → A is established, piston rod of the hydraulic
cylinder extends.
Record the measurements specified for the cylinder piston in the extended end position.

5. Move the lever of the directional control valve to the center position (P, T, A, B
closed), the piston rod of the hydraulic cylinder does not move.
Record the measurements specified for the directional control valve in the center position.

6. Actuate the directional control valve again (move the lever to the left, latches into
position), connection P → B is established, piston rod of the hydraulic cylinder retracts.
Record the measurements specified for the cylinder piston in the retracted end position.

Measured
Directional valve M1 M2 M3 qV values
Position
switching position p1 in bar p2 in bar p3 in bar in l/min

Piston rod extended P→A

Piston rod retracted P→B

Valve spool in center position 0

Switch off the hydraulic power unit after finishing the practical work!
Screw the pressure relief valve back to the minimum pressure setting!
CAUTION All manometers must show zero pressure!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 19
Distribution only for training purposes with indication of source.
 20 Project 06: 4/3 directional control valve Bosch Rexroth AG I R901385283

Assessment of work results

Task 1:
„ When a 4/3 directional control valve with pressureless circulation is in ......................
.................. the entire flow of the hydraulic pump is returned ....................................
to the tank via the directional control valve.

„ With this directional control valve version, the pressure difference and the power
loss depend only on the ...................................... in the valve and the return line.

06 „ Using a directional control valve with this spool type allows a reduction of the
...................................... compared to other versions.

Task 2:
„ In a 4/3 directional control valve where all ports are shut off in the center position,
................................... of the hydraulic pump is directed to the tank via .....................
....................... when the directional control valve spool is in the center position and
the opening pressure of the pressure relief valve has been reached.

„ In this directional control valve version, the pressure difference across the pressure
relief valve results in ............................................ that is dissipated as heat.

„ In a 4/3 directional control valve where all ports are shut off in the center position,
....................................... can cause a connected differential cylinder to extend if the
hydraulic pump is running when the valve is in the center position.

Notes

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Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 07: Non-return valve 21

Project 07: Non-return valve

Project definition
A pulling load is held in position in a fixture by a vertically mounted differential cylinder
using a non-return valve. The piston rod side of the cylinder is protected by a pressure
relief valve.

Lowering of the load via actuation of a shut-off valve must be possible, and this lower-
ing speed must be adjustable.

The customer requires documentation of the technical details in order to understand

the reasons for the suggested solution.
The customer also wishes to know if special problems can occur due to installation of a
non-return valve on the piston rod side. 07

Non-return valve for in-line pipe installation

Project tasks
„ Check customer requirements; organize implementation

„ Aquire knowledge of the functional principles and uses of non-return valves

„ Hold a pulling load in position with a non-return valve

„ Verify the danger of pressure intensification when installing a non-return valve on

the piston rod side

„ Pressure limitation of the pulling load with a pressure relief valve

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 21
Distribution only for training purposes with indication of source.
 22 Project 07: Non-return valve Bosch Rexroth AG I R901385283

Project execution steps

„ Informing: - Accept and comprehend the task

- Check the design and condition of the workstation

„ Planning: - Plan and organize the project task

- Read and assess the circuit diagram
- Assess the parameters to be used for selecting the hydraulic
components required (i.e. including examination of the data
sheets; e.g. "RE 20375 – Non-return valve (check valve)")
07
Deciding:
„  - Select the components required
- Define the connections between the components
- Define the measuring points

„ Executing: - Setup of the hydraulic circuit on the workstation

- Connect the measuring points; close all inactive measuring
points
- Execute the project exercises using a non-return valve to hold
a pulling load
- Setting a pressure relief valve for pressure safety
- Measure characteristic values of the system behavior
- Document the required measurements and perform any calcu-
lations if necessary

„ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

- Are there other possible solutions to achieve the require-
ments of the project task?
- Did any unexpected problems occur?

Notes

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 22
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 07: Non-return valve 23

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard. WARNING
When starting the system, hydraulic fluid can escape from open ports in a narrow
stream at high pressure, which can cause serious injuries (cutting jet).
07
General notes on setup of the hydraulic circuit:

Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch-
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized.
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device.
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.

When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

Exercise caution when a system is pressurized and/or electrical voltage is present:

„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 23
Distribution only for training purposes with indication of source.
 24 Project 07: Non-return valve Bosch Rexroth AG I R901385283

Parts list for circuit diagram of project exercise 07

Quan- Rexroth
Item Description Type
tity material number

for WS290: Load unit 15 kg R961000187

1.10 1
for WS200: Load unit 16 kg R961009507

1.20 1 4/3 directional control valve 4WMM6J5X/F R961002510

1.30
07 1.31
2 Pressure relief valve DBDH6G1X/100 R961002520

1.40 1 Non-return valve S6A05-1X/ R901462818

1.50 1 Shut-off valve R961002491

1.60 1 Throttle valve DV06-1-1X/V R961002539

1.70
1.71 3 Hydraulic distributor 4 ports R961002485
1.72
1.80
1.81 3 Manometer 0 to 100 bar R961002715
1.82
1.90 Hose line 1000 mm with
1.91 3 ZN10031-08-W90MM-1000 R961004330
1.92 Minimess port

2.00
2.01
2.02
6 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
2.03
2.04
2.05

Parts list of the hydraulic components for project exercise 07

Note:
This parts list represents the components and accessories required for executing this proj-
ect exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hose lines used correspond to the hose lines provided in
the associated Rexroth device set.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 24
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 07: Non-return valve 25

Circuit diagram for project exercise 07

07

Circuit diagram for project exercise 07

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 25
Distribution only for training purposes with indication of source.
 26 Project 07: Non-return valve Bosch Rexroth AG I R901385283

Arrangement of components

1.90 2.05

1.60
D
1.31
1.71
1.82 D
2.04

1.81 1.72
D
1.50
1.40
07
D
2.03

D 2.02
1.70 1.20
T

2.00
1.80
T

D
1.30
P

2.01
P
MP

1.92

1.10
1.91

D Connection between two hydraulic components without a hose

(components directly coupled to each other)
Recommended arrangement of the components for project exercise 07 (schematic representation)

Note:
The arrangement of the components (with item number as per the parts list) on a mount-
ing grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 26
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 07: Non-return valve 27

Project execution

Hang the required components and accessories in the workstation mounting grid
accor­ding to the table “Parts list of the hydraulic components for project exercise 07”
(see "Arrangement of components").

Project execution steps

1. Connect the hoses according to the circuit diagram for project exercise 07, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight. 07
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.

WS200 only: Screw the pressure relief valve in the P/T distributor clockwise all the
way to the end stop position (in this exercise the operating pressure is
set using the pressure relief valve of the exercise setup (item 1.30).)

2. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage.
Completely open the throttle valve (item 1.60) (screw the hand wheel fully out).
Set the pressure relief valve (item 1.31) to maximum pressure (screw the hand
wheel fully in).
Set the pressure relief valve (item 1.30) to minimum pressure (screw the hand
wheel fully out).
Completely close the shut-off valve (item 1.50) (lever at right-angles to the pipe).
All manometers must show zero pressure!

Task 1 – Function of the non-return valve:

The initial position of the load unit cylinder piston (pulling load) is the extended state
(see the “Using the load units” section before the description of the project exercises).

3. Actuate the directional control valve (item 1.20) (move the lever to the left), connec-
tion P → B is established.
While keeping the directional control valve lever actuated:
- Slowly increase the operating pressure (manometer M1) via the pressure relief
valve (item 1.30) until the piston rod of the hydraulic cylinder retracts.
- Record the pressure at manometer M2 (approx. 10 ... 15 bar).
- Retract the piston rod to the end position.

4. Set the directional control valve to the center position (lever not actuated);
observe the piston rod → no motion ( the load is held by the effect of the
non-­return valve)

5. Actuate the directional control valve (hold the lever pressed to the right), connection
P → A established; record the pressure at manometer M3 (approx. 20 ... 25 bar).

Pressureintensification can be observed:

→ Pressure at piston base side (M2) approx. 10 ... 15 bar
→ Pressure at piston rod side (M3) approx. 20 ... 25 bar (pressure intensific. + load)

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 27
Distribution only for training purposes with indication of source.
 28 Project 07: Non-return valve Bosch Rexroth AG I R901385283

6. The load is lowered by opening the shut-off valve (item 1.50).

The lowering speed can be influenced via the adjustable throttle valve (item 1.60).

Task 2 – Setting the pressure limitation:

The initial position of the load unit cylinder piston (pulling load) is the retracted state
(see the “Using the load units” section before the description of the project exercises).

7. The pressure relief valve (item 1.30) must remain in the last setting from task 1.
Completely close the shut-off valve (item 1.50) (lever at right-angles to the pipe).
07 Completely open the throttle valve (item 1.60) again (screw the hand wheel fully
out).

8. Actuate the directional control valve (hold the lever pressed to the right), connec-
tion P → A is established; slowly unscrew the pressure relief valve (item 1.31) until
the piston rod of the hydraulic cylinder extends (manometer M3 shows approx.
20 bar).

9. Check retraction and extension of the piston rod by moving the directional control
valve lever to the left and right.
→ The pressure limitation of the piston rod side is set to approx. 20 bar.

This setting compensates for the weight force when the directional control valve is
actuated (connection P → A).

Return the load unit to the initial position after finishing the practical work!
Switch off the hydraulic power unit!
CAUTION
Screw the pressure relief valve back to the minimum pressure setting!
Completely open the throttle valve!
All manometers must show zero pressure!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 28
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 07: Non-return valve 29

Assessment of work results

„ A non-return valve only allows fluid to flow .......................................

„ When holding a load with a non-return valve on the piston rod side of a differential
cylinder there is a danger of .....................................

„ The installation of a non-return valve results in ........................................ in the flow

direction.

„ Using .............................................. to provide pressure limitation for the piston rod

side of a differential cylinder can prevent excess pressure caused by pressure
intensification . 07

Notes

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 29
Distribution only for training purposes with indication of source.
 30 Project 07: Non-return valve Bosch Rexroth AG I R901385283

Notes

07

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 30
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 08: Non-return valve, pilot-operated 31

Project 08: Non-return valve, pilot-operated

Project definition
A pulling load is held in position in a fixture by a vertically mounted differential cylinder
using a pilot-operated non-return valve. The piston rod side of the cylinder is protected
by a pressure relief valve.
Unlike project exercise 07, the load can be lowered by opening the non-return valve via
a 4/2-directional control valve and the lowering speed is adjustable.

The customer requires documentation of the technical details in order to understand

the reasons for the suggested solution. The customer also wishes to know the issues
that must be taken into consideration when using a pilot-operated non-return valve.

08

Assembly with pilot-operated non-return valve

Project tasks
„ Check customer requirements; organize implementation

„ Aquire knowledge of the functional principles and uses of pilot-operated non-return

valves

„ Controlling a pilot-operated non-return valve via a directional control valve

„ Determine the conditions for hydraulically opening a non-return valve

„ Providing pressure limitation with a pressure relief valve

„ Setting the lowering speed of the cylinder piston via a throttle valve

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 31
Distribution only for training purposes with indication of source.
 32 Project 08: Non-return valve, pilot-operated Bosch Rexroth AG I R901385283

Project execution steps

„ Informing: - Accept and comprehend the task

- Check the design and condition of the workstation

„ Planning: - Plan and organize the project task

- Read and assess the circuit diagram
- Assess the parameters to be used for selecting the hydraulic
components required (including examination of the data
sheets; e.g. "RE 21460 – Non-return valve (check valve),
pilot-operated")

08 Deciding:
„  - Select the components required
- Define the connections between the components
- Define the measuring points

„ Executing: - Setup of the hydraulic circuit on the workstation

- Connect the measuring points; close all inactive measuring
points
- Execute the project exercises using a pilot-operated non-
return valve to hold a load and lower it in a controlled manner
- Setting a pressure relief valve for pressure safety
- Measure characteristic values of the system behavior
- Document the required measurements and perform any calcu-
lations if necessary

„ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

- Are there other possible solutions to achieve the require-
ments of the project task?
- Did any unexpected problems occur?

Notes

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 32
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 08: Non-return valve, pilot-operated 33

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard. WARNING
When starting the system, hydraulic fluid can escape from open ports in a narrow
stream at high pressure, which can cause serious injuries (cutting jet).

General notes on setup of the hydraulic circuit:

08
Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch-
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized.
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device.
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.

When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

Exercise caution when a system is pressurized and/or electrical voltage is present:

„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 33
Distribution only for training purposes with indication of source.
 34 Project 08: Non-return valve, pilot-operated Bosch Rexroth AG I R901385283

Parts list for circuit diagram of project exercise 08

Quan- Rexroth
Item Description Type
tity material number

for WS290: Load unit 15 kg R961000187

1.10 1
for WS200: Load unit 16 kg R961009507

1.20 1 4/3 directional control valve 4WMM6J5X/F R961002510

1.30
2 Pressure relief valve DBDH6G1X/100 R961002520
1.31

08 1.40 1 4/2 directional control valve 4WMM6C5X R961002552

Non-return valve,
1.50 1 SV6PB1-6X R961002513
pilot-operated

1.60 1 Throttle valve DV06-1-1X/V R961002539

1.70 1 Shut-off valve R961002491

1.80
1.81 3 Hydraulic distributor 4 ports R961002485
1.82
1.90
1.91 3 Manometer 0 to 100 bar R961002715
1.92
2.00 Hose line 1000 mm with
2.01 3 ZN10031-08-W90MM-1000 R961004330
2.02 Minimess port

2.10
2.11
2.12
2.13
8 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
2.14
2.15
2.16
2.17

Parts list of the hydraulic components for project exercise 08

Note:
This parts list represents the components and accessories required for executing this proj-
ect exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hose lines used correspond to the hose lines provided in
the associated Rexroth device set.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 34
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 08: Non-return valve, pilot-operated 35

Circuit diagram for project exercise 08

08

Circuit diagram for project exercise 08

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 35
Distribution only for training purposes with indication of source.
 36 Project 08: Non-return valve, pilot-operated Bosch Rexroth AG I R901385283

Arrangement of components

D
1.31
1.81 1.40
1.92 D
1.60
D
1.70
2.00

2.13 1.82 2.15

1.91
2.16
08 2.14
2.12 D
D
1.80
T

2.10
1.20 1.50
T

D
1.30
P

2.11
P

2.17
MP

1.90

2.02

1.10
2.01

D Connection between two hydraulic components without a hose

(components directly coupled to each other)
Recommended arrangement of the components for project exercise 08 (schematic representation)

Note:
The arrangement of the components (with item number as per the parts list) on a mount-
ing grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 36
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 08: Non-return valve, pilot-operated 37

Project execution

Hang the required components and accessories in the workstation mounting grid
accor­ding to the table “Parts list of the hydraulic components for project exercise 08”
(see "Arrangement of components").

Project execution steps

1. Connect the hoses according to the circuit diagram for project exercise 08, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.
08
WS200 only: Screw the pressure relief valve in the P/T distributor clockwise all the
way to the end stop position (in this exercise the operating pressure is
set using the pressure relief valve of the exercise setup (item 1.30).)

2. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage.
Completely open the throttle valve (item 1.60) ( screw the hand wheel fully out).
Completely open the shut-off valve (item 1.70) (lever parallel to the pipe).
Set the pressure relief valve (item 1.31) to maximum pressure (screw the hand-
wheel fully in ).

Task 1 – Function of the pilot-operated non-return valve:

The initial position of the load unit cylinder piston (pulling load) is the extended state
(see the “Using the load units” section before the description of the project exercises).

3. Actuate the 4/3 directional control valve (item 1.20) (move the lever to the left),
connection P → B is established.
While keeping the directional control valve lever actuated:
- Set the operating pressure (manometer M1) to approx. 15 bar via the pressure
relief valve (item 1.30).
- Retract the piston rod to the end position.

4. Set the 4/3 directional control valve in to the center position (lever not actuated);
Observe the piston rod → no motion ( load is held in position by the unactuated
non-return valve)

5. Actuate the 4/3 directional control valve (hold the lever pressed to the right), con-
nection P → A is established. Read the pressures at manometers M3 (approx.
25 bar) and M2 (approx. 15 bar).

6. Pressure intensification can be observed:

→ Pressure at piston base side (M2) approx. 15 bar
→ Pressure at piston rod side (M3) approx. 25 bar (pressure intensification + load)

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 37
Distribution only for training purposes with indication of source.
 38 Project 08: Non-return valve, pilot-operated Bosch Rexroth AG I R901385283

7. Keep the 4/3 directional control valve (item 1.20) actuated (hold the lever pressed
to the right), connection P → A remains established.
Slowly unscrew the pressure relief valve (item 1.31) counterclockwise until the
piston rod of the hydraulic cylinder extends (M3 shows approx. 25 bar).

8. Slowly screw the pressure relief valve (item 1.31) clockwise until the piston rod of
the hydraulic cylinder stops moving.
→ The pressure limitation for the piston rod side is now set according to the load +
operating pressure

9. Actuate the 4/3 directional control valve (item 1.20) (hold the lever pressed to the
left), connection P → B is established; retract the piston rod to the end position.

10. Actuate the 4/3 directional control valve (item 1.20) again (hold the lever pressed
08 to the right), connection P → A is established.
Additionally actuate the other 4/2-directional control valve (item 1.40) (hold the
lever pressed to the left), connection P → B is established.
Observe the piston rod → piston rod extends erratically

11. Retract the piston rod to the end position (see step 8).

12. Completely close the throttle valve (item 1.60) (by screwing the handwheel clock-
wise to the end position); then open the handwheel counterclockwise by a ¾ turn.

13. Actuate the 4/3 directional control valve (item 1.20) (hold the lever pressed to the
right), connection P → A is established.
Additionally actuate the 4/2-directional control valve (item 1.40) (hold the lever
pressed to the left), connection P → B is established.
Observe the piston rod → piston rod extends smoothly
(non-return valve is open)

Task 2 – Back-pressure in the non-return valve control line:

14. The pressure relief valve (item 1.30) must remain in the last setting from task 1.
Retract the piston rod to the end position (see step 8).
Completely close the shut-off valve (item 1.70) (lever at right-angles to the pipe).

15. Actuate the 4/3 directional control valve (item 1.20) (hold the lever pressed to the
right), connection P → A is established.
Additionally actuate the 4/2-directional control valve (item 1.40) (hold the lever
pressed to the left), connection P → B is established.
Extend the piston rod to the end position.

16. Retract the piston rod to the end position (see step 8).

17. Bring the 4/3 directional control valve to the center position (lever not actuated);
observe the piston rod → extends due to pulling load (non-return valve open,
residual pressure in the pilot line prevents it from closing)

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 38
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 08: Non-return valve, pilot-operated 39

18. Retract the piston rod to the end position (see step 8).

19. Bring the 4/3 directional control valve to the center position (lever not actuated),
completely open the shut-off valve (item 1.70) while the piston rod is extending.
Observe the piston rod → Extension motion stoppped (non-return valve closed)

Return the load unit to the initial position after finishing the practical work!
Switch off the hydraulic power unit!
CAUTION
Screw the pressure relief valve back to the minimum pressure position!
Completely open the throttle valve!
Completely open the shut-off valve!
All manometers must show zero pressure!
08

Assessment of work results

„ A pilot-operated non-return valve only allows fluid to flow in the ................................
when it is ................................... via a hydraulic control signal.

„ A pilot-operated non-return valve can only ........................... in the blocking direction

when ................................... is no longer present and the pilot line is .........................

„ There is a danger of .............................................. when holding a load with a pilot-

operated non-return valve on the piston rod side of a differential cylinder.

„ The installation of a pilot-operated non-return valve results in ....................................

in the flow direction.

„ Excess pressure can be avoided by using .................................... to provide pressure

limitation for the piston rod side of a differential cylinder.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 39
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 40 Project 08: Non-return valve, pilot-operated Bosch Rexroth AG I R901385283

Notes

08

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 Bosch Rexroth AG I R901385283 Project 09: Throttle valve, adjustable 41

Project 09: Throttle valve, adjustable

Project definition
Components are transported in a production line on a conveyor belt driven by a hy-
draulic motor. The transport speed of the conveyor belt must be adjustable in both
directions.

To simulate components of different weights, this project exercise uses a pressure

relief valve installed in the return line of the 4/3 directional control valve. The aim is to
illustrate the effect of differing component weights on the transport speed.

The customer requires documentation of the technical details in order to understand

the reasons for the suggested solution. The customer wishes a chart showing the rela-
tionships between flow, opening cross-section and pressure difference magnitude.

09

Adjustable throttle valve of type DV06

Project tasks
„ Check customer requirements; organize implementation

„ Aquire knowledge of the functional principles and uses of adjustable throttle valves

„ Determine the relationship between flow, opening cross-section and pressure

difference

„ Load simulation by using a pressure relief valve in the return line of the directional
control valve

„ Determination of the characteristic curve for a throttle valve

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 41
Distribution only for training purposes with indication of source.
 42 Project 09: Throttle valve, adjustable Bosch Rexroth AG I R901385283

Project execution steps

„ Informing: - Accept and comprehend the task

- Check the design and condition of the workstation

„ Planning: - Plan and organize the project task

- Read and assess the circuit diagram
- Assess the parameters to be used for selecting the hydraulic
components required (including examination of the data
sheets; e.g. "RE 32502 – Throttle/shut-off valve and throttle
check valve")

Decidings:
„  - Select the components required
- Define the connections between the components
09 - Define the measuring points

„ Executing: - Setup of the hydraulic circuit on the workstation

- Connect the measuring points; close all inactive measuring
points
- Execute the project exercises using an adjustable throttle valve
- Measure characteristic values of the system behavior
- Document the required measurements and perform any calcu-
lations if necessary
- Determination and charting of the pressure difference-flow
characteristic curves for different throttle valve opening
cross-sections

„ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

- Are there other possible solutions to achieve the require-
ments of the project task?
- Did any unexpected problems occur?

Notes

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 42
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 09: Throttle valve, adjustable 43

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard. WARNING
When starting the system, hydraulic fluid can escape from open ports in a narrow
stream at high pressure, which can cause serious injuries (cutting jet).

General notes on setup of the hydraulic circuit:

Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch- 09
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized.
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device.
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.

When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

Exercise caution when a system is pressurized and/or electrical voltage is present:

„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 43
Distribution only for training purposes with indication of source.
 44 Project 09: Throttle valve, adjustable Bosch Rexroth AG I R901385283

Parts list for circuit diagram of project exercise 09

Quan- Rexroth
Item Description Type
tity material number
Hydraulic motor
1.10 1 EPMM-S8C R961008748
(planetary motor)

1.20 1 4/3 directional control valve 4WMM6E5X/F R961002551

1.30 1)
2 1)/1 Pressure relief valve DBDH6G1X/100 R961002520
1.31

1.40 1 Throttle valve DV06-1-1X/V R961002539

1.50 1 Hydraulic distributor 4 ports R961002485

1.60
1.61 3 Manometer 0 to 100 bar R961002715
09 1.62
1.70
1.71 Hose line 1000 mm with
4 ZN10031-08-W90MM-1000 R961004330
1.72 Minimess port
1.73
1.80 1)
1.81 3 1)/2 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
1.82
for WS290:
R961002564
2.5 l measuring glass
1.90 1
for WS200:
R961009485
1.6 l measuring glass
1)
... only required with the WS290 (DS4) workstation
Parts list of the hydraulic components for project exercise 09

Note:
This parts list represents the components and accessories required for executing this proj-
ect exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hose lines used correspond to the hose lines provided in
the associated Rexroth device set.

Measuring technology

1 Tachometer, visual R961008893

1 Stopwatch, digital R900061256
alternatively
1 Gear wheel flow sensor R961002508
with: 1 x measuring instrument set 3020 R913038909
1 x hose line 630 mm (item 1.83) R961002474
Recommended additional measuring instruments for project exercise 09

Note:
The methods for measuring flow are described in the “Flow measurement” section before
the descriptions of the project exercises.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 44
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 Bosch Rexroth AG I R901385283 Project 09: Throttle valve, adjustable 45

Circuit diagram for project exercise 09

09

Circuit diagram for project exercise 09

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 45
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 46 Project 09: Throttle valve, adjustable Bosch Rexroth AG I R901385283

Arrangement of components

1.70 V

D 1.73
1.50 1.40 1.10

1.61
1.90 1.72 1.62

1.82

1.20
1.71
09
T

1.80 1) D
T

D 1.83
1.30 1) 1.31
P

1.81
P
MP

1.60

1) Component of the WS200 workstation, not in the exercise setup

D Connection between two hydraulic components without a hose
(components directly coupled to each other)
V Flow sensor (optional)
1.83 Hose line only required when using a flow sensor
1.71 Hose line only required when using a hydraulic motor with a leakage oil port
(on units R961004259, R961002811)
Recommended arrangement of the components for project exercise 09 (schematic representation)

Note:
The arrangement of the components (with item number as per the parts list) on a mount-
ing grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 46
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 Bosch Rexroth AG I R901385283 Project 09: Throttle valve, adjustable 47

Project execution
Hang the required components and accessories in the workstation mounting grid
accor­ding to the table “Parts list of the hydraulic components for project exercise 09”
(see "Arrangement of components").

Project execution steps

1. Connect the hoses according to the circuit diagram for project exercise 09, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.
2. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage.
All manometers must show zero pressure (except for the operating pressure display
on a WS200; see notes on using this workstation)! 09
3. Set the operating pressure at the pressure relief valve to 50 bar.
4. Actuate the directional control valve (item 1.20) (move the lever to the right,
latches into position); connection P → A is established; the hydraulic motor shaft
turns in a right-hand direction.

Throttle valve set to ¼ turn

5. First close the throttle valve (item 1.40) and then partially open the throttle valve
by turning the adjusting knob by ¼ turn (1st throttle valve position).
Keep the directional control valve actuated (lever latched in the right position) and
use the pressure relief valve (item 1.31) to set a load pressure of 20 bar in the
directional control valve return line (manometer M3).
6. The flow can be measured using a measuring glass and stopwatch or optionally
using a flow meter.
To determine the pressure difference Δp at the throttle valve, record the pressures
at manometers M2 and M3; enter the measured values into the table; calculate the
pressure difference.
7. Keep the throttle valve in the same position (1st position) and then increase the
load pressure to 25 bar, 30 bar, 35 bar, 40 bar and 50 bar.
For each of these load pressures, determine the flow and the pressures at M2 and
M3 and enter the measured values into the measurement table; calculate the
pressure differences.

The modification of rotational speed for different adjustments has to be observed;

if necessary during utilization of the recommended visual tachometer.

Throttle valve set to ¾ turn

8. Partially open the throttle valve by turning the adjusting knob by ¾ turn (2nd throttle
valve position); repeat steps 6 to 7 of this project task using this throttle valve
setting, enter the measurements and calculations into the table.

Throttle valve set to 1¾ turn

9. Partially open the throttle valve by turning the adjusting knob by 1¾ turn
(3rd throttle valve position); repeat steps 6 to 7 of this project task using this
throttle valve setting, enter the measurements and calculations into the table.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 47
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 48 Project 09: Throttle valve, adjustable Bosch Rexroth AG I R901385283

Measured values Load pressure M3

WS200 WS200 p3 in bar
20 25 30 35 40 50

M2
p2 in bar
Throttle valve M2 – M3
set to ¼ turn Δp in bar
qV
in l/min
M2
p2 in bar
Throttle valve M2 – M3
set to ¾ turn Δp in bar
qV
in l/min
M2
p2 in bar
Throttle valve M2 – M3
set to 1¾ turn Δp in bar

09 qV
in l/min

For the WS200 workstation, the measured and calculated values are to be used to chart
the pressure difference-flow characteristic curves for the individual throttle valve set-
tings (opening cross sections) in the following chart.

Δp
bar

25

20

15

10

0 qV
0 1 2 3 4 5 l/min
¼ Throttle valve set to ¼ turn
¾ Throttle valve set to ¾ turn
1¾ Throttle valve set to 1¾ turn
Pressure difference-flow characteristic curves of a throttle valve for different opening cross sections (with WS200)

Switch off the hydraulic power unit after finishing the practical work!
Screw the pressure relief valve back to the minimum pressure setting!
CAUTION
Completely open the throttle valve!
All manometers must show zero pressure!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 48
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 Bosch Rexroth AG I R901385283 Project 09: Throttle valve, adjustable 49

Measured values
WS290 (DS4) Load ppressure
in bar
M3 20 25 30 35 40 50
WS290
3

M2
p2 in bar
Throttle valve M2 – M3
set to ¼ turn Δp in bar
qV
in l/min
M2
p2 in bar
Throttle valve M2 – M3
set to ¾ turn Δp in bar
qV
in l/min
M2
p2 in bar
Throttle valve M2 – M3
set to 1¾ turn Δp in bar
qV
in l/min
09

For the WS290 workstation, the measured and calculated values are to be used to chart
the pressure difference-flow characteristic curves for the individual throttle valve set-
tings (opening cross sections) in the following chart.

Δp
bar

25

20

15

10

0 qV
0 1 2 3 4 5 6 8 l/min
¼ Throttle valve set to ¼ turn
¾ Throttle valve set to ¾ turn
1¾ Throttle valve set to 1¾ turn
Pressure difference-flow characteristic curves of a throttle valve for different opening cross sections (with WS290)

Switch off the hydraulic power unit after finishing the practical work!
Screw the pressure relief valve back to the minimum pressure setting!
CAUTION
Completely open the throttle valve!
All manometers must show zero pressure!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 49
Distribution only for training purposes with indication of source.
 50 Project 09: Throttle valve, adjustable Bosch Rexroth AG I R901385283

Assessment of work results

„ The project requirements can be satisfied using a ....................................

„ With a constant opening cross-section, an ........................................... in the flow

increases the pressure difference Δp.

„ With a .................................. flow, the pressure difference becomes larger as the .....
...................................... becomes smaller.

„ Due to the load dependency, an increasing load (higher weight) causes the ..............
and thus the conveyor speed ....................................

Notes
09

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 Bosch Rexroth AG I R901385283 Project 10: Throttle/non-return valve 51

Project 10: Throttle/non-return valve

Project definition
The extension or the retraction velocity of the hydraulic feed cylinder in a processing
station (bending machine) must be adjustable.

The customer requires information on the technical solution suggested, especially

information on meter-in control and meter-out control of a differential cylinder. In par-
ticular, the customer wishes a series of measurements for:

„ Meter-in control on:

- The piston base side (extend cylinder)
- The piston rod side (retract cylinder)

„ Meter-out control on :
- The piston base side (retract cylinder)
- The piston rod side (extend cylinder)

The customer also wishes to know the respective cases for which meter-in control or
meter-out control are to be used.
10

Adjustable throttle/non-return valve of type DRV06

Project tasks
„ Check customer requirements; organize implementation

„ Aquire knowledge of the functional principles and uses of adjustable throttle/

non-return valves

„ Determine the typical behavior resulting from meter-in control and meter-out control
a differential cylinder

„ Direction-dependent influencing of the speed of a differential cylinder

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 51
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 52 Project 10: Throttle/non-return valve Bosch Rexroth AG I R901385283

Project execution steps

„ Informing: - Accept and comprehend the task

- Check the design and condition of the workstation

„ Planning: - Plan and organize the project task

- Read and assess the circuit diagram
- Assess the parameters to be used for selecting the hydraulic
components required (i.e. including examination of the data
sheets; e.g. "RE 32502 – Throttle/shut-off valve and throttle/
non-return valve")

Deciding:
„  - Select the components required
- Define the connections between the components
- Define the measuring points

10
„ Executing: - Setup of the hydraulic circuit on the workstation
- Connect the measuring points; close all inactive measuring
points
- Execute the project exercises using an adjustable throttle/
non-return valve
- Measure characteristic values of the system behavior
- Document the required measurements and perform any calcu-
lations if necessary

„ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

- Are there other possible solutions to achieve the require-
ments of the project task?
- Did any unexpected problems occur?

Notes

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 52
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 10: Throttle/non-return valve 53

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard. WARNING
When starting the system, hydraulic fluid can escape from open ports in a narrow
stream at high pressure, which can cause serious injuries (cutting jet).

General notes on setup of the hydraulic circuit:

Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch-
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized. 10
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device.
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.

When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

Exercise caution when a system is pressurized and/or electrical voltage is present:

„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 53
Distribution only for training purposes with indication of source.
 54 Project 10: Throttle/non-return valve Bosch Rexroth AG I R901385283

Parts list for circuit diagram of project exercise 10

Quan- Rexroth
Item Description Type
tity material number

1.10 1 Differential cylinder CD70F25/16-200 R961009526

1.20 1 4/3 directional control valve 4WMM6E5X/F R961002551

1.30 1) 1 1)/0 Pressure relief valve DBDH6G1X/100 R961002520

1.40 1 Throttle/non-return valve DRV06-1-1X/V R961002495

1.50 1 Hydraulic distributor 4 ports R961002485

1.60
1.61 3 Manometer 0 to 100 bar R961002715
1.62
1.70 Hose line 1000 mm with
2 ZN10031-08-W90MM-1000 R961004330
1.71 Minimess port
10 1.80 1)
1.81
4 1)/3 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
1.82
1.83
1)
... only required with the WS290 (DS4) workstation
Parts list of the hydraulic components for project exercise 10

Note:
This parts list represents the components and accessories required for executing this proj-
ect exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hose lines used correspond to the hose lines provided in
the associated Rexroth device set.

Measuring technology

1 Stopwatch, digital R900061256

Recommended additional measuring instruments for project exercise 10

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 54
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 10: Throttle/non-return valve 55

Circuit diagram for project exercise 10 – Task 1

10

Circuit diagram 1 for project exercise 10: Meter-in control – extend cylinder piston

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 55
Distribution only for training purposes with indication of source.
 56 Project 10: Throttle/non-return valve Bosch Rexroth AG I R901385283

Circuit diagram for project exercise 10 – Task 2

10

Circuit diagram 2 for project exercise 10: Meter-in control – retract cylinder piston

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 56
Distribution only for training purposes with indication of source.
 Bosch Rexroth AG I R901385283 Project 10: Throttle/non-return valve 57

Circuit diagram for project exercise 10 – Task 3

10

Circuit diagram 3 for project exercise 10: Meter-out control – retract cylinder piston

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 57
Distribution only for training purposes with indication of source.
 58 Project 10: Throttle/non-return valve Bosch Rexroth AG I R901385283

Circuit diagram for project exercise 10 – Task 4

10

Circuit diagram 4 of project exercise 10: Meter-out control – extend cylinder piston

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 58
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 Bosch Rexroth AG I R901385283 Project 10: Throttle/non-return valve 59

Component arrangement – Tasks 1 and 2

1 1.61 1.10

1.71
1.70

1.40

1.62
D

1.20

1.81
T

1.80 1)
T

D
1.30 1) 1.82
10
P
P
MP

1.60

2 1.61 1.10

1.71
1.70

1.40

1.62
D

1.20

1.81
T

1.80 1)
T

D
1.30 1) 1.82
P
P
MP

1.60

1)
Component of the WS200 workstation, not in the exercise setup
DConnection between two hydraulic components without a hose
(components directly coupled to each other)
Recommended arrangement of the components for project exercise 10 – Tasks 1 and 2 (schematic representation)

Note: The arrangement of the components (with item number as per the parts list) on a
mounting grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

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 60 Project 10: Throttle/non-return valve Bosch Rexroth AG I R901385283

Arrangement of components – Tasks 3 and 4

3 1.61 1.10

1.71

1.50
D
1.40

1.83 1.70
1.62

1.20

1.81
T

1.80 1)
T

D
1.30 1) 1.82
10
P
P
MP

1.60

4 1.10

1.61 1.62

1.71 1.70

1.83 1.50
D
1.40

1.20

1.81
T

1.80 1)
T

D
1.30 1) 1.82
P
P
MP

1.60

1)
Component of the WS200 workstation, not in the exercise setup
DConnection between two hydraulic components without a hose
(components directly coupled to each other)
Recommended arrangement of components for project exercise 10 – Tasks 3 and 4 (schematic representation)

Note: The arrangement of the components (with item number as per the parts list) on a
mounting grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

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 Bosch Rexroth AG I R901385283 Project 10: Throttle/non-return valve 61

Project execution

Hang the required components and accessories in the workstation mounting grid
accor­ding to the table “Parts list of the hydraulic components for project exercise 10”
(see "Arrangement of components").

Project execution steps

1. Connect the hoses according to circuit diagram 1 of project exercise 10, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.

2. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage.
All manometers must show zero pressure (except for the operating pressure display
on a WS200; see notes on using this workstation)! 10
3. Set the operating pressure at the pressure relief valve to 50 bar.

Task 1: Meter-in control – extend cylinder piston:

4. Check that the hydraulic cylinder piston is in the required initial position.
→ For task 1: The cylinder piston is fully retracted
(if necessary, move the directional control valve handle to the left,
connection P → B is established)

5. Adjust the throttle/non-return valve (item 1.40) so that the differential cylinder
piston extends in 5 s:
- Actuate the directional control valve (item 1.20) to extend the piston (lever
across the center position to the right, connection P → A is established) and use
the throttle/non-return valve to set the specified extension time.
- While the cylinder piston is extending, record the pressures shown on mano­
meters M2 (piston base side) and M3 (piston rod side) and enter these values
into the table.

Switch off the hydraulic power unit before changing the setup for the sub­
sequent project steps!
CAUTION
Screw the pressure relief valve back to the minimum pressure setting!
All manometers must show zero pressure!

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 62 Project 10: Throttle/non-return valve Bosch Rexroth AG I R901385283

Task 2: Meter-in control – Retract cylinder piston:

6. Modify the setup according to circuit diagram 2 for project exercise 10, while taking
care to observe the general and project-specific safety instructions.

Repeat steps 2 to 3.

7. Check that the hydraulic cylinder piston is in the required initial position.
→ For task 2: The cylinder piston is fully extended (if necessary, move the direction-
al control valve handle to the right, connection P → A is established)

8. Adjust the throttle/non-return valve (item 1.40) so that the differential cylinder
piston retracts in 5 s:
- Actuate the directional control valve (item 1.20) again to retract the piston (lever
across the center position to the left; connection P → B is established) and use
the throttle/non-return valve to set the specified retraction time.
- While the cylinder piston is retracting, read the pressures shown on manometers
M2 (piston base side) and M3 (piston rod side) and enter these values into the
table.
10
Switch off the hydraulic power unit before changing the setup for the sub­
sequent project steps!
CAUTION Screw the pressure relief valve back to the minimum pressure setting!
All manometers must show zero pressure!

Task 3: Meter-out control – Retract cylinder piston:

9. Modify the setup according to circuit diagram 3 for project exercise 10, while taking
care to observe the general and project-specific safety instructions.

Repeat steps 2 to 3.

10. Check that the hydraulic cylinder piston is in the required initial position.
→ For task 3: Cylinder piston is fully extended (if necessary, move the directional
control valve lever to the right, connection P → A is established)

11. Adjust the throttle/non-return valve (item 1.40) so that the differential cylinder
piston retracts in 5 s:
- Actuate the directional control valve (item 1.20) again to retract the piston (lever
across the center position to the left; connection P → B is established) and use
the throttle/non-return valve to set the specified retraction time.
- While the cylinder piston is retracting, read the pressures shown on manometer
M2 (piston base side) and manometer M3 (piston rod side) and enter these values
into the table.

Switch off the hydraulic power unit before changing the setup for the sub­
sequent project steps!
CAUTION
Screw the pressure relief valve back to the minimum pressure setting!
All manometers must show zero pressure!

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 Bosch Rexroth AG I R901385283 Project 10: Throttle/non-return valve 63

Task 4: Meter-out control – Extend cylinder piston:

12. Modify the setup according to circuit diagram 4 for project exercise 10, while
taking care to observe the general and project-specific safety instructions.

Repeat steps 2 to 3.

13. Check that the hydraulic cylinder piston is in the required initial position.
→ For task 4: Cylinder piston is fully retracted (if necessary, move the directional
control valve lever to the left, connection P → B is established)

14. Adjust the throttle/non-return valve (item 1.40) so that the differential cylinder
piston extends in 5 s:
- Actuate the directional control valve (item 1.20) to extend (move the lever across
the center position to the right, connection P → A s established) and use the
throttle/non-return valve to set the specified extension time.
- While the cylinder piston is extending, read the pressures shown on mano­
meters M2 (piston base side) and mano­meter M3 (piston rod side) and enter
these values into the table.
10
The pressure values measured for the four cylinder motion throttling variants are to be Measured
entered into the following table. values

M2 M3
p2 in bar p3 in bar
Task 1:
Meter-in control of the Extend
piston base side
Task 2:
Meter-in control of the Retract
piston rod side
Task 3:
Meter-out control of the Retract
piston base side
Task 4:
Meter-out control of the Extend
piston rod side

Switch off the hydraulic power unit after finishing the practical work!
Screw the pressure relief valve back to the minimum pressure setting!
CAUTION
Completely open the throttle valve!
All manometers must show zero pressure!

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 64 Project 10: Throttle/non-return valve Bosch Rexroth AG I R901385283

Assessment of work results

„ A .......................................... allows the motion velocity of the feed cylinder to be
adjusted in ................................ direction.

„ A ...................................... is a combination of a throttle valve and a non-return valve

in a common housing.

„ The danger of ........................................... on the piston rod side must be taken into
consideration.
The size of this depends on the ........................................ in the differential cylinder
and with a ratio of (e.g.) 2 : 1 this is .................................. the operating pressure.

Notes

10

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 Bosch Rexroth AG I R901385283 Project 11: Flow control valve 65

Project 11: Flow control valve

Project definition
A drum is welded in a processing station and is then pivoted from a horizontal position
to a vertical position by a hydraulic rotary drive. This motion is implemented using a
hydraulic motor. The motor speed must remain constant despite a varying load.

Using the knowledge gained from project exercise 09 a flow control valve is to be used
for implementing load-independent speed control of a hydraulic motor.

The customer requires documentation of the technical details for a number of different
workpiece weights in order to understand the reasons for the suggested solution. The
customer also requires the respective flow-pressure difference-characteristic curves for
increasing loads and decreasing system pressures.

11

Hydraulic rotary drive for workpiece relocation

Project tasks
„ Check customer requirements; organize implementation

„ Aquire knowledge of the functional principles and uses of flow control valves

„ Learn the control circuit elements of a flow control valve

„ Verify constant flow under different loads or variable operating pressure

„ Determine and chart the characteristic curves of pressure dependency

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 66 Project 11: Flow control valve Bosch Rexroth AG I R901385283

Project execution steps

„ Informing: - Accept and comprehend the task

- Check the design and condition of the workstation

„ Planning: - Plan and organize the project task

- Read and assess the circuit diagram
- Assess the parameters to be used for selecting the hydraulic
components required (including examination of the data
sheets; e.g. "RE 28163 – 2-way flow control valve")

Deciding:
„  - Select the components required
- Define the connections between the components
- Define the measuring points

„ Executing: - Setup of the hydraulic circuit on the workstation

- Connect the measuring points; close all inactive measuring

11
points
- Execute the project exercises using a 2-way flow control valve
- Record and document the required measurements and per-
form any calculations required
- Determine the characteristic curves from the measurements

„ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

- Are there other possible solutions to achieve the require-
ments of the project task?
- Did any unexpected problems occur?

Notes

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 Bosch Rexroth AG I R901385283 Project 11: Flow control valve 67

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard. WARNING
When starting the system, hydraulic fluid can escape from open ports in a narrow
stream at high pressure, which can cause serious injuries (cutting jet).

General notes on setup of the hydraulic circuit:

Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch-
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized.
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.
11
When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device.
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.

When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

Exercise caution when a system is pressurized and/or electrical voltage is present:

„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

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 68 Project 11: Flow control valve Bosch Rexroth AG I R901385283

Parts list for circuit diagram of project exercise 11

Quan- Rexroth
Item Description Type
tity material number
Hydraulic motor (planetary
1.10 1 EPMM-S8C R961008748
motor)

1.20 1 4/3 directional control valve 4WMM6E5X/F R961002551

1.30 1)
2 1)/1 Pressure relief valve DBDH6G1X/100 R961002520
1.31

1.40 1 2-way flow control valve 2FRM6B36-3X R961002546

1.50
2 Hydraulic distributor 4 ports R961002485
1.51
1.60
1.61
4 Manometer 0 to 100 bar R961002715
1.62
1.63
1.70
1.71 Hose line 1000 mm with
1.72 5 ZN10031-08-W90MM-1000 R961004330
Minimess port
11
1.73
1.74
1.80 1)
1.81 3 1)/2 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
1.82
for WS290:
R961002564
2.5 l measuring glass
1.90 1
for WS200:
R961009485
1.6 l measuring glass
1)
... only required with the WS290 (DS4) workstation
Parts list of the hydraulic components for project exercise 11

Note:
This parts list represents the components and accessories required for executing this proj-
ect exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hose lines used correspond to the hose lines provided in
the associated Rexroth device set.

Measuring technology
1 Tachometer, visual R961008893
1 Stopwatch, digital R900061256
alternatively
1 Gear wheel flow sensor R961002508
with: 1 x measuring instrument set 3020 R913038909
1 x hose line 630 mm (item 1.83) R961002474
Recommended additional measuring instruments for project exercise 11

Note: The methods for measuring flow are described in the “Flow measurement” section
before the descriptions of the project exercises.

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 Bosch Rexroth AG I R901385283 Project 11: Flow control valve 69

Circuit diagram for project exercise 11

11

Circuit diagram for project exercise 11

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 70 Project 11: Flow control valve Bosch Rexroth AG I R901385283

Arrangement of components

1.74 1.62

1.51 D
1.61 1.31 1.40 1.10
D 1.72

1.71
1.90 V 1.83 1.50 1.63

1.82

1.20
1.73
T

1.80 1)
1.70
T

D
1.30 1)
P

1.81
11
P
MP

1.60

1) Component of the WS200 workstation, not in the exercise setup

D Connection between two hydraulic components without a hose
(components directly coupled to each other)
V Flow sensor (optional)
1.83 Hose line only required when using a flow sensor
1.73 Hose line only required when using a hydraulic motor with a leakage oil port
(on units R961004259, R961002811)
Recommended arrangement of the components for project exercise 11 (schematic representation)

Note:
The arrangement of the components (with item number as per the parts list) on a mount-
ing grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

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 Bosch Rexroth AG I R901385283 Project 11: Flow control valve 71

Project execution

Hang the required components and accessories in the workstation mounting grid
accor­ding to the table “Parts list of the hydraulic components for project exercise 11”
(see "Arrangement of components").

Project execution steps

1. Connect the hoses according to the circuit diagram for project exercise 11, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.

2. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage.
All manometers must show zero pressure (except for the operating pressure display
on a WS200; see notes on using this workstation)!

3. Set the operating pressure at the pressure relief valve to 50 bar.

11
Task 1 –
Determining the flow-pressure difference characteristic curve under increasing load
pressures:

4. Set the flow control valve (item 1.40) to scale setting 2.

→ The scale values on the 2-way flow control valve represent predefined opening
cross-sections in the valve, each of which allowing a defined flow.

5. Actuate the directional control valve (item 1.20) (lever to the right; latches into position),
connection P → A is established, hydraulic motor turns in a right-hand direction.
- While the motor is turning, use the pressure relief valve (item 1.31) in the return
line to set a load pressure of 10 bar (manometer M4) .
- To determine the pressure difference Δp at the flow control valve, record the
values shown on manometers M2 and M3 (before/after the flow control valve);
enter the values into the table; calculate the pressure difference.
- The flow qV can be measured using a measuring glass and stopwatch or optionally
using a flow measuring device; enter the values into the table.

6. Use the pressure relief valve (item 1.31) in the return line to increase the load
pressure (manometer M4) stepwise (5 bar per step) up to 40 bar
- Record the values shown on manometers M2 and M3 for each pressure step; enter
the values into the following table; calculate the pressure difference.
- Determine the flow qV and enter this into the table.

The modification of rotational speed for different adjustments has to be observed;

if necessary during utilization of the recommended visual tachometer.

7. Set the flow control valve to scale setting 4.

8. Repeat steps 5 to 6.

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 72 Project 11: Flow control valve Bosch Rexroth AG I R901385283

WS200 work station: Measured values, calculations and characteristic curve

Measured Enter the measurements for M2 and M3, the calculated pressure differences and the
values determined flows into the table for each of the specified load pressures and flow con-
trol valve scale settings.

M2 M3 M4 M2 – M3 Flow
p2 in bar p2 in bar p3 in bar Δp in bar qV in l/min

Scale Scale Scale Scale Scale Scale Scale Scale

Load
setting setting setting setting setting setting setting setting
pressure
2 4 2 4 2 4 2 4

10

15

20

25

30

11 35

40

The measured/calculated values are to be used to plot the respective flow-pressure

diffe­rence characteristic curves for increasing load pressures on the following chart.

qV
l/min
2,0

1,5

1,0

0,5

0 Δp
0 5 10 15 20 25 30 35 bar

2 Scale setting 2 at flow control valve

4 Scale setting 4 at flow control valve
Flow-pressure difference characteristic curve of a flow control valve under increasing load pressure (using WS200)

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 Bosch Rexroth AG I R901385283 Project 11: Flow control valve 73

WS290 (DS4) workstation: Measured values, calculations and characteristic curve

Enter the measurements for M2 and M3, the calculated pressure differences and the Measured
determined flows into the table for each of the specified load pressures and flow con- values
trol valve scale settings.

M2 M3 M4 M2 – M3 Flow
p2 in bar p2 in bar p3 in bar Δp in bar qV in l/min

Scale Scale Scale Scale Scale Scale Scale Scale

Load
setting setting setting setting setting setting setting setting
pressure
2 4 2 4 2 4 2 4

10

15

20

25

30

35
11
40

The measured/calculated values are to be used to plot the respective flow-pressure dif-
ference characteristic curves for increasing load pressures on the following chart.

qV
l/min
2,0

1,5

1,0

0,5

0 Δp
0 5 10 15 20 25 30 35 bar

2 Scale setting 2 at flow control valve

4 Scale setting 4 at flow control valve
Flow-pressure difference characteristic curve of a flow control valve under increasing load pressure (using WS290)

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 74 Project 11: Flow control valve Bosch Rexroth AG I R901385283

Task 2 –
Determining the pressure-flow characteristic curve with decreasing operating
pressure:

1. Use the pressure relief valve (item 1.31) in the return line to set the load pressure
(manometer M4) to minimum (spring unloaded).

2. Set the flow control valve to scale setting 2.

3. Actuate the directional control valve (move the lever to the right; latches into
position), connection P → A is established, hydraulic motor turns in a right-hand
direction.
- To determine the pressure difference Δp record the values shown on manometers
M1 (before the directional control valve) and M3 (after the flow control valve);
enter the values into the following table.
- The flow qV can be measured using a measuring glass and stopwatch or optionally
using a flow measuring device; enter the values into the table.

The modification of rotational speed for different adjustments has to be observed;

if necessary during utilization of the recommended visual tachometer.

11 4. Use the pressure relief to decrease the operating pressure stepwise according to
the values specified into the table until reaching the minimum pressure of 10 bar.

Measured Enter the measurements for M3 and the determined flows for each of the decreasing
values pressures into the table.

M1 M3 Volumenstrom
p1 in bar p3 in bar qV in l/min

45

35

25

15

10

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 Bosch Rexroth AG I R901385283 Project 11: Flow control valve 75

The measured values are to be used to chart the pressure-flow characteristic curve for
decreasing operating pressure in the following chart.

qV
l/min
0,5

0,4

0,3

0,2

0,1

0 p
0 5 10 15 20 25 30 35 40 45 bar
Pressure-flow characteristic curve of a flow control valve under decreasing operating pressure

11
Switch off the hydraulic power unit after finishing the practical work!
Screw the pressure relief valve back to the minimum pressure setting!
CAUTION
Completely open the flow control valve (scale value 10)!
All manometers must show zero pressure!

Assessment of work results

„ The physical design of a flow control valve consists of an adjustable orifice and
.........................................., that ensures a constant pressure difference at the
orifice.

„ A flow control valve has a closed-loop hydraulic ...........................................

„ The flow remains ....................................... under variable load pressures.

„ The flow remains ....................................... under variable operating pressures.

„ When pressure difference is below a minimum ........................................ decreases.

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 76 Project 11: Flow control valve Bosch Rexroth AG I R901385283

Notes

11

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 Bosch Rexroth AG I R901385283 Project 14: Pressure reducing valve 103

Project 14: Pressure reducing valve

Project definition
In project exercise 11 a workpiece is to be pivoted into a processing station using a
hydraulic motor.
This project exercise is then extended by clamping the workpiece at reduced pressure.
The output side of the motor is hydraulically preloaded to ensure that the hydraulic
motor does not start the pivoting movement until the workpiece clamping process is
completed,

The customer requires a solution proposal for simple implementation of the control
system. The customer requires documentation of the technical details and also requires
verification of the required system parameters. Information on adjustment possibilities
is also required.

14

Assembly with pressure reducing valve of type DR6DP

Project tasks
„ Check customer requirements; organize implementation

„ Aquire knowledge of the functional principles and uses of pressure reducing valves

„ Determine the behavior of pressure reducing valves in a practical application

„ Actuation of two consumers with different pressures

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 104 Project 14: Pressure reducing valve Bosch Rexroth AG I R901385283

Project execution steps

„ Informing: - Accept and comprehend the task

- Check the design and condition of the workstation

„ Planning: - Plan and organize the project task

- Read and assess the circuit diagram
- Assess the parameters to be used for selecting the hydraulic
components required (including examination of the data
sheets; e.g. "RE 26564 – Pressure reducing valve")

Deciding:
„  - Select the components required
- Define the connections between the components
- Define the measuring points

„ Executing: - Setup of the hydraulic circuit on the workstation

- Connect the measuring points; close all inactive measuring
points
- Execute the project exercises using a pressure reducing valve
and a 4/3 directional control valve
- Measure characteristic values of the system behavior
- Document the required measurements and perform any calcu-
lations if necessary

14 „ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

- Are there other possible solutions to achieve the require-
ments of the project task?
- Did any unexpected problems occur?

Notes

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 Bosch Rexroth AG I R901385283 Project 14: Pressure reducing valve 105

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard. WARNING
When starting the system, hydraulic fluid can escape from open ports in a narrow
stream at high pressure, which can cause serious injuries (cutting jet).

General notes on setup of the hydraulic circuit:

Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch-
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized.
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device. 14
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.

When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

Exercise caution when a system is pressurized and/or electrical voltage is present:

„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

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 106 Project 14: Pressure reducing valve Bosch Rexroth AG I R901385283

Parts list for circuit diagram of project exercise 14

Quan- Rexroth
Item Description Type
tity material number

1.10 1 Differential cylinder CD70F25/16-200 R961009526

Hydraulic motor (planetary

1.20 1 EPMM-S8C R961008748
motor)

1.30 1 4/3 directional control valve 4WMM6E5X/F R961002551

1.40 1)
2 1)/1 Pressure relief valve DBDH6G1X/100 R961002520
1.41

1.50 1 Pressure reducing valve DR6DP1-5X/V R961002544

1.60 1 Non-return valve S6A05-1X/ R901462818

1.70
1.71 3 Hydraulic distributor 4 ports R961002485
1.72
1.80
1.81 3 Manometer 0 to 100 bar R961002715
1.82
1.90
1.91 Hose line 1000 mm with
4 ZN10031-08-W90MM-1000 R961004330
1.92 Minimess port
1.93
2.00
2.01
2.02
14 2.03
2.04
7 1)/6 Hose line 630 mm ZN10031-08-W00NN-630 R961002474

2.05
2.06 1)
for WS290:
R961002564
2.5 l measuring glass
2.10 1
for WS200:
R961009485
1.6 l measuring glass
1)
... only required with the WS290 (DS4) workstation
Parts list of the hydraulic components for project exercise 14

Note:
This parts list represents the components and accessories required for executing this proj-
ect exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hose lines used correspond to the hose lines provided in
the associated Rexroth device set.

In this project exercise the measuring glass is only used for viewing the flow through the
pressure reducing valve. This allows the opened state of the valve to be made visible.

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 Bosch Rexroth AG I R901385283 Project 14: Pressure reducing valve 107

Circuit diagram for project exercise 14

14

Circuit diagram for project exercise 14

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 108 Project 14: Pressure reducing valve Bosch Rexroth AG I R901385283

Arrangement of components

2.03 1.10
1.20 1.60 1.72
1.91 D
1.92
D
1.90 D 1.82
2.10 1.50

1.41 2.04 2.05

1.81
1.93

1.70
D D
T

2.06 1) 1.71 2.02

1.30
T

D
1.40 1) 2.01
P
P

2.00
1.80
MP

1) Component of the WS200 workstation, not in the exercise setup

D Connection between wo hydraulic components without a hose
(components directly coupled to each other)

14 1.81 Hose line only required when using a hydraulic motor with a leakage oil port

Recommended arrangement of the components for project exercise 14 (schematic representation)

Note:
The arrangement of the components (with item number as per the parts list) on a mount-
ing grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

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 Bosch Rexroth AG I R901385283 Project 14: Pressure reducing valve 109

Project execution

Hang the required components and accessories in the workstation mounting grid
accor­ding to the table “Parts list of the hydraulic components for project exercise 14”
(see "Arrangement of components").

Project execution steps

1. Connect the hoses according to the circuit diagram for project exercise 14, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.

Ensure the correct mounting direction of the non-return valve (item 1.60)!
Screw the pressure relief valve back to the minimum pressure setting!
CAUTION Completely open the throttle valve!
Unload the pressure reducing valve (screw the adjusting element counter-
clockwise until reaching the stop)!

Task 1 – Control using a non-return valve:

2. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage. 14
The initial position of the cylinder piston is the retracted state.
All manometers must show zero pressure (except for the operating pressure display
on a WS200; see notes on using this workstation)!

3. Set the operating pressure at the pressure relief valve to 50 bar.

4. Actuate the directional control valve (item 1.30) (move the lever to the right;
latches into position), connection P → A is established, hydraulic motor turns in a
right hand direction.
While the motor is turning, use the pressure relief valve (item 1.41) to set port B of
the hydraulic motor to a load pressure of 40 bar (manometer M2).
Screw the adjustment element of the pressure reducing valve (item 1.50) slowly
clockwise until cylinder piston extends.

5. With the cylinder piston extended, set the clamping pressure at the pressure reduc-
ing valve (item 1.50) to 20 bar (manometer M3).

6. Actuate the directional control valve (move the lever to the left; latches into posi-
tion), connection P → B is established, cylinder piston retracts.
During retraction, record the values shown on manometers M1, M2 and M3 and
enter these into the table.

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 110 Project 14: Pressure reducing valve Bosch Rexroth AG I R901385283

7. Actuate the directional control valve again (move the lever across the center posi-
tion to the right; latches into position), connection P → A is established, cylinder
piston extends.
During extension, record the values shown on manometers M1, M2 and M3 and
enter these into the table.

If necessary, repeat steps as of 6. several times.

Also record the pressures at the end positions of the piston after extending and retracting
and enter these into the table.

Switch off the hydraulic power unit before changing the setup for the sub­
sequent project steps!
CAUTION Bring the directional control valve into the center position!
All manometers must show zero pressure!

Task 2 – Control without a non-return valve:

1. Modify the hydraulic circuit setup according to the task specifications; remove the
non-return valve (item 1.60) and connecting hose (item 2.03) for this.

Do not change the settings of the pressure relief valve and the pressure reducing
valve!

Switch on the hydraulic power unit of the workstation and check the constructed
circuit for any leakage.
The initial position of the cylinder piston is the retracted state.
14
2. Actuate the directional control valve (move the lever to the right, latches into
position), connection P → A is established, cylinder piston extends.
During extension, record the values shown on manometers M1, M2 and M3 and
enter these into the table.

3. Actuate the directional control valve again (move the lever across the center posi-
tion to the left; latches into position), connection P → B is established, cylinder
piston retracts.
While the piston is retracting, record the measurements shown on manometers
M1, M2 and M3 and enter these values into the table; observe the measuring glass.

Note:
When retracting the cylinder piston by actuating the directional control valve (lever to
the left) the piston moves against the clamping pressure of 20 bar.
In this case the pressure reducing valve performs a pressure relief function.

Also record the specified pressures when the cylinder piston is at the end positions after
extending and retracting and enter these values into the table.

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 Bosch Rexroth AG I R901385283 Project 14: Pressure reducing valve 111

Measured values
With non-return valve Without non-return valve
WS200
Motion of the
cylinder rod M1 M2 M3 M1 M2 M3
p1 in bar p2 in bar p3 in bar p1 in bar p2 in bar p3 in bar

Extend

End position
after extending

Retract

End position
after retracting

Measured values
With non-return valve Without non-return valve
Motion of the WS290
cylinder rod M1 M2 M3 M1 M2 M3
p1 in bar p2 in bar p3 in bar p1 in bar p2 in bar p3 in bar

Extend

End position
after extending

Retract
14
End position
after retracting

Switch off the hydraulic power unit after finishing the practical work!
Screw the pressure reducing valve and the pressure relief valve back to the
CAUTION minimum pressure position!
All manometers must show zero pressure!

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 112 Project 14: Pressure reducing valve Bosch Rexroth AG I R901385283

Assessment of work results

„ A pressure reducing valve can be used to supply a secondary consumer at a .............
pressure than the ..................................

„ The operating pressure (M1) must always be ............................... than the secondary
pressure (M3).

„ In the case of a pressure increase at port A of the pressure reducing valve (e.g.
pressure spikes or secondary consumer load changes) the ....................... is relieved
to the tank via .......................... of the pressure reducing valve.

„ A pressure reducing valve without a non-return valve in the bypass blocks the flow in
the same manner as a ...............................

„ The pressure relief valve at the hydraulic motor blocks like a ................................ on
actuation from T to P.

Notes

14

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 Bosch Rexroth AG I R901385283 Project 16: Regenerative circuit 125

Project 16: Regenerative circuit

Project definition
In a machine-tool, the extension time of the cylinder piston, and thus the system cycle
time, is to be reduced without changing the flow generated by the hydraulic pump.
In the future, the velocity of the feed cylinder should be adjustable independent of the
load.

The customer requires documentation of the technical details in order to understand

the reasons for the suggested solution. This includes an overview of the cylinder piston
motion times for different flow control valve settings and verification of “return fluid
regeneration”.

16
Manifold with hydraulic components for constructing a regenerative circuit (example)

Project tasks
„ Check customer requirements; organize implementation

„ Aquire knowledge of the advantages and uses of a regenerative circuit

„ Setup a regenerative circuit

„ Control of a hydraulic cylinder with a directional control valve and a flow control
valve

„ Determine the typical system behavior when using a regenerative circuit

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 126 Project 16: Regenerative circuit Bosch Rexroth AG I R901385283

Project execution steps

„ Informing: - Accept and comprehend the task

- Check the design and condition of the workstation

„ Planning: - Plan and organize the project task

- Read and assess the circuit diagram
- Assess the parameters to be used for selecting the hydraulic
components required (including examination of the data
sheets; e.g. "RE 08103 – Standard speed controls in series
and parallel circuit")

Deciding:
„  - Select the components required
- Define the connections between the components
- Define the measuring points

„ Executing: - Setup of the hydraulic circuit on the workstation

- Connect the measuring points; close all inactive measuring
points
- Execute the project exercises using a regenerative circuit
- Measure characteristic values of the system behavior
- Document the required measurements and perform any calcu-
lations if necessary

„ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

16 - Are there other possible solutions to achieve the require-

ments of the project task?
- Did any unexpected problems occur?

Notes

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 Bosch Rexroth AG I R901385283 Project 16: Regenerative circuit 127

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard. WARNING
When starting the system, hydraulic fluid can escape from open ports in a narrow
stream at high pressure, which can cause serious injuries (cutting jet).

General notes on setup of the hydraulic circuit:

Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch-
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized.
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device.
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.
16
When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

Exercise caution when a system is pressurized and/or electrical voltage is present:

„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

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Distribution only for training purposes with indication of source.
 128 Project 16: Regenerative circuit Bosch Rexroth AG I R901385283

Parts list for circuit diagram of project exercise 16

Quan- Rexroth
Item Description Type
tity material number

1.10 1 Differential cylinder CD70F25/16-200 R961009526

1.20 1 4/2 directional control valve 4WMM6C5X/ R961002552

1.30 1 4/3 directional control valve 4WMM6E5X/F R961002551

1.40 1 2-way flow control valve 2FRM6B36-3X R961002546

1.50 1) 1 1)/0 Pressure relief valve DBDH6G1X/100 R961002520

1.60 1 Non-return valve S6A05-1X/ R901462818

Non-return valve,
1.70 1 SV6PB1-6X R961002513
pilot-operated
1.80
2 Hydraulic distributor 4 ports R961002485
1.81
1.90
1.91 3 Manometer 0 to 100 bar R961002715
1.92
2.00
Hose line 1000 mm with
2.01 3 ZN10031-08-W90MM-1000 R961004330
Minimess port
2.02
2.10 1)
2.11
2.12 5 1)/4 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
2.13
2.14
for WS290:
R961002564
2.5 l measuring glass
2.20 1
for WS200:
16 1.6 l measuring glass
R961009485

1)
... only required for WS290 (DS4) workstation
Parts list of the hydraulic components for project exercise 16

Note:
This parts list represents the components and accessories required for executing this proj-
ect exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hose lines and components used correspond to the parts
provided in the associated Rexroth device set. For this reason, in task 2 of this project exer-
cise a pilot-operated non-return valve is used as a second non-return valve. In this case the
pilot-operated unlocking function of the valve is not used (control port closed off).

Measuring technology

1 Stopwatch, digital R900061256

Recommended additional measuring instruments for project exercise 16

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 Bosch Rexroth AG I R901385283 Project 16: Regenerative circuit 129

Circuit diagram for project exercise 16 – Task 1

16

Circuit diagram 1 for project exercise 16: Velocities at the hydraulic cylinder

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 130 Project 16: Regenerative circuit Bosch Rexroth AG I R901385283

Circuit diagram for project exercise 16 – Task 2

16

Circuit diagram 2 for project exercise 16: Pressures and flows in a regenerative circuit

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 Bosch Rexroth AG I R901385283 Project 16: Regenerative circuit 131

Arrangement of components

1
2.00

1.20 1.10
1.91

1.80 2.01

1.92
2.12
1.82
T

2.10 1)
1.40
T

D
1.50
1.301)
P
P

2.11
MP

1.60

2 1.91 1.10
1.92

2.01

2.02 2.00 1.60

2.20 D 2.14 1.81

2.13
1.30

16
2.11 1.70 2.12
T

2.10 1)
T

D
1.50
1.301)
P

D
1.80
P
MP

1.60

1)
Component of the WS200 workstation, not in the exercise setup
DConnection between two hydraulic components without a hose
(components directly coupled to each other)
Recommended arrangement of the components for project exercise 16 – Tasks 1 and 2 (schematic representation)

Note:
The arrangement of the components (with item number as per the parts list) on a mount-
ing grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

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 132 Project 16: Regenerative circuit Bosch Rexroth AG I R901385283

Project execution

Hang the required components and accessories in the workstation mounting grid
accor­ding to the table “Parts list of the hydraulic components for project exercise 16”
(see "Arrangement of components").

Project execution steps

Task 1 – Velocities at the hydraulic cylinder:

1. Connect the hoses according to circuit diagram 1 for project exercise 16, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.
Connect the measuring hoses of the other manometers to the Minimess ports of
the respective hydraulic hoses and tighten hand-tight.

2. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage.
All manometers must show zero pressure (except for the operating pressure display
on a WS200; see notes on using this workstation)!

3. Set the operating pressure at the pressure relief valve to 50 bar.

Set the flow control valve (item 1.40) to scale setting 1.0.

4. Actuate the 4/2-directional control valve (item 1.20) (hold the lever pressed to the
left), connection P → B is established, the piston rod of the hydraulic cylinder
extends.
Measure the extension time of the piston rod and enter this value into the table.

16 5. Actuate the directional control valve again (release the lever → valve spool returns
to the initial position), connection P → A is established, the piston rod retracts
again.
Measure the retraction time of the piston rod and enter this value into the table.

6. Set the flow control valve sequentially to scale settings of 1.2, 1.4, 1.6, 1.8 and 2.0,
repeat steps 4 and 5 for each setting and enter the respective values into the table.

7. Calculate the motion velocities of the cylinder piston (v = s/t) and enter the respec-
tive values into the following table.

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 Bosch Rexroth AG I R901385283 Project 16: Regenerative circuit 133

Specifications: Cylinder piston stroke s = 200 mm

Measured
values
Scale value (SkW) 1) at Motion time Motion velocity
Cylinder piston
the flow control valve t in s v in mm/s

Extend
1.0
Retract

Extend
1.2
Retract

Extend
1.4
Retract

Extend
1.6
Retract

Extend
1.8
Retract

Extend
2.0
Retract
16
1)
... The scale values on the 2-way flow control valve represent predefined opening cross-sec-
tions in the valve, each of which allowing a definded flow.

Use the calculated cylinder piston motion velocity values to show the dependencies
between flow and velocity in a differential cylinder as a characteristic curve in the fol-
lowing chart.
The size of the flow is directly dependent on the opening cross-section in the flow con-
trol valve. The higher the scale value of the valve setting, the larger the cross-section in
the flow control valve and the higher the flow.

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 134 Project 16: Regenerative circuit Bosch Rexroth AG I R901385283

v
mm/s

40

35

30

25

20

15

10

0
0.5 1.0 1.2 1.4 1.6 1.8 2.0 2.2 SkW

KA Characteristic curve for extending the cylinder piston

KE Characteristic curve for retracting the cylinder piston
SkW Scale value on adjustable flow control valve
Flow-velocity characteristic curves of a differential cylinder

Switch off the hydraulic power unit before changing the setup for the sub­
sequent project steps!
CAUTION
Screw the pressure relief valve back to the minimum pressure setting!
Completely open the flow control valve (scale value 10)!
All manometers must show zero pressure!

Task 2 – Pressures and flows in a regenerative circuit:

16 1. Modify the setup according to circuit diagram 2 of project exercise 16, while taking
care to observe the general and project-specific safety instructions.
Ensure the correct mounting direction of the non-return valves (item 1.60, 1.70)!
Connect the manometer for setting/monitoring the operating pressure to the
measuring port of the distributor on the workstation and screw it hand-tight.

2. Switch on the hydraulic power unit of the workstation and check the constructed
circuit for any leakage.
All manometers must show zero pressure (except for the operating pressure display
on a WS200; see notes on using this workstation)!

3. Set the operating pressure at the pressure relief valve to 50 bar (manometer M1).

4. The piston of the hydraulic cylinder can be moved by actuating the 4/3 directional
control valve via the lever. The following applies to this valve version:
- Move the lever to the right (latches into position), connection P → A is established
- Move the lever to the left (latches into position), connection P → B is established

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 Bosch Rexroth AG I R901385283 Project 16: Regenerative circuit 135

5. Enter the measured values for manometer M1 and the observations made at the Measured
measuring glass for different extension states of the cylinder piston into the table. values

M1 M2 M3 Observation of fluid in measur-

Cylinder rod position
p1 in bar p2 in bar p3 in bar ing glass

Initial position

During extension

Extension end position

During retraction

Retraction end position

Switch off the hydraulic power unit after finishing the practical work!
Screw the pressure relief valve back to the minimum pressure setting!
CAUTION Completely open the flow control valve (scale value 10)
All manometers must show zero pressure!

Assessment of work results

„ In a regenerative circuit, hydraulic fluid is only returned to the tank ............................ 16
the cylinder piston.

„ In a regenerative circuit, the hydraulic fluid volume displaced on the piston rod side
during extension is fed back to the ......................................

„ The operating pressure decreases ................................. during extension than during

retraction.

„ In a regenerative circuit with a fixed displacement pump, the extension velocity of

the cylinder piston is ................................. than the retraction velocity.

„ In a regenerative circuit with a regulated hydraulic pump, the required ......................

.......................... can be reduced.

© Bosch Rexroth AG 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing as well as in the event of applications for industrial property rights. 97
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98
 Bosch Rexroth AG I R901385285 Project 20: Rapid traverse/creep speed circuit 395

Project 20: Rapid traverse/creep speed circuit

Project definition
At the end of a production line workpieces are to be pushed from a conveyor onto
a pallet. The pushing movement is realized with the help of a hydraulic cylinder.
To achieve short cycle times, the fastest possible motions (rapid traverse) for work-
piece transport and high positioning accuracy are required.
The workpiece transport should be completed by a positioning movement at reduced
speed (creep speed).
Due to changing workpiece weights this movement must be independent of the load.
The retraction of the cylinder piston is to be again carried out with maximum speed
(rapid traverse).

The hydraulic circuit diagram, the electric circuit diagram and parts list are needed so
that the customer can understand the proposed solution. Also needed is the character-
istic curve of the distance-time behavior of the proposed speed control.

Production line with hydraulic drive technology

Project tasks
20
„ Check customer requirements; organize implementation

„ Learn the speed control methods for differential cylinders

„ Learn the possibilities of using inductive proximity switches

„ Design of a rapid traverse/creep speed circuit

„ Development of characteristic curve for timing the speed control

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 396 Project 20: Rapid traverse/creep speed circuit Bosch Rexroth AG I R901385285

Project execution steps

„ Informing: - Accept and understand the assignment

- Check the design and condition of the workstation

„ Planning: - Planning and organizing of the project contract

- Read and assess the hydraulic circuit diagram
- Reading the electric circuit diagram
- Considerations for selecting the required hydraulic components
(i.e. including examination of the data sheets;
e.g. “RE 08103 – Standard speed controls”)

„ Deciding: - Select the required components

- Define connections between components
- Determination of measuring points

„ Executing: - Wiring of the electrical circuit according to current circuit

diagram
- Setup of the hydraulic circuit at the workstation
- Connect measuring points; secure inactive measuring points
- Placement of the proximity switch on the housing of the
hydraulic cylinder according to the task
- Capturing of characteristic values for the system behavior
- Documentation of required readings, possibly perform calculations

„ Checking: - Have all tasks for this project been completed?

„ Evaluating: - Do the results satisfy the project requirements?

- Are there other possible solutions satisfying the requirements
of the project task?
- Did any unexpected problems occur?

Notes

20

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 Bosch Rexroth AG I R901385285 Project 20: Rapid traverse/creep speed circuit 397

Safety information for the project exercise

All safety regulations must always be observed before and during execution of the
project, to ensure correct operation of the system and to recognize and avoid any
hazards presented by machines and the hydraulic system.

The system must always be checked to ensure that all components and assemblies
are correctly connected in a functionally safe manner according to the specified
exercise setup and that all unused ports are safely closed using suitable plugs. Leak-
age oil can drip from open ports onto the floor and present a slipping hazard. WARNING
When starting the system, hydraulic fluid can escape from open ports in a narrow
stream at high pressure, which can cause serious injuries (cutting jet).

General notes on setup of the hydraulic circuit:

Always check that all pressure control valves are set to minimum pressure (spring unloaded)
and all throttle valves are open before commissioning the hydraulic system, i.e. before switch-
ing on the hydraulic pump. All hydraulic accumulators that may be present must first be
depressurized.
The tank of the hydraulic power unit must also be checked to ensure that it contains the
correct amount of hydraulic fluid according to the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily plugged onto the cou-
pling plugs when all residual pressure has been removed from the workstation.
The following actions (depending on the exercise setup) are recommended in order to
remove all residual pressure from the workstation:
▶▶ Move the hydraulic cylinder with load unit to the lower limit stop.
▶▶ Hydraulically depressurize the hydraulic accumulator using the handwheel of the
unloading device.
▶▶ Screw on pressure reducing valve counterclockwise until reaching the end stop.
▶▶ Screw on throttle valve counterclockwise until reaching the end stop.
▶▶ Screw on pressure relief valve counterclockwise until reaching the end stop.
▶▶ Actuate the directional valve.

When setting up the hydraulic circuits the components are connected using hydraulic hose lines
with quick couplings. You can lightly turn the hose to check that the connection between the
hose and the component has latched securely into position.

Never use force!!!

General notes on working with hydraulic training systems:

20
Exercise caution when a system is pressurized and/or electrical voltage is present:
„ Do not release any line connections, ports or components when the exercise setup is
under pressure (also check any hydraulic accumulators that may be present)!
„ Do not connect or disconnect any electrical systems when the hydraulic power unit and/
or the exercise setup is connected to the electrical power supply!

Adjusting the settings of pressure relief valves and pressure switches on the exercise setup:
„ The workstation may only be operated with a maximum pressure of 50 bar!

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 398 Project 20: Rapid traverse/creep speed circuit Bosch Rexroth AG I R901385285

Parts list for hydraulic circuit diagram of project exercise 20

Rexroth
Item Quantity Designation Type
material number

1.10 1 Differential cylinder CD70F25/16-200 R961009526

1.20
2 4/2 directional control valve 4WE6C6X/ R961002547
1.21

1.30 1) 1 1)/0 Pressure relief valve DBDH6G1X/100 R961002520

1.40 1 2-way flow control valve 2FRM6B36-3X R961002546

1.50
2 Hydraulic distributor 4 ports R961002485
1.51
1.60
1.61 3 Manometer 0 to 100 bar R961002715
1.62
1.70 Hose line 1,000 mm
2 ZN10031-08-W90MM-1000 R961004330
1.71 with Minimess port
1.80
1.81
1.82
6 1)/5 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
1.83
1.84
1.85 1)
1)
... only required with the WS290 (DS4) workstation
Parts list of the hydraulic components for project exercise 20

Note:
This parts list describes the hydraulic components and accessories required for executing
this project exercise in conjunction with the suggested component arrangement.
The versions and quantities of the hose lines used correspond to the hose lines provided in
the associated Rexroth device set.

Measuring technology

1 Stopwatch, digital R900061256

Recommended additional measuring instruments for project exercise 20

20

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 Bosch Rexroth AG I R901385285 Project 20: Rapid traverse/creep speed circuit 399

Hydraulic circuit diagram for project exercise 20

20
Hydraulic circuit diagram for project exercise 20

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 400 Project 20: Rapid traverse/creep speed circuit Bosch Rexroth AG I R901385285

Parts list for electric circuit diagram of project exercise 20

Rexroth
Item Quantity Designation
material number
for WS290:
- Control unit “BIBB module for 19" installations” 1) R961009676
1
for WS200:
- Control unit “BIBB module in housing design” R961009678
B1
2 Proximity switch, inductive R961003106
B2
Solenoid cable with plug form A, black, with LED,
2 R901457044
with protective circuit

1 Measurement cable set, small R900029597

1)
... For the 19" version an additional adapter plate (R901384795) is required for the mains connection.
Parts list of the electric components for project exercise 20

Note:
Alternatively, the control unit can be replaced by interconnecting different control modules
from the range of electric components for Rexroth training systems (see catalog “Training
systems for hydraulics”, R999000178).

20

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 Bosch Rexroth AG I R901385285 Project 20: Rapid traverse/creep speed circuit 401

Electric circuit diagram for project exercise 20

Note:
By pressing the S2 button,
the self-retaining
and the interlocking
functions of the relay K1
are cleared.

RD ... red connection cable

BK ... black connection cable
BU ... blue connection cable 20
Electric circuit diagram of the project Exercise 20 (with color coding according to IEC 60757)

Note:
This electric circuit diagram is a sample solution using a Rexroth control unit.
If you use other electric components, the designations may vary.

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 402 Project 20: Rapid traverse/creep speed circuit Bosch Rexroth AG I R901385285

Arrangement of the hydraulic components

1.10
1.61 B1 B2
1.70
1.71
1.62

1.50 1.40

1.82 1.51
D
D

1.20 1.84
1.81
1.21
T

1.85 1)
T

D
1.30
1.301) 1.80 1.83
P
P
MP

1.60

1) Component of the WS200 workstation, not in the exercise setup

D Connection between two hydraulic components without a hose
(components directly coupled to each other)
Recommended arrangement of the hydraulic components for project exercise 20 (schematic representation)

Note:
The arrangement of the components (with item number as per the parts list) on a mount-
ing grid is specially designed for use on Rexroth workstations.
Position and design of the distributor (in this case MP/P/P/T/T) depend on the utilized
workstation and are not in general shown as above.

20

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 Bosch Rexroth AG I R901385285 Project 20: Rapid traverse/creep speed circuit 403

Project execution
Hang the required components and accessories in the workstation mounting grid
according to the table “Parts list of the hydraulic components for project exercise 20”
(see “Arrangement of the hydraulic components”).

Project execution steps

Setting up and testing the electrical control

Setting up the electrical control according to the electric circuit diagram of the project
exercise 20 by wiring the corresponding elements (create connections on the front panel
of the control unit and to the valve solenoids).

The functioning of the electrical circuit according to the project requirements is to be

tested in advance. For visualization of the switching status LEDs are built into the relay
and the valve plugs.

Functional testing of the electrical circuit:

„ Move switch S1 of the control unit to switch position “1” (ON)

„ By pressing the button S3 relay K1, and thus its self-retaining feature, is activated
(LED from relay K1 lights up).
„ At the same time the solenoid Y1 of the first 4/2 directional valve is electrified via
the K1 NO contact in current path 7 (LED on the controlled valve plug lights);
Directional control valve switches connection P → B
(Cylinder piston would extend)
„ If the piston rod has reached the position of the inductive proximity switch B1
(replicate by moving a metal object over B1), B1 switches resulting in:
- Relay K2, and thus its self-retaining feature, is activated (LED from relay K2 lights up).
- At the same time the solenoid Y2 of the second directional valve is electrified via
the K2 NO contact in current path 8 (LED on the controlled valve plug lights);
Directional control valve switches connection P → B
(Cylinder piston would continue to extend at reduced speed)

This switching status remains active even after disabling the proximity switch B1 by
the self-retaining relay K2.

„ If the piston rod has reached the position of the proximity switch B2 (replicate by
moving a metal object over B2), B2 switches resulting in:
- Relay K3, and thus its self-retaining feature, is activated (LED from relay K3 lights up).
- The self-retaining function of relay K1 and K2 will be deactivated by K3 NC contacts in
current paths 1 and 4; Relays return to the starting position and de-energize the valve
solenoids Y1 and Y2 (current paths 7 and 8 open again) 20
The return spring of the directional control valve push the respective valve piston back
into the starting position (connection P → A) and retract the cylinder piston again at
top speed.

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 404 Project 20: Rapid traverse/creep speed circuit Bosch Rexroth AG I R901385285

By pressing the button S3 the self-retaining feature of relay K3 can be removed (S3 NC
in current path 6). In addition, the control process described is restarted.
The switch S2 (reset) deactivates all relays that are located in the switching position,
independently of the switching state of the proximity switch.

Upon completion of the setup of the electrical control and, if necessary, the
carrying out of the functional test, the original state is to be returned to by
pushing the button S2 (reset). The switch S1 of the control unit remains in
position “1” (ON).

Further steps in the project implementation

1. Connect the hoses according to the circuit diagram for Project Exercise 20, while
taking care to observe the general and project-specific safety instructions.
Connect the manometer for setting/monitoring the operating pressure to the
measuring connection of the distributor on the workstation and screw it hand-tight.
The initial position of the cylinder piston is the retracted state.

2. Mount the inductive proximity switch B1 onto the retaining profile of the hydraulic
cylinder centered at scale value 150 mm (graduated scale on the protective hood of
the hydraulic cylinder).
Mount the inductive proximity switch B2 centered at scale value 195 mm.

3. Switch on the hydraulic power unit of the workstation and check the hydraulic
setup for any leakage.

4. Set the operating pressure at the pressure relief valve to 30 bar (manometer M1).

5. Set the flow control valve (item 1.40) to scale setting 1.0.

6. Actuate the directional control valve (press button S3), connection P → B is established.
While the cylinder piston is in motion, collect the required values and write them
down in the following table:
-Extension time of the cylinder piston and pressures M2 and M3 to position B1
(rapid traverse)
- Extension time of the cylinder piston and pressures M2 and M3 from position B1
to position B2 (creep speed)
- Retraction time of the cylinder piston and pressures M2 and M3 from position B2
back to the starting position (return stroke at rapid traverse speed)

20 By pressing the S3 button again, the movement of the hydraulic cylinder can be repeated.

7. Set the flow control valve (item 1.40) to scale setting 1.5.

8. Repeat step 6 with changed setting of the flow control valve.

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 Bosch Rexroth AG I R901385285 Project 20: Rapid traverse/creep speed circuit 405

Measured
Scale value 1) at Motion Travel
M3 M2 values
the flow control Cylinder movement time distance
p3 in bar p2 in bar
valve t in s s in mm

Feed (rapid traverse)

Positioning
1.0
(creep speed)
Return stroke
(rapid traverse)

Feed (rapid traverse)

Positioning
1.5
(creep speed)
Return stroke
(rapid traverse)
1)
... The scale values on the 2-way flow control valve represent pre-defined opening cross-sections
in the valve, where each setting allows a defined flow.

Using the values obtained, the path-time characteristic curve of the hydraulic cylinder
used is to be created for both flow control valve settings.

s
mm
250

200

150

100

50

0 t
2 4 6 8 10 s
1 Feed (rapid traverse) 1.0 Characteristic curve for flow control valve setting 1.0
2 Positioning (creep speed) 1.5 Characteristic curve for flow control valve setting 1.5
3 Return stroke (rapid traverse) B1, B2 Switching points of the proximity switches
Path-time characteristic curve of a differential cylinder with speed control
20

Switch off the hydraulic power unit after finishing the practical work and
turn off the switch S1 of the control unit!
CAUTION
Screw the pressure relief valve back to the minimum pressure setting!
No pressure is to be shown on the manometer!

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 406 Project 20: Rapid traverse/creep speed circuit Bosch Rexroth AG I R901385285

Assessment of work results

„ Electrically operated directional valves can be controlled with ...................................
..................

„ With a ................................................, the extension velocity can be changed inde-

pendently of the load (values of the manometer M3 will not change when changing
the scale setting of the flow control valve).

„ In the feed, the piston of the hydraulic cylinder extends at ................................... (pump
flow).

„ At creep speed, the piston of the hydraulic cylinder extends at ..................................

due to the setting of the flow control valve.

„ During return stroke, the piston of the hydraulic cylinder retracts at ..........................
................ (pump flow).

„ During extension, .................................................. arises when the flow rate on the

piston rod side is throttled.

Notes

20

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Bosch Rexroth AG I R901441854 Exercise 01: Command value preset by potentiometer 87

Exercise 01: Moving a cylinder piston on the basis 01

of a command value presetting by a
potentiometer

Topic of the exercise

Prior to commissioning, a still unknown hydraulic press must be checked for its
functionality. To this end, the machine must initially be controlled on the basis of
manually specified command values. By monitoring the machine, the correlation
between the control functions and the machine behavior is to be determined.
The purpose of this exercise is to determine the relation between the manual
command values specified by a potentiometer and the resulting motion velocity
of a cylinder piston.

Assembly with potentiometer as set-point adjuster in a 19-inch front plate

Exercise contents
▶ Checking the valve function by measuring command value and actual value

▶ Determining the value of the command value voltage when the cylinder piston starts
moving (identifying the overlap of the valve spool)

▶ Checking the command value polarities and their effect

▶ Determining the correlation between the command value and the motion time of the
cylinder piston

▶ Gaining knowledge of the functionality of proportional directional control valves

▶ Learning and understanding the proportionality of command value, opening cross-

section, flow and resulting motion velocity

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111
 88 Exercise 01: Command value preset by potentiometer Bosch Rexroth AG I R901441854

01
Learning path for exercise execution
„ Informing: - Accepting and understanding the order
- Checking the setup and state of the workstation

„ Planning: - Planning and organizing the exercise execution

- Reading and evaluating the hydraulic circuit diagram
- Reflecting on the selection of the required hydraulic
components (e.g. by consulting data sheets)

„ Deciding: - Selecting the required components

- Defining connections between the components
- Defining measuring points

„ Executing: - Wiring of the electric circuit according to the electric block

circuit diagram
- Setting up the hydraulic circuit at the workstation
- Connecting the measuring points; securing inactive measuring
points
- Working through the tasks; determining the required values
- Documenting the required measured values; making
calculations, if necessary
- Determining the required characteristic command value -
velocity curve

„ Checking: - Is the desired direction of motion of the cylinder piston

achieved with the specified command value polarity?
- Are all tasks assigned to this exercise completed?

„ Evaluating: - Do the results match the tasks assigned to this exercise?
- Are there other possible solutions to complete the tasks
assigned to this exercise?
- Did any unpredictable problems occur?

Notes

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112
Bosch Rexroth AG I R901441854 Exercise 01: Command value preset by potentiometer 89

01
Safety instructions for exercise execution
To ensure operating efficiency and to detect and avoid possible dangers of machines
and systems, the relevant safety regulations must be observed before and during
exercise execution.

It must be ensured that all components and assemblies are connected according to
the specified exercise setup in a fail-safe manner and that all ports which are not
required are securely closed with appropriate plugs.
Leakage oil can drop onto the floor through non-closed ports and create a slip WARNING
hazard.
During commissioning, there is a danger that hydraulic fluid could stream out
through non-closed ports and lead to severe injuries (cutting jet).

General notes on the setup of the hydraulic circuit:

Prior to commissioning the hydraulic control, i. e. prior to starting the hydraulic pump,
it must be checked that all pressure control valves are set to minimum pressure (unloaded
spring) and all throttle valves have been opened. If hydraulic accumulators are available,
they must be hydraulically unloaded.
It must also be checked whether the hydraulic fluid in the tank of the hydraulic power unit
corresponds to that specified in the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily slipped on the
coupling plugs if the residual pressure of the workstation has been relieved.
To relieve the residual pressure of the workstation, the following actions are
recommended:
▶▶ Completely relieve all pressure relief valves (counter-clockwise).
▶▶ Actuate all directional control valves.

To set up hydraulic circuits, the components are connected by hydraulic hoses with
quick couplings. By slightly twisting the hoses, it can be checked whether the connection
between hose and component has securely clicked into place.

Never use force!!!

General notes on the work at hydraulic training systems:

Caution if the system is pressurized or energized:

„ Do not loosen any line connections, ports or components as long as the exercise setup
is under pressure (observe the hydraulic accumulator, if applicable)!
„ Do not establish or disconnect any electrical connections as long as the hydraulic power
unit and the exercise setup are connected to the power supply!

Setting of pressure relief valves and pressure switches of the exercise setup:
„ The workstation may only be operated at a maximum pressure of 50 bar!

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113
 90 Exercise 01: Command value preset by potentiometer Bosch Rexroth AG I R901441854

01
Parts list for the hydraulic circuit diagram of exercise 01

Rexroth
Item Quantity Designation Type
material number

1.10 1 Differential cylinder CD70F25/16-400 R961003495

4/3 proportional directional

control valve
1.20 1 4WREE6E08-2X/ R961003533
(assembly with load
simulation)

1.30 1 Pressure relief valve DBDH6G1X/100 R961002520

1.40 1 Non-return valve S6A05-1X/ R901462818

1.50
1.51 3 Manometer 0 to 100 bar R961002715
1.52
1.60 Hose line 1000 mm with
2 ZN10031-08-W90MM-1000 R961004330
1.61 Minimess port
1.70
1.71
4 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
1.72
1.73
Parts list of the hydraulic components for exercise 01

Note:
This parts list indicates the hydraulic components and accessories required to perform
this exercise in conjunction with the associated component arrangement.
The design and number of the hose lines used match the inventory in the corresponding
Rexroth device set.

Measurement technology

1 Multimeter VC175 R913038027

1 Stop watch, digital R900061256

Recommended additional measurement technology for exercise 01

Notes

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114
Bosch Rexroth AG I R901441854 Exercise 01: Command value preset by potentiometer 91

01
Hydraulic circuit diagram for exercise 01

Hydraulic circuit diagram of exercise 01

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115
 92 Exercise 01: Command value preset by potentiometer Bosch Rexroth AG I R901441854

01
Parts list for the electric block circuit diagram of exercise 01

Rexroth
Item Quantity Designation
material number
Control unit "BIBB module"
1 R961009676
(module for 19-inch assembly carrier)

Adapter plate with switch and cold-device socket

1 R901384795
(module for 19-inch assembly carrier)

Set-point adjuster ±10 V with polarity switching

1 R961009632
(potentiometer module for 19-inch assembly carrier)

Adapter plate with 7-pole socket for valve connection

1 R961009630
(module for 19-inch assembly carrier)

Display unit with 2 display fields

1 R961009623
(module for 19-inch assembly carrier)

7-pole cable, to connect continuous control valves with

1 R961003550
integrated electronics

1 Cable set, large, 4 mm measuring lines R900021502

Cable set for command/actual value measurement,

1 R901461031
2 mm/2 mm and 2 mm/4 mm

Parts list of the electric components for exercise 01

Note:
This parts list indicates the electric components and accessories required to perform this
exercise in conjunction with the associated electric block circuit diagram.
Any components indicated and the required accessory elements (including cables) are
included in the corresponding Rexroth device set "Continuous control valve technology -
Proportional hydraulics, complete" (Material number R901386162).

Notes

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116
Bosch Rexroth AG I R901441854 Exercise 01: Command value preset by potentiometer 93

01
Electric block circuit diagram for exercise 01
Display unit

R961009623
Voltage supply
Umax ±20 V DC

Umax ±20 V DC
Reference

Reference
Display 1

Display 2

+24 V DC
0V

b
- (C)

- (B)
- (E)
valve connection
Adapter plate for

Command value

Voltage supply

b
R961009630
Actual value

24 V DC

T
B
10 V

10 V

0
D
A

E
F

P
A

a
output
Valve

+ (A)
+ (D)

+ (F)

a
0 Reference
Command value output
± 10V

-
Set-point adjuster
(potentiometer)

Voltage supply

R961009632
-

24 V DC
+

+24 V
0V

Electric block circuit diagram for exercise 01

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117
 94 Exercise 01: Command value preset by potentiometer Bosch Rexroth AG I R901441854

01
Arrangement of the hydraulic components

1.10

1.51 1.52

1.61 1.60

MX

1.73
1.20
LS

1.72
T1

1.70 D
1.40
P1 T2
MP

D
1.30
P3 P2

1.71

1.50

D Connection of two hydraulic components without hose (components coupled directly)

Recommended arrangement of the hydraulic components for exercise 01 (schematic illustration)

Note:
The component arrangement (with item number acc. to parts list) on a mounting grid is
tailored to the use with the Rexroth workstation.

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118
Bosch Rexroth AG I R901441854 Exercise 01: Command value preset by potentiometer 95

01
Exercise execution

Hook the components and accessories required according to the table "Parts list of
the hydraulic components for exercise 01" into the mounting grid of the workstation
(see "component arrangement").

Action steps for exercise execution

Setup of the electrical control

Set up the electrical control according to the block diagram of this exercise by wiring
the appropriate elements (establish connections at the front side of the 19-inch
modules and to the proportional directional control valve).

Note:
The yellow sockets at the front plates of the 19-inch modules are intended for ±10 V signal
voltage only. Do not connect them to a voltage of 24 V under any circumstance!
This might damage electronic components.

Setup of the hydraulics and check of the electric valve function

1. Connect the hoses according to the hydraulic circuit diagram of exercise 01.
Observe the general and exercise-specific safety instructions.
Connect the manometer which is used to set/check the working pressure to the
measuring port (MP1) of the distributor of the workstation and screw it on
hand-tight. Screw on the measuring lines of the other manometers at the Minimess
port of each hydraulic hose hand-tight.

The hydraulic working pressure is not yet required; therefore, the hydraulic pump
of the workstation is not yet switched on.

2. Connect the operating voltage of the electrical control.

For voltage measurements, the signal (±10 V) must generally be measured against
a reference ( ). Regarding the measuring points on the adapter plate, the
sockets D (±10 V) and E ( ) are used for the command value and the
sockets F (±10 V) and C ( ) are used for the actual value.
Use the set-point adjuster (potentiometer) to set the command value presetting
beginning with 0 V to +10 V ("positive" polarity).

3. The voltage values can be monitored on the display unit. Command value
(display 1) and actual value (display 2) must always have the same value (±0.05 V).
If the actual value considerably differs from the command value, there is a fault in
the electrical setup, in the hydraulic valve, or in the valve electronics.

4. Set the command value presetting beginning with 0 V to -10 V with "negative"
polarity at the set-point adjuster (potentiometer) and monitor the values on the
displays.

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119
 96 Exercise 01: Command value preset by potentiometer Bosch Rexroth AG I R901441854

01
Moving the cylinder piston on the basis of the command value presetting

1. First rotate the command value potentiometer on the set-point adjuster assembly
to the left stop (0 V) and set the switch for polarity to the "0" position.
Thus, a premature motion of the cylinder piston is avoided once pressure has built
up in the hydraulic system.

2. Set the pressure relief valve (pos. 1.30) for the working pressure to minimum
pressure (screw out the adjustment element counter-clockwise).

3. Set the pressure relief valve for the load simulation of the assembly of the 4/3
directional control valve (pos. 1.20) to minimum pressure (screw out the
adjustment element counter-clockwise to the stop).

4. Switch on the hydraulic power unit of the workstation.

5. Establish the hydraulic connection from the hydraulic pump to the exercise setup
at the workstation below the P/T/X distributor using the 3-way ball valve.
→  Move the lever to a horizontal position
Check the setup for possible leakage.
No manometer may display any pressure!

6. Set the working pressure at the pressure relief valve (pos. 1.30) to 20 bar (M1).

7. Switch the polarity switch ("+/-") of the set-point adjuster to positive polarity.
Use the potentiometer to slowly increase the command value starting with 0 V.
Monitor the value at which the cylinder piston starts moving.

8. Keep increasing the command value slowly while monitoring the velocity of the
piston motion.

9. Change the direction of motion of the cylinder piston by switching the polarity
switch ("+/-").
The cylinder piston is to retract with negative command values.

Notes:
If the cylinder piston does not extend with positive command values, the hoses of the
working ports A and B of the valve at the hydraulic cylinder are mixed up, or the poles at
the command value input (D, E) of the valve port are reversed. Ensure the correct polarity
when monitoring the display unit for the command value/actual value display.
The measuring points for the command value of the valve are connected to the output
sockets of the set-point adjuster.

Possible fault causes (applicable to all exercises of this book):

▶▶ Actual value always 0 V
→ Valve electronics defective; no voltage supply
▶ Actual value remains at constant voltage value (e.g. 2.7 V)
→ Control spool blocked in the valve housing
▶ Command value and actual value have different algebraic signs
→ Wiring fault (polarity)

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120
Bosch Rexroth AG I R901441854 Exercise 01: Command value preset by potentiometer 97

01
10. Set the command value to -1.5 V (display 1) with the cylinder piston completely
retracted. Then turn the polarity switch to the "0" position.

11. Set the working pressure at the pressure relief valve (pos. 1.30) to 50 bar (M1).
The pressure relief valve for the load simulation of the assembly of the 4/3
directional control valve (pos. 1.20) remains at minimum pressure.

12. Turn the polarity switch to the "+" position and extend the cylinder piston by
setting a command value of +1.5 V. The extension times for the complete piston
stroke must be measured with the stop watch.
The completely retracted cylinder piston is the starting position; the end position is
reached when the piston is completely extended.

13. Retract the cylinder piston by setting a negative command value (polarity switch at
position "–"); then repeat the process beginning with action step 12 applying the
further command values listed in the table below.

Enter the measured values for the extension time in themeasurement table.
Then calculate the velocity of the extension motion as a function of the command value
presetting and enter the results in the measurement table.
Create a characteristic command value - velocity curve on the basis of the preset and
calculated values.

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121
 98 Exercise 01: Command value preset by potentiometer Bosch Rexroth AG I R901441854

01
Measured Specification: Total stroke of the cylinder piston s=4
 00 mm
values (according to the data sheet)

Motion time of the cylinder

Specified command value w Velocity of the cylinder piston
piston
Ucommand in V v in mm/sec
t in sec

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

6.0

8.0

10.0

v
mm/s
260
240
220
200
180
160
140
120
100
80
60
40
20
w
0 1 2 3 4 5 6 8 9 10 V

Characteristic command value - velocity curve of the proportional directional control valve

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122
Bosch Rexroth AG I R901441854 Exercise 01: Command value preset by potentiometer 99

01
When the practical work is completed, switch off the hydraulic power unit!
Close the 3-way ball valve to the workstation (lever in vertical position)!
CAUTION
Control one proportional directional control valve after the other with
positive and negative command values in order to relieve the residual
pressure from the connecting lines to the actuator!
Turn the pressure relief valves back to minimum pressure!
No manometer may display any pressure!
Switch off the main switch of the electrical voltage supply!

Evaluating the work results

▶ From ................................................................, the cylinder piston has moved
considerably.

▶ Motion is not possible at any lower command value voltage since the control spool
of the directional control valve has .............................................. of approx. 15%.

▶ The ................................................... in the proportional directional control valve

increases with increasing command value.

▶ The flow through the valve and thus the motion velocity of the cylinder piston
increases ............................................ with increasing opening cross-section.

▶ The maximum velocity of the cylinder piston is limited by the .....................................

................... of the hydraulic pump. This limitation starts with a command value of
............................ and becomes apparent due to the "collapsing" ...............................

▶ The direction of motion of the cylinder piston depends on .........................................

................, which determines the direction of motion .................................................
and thus ................................... through the directional control valve to the actuator.

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123
 100 Exercise 01: Command value preset by potentiometer Bosch Rexroth AG I R901441854

01
Notes

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124
Bosch Rexroth AG I R901441854 Exercise 02: Command value preset by command value module 101

Exercise 02: Moving a cylinder piston on the basis

of a command value presetting by
a command value module 02

Topic of the exercise

Different alternatives for the electric control of a proportional directional control valve
must be examined for the upgrade of the hydraulic drive of the press. As an alternative
for the command value presetting by a potentiometer, the use of an analog command
value module must be checked.
To document the advantages of this technology, information on the functions and
possible signal sequences of the command value module VT-SWMA-1 must be
collected.

Assembly with the analog command value module VT-SWMA-1 in a 19-inch front plate

Exercise contents
▶ Getting to know and understand the functions of the command value module
VT-SWMA-1

▶ Setting of different command value voltages in the command value module

▶ Calling up a preset command value by means of an electric signal

▶ Checking the command value polarities

▶ Applying command value inverting

▶ Measuring the command value voltage at the measuring sockets of the command
value module

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125
 102 Exercise 02: Command value preset by command value module Bosch Rexroth AG I R901441854

02 Learning path for exercise execution

„ Informing: - Accepting and understanding the order
- Checking the setup and state of the workstation

„ Planning: - Planning and organizing the exercise execution

- Reading and evaluating the hydraulic circuit diagram
- Reflecting on the selection of the required hydraulic
components (e.g. by consulting data sheets)

„ Deciding: - Selecting the required components

- Defining connections between the components
- Defining measuring points

„ Executing: - Wiring of the electric circuit according to the electric block

circuit diagram
- Setting up the hydraulic circuit at the workstation
- Connecting the measuring points; securing inactive measuring
points
- Working through the tasks; determining the required values

„ Checking: - Is the desired direction of motion of the cylinder piston

achieved with the specified command value polarity?
- Are all tasks assigned to this exercise completed?

„ Evaluating: - Do the results match the tasks assigned to this exercise?
- Are there other possible solutions to complete the tasks
assigned to this exercise?
- Did any unpredictable problems occur?

Notes

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126
Bosch Rexroth AG I R901441854 Exercise 02: Command value preset by command value module 103

Safety instructions for exercise execution 02

To ensure operating efficiency and to detect and avoid possible dangers of machines
and systems, the relevant safety regulations must be observed before and during
exercise execution.

It must be ensured that all components and assemblies are connected according
to the specified exercise setup in a fail-safe manner and that all ports which are not
required are securely closed with appropriate plugs.
Leakage oil can drop onto the floor through non-closed ports and create a slip WARNING
hazard.
During commissioning, there is a danger that hydraulic fluid could stream out
through non-closed ports and lead to severe injuries (cutting jet).

General notes on the setup of the hydraulic circuit:

Prior to commissioning the hydraulic control, i. e. prior to starting the hydraulic pump,
it must be checked that all pressure control valves are set to minimum pressure (unloaded
spring) and all throttle valves have been opened. If hydraulic accumulators are available,
they must be hydraulically unloaded.
It must also be checked whether the hydraulic fluid in the tank of the hydraulic power unit
corresponds to that specified in the operating instructions.

When setting up the hydraulic circuit, the hose couplings can be easily slipped on the
coupling plugs if the residual pressure of the workstation has been relieved.
To relieve the residual pressure of the workstation, the following actions are
recommended:
▶▶ Completely relieve all pressure relief valves (counter-clockwise).
▶▶ Actuate all directional control valves.

To set up hydraulic circuits, the components are connected by hydraulic hoses with
quick couplings. By slightly twisting the hoses, it can be checked whether the connection
between hose and component has securely clicked into place.

Never use force!!!

General notes on the work at hydraulic training systems:

Caution if the system is pressurized or energized:

„ Do not loosen any line connections, ports or components as long as the exercise setup
is under pressure (observe the hydraulic accumulator, if applicable)!
„ Do not establish or disconnect any electrical connections as long as the hydraulic power
unit and the exercise setup are connected to the power supply!

Setting of pressure relief valves and pressure switches of the exercise setup:
„ The workstation may only be operated at a maximum pressure of 50 bar!

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127
 104 Exercise 02: Command value preset by command value module Bosch Rexroth AG I R901441854

02 Parts list for the hydraulic circuit diagram of exercise 02

Rexroth
Item Quantity Designation Type
material number

1.10 1 Differential cylinder CD70F25/16-400 R961003495

4/3 proportional directional

control valve
1.20 1 4WREE6E08-2X/ R961003533
(assembly with load
simulation)

1.30 1 Pressure relief valve DBDH6G1X/100 R961002520

1.40 1 Non-return valve S6A05-1X/ R901462818

1.50
1.51 3 Manometer 0 to 100 bar R961002715
1.52
1.60 Hose line 1000 mm with
2 ZN10031-08-W90MM-1000 R961004330
1.61 Minimess port
1.70
1.71
4 Hose line 630 mm ZN10031-08-W00NN-630 R961002474
1.72
1.73
Parts list of the hydraulic components for exercise 02

Note:
This parts list indicates the hydraulic components and accessories required to perform
this exercise in conjunction with the associated component arrangement.
The design and number of the hose lines used match the inventory in the corresponding
Rexroth device set.

Measurement technology

1 Multimeter VC175 R913038027

1 Stop watch, digital R900061256

Recommended additional measurement technology for exercise 02

Notes

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128
Bosch Rexroth AG I R901441854 Exercise 02: Command value preset by command value module 105

Hydraulic circuit diagram for exercise 02 02

Hydraulic circuit diagram of exercise 02

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129
 106 Exercise 02: Command value preset by command value module Bosch Rexroth AG I R901441854

02 Parts list for the electric block circuit diagram of exercise 02

Rexroth
Item Quantity Designation
material number
Control unit "BIBB module"
1 R961009676
(module for 19-inch assembly carrier)

Adapter plate with switch and cold-device socket

1 R901384795
(module for 19-inch assembly carrier)

Analog command value module VT-SWMA-1

1 R961009631
(module for 19-inch assembly carrier)

Adapter plate with 7-pole socket for valve connection

1 R961009630
(module for 19-inch assembly carrier)

Display unit with 2 display fields

1 R961009623
(module for 19-inch assembly carrier)

7-pole cable, to connect continuous control valves with

1 R961003550
integrated electronics

1 Cable set, large, 4 mm measuring lines R900021502

Cable set for command/actual value measurement,

1 R901461031
2 mm/2 mm and 2 mm/4 mm

Parts list of the electric components for exercise 02

Note:
This parts list indicates the electric components and accessories required to perform this
exercise in conjunction with the associated electric block circuit diagram.
Any components indicated and the required accessory elements (including cables) are
included in the corresponding Rexroth device set "Continuous control valve technology -
Proportional hydraulics, complete" (Material number R901386162).

Notes

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130
 S1
+24 V 13 14
Bosch Rexroth AG

13 13
I

14 14 Display unit
S2 S3 Assembly with command
value module SWMA-1 Adapter plate for
valve connection Display 1
Differential input Output Command value Umax ±20 V DC
± 10V ±10 V control output + (D) 10 V - (E) Reference
R901441854

Reference Reference Actual value

Electric block circuit diagram for exercise 02

Display 2
Command value call-ups + (F) 10 V - (C) Umax ±20 V DC
4
Reference
3 7 8 9 10 11 12 A
Valve F B
2 Voltage supply
E C
REXROTH output D
1 VT-SWMA-1-xx
+24 V DC
4-Q Inv 0V
4-quadrants operation
t1 w1 Voltage supply
4-Q t2 w2 R961009623
t3 w3 + (A) 24 V DC - (B)
Inverting t4 w4
t5 G
R961009630
Inv
Electric block circuit diagram for exercise 02

Z
t w
Voltage supply
+24 V DC
1 2 3 4 5 6
0V A B
G

R961009631 a 0 b

of applications for industrial property rights. Distribution only for training purposes with indication of source.
a b
P T

+24 V
0V

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Exercise 02: Command value preset by command value module
107

131
02
 108 Exercise 02: Command value preset by command value module Bosch Rexroth AG I R901441854

02 Arrangement of the hydraulic components

1.10

1.51 1.52

1.61 1.60

MX

1.73
1.20
LS

1.72
T1

1.70 D
1.40
P1 T2
MP

D
1.30
P3 P2

1.71

1.50

D Connection of two hydraulic components without hose (components coupled directly)

Recommended arrangement of the hydraulic components for exercise 02 (schematic illustration)

Note:
The component arrangement (with item number acc. to parts list) on a mounting grid is
tailored to the use with the Rexroth workstation.

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132
Bosch Rexroth AG I R901441854 Exercise 02: Command value preset by command value module 109

Exercise execution 02
Hook the components and accessories required according to the table "Parts list of
the hydraulic components for exercise 02" into the mounting grid of the workstation
(see "component arrangement").

Action steps for exercise execution

Setup of the electrical control

Setting up the electrical control according to the block diagram of this exercise by
wiring the appropriate elements (establishing connections at the front side of the
control unit, the 19-inch modules and to the proportional directional control valve).

Note:
The yellow sockets at the front plates of the 19-inch modules are intended for ±10 V signal
voltage only. Do not connect them to a voltage of 24 V under any circumstance! This might
damage electronic components.

Default setting and test of the command values

Note:
Without the activation of a command value, the command value voltage must be 0 V.
Any display of a voltage ≠0 V indicates that the zero point potentiometer "Z" was not set
precisely at the command value module. In this case, the display value must be recalibrated
to 0 V using this potentiometer.

1. Set all potentiometers of the command value module ("w1"..."w4", "t1"..."t5") to

0 V (counter-clockwise rotation until it stops or until a click sound is heard).

2. Connect the control voltage by turning switch S1 of the control unit to switching
position "1" (ON).

3. Test the command value "w1" from 0 V to 10 V with positive and negative polarity
at the command value module. To this end, call-up "1" must be activated
(keep push button S3 pressed).
To change the command value polarity, the "Inv" input (inverting) must also be
activated with push button S2 (keep push button S2 pressed).

4. The voltage values can be read from the display unit or the multimeter.

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133
 110 Exercise 02: Command value preset by command value module Bosch Rexroth AG I R901441854

02 Setup and activation of the hydraulic circuit

1. Connect the hoses according to the hydraulic circuit diagram of exercise 02. Observe
the general and exercise-specific safety instructions.
Connect the manometer which is used to set/check the working pressure to the
measuring port (MP1) of the distributor of the workstation and screw it on hand-tight.
Screw on the measuring lines of the other manometers at the Minimess port of each
hydraulic hose hand-tight.

2. Make sure that a value of 0 V is set for the command value "w1" and that the electrical
zero point has not shifted (if necessary, adjust it with potentiometer "z" at the
command value module).
This prevents a premature, unintended motion of the cylinder piston once pressure
has built up in the hydraulic system.

3. Set the pressure relief valve (pos. 1.30) for the working pressure to minimum
pressure (screw out the adjustment element counter-clockwise).

4. Set the pressure relief valve for the load simulation of the assembly of the
4/3 directional control valve (pos. 1.20) to minimum pressure (screw out the
adjustment element counter-clockwise to the stop).

5. Switch on the hydraulic power unit of the workstation.

6. Establish the hydraulic connection from the hydraulic pump to the exercise setup
at the workstation below the P/T/X distributor using the 3-way ball valve.
→  Move the lever to a horizontal position
Check the setup for possible leakage.
No manometer may display any pressure!

7. Set the working pressure at the pressure relief valve (pos. 1.30) to 50 bar (M1).

Moving the cylinder piston on the basis of the command value module
presetting

1. Activate the command value "w1" by pressing push button S3 and keeping it pressed.

2. Beginning with 0 V, slowly increase the command value "w1" with positive polarity
at the command value module until the cylinder piston starts extending.
Completely extend the piston and monitor the velocity.
Before increasing the command value the next time, the cylinder piston must be
completely retracted; see action step 3.

3. For retracting the cylinder piston, the polarity of the command value must be
reversed. To this end, activate the input "Inv" of the command value module using
push button S2 (keep push button S2 pressed).
→  With negative polarity and sufficiently large command value, the cylinder piston
will retract.

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Bosch Rexroth AG I R901441854 Exercise 02: Command value preset by command value module 111

4. Alternating between extension and retraction with increased command value, the 02
effects on the extension and retraction speed of the cylinder piston must be
monitored (if necessary, use a stop watch to this end and compare the velocities).

When the practical work is completed, switch off the hydraulic power unit!
Close the 3-way ball valve to the workstation (lever in vertical position)!
CAUTION Control one proportional directional control valve after the other with
positive and negative command values in order to relieve the residual
pressure from the connecting lines to the actuator!
Turn the pressure relief valves back to minimum pressure!
No manometer may display any pressure!
Switch off the control voltage using switch S1!
Switch off the main switch of the electrical voltage supply!

Evaluating the work results

▶ The command values are preset at the command value module ..................................

▶ To activate (call up) the command values, ................................... must be connected

to each input.

▶ To reverse the command value polarity, the signal input "......................................" is

activated.

▶ The current command value can be directly measured at the command value module
at ...........................................................

▶ The LED "w1" lights up if ......................................... is active.

▶ If no command value is activated, the command value voltage must be .....................

Any differing value can be corrected with .................................

▶ If only one command value is used and if the inverting function is active, the value of
the command value voltages is ...........................

▶ Due to ........................................................ at the cylinder piston, the extension and

retraction velocities are different even if the command value voltages are equal.

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