Bosch Rexroth UPE2 Operating instructions

Operating instructions
RE 51150-B/07.11
Material no. R901310980
Replaces: -
English
General operating instructions for clamping
and drive modules and drive modules with
and without control modules

The data specified below only serve to describe
the product. Any information with regard to use
only refers to application examples and recom-
mendations. Data available in catalogs are no
guaranteed characteristics. The information given
does not exempt the user from making own evalu-
ations and tests. Our products are subject to a
natural process of wear and aging.
© This document, as well as the data, specifica-
tions and other information set forth in it, are the
exclusive property of Bosch Rexroth AG. It may
not be reproduced or given to third parties without
its consent.
The cover shows an example configuration. The
product supplied may therefore differ from the
photo shown.
The original operating instructions were prepared
in German.

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Content
1 About this documentation........................................................................5
1.1 Validity of the documentation ......................................................................5
1.2 Necessary and amending documentation...................................................5
1.3 Illustration of information .............................................................................6
1.3.1 Safety instructions..............................................................................................................6
1.3.2 Symbols ..............................................................................................................................7
1.3.3 Abbreviations......................................................................................................................7
2 Safety instructions....................................................................................8
2.1 General information on this chapter ............................................................8
2.2 Intended use ...............................................................................................8
2.3 Improper use ...............................................................................................9
2.4 Qualification of personnel............................................................................9
2.5 General safety instructions..........................................................................9
2.6 Product- and technology-related safety instructions .................................10
2.7 Safety equipment ......................................................................................11
2.8 Obligations of the machine manufacturer .................................................11
2.9 Obligations of the operator........................................................................12
3
General warnings of damage to property and damage to the product .. 13
4 Scope of delivery ....................................................................................15
5 Information on this product ...................................................................16
5.1 Performance description ...........................................................................16
5.2 Product description ...................................................................................16
5.3 Interfaces ..................................................................................................19
5.3.1 Hydraulic connections .....................................................................................................19
5.3.2 Electrical connections ......................................................................................................21
5.4 Product identification.................................................................................23
6 Transport and storage ............................................................................25
6.1 Transporting drive modules.......................................................................25
6.1.1 Preparing the drive module for transport.......................................................................25
6.1.2 Manual transport ..............................................................................................................25
6.1.3 Transport using forklifts and similar floor conveyors ....................................................25
6.1.4 Transport by means of lifting gear and attachment points ..........................................26
6.1.5 Freight transport ...............................................................................................................28
6.2 Storing drive modules ...............................................................................28
7 Assembly .................................................................................................29
7.1 Unpacking .................................................................................................29
7.2 Drive module assembly.............................................................................29
7.3 Hydraulically connecting the drive module................................................29
7.4 Connecting to the water supply.................................................................30
7.5 Connecting the electric supply ..................................................................30
7.5.1 Earthing and potential equalization................................................................................30
7.5.2
Laying the power supply and control cables and connecting the electricity supply ...30
7.5.3 Installing the electrical control and monitoring equipment...........................................30
8 Commissioning .......................................................................................31
8.1 First commissioning ..................................................................................31
8.1.1 Before commissioning.....................................................................................................31
8.1.2 Valve settings ...................................................................................................................31
8.1.3 Safe handling of pressure tapping points......................................................................32
8.1.4 Accumulator......................................................................................................................32
8.1.5 Filling the hydraulic system .............................................................................................33
8.1.6 Activating the electric supply...........................................................................................33
8.1.7 Bleeding the complete hydraulic system of the machine............................................33
8.1.8 Commissioning.................................................................................................................34
8.1.9 Flushing the hydraulic system ........................................................................................34
8.1.10 The most frequent errors during commissioning..........................................................35
8.2 Re-commissioning after extended standstill..............................................36
Content

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9 Operation .................................................................................................37
10 Maintenance and repair ..........................................................................39
10.1 Maintenance documentation .....................................................................39
10.2 Inspection, maintenance, repair ................................................................39
10.2.1 Filling level.........................................................................................................................40
10.2.2 Oil temperature (optional)................................................................................................40
10.2.3 Filter clogging indicator (optional)...................................................................................41
10.2.4 Pressure values................................................................................................................42
10.2.5 Oil maintenance ...............................................................................................................42
10.2.6 Hydraulic accumulator ....................................................................................................42
10.2.7 Hose lines .........................................................................................................................43
10.2.8 Piping ................................................................................................................................44
10.2.9 Heat exchanger (UPE5)..................................................................................................44
10.2.10 External inspection of the tank........................................................................................45
10.3 Repair........................................................................................................46
10.4 Spare and wear parts................................................................................46
11 Decommissioning ...................................................................................47
11.1 Preparing for decommissioning.................................................................47
11.2 Decommissioning the drive module ..........................................................47
12 Disassembly and exchange ...................................................................48
12.1 Preparing disassembly..............................................................................48
12.2 Disassembling the drive module ...............................................................48
13 Disposal ...................................................................................................49
14 Extension and conversion .....................................................................50
15 Troubleshooting......................................................................................51
15.1 How to proceed for troubleshooting ..........................................................51
15.1.1 Overview of the impact of defects ..................................................................................51
16 Technical data .........................................................................................54
17 Appendix..................................................................................................55
17.1 List of addresses .......................................................................................55

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About this documentation
About this documentation1
Validity of the documentation1.1
This documentation applies to the following products:
Clamping and drive module UPE2•
Drive module UPE5•
This documentation is intended for assembly fitters, service technicians and
plant operators.
This documentation contains important information on the safe and appropriate
transport and assembly, commissioning, maintenance, disassembly and simple
troubleshooting of clamping and drive modules and drive modules with and with-
out control modules, hereinafter only referred to as "drive module".
Read this documentation completely, especially chapter 2 "General safetyf
instructions" before working with the drive module.
Necessary and amending documentation1.2
These are general operating instructions pertaining to drive modules that have
been designed and manufactured to customer specifications.
For this reason you should keep the general and product-specific documenta-f
tion to hand when reading these instructions (see Chapter 4 "Scope
of delivery").
You should observe the documentation for the complete machine.f
You should also observe the documentation pertaining to the other compo-f
nents, assemblies and partly completed machinery, which form part of the
complete machinery.
The drive module may not be commissioned until you are provided with thef
documentation marked with the book symbol , which applies to your or-
dered drive module and have understood and observed it.
Necessary and amending general documentationTable 1:
Title Document number Document type
Clamping and drive module UPE2 51142 Data sheet
Drive module UPE5 51145 Data sheet
Control module IH15A 51144 Data sheet
Control module IH15B 51156 Data sheet
Hydraulic fluids on mineral oil
basis and related hydrocarbons
90220 Data sheet
You can find these operating instructions as well as related documents in the
media directory under
www.boschrexroth.com/various/utilities/mediadirectory/

6/56 Bosch Rexroth AG Drive modules | RE 51150-B/07.11
About this documentation
Illustration of information1.3
Consistent safety instructions, symbols, terms and abbreviations are used so that
you can quickly and safely work with your product using this documentation. For a
better understanding, they are explained in the following sections.
Safety instructions1.3.1
In this documentation, safety instructions are indicated whenever sequences of
operations are explained which bear the risk of personal injury or damage to prop-
erty. The measures described for preventing these hazards must be observed.
Safety instructions are set out as follows:
SIGNAL WORD
Type and source of danger
Consequences in case of non-compliance
Measures for the prevention of dangersf
<Enumeration>f
Warning sign:•Draws attention to the hazard
Signal word:•Identifies the degree of hazard
Type and source of danger:•Specifies the type and source of the hazard
Consequences:•Describes the consequences of non-compliance
Precautions:•Specifies how the hazard can be prevented
Risk classes according to ANSI Z535.6-2006Table 2:
Warning sign, signal word Meaning
DANGER Indicates a dangerous situation which may cause death
or severe personal injuries if not avoided.
WARNING Indicates a dangerous situation which may cause death
or severe personal injuries if not avoided.
CAUTION Indicates a dangerous situation which may cause minor
or medium personal injuries if not avoided.
NOTICE Damage to property: The product or the environment
could be damaged.

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About this documentation
1.3.2 Symbols
The following symbols indicate notes which are not safety-relevant but increase
the understanding of the documentation.
Meaning of the symbolsTable 3:
Symbol Meaning
If this information is not observed, the product cannot be used and/
or operated optimally.
fIndividual, self-dependent step
1.
2.
3.
Numbered instruction:
The numbers indicate that the steps must be carried out one after
the other.
1.3.3 Abbreviations
The following abbreviations are used in this documentation:
AbbreviationsTable 4:
Abbreviation Meaning
REXXXXX-B Rexroth document in English language
RXXXXXX-B Rexroth document in another language
UPE Unit Power Energy
IH Industrial Hydraulics

8/56 Bosch Rexroth AG Drive modules | RE 51150-B/07.11
Safety instructions
Safety instructions2
General information on this chapter2.1
The drive module was designed and manufactured considering the provisions
of directives, standards and specifications relating to this technology. However,
there is still the risk of personal injury and damage to property if you do not ob-
serve this chapter and the safety instructions in this documentation.
Read this documentation completely and thoroughly before working with thef
drive module.
Also keep the general and product-specific documentation to hand when read-f
ing this documentation (see Chapter 4 "Scope of delivery").
This documentation together with the relevant product-specific documentationf
should be kept so as to be readily accessible to all users.
Always include the required documentation when you pass the drive modulef
on to third parties.
Due to the interaction between the drive module and the complete machine, the
installation of the drive module into the machinery will result in additional poten-
tial hazards. This applies in particular to the influence of hydraulic and electric
controls on hydraulic drives generating mechanical movements. It is therefore
essential for the manufacturer of the complete machine to have undertaken an
independent risk assessment. Furthermore, the manufacturer must on this basis
have prepared operating instructions for the complete machine
2.2 Intended use
The drive module constitutes partly completed machinery in terms of EC Ma-
chinery Directive 2006/42/EC. In terms of the EC Machinery Directive, the drive
module is not considered to be a ready-to-use machine. The drive module is
exclusively intended for integration into a machine or system or for assembly with
other components to form a machine or a system. The drive module may be com-
missioned only if it has been integrated into the machine or system for which it is
designed and if the machine or system fully complies with the requirements of the
EC Machinery Directive.
The drive module is not considered to be a safety component in terms of
EC Machinery Directive 2006/42/EC.
UPE2 clamping and drive modules may be used as follows:
In the general mechanical engineering sector•
For test machines and test stands•
For clamping, locking, releasing and indexing at machines•
As drive for hydraulic tools•
The UPE5 drive module may be used as follows:
In the general mechanical engineering sector•
For test stands•
For lifting platforms•
For conveyors•
For winding machines•
The drive module is only intended for professional use and not for private use.

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Safety instructions
Intended use includes having read and understood this documentation complete-
ly, especially the chapter 2 "Safety instructions".
Improper use2.3
Any use deviating from the intended use is improper and thus not admissible.
Bosch Rexroth AG does not assume any liability for damage caused by improper
use. The user assumes all risks involved with improper use.
2.4 Qualification of personnel
The activities described in this documentation require basic knowledge of me-
chanics, electrics and hydraulics as well as of the appropriate technical terms.
In order to ensure operational safety, these activities may only be carried out by
corresponding experts or an instructed person under the direction and supervision
of an expert.
Experts are those who can recognize potential hazards and apply the appropriate
safety measures due to their professional training, knowledge and experience, as
well as their understanding of the relevant conditions pertaining to the work to be
undertaken. An expert must observe the relevant specific professional rules.
Hydraulic expert knowledge means, e.g. that the personnel are able to read and
completely understand hydraulic schemes. Particularly the functionality of the in-
stalled safety components in the overall concept must be completely understood.
2.5 General safety instructions
Observe the valid regulations on accident prevention and for environmental•
protection.
Observe the safety regulations and provisions of the country where the product•
is implemented/used.
Exclusively use Rexroth products in good technical order and condition.•
Observe all notes on the product.•
Persons who assemble, operate, disassemble or maintain Rexroth products•
must not consume any alcohol, drugs or pharmaceuticals that may affect their
ability to react.
Only use accessories and spare parts authorized by the manufacturer in order•
to exclude hazards to persons due to inappropriate spare parts.
Comply with the technical data and environmental conditions indicated in the•
product documentation according to chapter 16.
The installation or use of inappropriate products in safety-relevant applications•
could result in unintended operating conditions when being used which in turn
could cause personal injuries and/or damage to property. Therefore please only
use a product for safety-relevant applications if this use is expressly specified
and permitted in the documentation of the product.
Do not commission the product until you can be sure that the end product (for ex-•
ample a machine or system) where the Rexroth product is installed complies with
the country-specific provisions, safety regulations and standards of the application.
Never remove or damage lead seals that have been fitted by Bosch Rexroth.•

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Safety instructions
2.6 Product- and technology-related safety instructions
WARNING
Pressurized system!
Danger to life, risk of injury, severe injury when working at systems that have not
been stopped! Damage to property!
Ensure that the drive module is completely depressurized.f
Do not disconnect lines, connections or components as long as the drivef
module is under pressure.
Switch off all force-transmitting components and ports (electric, pneumatic,f
hydraulic) according to the manufacturer's instructions and secure them
against restarting. If possible, remove the main fuse of the system.
High electrical voltage!
Danger to life, risk of injury caused by electric shock or severe injury!
Make sure the relevant system part is de-energized before assembling thef
drive module or when connecting and disconnecting connectors.
Protect the system against being switched on.f
Leaking hydraulic fluid mist due to defective or improperly assem-
bled seals!
Risk of fire, risk of explosion, risk due to allergic reactions, environmental pollution!
Welding works may only be undertaken when the drive module is depressurized.f
Keep open fire and sources of ignition away from the drive module.f
CAUTION
Leaking hydraulic fluid due to leakage of the drive module/the hydrau-
lic system!
Risk of burning! Risk of injury!
Switch the system off immediately (emergency stop switch).f
Identify and remedy the cause of the leakage.f
Never try to stop or seal the leak or the oil jet using a cloth.f
Avoid direct contact with the leaking hydraulic fluid. It might be underf
high pressure.
Carry out visual inspections for tightness of the drive module and the oil-f
containing components on a regular basis.
Slip hazard due to oily surfaces!
Risk of injury!
Protect and mark the danger zone.f
Use an oil binding agent in order to bind the leaked hydraulic fluid.f
Remove and dispose of (see chapter 13 "Disposal") the contaminated oilf
binding agent.
Wear your personal protective equipment like safety boots.f

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Safety instructions
CAUTION
Danger due to insufficient fastening!
Risk of injury!
Always ensure a vertical installation position (UPE2).f
Fasten the product using all screws according to the connection dimensionsf
specified in the relevant data sheet.
Hazard due to incorrect connection of the control and supply lines!
Unforeseeable reactions, risk of injury!
Ensure that only trained specialists are commissioned with the assembly.f
Observe the circuit diagrams located at the device when assemblingf
the product.
Safety equipment2.7
Make sure that all safety devices belonging to the drive module are present,•
have been installed properly and are fully functional. Do not displace, bypass or
disable safety equipment.
If it should be necessary to disable any safety equipment temporarily, for•
example for commissioning or maintenance work, always take the appropriate
measures to ensure that no hazard to a person's life or health or to property
may occur. Also observe the superordinate operating instructions for the ma-
chine or system.
Obligations of the machine manufacturer2.8
In order to ensure safety when handling the drive module, the manufacturer of the
machine must:
Select the safest installation position for the drive module possible in order to•
avoid possible damage of the drive module.
Provide for sufficient protection of the drive module including all attachment•
parts depending on the selected installation position in order to avoid possible
damage of the drive module and its attachment parts.
Prescribe the wearing of personal protective equipment or perform suitable•
protection measures in order to reduce the risk of collision, the risk of hear-
ing damage and the risk of burns at hot surfaces for operating or maintenance
personnel.
Label the hydraulic components according to the specifications of•
EN 982, 7.3 et sqq.
Take suitable protective measures in order to reduce the slip hazard caused by•
oily surfaces around the drive module.

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Safety instructions
Obligations of the operator2.9
The operator of the Bosch Rexroth drive modules must provide personnel training
on the following topics and on a regular basis:
Observation and use of the operating instructions and the legal regulations•
Intended use and operation of the Bosch Rexroth product•
Observation of the instructions from the factory security office as well as the•
operator’s operating instructions
How to behave in case of emergency•
Bosch Rexroth offers measures supporting the training in specific fields. You
can find an overview of the training contents on the Internet at
http://www.boschrexroth.de/didactic.

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General warnings of damage to property and damage to the product
General warnings of3 damage to property
and damage to the product
NOTICE
Danger due to improper handling!
Damage to property!
The product may only be operated according to section 2.2 "Intended use".f
Do not hit against areas relevant for the functioning (e.g. sealing surfaces)f
and attachment parts (e.g. control, accumulator, valves).
Mixing hydraulic fluids!
Damage to property!
Any mixing of hydraulic fluids of different manufacturers and/or of differentf
types of the same manufacturer is generally not admissible.
Pollution by fluids and foreign bodies!
Early wear and malfunctions!
Take the following measures for protecting the drive module:
During assembly, provide for cleanliness in order to prevent foreign bodiesf
e.g. welding beads or metal chips from getting into the hydraulic lines and
causing product wear or malfunctions.
Make sure that all connections, hydraulic lines and attachment partsf
(e.g. measuring instruments) are clean and free of chips.
For removing lubricants or any other heavy pollution, use industrial residue-f
free wipes.
Before commissioning, ensure that all hydraulic and mechanical connectionsf
are connected.
During filling, filter the hydraulic fluid using a suitable filter system in order tof
minimize the solid particle contamination and water in the system.
Improper cleaning!
Damage to property!
Cover all openings with the appropriate protective plugs in order to preventf
cleaning agents from penetrating the system.
Check that all seals and electrical plug-in connections are firmly fitted tof
prevent the penetration of cleaning agents.
Do not use aggressive cleaning agents for the cleaning. Clean the drive mod-f
ule using a suitable cleaning liquid.
Do not use a pressure washer.f
Operation with a lack of hydraulic fluid!
Damage to property!
Observe the data sheet specifications regarding the point "Control of thef
hydraulic fluid" and the prescribed remedial measures for the control result.

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General warnings of damage to property and damage to the product
NOTICE
Leaking or spilt hydraulic fluid!
Environmental pollution and pollution of the ground water!
Use an oil binding agent in order to bind the leaked hydraulic fluid.f
When filling and draining the hydraulic fluid, always put a drain tray under thef
drive module.
Observe the information in the safety data sheet of the hydraulic fluid and thef
system manufacturer's specifications.

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Scope of delivery
Scope of delivery4
These operating instructions have been prepared for drive modules.
In addition to the actual product itself, the scope of delivery for drive modules also
includes both general and product-specific documentation.
These documents are listed in the following table:
Scope of delivery documentsTable 5:
Document Drive module Assembly
Product-specific documentation
Technical specification x x
Hydraulic diagram x Catalog sheet,
if applicable
Component list to the hydraulic
diagram xCatalog sheet, if applicable
Assembly drawing x Catalog sheet,
if applicable
EC declaration of incorporation x —
General
documentation
Operating instructions
(this document) x x
Data sheet x x
Assembly instructions x —

16/56 Bosch Rexroth AG Drive modules | RE 51150-B/07.11
Information on this product
Information on this product5
Performance description5.1
A drive module constitutes a complete drive system that is delivered ready for
connection. It is used for supplying hydraulic circuits with hydraulic fluid.
Product description5.2
The drive module for which these operating instructions have been prepared is
exclusively intended for installation into machinery. This product has generally
been designed and manufactured to customer specifications. For the specific
description of your product, please refer to the relevant product-specific documen-
tation consisting of:
•Technical specification: Description of the operating conditions and information
on the installation into the machinery
Hydraulic diagram: Function(s) and logic mode of operation of the product•
Component list to the hydraulic diagram•
Assembly drawing: Structural design, dimensions, connections, etc.•
Drive modules according to these operating instructions at least consist of:
Electric motor and pump•
Tank•
Oil level display•
Apart from that, drive modules may comprise:
Hydraulic control•
Accumulator•
Pump pressure limiting device•
Additional protective devices to prevent unintended pressures•
Additional equipment for recording defined operating conditions•
(pressure, temperature, filling level, filter contamination)
Pipe / hose line, fittings, etc.•
For reasons in connection with the thermal load, operate the drive module inf
short-time operation, intermittent operation or continuous operation, depend-
ing on the type.
Select the duty cycle depending on the power output and the environmen-f
tal conditions so that the maximum admissible operating temperature is not
exceeded.
Product-specific documentation
Basic elements
Extensions

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Information on this product
Drive module UPE2Fig. 1:
Tank with electric motor and pump1
Filling plug2
Oil level display3
Name plate4
Terminal box5
Control connection surface6
Through holes for fastening screws7
Oil drain screw8
Explanation of the function: See table 6.
1
2
3
4
5
67
8
UPE2

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Information on this product
Drive module UPE5Fig. 2:
Tank with electric motor and pump1
Filling plug2
Oil level display3
Name plate4
Terminal box5
Control connection surface6
Through holes for fastening screws7
Oil drain screw (not visible)8
Oil-air cooler9
Functions elements drive modulesTable 6:
No. Element Function
1 Tank with electric motor and pump Tank is used for accepting the hydraulic fluid
2 Filling plug Filling of the tank with hydraulic fluid
3 Oil level display Hydraulic fluid level monitoring
4 Name plate Name plate for the unambiguous identification
of the drive module
5 Terminal box Connection electric motor as well as connec-
tion temperature switch (optional)
6 Control connection surface
Connection surface for attaching the filling plug
7 Through holes and/or tapped holes
for attachment
Through holes and/or tapped holes for attach-
ment of the drive module
8 Oil drain screw Tank draining
9 Oil-air cooler Cooler is used for cooling the hydraulic fluid
UPE5
1
2
3
5
6
7
4
9
8

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Information on this product
Interfaces5.3
Hydraulic connections5.3.1
Hydraulic connections drive module UPE2Fig. 3:
Pump connection "P" for con-1
trol modules
Tank port "T" for control modules2
Oil drain screw3
Explanation of the function: See table 7.
1
2
3
UPE2

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Information on this product
Hydraulic connections drive module UPE5Fig. 4:
1 Pump connection "P" for con-
trol modules
3 Oil drain screw (not visible)
4 Cooler connection "K1" for leak-
age oil
5 Tank port "T1"
6 Tank port "T2, T3, T4, T5"
7 Suction port "S"
8 Cooler connection "K2" for con-
trol modules
Hydraulic connections drive modulesTable 7:
No. Element Function
1 Pump connection "P" Via the pump connection, the control mod-
ules are supplied with hydraulic fluid
2 Tank port "T" Via the tank port, the hydraulic fluid of the
control modules is led back into the tank
3 Oil drain screw Tank draining
4
Cooler connection "K1" for leakage oil Control pump leakage oil connection
5 Tank port "T1" Oil leakage in the tank under minimum
oil level
6 Tank port "T2, T3, T4, T5" External actuator tank oil connection
7 Suction port "S" Through the port, the pump sucks hydraulic
fluid from the tank
8 Cooler connection "K2" for con-
trol modules
Via the cooler connection, the hydraulic
fluid of the control modules is led back into
the tank via the cooler
UPE5
1
3
4
8
6
7
56