Bosch Rexroth WS200 User manual

WS200 work station
Operating instructions
DCA-DE-000151 / 10.2013
Replaces:
English

The data specified above only serve to
describe the product. No statements
concerning a certain condition or
suitability for a certain application can be
derived from our information. The
information given does not release the
user from the obligation of own judgment
and verification. It must be remembered
that our products are subject to a natural
process of wear and aging.
 This document, as well as the data,
specifications and other information set
forth in it, are the exclusive property of
Bosch Rexroth AG. It may not be
reproduced or given to third parties
without its consent.
The cover page shows an example
configuration. The product supplied may
therefore differ from the figure.
The original operating instructions were
prepared in German.

Contents 3/92
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Contents
1About this documentation...................................................................................5
1.3.1 Safety instructions .............................................................................................6
1.3.2 Symbols .............................................................................................................7
1.3.3 Abbreviations .....................................................................................................7
2Safety instructions..............................................................................................7
2.4.1 Teaching.............................................................................................................9
2.4.2 Transport, set-up, installation and commissioning .............................................9
2.4.3 Troubleshooting, maintenance and repair ..........................................................9
3General information on damage to property and damage to the product ...........16
4Scope of delivery ..............................................................................................17
5Information on this product ..............................................................................18
5.4.1 Set-up ..............................................................................................................20
5.4.2 Hydraulic circuit schematic ..............................................................................21
5.4.3 Control box ......................................................................................................21
5.4.4 Assemblies and functions.................................................................................22
5.4.5 Hydraulic oil supply for 2 workplaces...............................................................23
6Transport and storage.......................................................................................32
7Assembly of the WS200 work station ................................................................35
7.4.1 Base frame .......................................................................................................37
7.4.2 P/T distributor with integrated pressure relief valve ........................................38
7.4.3 Tray ..................................................................................................................39
1.1 Validity of the documentation.............................................................................5
1.2 Necessary and amending documentation ...........................................................
5
1.3 Representation of information............................................................................
6
2.1 General information on this chapter...................................................................7
2.2 Intended use ......................................................................................................
8
2.3 Improper use......................................................................................................
8
2.4 Qualification of personnel ..................................................................................
9
2.5 General safety instructions...............................................................................10
2.6 Product- and technology-dependent safety instructions...................................
11
2.7 Personal protective equipment ........................................................................
13
2.8 Obligations of the machine end-user................................................................
13
2.9 Safety equipment .............................................................................................
14
2.10 Operator workplaces........................................................................................
15
5.1 General information .........................................................................................18
5.2 Product description..........................................................................................
18
5.3 Base frame .......................................................................................................
19
5.4 Compact hydraulic power unit .........................................................................
20
5.5 P/T distributor..................................................................................................24
5.6 Tray ..................................................................................................................
25
5.7 Grid frame ........................................................................................................
26
5.8 Grooved plate ..................................................................................................
27
5.9 Identification and name plate...........................................................................
28
5.10 Preferred types of the WS200 work station......................................................29
6.1 Dimensions of the WS200 work station............................................................32
6.2 Transport .........................................................................................................
33
6.3 Storage ............................................................................................................
34
7.1 Unpacking the WS200 work station..................................................................35
7.2 Necessary tools ................................................................................................
36
7.3 Aids ..................................................................................................................
36
7.4 Assembling the WS200 work station ................................................................
36

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7.4.4 Compact hydraulic power unit......................................................................... 41
7.4.5 Grid frame ....................................................................................................... 43
7.4.6 Grooved plate .................................................................................................. 48
7.5.1 Accessory set 1................................................................................................ 50
7.5.2 Accessory set 2................................................................................................ 52
7.5.3 Accessory set 3................................................................................................ 54
8Commissioning................................................................................................. 58
9Operation......................................................................................................... 63
10 Maintenance and repair.................................................................................... 70
10.5.1 Exchanging the hydraulic fluid ......................................................................... 72
10.5.2 Exchanging hydraulic hose lines ...................................................................... 74
11 Disposal ........................................................................................................... 77
12 Troubleshooting ............................................................................................... 78
13 Technical data and dimensions......................................................................... 82
14 Alphabetical index............................................................................................ 83
15 Appendix.......................................................................................................... 84
7.5 Accessory set assembly ................................................................................... 50
7.6 Hydraulically connecting the WS200 work station ........................................... 56
8.1 Setting the WS200 work station up ................................................................. 58
8.2
Checking the hydraulic supply ......................................................................... 59
8.3
Filling the oil tank ............................................................................................ 59
8.4
Electric installation .......................................................................................... 61
8.5
Initial commissioning of the compact hydraulic power unit ............................. 62
9.1 Switch-on of the work station in hydraulic form .............................................. 63
9.2
Switch-off ........................................................................................................ 64
9.3
Resetting the EMERGENCY OFF....................................................................... 64
9.4
Mounting variant for installation into the grid.................................................. 65
9.5
Mounting technique for attachment at the grooved plate ................................ 67
9.6
The hydraulic coupling..................................................................................... 68
9.7 Handling of hydraulic hose lines ...................................................................... 69
10.1
Cleaning and care ............................................................................................ 70
10.2
Inspection........................................................................................................ 71
10.3
Maintenance schedule ..................................................................................... 71
10.4
Maintenance .................................................................................................... 72
10.5 Replacing parts................................................................................................ 72
10.6 Spare parts ...................................................................................................... 76
12.1 Fault table ....................................................................................................... 78
13.1 Technical data ................................................................................................. 82
15.1
Data sheet of the recommended hydraulic fluid .............................................. 84
15.2 Declaration of conformity ................................................................................ 91

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1About this documentation
1.1 Validity of the documentation
This documentation describes the configurable WS200 work station. The equipment of
the work station is configurable. Here, a hydraulic or pneumatic form is possible or
a combination of both forms.
This documentation is intended for assemblers, operators, service engineers and the
system end-user.
This documentation contains important information on the safe and proper assembly,
transport, commissioning, operation, use, maintenance, disassembly and simple
troubleshooting of the product.
You should read this documentation thoroughly, and in particular the chapter "Safety
instructions" before working with the product.
1.2 Necessary and amending documentation
The product must not be commissioned until you have been provided with the
documentation marked with the book symbol (see table 1) and you have understood
and observed it.
Table 1: Necessary and amending documentation
Title Document number Document type
"Hydraulic fluids on mineral oil basis
and related hydrocarbons"
RE 90220 Data sheet
"Hydraulic fluids on mineral oil basis for
axial piston units"
RE 90220-01 Data sheet
Basic hydraulics compact knowledge Technical book
Hose lines, dimensions, requirements DIN 20066 German standard
You can find these operating instructions as well as the related documents and data sheets
in the Bosch Rexroth media directory at:
www.boschrexroth.com/various/utilities/mediadirectory/
The current training offer and other knowledge products of the Drive & Control Academy
are available on the Internet at:
www.boschrexroth.de/academy

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1.3 Representation of information
Uniform 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.
1.3.1 Safety instructions
In this documentation, safety instructions are included whenever sequences of actions are
explained which bear the danger of personal injury or damage to property. The hazard
avoidance measures described must be observed.
Safety instructions are set out as follows:
•Warning sign: Draws attention to the danger
•Signal word: Identifies the degree of danger
•Type and source of danger:Specifies the type and source of danger
•Consequences: Describes the consequences of non-compliance
•Precautions: Specifies how the danger can be prevented
The following table shows an overview of the individual warning levels starting with
"Notice" up to "Danger". It describes the risk in case of non-compliance with the
safety instruction.
Table 2: Risk classes according to ANSI Z535.6-2006
Warning sign,
signal word
Meaning of the risk class
DANGER Indicates a dangerous situation which will cause death
or severe injuries if not avoided.
WARNING Indicates a dangerous situation which may cause death
or severe injuries if not avoided.
CAUTION Indicates a dangerous situation which may cause minor
to medium personal injuries if not avoided.
NOTICE Indicates damage to property: The product or the
environment could be damaged.
SIGNAL WORD
Type and source of danger
Consequences in case of non-compliance

Hazard avoidance measures
<Enumeration>

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1.3.2 Symbols
The following symbols indicate notices which are not safety-relevant but increase the
comprehensibility of the documentation.
Table 3: Meaning of the symbols
Symbol Meaning
Indicates useful information for the perfect use and operation of
the product.
Individual, independent action.
The text following this symbol describes activities that are to be
completed in the specified order from top to bottom.
1.
2.
3.
Numbered instruction:
The numbers indicate that the actions must be carried out one after
the other.
1.3.3 Abbreviations
The following abbreviations are used in this documentation:
Table 4: Abbreviations
Abbreviation
Meaning
WS200 WS200 work station
Hydraulic
power unit
Compact hydraulic power unit
MDTightening torque of the connection elements (in Nm)
2Safety instructions
2.1 General information on this chapter
The product has been manufactured according to the generally accepted codes of practice.
However, there is still the risk of personal injury and damage to property if you do not
observe this chapter and the safety instructions in this documentation.
Before the commissioning, the operating, maintenance and safety instructions are to be
read. If you have not clearly understood the documentation in the available language,
please contact your responsible Bosch Rexroth sales representative.
Keep this documentation in a location where it is accessible to all users at all times.
Always include the required documentation when you pass the product on to
third parties.
The unobjectionable and safe operation of this device requires appropriate and proper
transport, storage, assembly and installation as well as careful operation
and maintenance.

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2.2 Intended use
The WS200 work station is a hydraulic, pneumatic and electric system.
It may only be used to impart knowledge and skills in the technical training and further
education in the field of hydraulics, pneumatics as well as control technology and
control engineering.
For the set-up of control circuits and simulations, only the devices and device sets
approved for the WS200 work station may be used.
The operation is only admissible under the operating conditions indicated in chapter 9.
The product is only intended for academic and industrial use and not for private use.
Intended use also includes having read and understood this documentation completely,
especially chapter 2 "Safety instructions" and chapter 3 "General information on damage to
property and damage to the product".
2.3 Improper use
Any use deviating from the intended use is improper and thus inadmissible.
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. For example, in explosion-protected areas or in safety-related parts of control
systems (functional safety).
Bosch Rexroth AG does not assume any liability for damage caused by improper use.
The user assumes all risks involved with improper use.
In particular, improper use of the product includes:
•using the WS200 in a non-professional way and playing with it during the practical
exercises and outside the training sessions,
•using other devices and device sets than those approved for the WS200.

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2.4 Qualification of personnel
2.4.1 Teaching
Learners and apprentices may only work with the WS200 work station
•under direct supervision,
•under the appropriate guidance
of an instructor or trained personnel.
The instructor for the WS200 work station must be a skilled and qualified expert having
experience in the field to be taught.
The instructor has to
•give clear instructions if apprentices or persons participating in further training are
supposed to install control circuits at the work station,
•check the installation and functional consequences of the control circuits, before they are
switched on, in order to ensure a safe operation.
For the supervision during the exercises, trained personnel may also be used.
These are qualified people who were instructed and briefed in relation to:
•duties ordered,
•possible dangers in the event of improper use,
•safeguards and protective measures.
2.4.2 Transport, set-up, installation and commissioning
Any work carried out at the work station such as set-up, connection, maintenance and
repairs, may only be performed by authorized specialist personnel or persons being
sufficiently qualified and entitled.
Persons authorized to perform work at the work station have to be able to follow the
information provided in this documentation and to perform, in addition and independently,
any information possibly missing due to their personal professional qualification.
2.4.3 Troubleshooting, maintenance and repair
Maintenance and repair works as well as fault finding and troubleshooting measures
require special knowledge and must only be carried out by qualified experts!
•Work on electrical equipment may only be performed by a specialized electrician.
Specialized electricians are those who can assess the work to be undertaken, 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 regulations.
•Works on hydraulic components must only be carried out by specialists with special
knowledge and experiences in the hydraulic field! Special knowledge of hydraulics means
that the personnel have to be able to read and completely understand hydraulic plans.
In particular completely understand the correlations regarding the installed safety
equipment and have knowledge of the function and set-up of hydraulic components.
Instructor
Trained
personnel

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•Any work to be carried out with regard to pneumatic components may only be performed
by specialist personnel having special knowledge and experience in pneumatics. Special
knowledge of pneumatics means that the personnel have to be able to read and
completely understand pneumatic plans. In particular completely understand the
correlations regarding the installed safety equipment and have knowledge of the function
and set-up of pneumatic components.
Bosch Rexroth offers measures supporting the training. An overview of the training
contents is available online at:
www.boschrexroth.de/academy
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 Bosch Rexroth products in good technical order and condition.
•Observe all notices on the product.
•Persons who assemble, operate, disassemble or maintain Bosch Rexroth products must
not consume any alcohol, drugs or medication that may affect their ability to react.
•Only use accessories and spare parts approved by the manufacturer in order to exclude
hazards to persons due to unsuitable spare parts.
•Comply with the technical data and environmental conditions specified in the
product documentation.
•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.

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2.6 Product- and technology-dependent safety instructions
WARNING
High electrical voltage!
Danger to life, risk of injury by electric shock!

Always de-energize the work station before assembling or disassembling
the drive module.

For the operation of the work station, earthed industrial mains are required
(TN-S mains type) 1 x AC 230 V (±10 %), 50-60Hz.

The mains connection has to be established by means of a Schuko socket

Only operate the work station in mains with functional FI circuit breaker.

The electric voltages led through the training components and training circuits
must not exceed 24 V.

Electric training circuits may only be set-up and dismounted when the system
is de-energized.
Manipulated and/or non-functioning safety equipment and safeguards!
Risk of serious injury!

Stop the system immediately!

The fault or manipulation has to be promptly remedied by specialist personnel!

Never increase the pressure setting at the pressure relief valve of the hydraulic
power unit to a value of more than 70 bar.
Danger due to faulty assembly and installation!
Risk of serious injury in the subsequent operation!

Have maintenance works performed by specialist personnel only.

Lay connection cables so that they do not constitute a risk of tripping.
Leaking oil mist!
Risk of fire, risk due to allergic reactions, environmental pollution!

Only carry out repair and maintenance works when the drive module
is depressurized.

Keep open fire and ignition sources away from the drive module.

Do not enter the danger zone if you are an allergic person.
Leaking hydraulic fluid due to leakage of the drive module or incomplete or faulty
components of the work station!
Risk of burning! Risk of injury! Risk of fire!

Switch the system off immediately (EMERGENCY OFF pushbutton).

Identify and remedy the cause of the leakage.

Never try to stop or seal the leakage or the oil jet using a cloth.

Never come into contact with the splashing high-pressure oil jet.

Carry out visual inspections for leak-tightness of the hydraulic power unit and
the hydraulic components on a regular basis and make sure that hydraulic hose
lines, hydraulic couplings are correctly connected.

Wash your hands after contact with hydraulic fluid.

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WARNING
Danger due to parts flying around due to excessive pressure!
Risk of serious injury!

Before decoupling a hose line, always depressurize the hydraulic or pneumatic
training set-up.

Look out for damaged or uncoupled hose lines during the training set-up.

Look out for loose, unfastened attachments.

Do not work at hydraulic components without safety goggles; there is the risk of
eye injuries.
Slip hazard due to oily surfaces!
Risk of injury!

Enter the danger zone with corresponding protective equipment, e.g. with
safety shoes.

Protect and mark the danger zone.

Use an oil binding agent in order to bind the leaked hydraulic fluid.

Dispose of any supplies and auxiliary materials spilled and used as prescribed
pursuant to the country-specific legal provisions.
Hot surfaces during and after operation!
Risk of injury! Risk of burning!

Only touch the surfaces of the hydraulic power unit and the hydraulic training
components with protective gloves. Especially actuation solenoids for electrically
operated valves heat up considerably during operation.

During or after the operation, the temperatures of the components and the
hydraulic fluid may rise to values higher than 50 °C, depending on the
operating conditions.

Allow the components to cool down sufficiently before touching them, e.g. before
dismantling the training circuits.
Danger of crushing due to pressurized movable elements!
Risk of injury!

Under no circumstances, remove any safety instructions and signs.

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2.7 Personal protective equipment
The personal protective equipment for users of the product consists of:
•Safety shoes during the entire teaching
•Protective gloves and eye protection during the set-up and operation of the hydraulic
training circuits
All parts of the personal protective equipment must be in full working order.
2.8 Obligations of the machine end-user
The machine end-user has to guarantee the required prerequisites for the set-up and
the installation of the WS200 work station and
•ensure a safe set-up by their personnel and/or the persons authorized by them; in this
respect, they pay particular attention to that the ground
•is sufficiently load bearing and
•even and horizontal;
•ensure that the accident prevention regulations, the safety regulations of the professional
unions as well as further internal and local requirements are observed.
They instruct their employees and/or those of third party companies on possible dangers at
the place of installation.
The machine end-user has to make available sufficient lighting at the place of set-up of
the work station.
They have to provide for personnel training on the following subjects on a regular basis:
•observation and use of the operating instructions and the legal regulations;
•intended operation of the work station;
•observation of the instructions from the factory security offices as well as the machine
end-user’s operating instructions;
•behavior in case of emergency.

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2.9 Safety equipment
To protect people, the WS200 work station is equipped with the following
safety equipment:
•EMERGENCY OFF pushbutton (with hydraulic version)
•Motor protection relay (with hydraulic version)
•Fuse protection of the electr. switching contacts (with hydraulic version)
•Hydraulic pressure limitation
•Quick-release coupling
•Mechanical safeguards
The facilities set out are described in more detail below.
At the control box of the WS200 work station, there is an EMERGENCY OFF pushbutton.
The EMERGENCY OFF pushbutton has to be pushed in order to prevent dangers for
persons or the work station. Operation of the EMERGENCY OFF pushbutton interrupts the
power supply to the control in the control box and the function of the connected electric
actuators. The hydraulic power unit and thus the hydraulic oil supply are switched off.
In the control box of the WS200 work station, a motor protection relay and a power
contactor are installed. The motor protection relay is used to protect the electric motor
against short-circuit and thus thermal overload. Upon activation, the hydraulic power unit
and thus the hydraulic oil supply are switched off. In case of triggering due to thermal
overload, the hydraulic power unit can only be switched on again after a cool-down phase.
In addition to the motor protection relay function, the circuit arrangement in the control
box has another function. Protection against automatic start-up of the hydraulic power unit
after an interruption in the supply voltage. This may e.g. be the case if the mains plug is
pulled out of the mains socket while the hydraulic power unit is switched on. If this is the
case, the hydraulic power unit can be switched on again by means of the "ON" pushbutton
after the problem has been solved.
To protect the electric switching contact in the control box against welding in case of
excessive currents, a micro-fuse has been installed. The technical data has to be observed
in case of exchange. For details please refer to chap. 10.6, table 36.
The work station may only be operated with a maximum hydraulic operating pressure
of 60 bar which can be set via the pressure relief valve in the P/T distributor. The safety
pressure has been pre-set at the factory to 70 bar by means of a pressure relief valve at the
hydraulic power unit.
To monitor the pressure of training circuits during teaching, corresponding pressure gauges
are to be integrated into the training circuit. The machine end-user is responsible for this.
With hydraulic components for training set-ups, quick-release couplings are mounted at the
measuring glass and at the P/T distributor for the hydraulic connection. They prevent
leakage of hydraulic fluid if this connection is separated.
EMERGENCY OFF
pushbutton
Motor protection
relay
Fuse protection
switching contacts
Hydraulic
pressure limitation
Quick-release
coupling

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The following mechanical safeguards exist:
•Parking device on the transport rollers
•Protective covers at the actuators like e.g. cylinders, motors (depending on the
equipment type)
2.10 Operator workplaces
The following space is to be provided for the operation of the work station by the operator:
Fig. 1: Space required (in cm), WS200
Depending on the use of the WS200 work station, the following training places are
provided for:
Table 5: Training places at one side of the work station
Work step Recommended number of persons
Set-up 2
Operation 2
Mechanical safeguards
Training places

16/92 General information on damage to property and damage to the product
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3General information on damage to property
and damage to the product
The warranty only applies to the delivered configuration.
The claim to warranty expires if the product is incorrectly assembled, commissioned and
operated, not used as intended and/or handled improperly.
NOTICE
Danger due to improper handling!
Damage to property!

The product may only be operated according to section 2.2 "Intended use".

Avoid impacts against functionally relevant areas (e.g. sealing surfaces) and attachment
parts (e.g. control system, accumulator, valves).
Mixing hydraulic fluids!
Damage to property!
Any mixing of hydraulic fluids of different manufacturers and/or of different types of the
same manufacturer is generally not admissible.
Contamination by foreign particles!
Early wear and malfunctions!

During assembly, provide for cleanliness in order to prevent foreign particles from getting
into the hydraulic lines and causing wear or malfunctions.

Before commissioning, ensure that all hydraulic and mechanical connections
have been made.

During filling, filter the hydraulic fluids using a suitable filter system in order
to minimize the solid particle contamination in the system.
Pressurized and live system!
Damage to property!

Do not disconnect lines, connections or components as long as the hydraulic power unit
and the training set-up are under pressure.

Do not disconnect lines, connections or components as long as the pneumatic training set-
up is pressurized.

Do n
ot disconnect electric connections as long as the hydraulic power unit and the training
set-up are connected to the power supply.
Incorrect setting of the pressure relief valves and the pressure switches of the hydraulic
and pneumatic components!
Damage to property!

The hydraulic form of the work station may only be operated with a max. pressure
of 60 bar.

The pneumatic form of the work station may only be operated with a max. pressure
of 6 bar.
Hazard for the electrical equipment due to high electric currents!
Damage to property!

Make sure that excess-current protection equipment is available.

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4Scope of delivery
Depending on the ordered configuration, the WS200 work station can be supplied as
mounted system or unmounted for self-assembly. For a more detailed description of the
available mounted variants of the WS200 work station please refer to chap. 5.10.
The work station will in each case be packed in a wooden box. Details regarding the scope
of delivery according to the order confirmation.
Fig. 2: Mounted variant of the WS200 work station
Fig. 3: Unmounted variant of the WS200 work station

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5Information on this product
5.1 General information
The WS200 work station allows for the realization of training set-ups from the area of
hydraulics, pneumatics and automation technology. For this purpose, complementary
device sets with corresponding project manuals are available.
The WS200 work station can be used on both sides. If two grids or one grooved plate are/is
used, two workplaces for the training set-up are thus available.
The work station also offers extension possibilities with regard to the space required by
the training area. A connection kit allows for the coupling of two work stations; in this way,
the space of the training area is doubled.
Due to the small dimensions, it is perfectly suited as entry-level package for the world of
hydraulics and pneumatics. All this turns the WS200 work station into a complete,
customer-specific training and further education system with practical orientation.
5.2 Product description
x section
1Base frame with transport rollers
2Grid frame
3Grooved plate
4Connection kit
5P/T distributor
6Tray
7Hose holder (accessory)
8 Hydraulic power unit in duplicate with one control
box each
Fig. 4: Configured WS200 work station for 2 workplaces (with grooved plate)

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5.3 Base frame
The base frame is the basis of the WS200 work station and consists of a modular device
carrier (1). AT this carrier, all other components are mounted. The device carrier is
equipped with four stable, lockable and steerable transport rollers (2) and an oil pan (3).
The oil pan is used to collect drip losses at the hydraulic power unit and drip losses of
hydraulic hose lines at the hose holder.
In a configuration with pneumatic set-up, you an also place a compressor for
the compressed air supply in this oil pan.
1 Device carrier
2 Transport rollers
2.1 Locking device of the transport rollers
3 Oil pan
Fig. 5: WS200 base frame

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5.4 Compact hydraulic power unit
5.4.1 Set-up
The hydraulic power unit provides a workplace with hydraulic fluid.
1 Oil tank 3 Asynchronous one-phase motor
1.1 Oil level display 4 Control box with connection line
1.2 Measuring glass connection 5 Cross member
1.3 Filler neck 6 External gear pump
2 Central connection block 7 Vibration damper
2.1 Pressure relief valve
2.2 Pressure line - port P
2.3 Tank line - port T
Fig. 6: Individual compact hydraulic power unit