Bosch Rexroth WS290 User manual

RE 00225-B/12.15
Operating instructions
Replaces: 02.15
English
Hydraulics training system WS290

The data specified above serves to describe the
product. If there is also information on the use, it is
only to be regarded as application examples and
proposals. Catalogue information does not
constitute warranted properties. The information
given does not release the user from the obligation
of own judgment and verification. 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.
Original operating instructions

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Contents
Contents
1About this documentation ............................................................................ 6
1.1Validity of the documentation ............................................................. 6
1.2In these instructions, the following signs and symbols are used ........ 6
1.3Required and amending documentation ............................................ 6
1.4Representation of information ............................................................ 6
1.4.1Safety instructions .............................................................. 6
1.4.2Symbols .............................................................................. 7
1.4.3Abbreviations ...................................................................... 8
2Safety instructions ....................................................................................... 9
2.1General information on this chapter ................................................... 9
2.2Intended use ...................................................................................... 9
2.3Improper use ...................................................................................... 9
2.4Qualification of personnel ................................................................. 10
2.4.1Teaching ........................................................................... 10
2.4.2Transport, set-up, installation and commissioning ............ 10
2.4.3Troubleshooting, maintenance and repair ........................ 11
2.5General safety instructions ............................................................... 11
2.6Product- and technology-dependent safety instructions ................... 12
2.7Personal protective equipment ......................................................... 14
2.8Obligations of the machine end-user ................................................ 14
2.9Safety equipment ............................................................................. 15
2.10Operator workplaces ........................................................................ 16
3General warnings of damage to property and damage to the product ........ 16
4Scope of delivery ....................................................................................... 18
5Information on this product ........................................................................ 19
5.1General ............................................................................................ 19
5.2Product description .......................................................................... 20
5.3Base frame/device carrier ................................................................ 21
5.4Hose storage .................................................................................... 24
5.4.1Hose storage for 9 hoses ................................................. 24
5.4.2Hose storage for 50 hoses ............................................... 24
5.5Racks ............................................................................................... 25
5.6Power supply unit ............................................................................. 26
5.7Control box "Energy supply" assembly ............................................ 27
5.8Hydraulic power unit with single pump ............................................. 28
5.8.1General............................................................................. 28
5.8.2Assemblies and functions ................................................. 29
5.9Hydraulic power unit with double pump ............................................ 31
5.9.1General............................................................................. 31
5.9.2Assemblies and functions ................................................. 32
5.10LS hydraulic power unit with double pump ....................................... 34
5.10.1General............................................................................. 34
5.10.2Assemblies and functions ................................................. 35
5.11P/T distributor with depressurized circulation ("circulation circuit") .. 37
5.12Load-sensing control block (LS control block) .................................. 38
5.13Measuring glass ............................................................................... 39

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Contents
5.14Load simulator, rotatable .................................................................. 41
6Technical data and dimensions .................................................................. 43
6.1Technical data .................................................................................. 43
6.1.1Constant pressure training system WS290 ....................... 4 3 
6.1.2WS290 training system with load-sensing ......................... 44
6.2Dimensions of the hydraulics training system WS290 ...................... 45
6.3Identification of the hydraulics training system WS290 ..................... 46
7Operating and display elements ................................................................. 47
7.1EMERGENCY OFF pushbutton ........................................................ 47
7.2Operating elements at the control box .............................................. 48
7.3Operating and display elements at the hydraulic power unit ............. 49
7.4P/T distributor with depressurized circulation ("circulation circuit") .. 50
7.5Load-sensing control block (LS control block) .................................. 52
7.6Measuring glass ................................................................................ 54
7.7Power supply unit 24 V ..................................................................... 55
7.8Load simulator, rotatable .................................................................. 56
8Transport and storage ................................................................................ 58
8.1Delivery and unpacking ..................................................................... 58
8.2Transportation ................................................................................... 59
8.2.1Transportation within a building ........................................ 59
8.2.2Transportation between two buildings ............................... 60
8.3Storage ............................................................................................. 61
9Set-up, installation and commissioning ...................................................... 62
9.1Setting the WS290 training system up .............................................. 62
9.2Checking the hydraulic supply .......................................................... 63
9.3Filling the oil tank .............................................................................. 63
9.4Electric installation ............................................................................ 65
9.5Checking the functions...................................................................... 66
9.5.1Checking the EMERGENCY OFF circuit ........................... 66
9.5.2Checking the direction of rotation of the electric motor/the
pump ................................................................................. 67
9.5.3Checking the pump circulation .......................................... 67
9.5.4Testing the hydraulic fluid condition .................................. 69
9.5.5Checking the running noise of motor and pump(s) ........... 71
9.5.6Checking the operating pressure ...................................... 71
9.5.6.1Pressure test of the zero stroke control with a constant
pressure system ................................................................ 72
9.5.7Pressure test in circulation operation ................................ 73
9.5.8Standby pressure test at the load-sensing system ............ 74
9.5.8.1Test of the maximum operating pressure at the load-
sensing system ................................................................. 74
9.6Commissioning the hydraulic power unit ........................................... 75
9.6.1Prerequisites: .................................................................... 75
9.6.2How to commission the hydraulic power unit: ................... 7 5 
10Operation ................................................................................................... 77
10.1Switch-on 77
10.1.1Proceed as follows to switch on the system: ..................... 77
10.1.2Constant pressure system ................................................ 78

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Contents
10.1.3Load-sensing system ....................................................... 78
10.2Switch-off 78
10.3Resetting the EMERGENCY OFF .................................................... 79
11Help in case of faults ................................................................................. 80
12Maintenance and control ........................................................................... 81
12.1General information .......................................................................... 81
12.2Maintenance and control plan .......................................................... 82
13Maintenance works .................................................................................... 84
13.1General information .......................................................................... 84
13.2Maintenance schedule ..................................................................... 85
13.2.1Supplies, auxiliary materials, tools and measuring devices
......................................................................................... 87
13.2.2Exchanging parts .............................................................. 87
13.2.3Hydraulic oil maintenance ................................................ 88
13.2.4Performing the oil exchange ............................................. 88
13.2.5Exchanging the filter element ........................................... 90
13.2.6Exchanging hydraulic hose lines ...................................... 92
14Disposal .................................................................................................... 94
15Hydraulic oil data sheet ............................................................................. 95
16Declaration of conformity ......................................................................... 102

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About this documentation
1About this documentation
1.1 Validity of the documentation
This documentation describes the "Hydraulics training system WS290", formerly
called and described as “DS4”.
For simplicity, the term "WS290 training system" will be used over the further
course of the operating instructions.
Apart from that, the load-sensing control block is mentioned which will in the
present text shortly be referred to as LS control block in order to improve
the readability.
This documentation is intended for assemblers, operators, service engineers and
the system end-user.
This documentation contains important information on the safe and appropriate
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 In these instructions, the following signs and symbols
are used
Activity symbol: The text following this symbol describes activities that are to
be completed in the specified order from top to bottom.
1.3 Required and amending documentation
In addition to these operating instructions for the (ready-for-use) WS290 training
system, there is also the following amending documentation:
"Teachware" Teacher’s and pupil’s manuals and software
– Contains exercises according to the recommendations of BIBB,
– Textbooks and informative guides dealing with the topic "Hydraulics".
1.4 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.
1.4.1 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.

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About this documentation
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
Precaution: Specifies how the danger can be prevented
Table 1: Risk classes according to ANSI Z535.6-2006
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 Indicates damage to property: The product or the
environment could be damaged.
1.4.2 Symbols
The following symbols indicate notices which are not safety-relevant but increase
the comprehensibility of the documentation.
Table 2: Meaning of the symbols
Symbol Meaning
If this information is not observed, the product cannot be
used and/or operated optimally.
Individual, self-dependent step.
1.
2.
3.
Numbered instruction:
The numbers indicate that the actions must be carried out
one after the other.
SIGNAL WORD
Type and source of danger
Consequences in case of non-compliance
Hazard avoidance measures
<Enumeration>

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About this documentation
1.4.3 Abbreviations
The following abbreviations are used in this documentation:
Table 3: Abbreviations
Abbreviation Meaning
LS control block Load-sensing control block
WS290 training system Hydraulics training system WS290
Hy power unit Hydraulic power unit

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Safety instructions
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.
Read this documentation completely and thoroughly before working with
the product.
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.
2.2 Intended use
The WS290 training system is a hydraulic 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 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 WS290 training system may be used.
The operation is only admissible under the operating conditions indicated in
chapter 5.
The product is only intended for professional use and not for private use.
Intended use includes having read and understood this documentation
completely, especially the chapter "Safety instructions".
2.3 Improper use
Any use deviating from the intended use is improper and thus not admissible.
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 control components (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.

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Safety instructions
In particular, improper use of the product includes:
Using the WS290 training system in a non-professional way and playing with it
during the practical exercises and outside the training sessions,
Using the components with another training system,
Using other devices and device sets than those approved for the WS290
training system,
Combining pressure circuits.
2.4 Qualification of personnel
2.4.1 Teaching
Learners and apprentices may only work with the WS290 training system
under direct supervision,
under the appropriate guidance
of an instructor or trained personnel.
The instructor for the WS290 training system must be a skilled and qualified
expert having experience with electric, hydraulic and mechanical systems, as well
as in the mechatronics field.
The instructor has to
give clear instructions if apprentices or persons participating in further training
are supposed to install control circuits at the WS290 training system,
check the installation and functional effects of the control circuit for a safe
sequence before switching on the system,
answer questions in a clear and comprehensible manner.
To supervise the WS290 training system 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 WS290 training system 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 WS290 training system 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.
Instructor
Trained personnel

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Safety instructions
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 experience in the hydraulic field! Special knowledge of
hydraulics means that the personnel has 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.
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 technically perfect condition.
Observe all notices on the product.
Persons assembling, operating, disassembling or maintaining Rexroth products
must not be under the influence of alcohol, other drugs or medications
influencing the ability to react.
Only use accessories and spare parts approved of 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.
Do not commission the product until you can be sure that the end product (for
example a machine or system) where the Rexroth product is installed complies
with the country-specific provisions, safety regulations and standards of
the application.

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Safety instructions
2.6 Product- and technology-dependent safety instructions
WARNING
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 the
drive module or when connecting and disconnecting connectors.
Secure the system against restarting.
Do not operate any device control boxes or sockets that are not connected
to the power supply (electrical cabinet) of the WS290 training system. All
components which are not powered via the device-own electrical control box
but are installed (used) with the WS290 training system are not affected by
an EMERGENCY OFF circuit (and OFF circuit). The mains voltage
continues to be applied in the electrical control box.
Do not use the hydraulic power units in IT networks.
Only operate the WS290 training system in a grid with functional FI
protective earthing conductor or a protective earthing.
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 change the pressure setting at the safety valve and never damage or
remove the lead seal installed there.
Danger due to faulty assembly and installation!
Risk of serious injury in the subsequent operation!
Assembly works and commissioning may only be performed by employees
of Bosch Rexroth. This also applies to the re-commissioning following
repair works.
Have maintenance work performed by specialist personnel only.
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.

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Safety instructions
WARNING
Leaking hydraulic fluid due to leakage of the drive module or incomplete or
faulty components of the hydraulic system!
Risk of burning! Risk of injury! Risk of fire!
Switch the system off immediately (EMERGENCY OFF switch).
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 drive module and the
oil-containing components on a regular basis and make sure that hose
lines/hose couplings are correctly connected.
Wash your hands after contact with hydraulic oil.
Danger due to parts flying around due to excessive pressure in the
hydraulic system!
Risk of serious injury!
Before decoupling the hoses, always depressurize the hydraulic circuit.
Look out for damaged, uncoupled hose lines.
Look out for loose, unfastened set-ups.
Do not work without safety goggles; there is the risk of eye injuries.
Slip hazard due to oily surfaces!
Risk of injury!
Protect and mark the danger zone.
Use an oil binding agent in order to bind the leaked hydraulic oil.
Provide binding material already before filling, refilling or changing
hydraulic oil.
Remove and dispose of the contaminated oil binding agent.
Wear your protective equipment, such as safety shoes.
Hot surfaces at the drive module!
Risk of injury! Risk of burning!
Only touch the surfaces of the drive module with protective gloves or do not
work at hot surfaces. During or after the operation, the temperatures of the
components and the oil may rise to values higher than 50 °C, depending on
the operating conditions.
Allow the drive module to cool down sufficiently before touching it.
Observe the protective measures of the end machine manufacturer.
Danger of crushing due to pressurized movable elements!
Risk of injury!
Correctly mount the required protective cover e.g. at the load simulator.
Under no circumstances, remove any safety instructions and signs and/or
make sure that they are mounted.

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Safety instructions
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 of the 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 WS290 training system and
Ensure a safe set-up of the WS290 training system 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;
Ensures that the accident prevention regulations, the safety regulations of the
professional unions as well as further internal, local requirements are observed.
They instruct their employees and/or those of third party companies on possible
dangers at the place of set-up.
The machine end-user has to make available sufficient lighting at the place of set-
up of the training system.
They have to provide for personnel training on the following subjects on a
regular basis:
Observation and use of the operating instructions as well as the
legal provisions;
Intended operation of the WS290 training system;
Observation of the instructions from the factory security offices as well as the
machine end-user’s operating instructions;
Behavior in case of emergency.
WARNING
Danger from falling objects!
Risk of injury!
Provide free slots at the rack with covers in order to prevent objects from
being put down.

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Safety instructions
2.9 Safety equipment
To protect people, the training system is equipped with the following
safety equipment:
EMERGENCY OFF pushbutton
Hydraulic pressure limitation with the constant pressure system
Hydraulic pressure limitation with the load-sensing system
Mechanical safeguards
Temperature switch for WS290 training system with load-sensing system
Sealed safety valve
The facilities set out are described in more detail below.
On every side of the WS290 training system there is an EMERGENCY OFF
pushbutton which must be within easy reach.
The EMERGENCY OFF pushbutton has to be pressed in order to prevent any
danger for persons or the WS290 training system.
Operation of the EMERGENCY OFF pushbutton interrupts the power supply to
the control in the electrical control box and the function of the connected
actuators. The hydraulic oil supply is switched off and the WS290 training system
is stopped.
The training system may only be operated with a maximum operating pressure
of 50 bar. The pressure has been pre-set at the factory by means of a zero stroke
control and sealed with red painting at the setscrew.
At the pump, a so-called standby pressure of 15 bar has been pre-set and sealed.
The maximum operating pressure is limited by means of a load-sensing pressure
relief valve to 50 bar (industrial hydraulics) or to 60 bar (mobile hydraulics).
To monitor the pressure of practice circuits during teaching, the corresponding
pressure gauges and/or pressure limitation devices are to be integrated into the
practice circuit where appropriate. The instructor is responsible for this.
The following mechanical safeguards exist:
Parking device on the transport rollers
Protective covers at the actuators like e.g. cylinders, motors and load
simulators (depending on the equipment type)
Locking bolts and clamping lever as transport lock at the rotatable load
simulator (depending on the equipment type)
In the Emergency Off circuit, the WS290 training system is switched off at > 50 °C
oil temperature and only switched on again after cooling down to 40 °C
oil temperature.
The pump circuits are protected with sealed safety valves with 70 bar which must
not be adjusted.
EMERGENCY OFF pushbutton
Hydraulic pressure limitation
(constant pressure system)
Hydraulic pressure limitation
(load-sensing system)
Mechanical safeguards
Temperature switch for
WS290 training system with
load-sensing system
Sealed safety valve

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General warnings of damage to property and damage to the product
2.10 Operator workplaces
In order to be able to teach and learn the processes on the WS290 training
system, the following space is provided for the WS290 training system:
480-560
150-200 85-100 85-100
Fig. 1: Space required (in cm), WS290 training system
Depending on the use of the WS290 training system, the following training places
are provided for:
Table 4: Training places at a WS290 hydraulic training system
Work step Number of persons
Set up 3
Operation 2
A maximum number of three persons may work at the WS290 training system
during set-up at the same time. During operation, a maximum of two persons plus
instructor may work at the system.
3General warnings of damage to property and
damage to the product
Training places
NOTIC
E
Pressurized and live system!
Damage to property!
Ensure that the drive module has been completely hydraulically unloaded
and pressure-relieved.
Do not disconnect lines, connections or components as long as the drive
module is under pressure.
Do not disconnect any plug-in connections as long as the system is under
voltage. Switch off all force-transmitting components and ports (electric,
pneumatic, hydraulic) according to the manufacturer's specifications and

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General warnings of damage to property and damage to the product
secure them against restarting. De-energize the system at the main switch.
Incorrect setting of the pressure relief valves and the pressure switches of the
hydraulic components!
Damage to property!
Only operate the hydraulic components with the pressure values prescribed.
Hazard for the electrical equipment due to high electric currents!
Damage to property!
Make sure that excess-current protection equipment is available.
Secure the mains socket by pulling the mains plug.

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Scope of delivery
4Scope of delivery
The WS290 training system is supplied as a packed system ready for operation.
The WS290 training system stands on a subplate and is firmly tensioned by
means of plastic straps. It stands in a wooden box which is closed at the front with
a cover. The cover is fixed by means of nails. The box is moreover secured by
means of several steel straps.
Table 5: Dimensions of the wooden box
Denomination Unit Value
Dimensions Length mm 2100
Width mm 1000
Height mm 2360
1
5
4
2
3
Fig. 2: Box with marking
The following information is affixed to the box:
1Transport instructions or warnings
as required
2Shipping number/bar code
3Shipping note in plastic bag
4Imprint: Gross weight/possibly
net weight
5Imprint: Packaging according to
IPPC standard
The scope of delivery of the WS290 training system encompasses:
Base frame with the mounted functional assemblies and hydraulic power unit
(without oil)
With load simulator, depending on the version
With measuring glass, depending on the version
Optional accessories (according to the delivery note; 2nd copy inside)
Dimensions of the wooden box
Scope of delivery

Hydraulics training system WS290 | RE 00225-B/12.15 Bosch Rexroth AG 19/104
Information on this product
5Information on this product
5.1 General
The following sections of these operating instructions illustrate as an example
a variant of the WS290 training system and its components.
A selection of attachments and device sets is available for the WS290 training
system. These components turn the WS290 training system into a complete,
customer-specific training and further education system with practical orientation.

20/104 Bosch Rexroth AG Hydraulics training system WS290 | RE 00225-B/2.15
Information on this product
5.2 Product description
Fig. 3: Constant pressure system with 2 workplaces
1Base frame with transport rollers
2Grid with reinforcement and mounting frame;
variant: central grooved plate
3Oil drip sheet
3a Writing surface, one- or double-sided
4Hose storage for 50 hoses;
Variant: hose storage for 9 hoses
5Installation container
6LS Hy power unit
Versions: Double pump 230 V/50 Hz or 60 Hz; 1.5 kW or
400 V/50 Hz; 2.2 kW
Variant: Hy power unit
Versions:
Single pump 230 V/50 Hz; 1.5 kW or 400 V/50 Hz; 2.2 kW
Double pump 230 V/50 Hz; 1.5 kW or 400 V/50 Hz; 2.2 kW
7Oil pan
8Control box; versions:
230 V/50 Hz or 400 V/50 Hz;
2 x Emergency Off; 3 sockets;
with or without FI
9P/T distributor with depressurized circulation for
Hy power unit
Variant:
P/T/X distributor for LS Hy power unit
10 Load simulator 15 kg rotatable
11 Power supply unit
12 Measuring glass 2.5 l
13 Rack two-row
Variant: Rack one-row