Bosch Rexroth 50 NFF2 User manual

Operating instructions
RE 51433-B/04.10
Replaces: -.-
English
Off-line filter system
30 NFF2, 50 NFF2, 80 NFF2

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 obliga-
tion 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, 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 page shows an example configuration.
The product supplied may therefore differ from the
photo shown.
The original operating instructions were prepared
in German.

RE 51433-B/04.10 | 30, 50, 80 NFF2 Bosch Rexroth AG 3/30
Inhalt
Inhalt
1 About this document......................................................................................5
1.1 Related documents..................................................................................5
1.2 Abbreviations used ..................................................................................5
2 General safety instructions............................................................................5
2.1 Intended use ............................................................................................6
2.2 Improper use............................................................................................6
2.3 Qualification of personnel ........................................................................6
2.4 Safety instructions in this document ........................................................7
2.5 Adhere to the following instructions .........................................................8
2.6 Obligations of the operator ......................................................................9
2.7 Safety equipment.....................................................................................9
3 Scope of delivery ..........................................................................................10
4 Product description......................................................................................11
4.1 Performance description........................................................................11
4.2 Device description .................................................................................11
4.3 Component overview .............................................................................12
4.4 Product identification .............................................................................14
5 Transport and storage..................................................................................15
5.1 Transporting the off-line filter system.....................................................15
5.2 Storing the off-line filter system .............................................................15
6 Assembly.......................................................................................................16
6.1 Assembling the off-line filter system ......................................................16
7 Commissioning.............................................................................................17
7.1 First commissioning ...............................................................................17
8 Operation.......................................................................................................18
9 Maintenance and repair................................................................................19
9.1 Cleaning and care..................................................................................19
9.2 Maintenance ..........................................................................................19
9.3 Replacing wear parts .............................................................................19
9.4 Exchanging the suction filter (protective pump filter) .............................20
9.5 Exchanging the filter element ................................................................20
9.6 Repair ....................................................................................................22
9.7 Spare parts ............................................................................................22
10 Disposal.........................................................................................................23
10.1 Environmental protection ....................................................................... 23
11 Extension and conversion ...........................................................................24
12 Troubleshooting............................................................................................25
12.1 How to proceed for troubleshooting.......................................................25
13 Technical data...............................................................................................26
14 Appendix........................................................................................................27
14.1 Address directory...................................................................................27
14.2 Declaration of conformity ....................................................................... 27

4/30 Bosch Rexroth AG 30, 50, 80 NFF2 | RE 51433-B/04.10
Contents

RE 51433-B/04.10 | 30, 50, 80 NFF2 Bosch Rexroth AG 5/30
About this document
About this document
1 About this document
These instructions contain important information on the safe and appropriate
assembly, transport, commissioning, operation, maintenance, disassembly and
simple troubleshooting of the off-line filter system.
Read these instructions completely, especially chapter "2 General safetyf
instructions" before working with the off-line filter system.
1.1 Related documents
You can find these operating instructions as well as the related documents in the
media directory under www.boschrexroth.com/various/utilities/mediadirectory/.
Also observe the generally applicable, legal or otherwise binding regulations of
the European or national legislation and the regulations on accident prevention
and environmental protection applicable in your country.
1.2 Abbreviations used
AbbreviationsTable 1:
Abbreviation Meaning
NFF2 Off-line filter system, movable
2 General safety instructions
The off-line filter system has been manufactured according to the accepted rules
of current technology. There is, however, still a risk of personal injury or dam-
age to property if the following general safety instructions and safety instructions
before instructions contained in these operating instructions are not observed.
Read these instructions completely and thoroughly before working with thef
off-line filter system.
Keep these instructions in a location where they are accessible to all users atf
all times.
Always include the operating instructions when you pass the off-line filterf
system on to third parties.

6/30 Bosch Rexroth AG 30, 50, 80 NFF2 | RE 51433-B/04.10
General safety instructions
General safety instructions
Intended use2.1
The off-line filter system is exclusively intended for the filtration of hydraulic fluids
and lubricants with a viscosity of 10 - 200 mm2/s on the bypass.
You should observe the performance limits specified in chapterf
"15 Technical data".
The off-line filter system is technical equipment and not designed for private use.
Intended use includes having read and understood these instructions, especially
the chapter "2 General safety instructions".
Improper use2.2
Any use of the off-line filter system other than described in chapter "2.1 Intended
use" is considered as improper.
Qualification of personnel2.3
Assembly, commissioning and operation, disassembly, service (including mainte-
nance and repair) require basic mechanical, electrical and hydraulic knowledge,
as well as knowledge of the appropriate technical terms. In order to ensure opera-
tional 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.

RE 51433-B/04.10 | 30, 50, 80 NFF2 Bosch Rexroth AG 7/30
General safety instructions
About this document | General safety instructions
Safety instructions in this document2.4
In these instructions, there are safety instructions before an instruction whenever
there is a risk of personal injury or damage to property. The measures described
for preventing these hazards must be observed.
Safety instructions are set out as follows:
Type of risk!
Consequences
Precautionsf
Warning sign (warning triangle):•Draws attention to the danger
Signal word:•Identifies the degree of danger
Type of risk:•Specifies the type or source of danger
Consequences:•Describes the consequences of non-compliance
Precautions:•Specifies how the danger can be prevented
The signal words have the following meaning:
Signal words/warning signsTable 2:
Signal word Application
DANGER! Indicates an imminently hazardous situation which, if not avoided,
will certainly result in serious injury or even death.
WARNING! Indicates a potentially hazardous situation, which, if not avoided,
could result in serious injury or even death.
CAUTION! Indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury or damage to equipment.
If this information is disregarded, the operating procedure may be im-
paired.
SIGNAL WORD!

8/30 Bosch Rexroth AG 30, 50, 80 NFF2 | RE 51433-B/04.10
General safety instructions
Adhere to the following instructions2.5
General notes2.5.1
Observe the regulations on accident prevention and environmental protection•
for the country where the product is used and at the workplace.
Rexroth hydraulic systems should be used only if in a sound technical condition.•
Check the product for visible defects, for example cracks in the housing or•
missing screws and seals.
Do not modify or retrofit the off-line filter system.•
Only use the product within the performance range provided in the technical data.•
Persons who assemble, operate, disassemble or maintain Rexroth products•
must not consume any alcohol, drugs or pharmaceuticals that may affect their
ability to react.
The warranty only applies to the delivered configuration. The warranty expires if•
the product is incorrectly assembled, not used as intended and/or handled im-
properly.
Do not expose the product to any mechanical loads under any circumstances.•
Never use the product as a handle or step. Do not place any objects on top of it.
During assembly2.5.2
Make sure the relevant system component is de-pressurized and de-energized•
before assembling the product or when connecting and disconnecting connec-
tors. Protect the off-line filter system against re-activation.
Lay the cables and lines so that they cannot be damaged and no one can trip•
over them.
Before commissioning, make sure that all the seals and caps of the plug-in•
connections are installed correctly and undamaged to ensure that fluids and
contamination parts are prevented from penetrating the product.
When assembling, provide for absolute cleanness in order to prevent welding•
beads or metal chips from getting into the hydraulic lines and causing product
wear or malfunctions.
During commissioning2.5.3
Let the product acclimate itself for several hours before commissioning, as•
otherwise water may condense in the housing.
Make sure that all electrical and hydraulic connections are either used or cov-•
ered. Commission the product only if it is installed completely.
During operation2.5.4
In case of emergency, failure or in case of other irregularities switch off the•
system and secure it against re-activation.

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General safety instructions
During cleaning2.5.5
Cover all openings with the appropriate protective devices in order to prevent•
cleaning agents from penetrating the system.
Never use solvents or aggressive cleaning agents. Only clean the product us-•
ing a slightly damp, lint-free cloth. Only use water and a mild cleaning agent, if
necessary, to do so.
Do not use a pressure washer for cleaning.•
During maintenance and repair2.5.6
Perform the prescribed maintenance works at the intervals specified in these•
operating instructions.
Make sure that no lines, connections or components are disconnected as long•
as the system is under pressure and voltage. Protect the system against re-
activation.
During disposal2.5.7
Dispose of the product in accordance with the currently applicable national•
regulations in your country.
Dispose of the hydraulic fluid in accordance with the currently applicable na-•
tional regulations in your country.
Dispose of hydraulic fluid residues according to the applicable safety data•
sheets for hydraulic fluids.
Obligations of the operator2.6
The operator of the Bosch Rexroth off-line filter system is bound to provide for
personnel training on a regular basis regarding the following subjects:
Observation and use of the operating instructions as well as the legal stipulations•
Intended use of the off-line filter system•
Observation of the instructions from the factory security office as well as the•
operator’s operating instructions
What to do in an emergency•
Safety equipment2.7
Personal protective equipment2.7.1
The operator must provide personal safety equipment (e.g. gloves, safety shoes,
safety goggles, overall, etc.).

10/30 Bosch Rexroth AG 30, 50, 80 NFF2 | RE 51433-B/04.10
Scope of delivery
Scope of delivery3
The scope of delivery includes:
1 off-line filter system 30 (50, 80) NFF2•
1 suction hose, flexible, 2 m•
1 pressure hose, flexible, 2 m•
2 lances, 1 m•
1 operating instructions for the off-line filter system 30 (50, 80) NFF2•

RE 51433-B/04.10 | 30, 50, 80 NFF2 Bosch Rexroth AG 11/30
Product description
Product description4
Performance description4.1
The off-line filter system 30 (50, 80) NFF2 is a mobile filter system for the filtration
of hydraulic fluids and lubricants with a viscosity of 10 - 200 mm2/s on the bypass.
Separate installation in the bypass or cooling circuit for the fine filtration and
unloading of the main flow filter is just as feasible as the filtration of fresh oil and
the cleaning (flushing) of polluted systems for protecting components and system
against wear and tear.
The flow amounts to 30 l/min (30 NFF2) or 50 l/min (50 NFF2) or 80 l/min (80 NFF2).
The operating temperature ranges from –10 °C to 60 °C.
Device description4.2
The 30 (50, 80) NFF2 off-line filter system consists of a one-axis supporting frame
to which a filter pump unit has been attached. The 80 NFF2 0270 is an exception;
it has been attached to a two-axis frame. The filter pump unit consists of an elec-
trically operated filter pump with exchangeable suction filter and a main filter with
electronic maintenance indicator. If the pressure differential exceeds the value of
2.5 bar, the pressure resistance in the suction line is too high. A vacuum meter
monitors the pump suction pressure and displays the pressure. The on/off switch
is located at a control box. The suction hose is connected at the suction-side port
of the protective pump filter and the pressure hose at the main filter output. At
their ends, the hoses are in each case equipped with a lance. When they are not
used or during transport, they can be fixed in a receiving tube.

12/30 Bosch Rexroth AG 30, 50, 80 NFF2 | RE 51433-B/04.10
Product description
Component overview4.3
(Figure 1 shows 30 NFF2; 50 NFF2 and 80 NFF2 0120 are identical in construction.)
Device overview 30 NFF2Fig. 1:
Frame (one-axis)1
Suction filter (protective pump filter)2
Vacuum meter3
Main filter4
Suction hose5
Pump power unit6
Pressure hose7
Control box8

RE 51433-B/04.10 | 30, 50, 80 NFF2 Bosch Rexroth AG 13/30
Product description
(Figure 2 shows 80 NFF2 0270.)
Device overview 80 NFF2 0270Fig. 2:
Drain (oil tray)1
Frame (two-axis)2
Pump power unit3
Suction filter (protective pump filter)4
Vacuum meter5
Suction hose6
Control box7
Main filter8
Pressure hose9

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Product description
Control boxFig. 3:
Main switch1
START/STOP2
Display voltage ON3
Display operation4
Maintenance indicator main filter5
Product identification4.4
Name plateFig. 4:
Machine number1
Designation of the machine2
Designation of the filter element indicating the rating3

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Transport and storage
Transport and storage5
Transporting the off-line filter system5.1
The 30 (50, 80) NFF2 off-line filter system must be transported horizontally as
there is always a certain amount of oil within the filter unit (in the filter, in the
pump as well as in the hoses) that will leak in case of any other transport and lead
to pollution.
Please observe the information in chapter "2 General safety instructions".f
Storing the off-line filter system5.2
The 30 (50, 80) NFF2 off-line filter system should be stored in a closed room in
order to protect it against humidity and condensate formation.
Risk of chemical reactions!
Chemical substances in the immediate vicinity of the off-line filter system may
react and lead to destruction of the system and injuries of persons staying in the
immediate vicinity of the system.
It is forbidden to store the system in the immediate vicinity of chemically activef
substances like acids, bases, salts, organic solvents and rechargeable batteries.
The ambient temperature during storage of the 30 (50, 80) NFF2 off-line filter sys-
tem should lie between +5 °C and +30 °C with an air humidity of maximally 80 %.
Before storage for a period of more than 6 months, the system should be filled
with oil in order to preserve it as protection against rust formation.
DANGER!

16/30 Bosch Rexroth AG 30, 50, 80 NFF2 | RE 51433-B/04.10
Assembly
Assembly6
Assembling the off-line filter system6.1
Hydraulically connecting the off-line filter system6.1.1
Firstly take the pressure tube lance out of the receiving tube and position it inf
the container into which the purified oil is to be delivered.
Make sure that the lance is below the oil level (fig. 5).f
Proceed with the suction tube lance in the same way; put it into the containerf
with the oil to be purified (fig. 5).
Lance positionsFig. 5:
If the containers have been provided with fittings for connecting the off-line filter
system, the lances can also be disassembled and the hoses can be directly at-
tached to the containers using the corresponding fittings.
Missing seals and caps will lead to non-compliance with protection
class IP 54!
Liquids and contamination parts may penetrate and damage the product.
Ensure before the assembly that all seals and caps of the plug-in connectionsf
are tight.
CAUTION!

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Commissioning
Commissioning7
Missing seals and caps will lead to non-compliance with protection
class IP 54!
Liquids and contamination parts may penetrate and damage the product.
Before commissioning, ensure that all seals and plugs of the plug-in connec-f
tion are leak-proof.
Product damage!
Polluted hydraulic fluid could result in wear and malfunctions. In particular, con-
tamination parts like e.g. welding beads or metal chips in the suction lines may
damage the off-line filter system.
When commissioning you should ensure absolute cleanliness.f
First commissioning7.1
Activating the hydraulic supply7.1.1
Proceed as described in chapter "6.1 Assembling the off-line filter system".
Activating the electric supply7.1.2
Proceed as follows to commission the off-line filter system:
Switch on the 400 V AC supply voltage at the control box.1.
CAUTION!
CAUTION!

18/30 Bosch Rexroth AG 30, 50, 80 NFF2 | RE 51433-B/04.10
Operation
Operation8
Make sure that the off-line filter system is not operated unattended.f
Observe the vacuum meter. If the pressure exceeds 2.5 bar, the machine isf
switched off automatically and a fault is displayed at the control box (fig. 3,
item 5). The filter cartridge has to be exchanged (chapter "9.5 Exchanging the
filter cartridge").
The pump must not run dry for more than 30 seconds. Switch off the pump atf
the on/off switch at the control box.
The vacuum meter monitors the pump's suction pressure. It should be within the
range of -0.5 - 0 bar (fig. 6). If the suction pressure falls below –0.5 bar, there is a
risk of cavitation.
Vacuum meterFig. 6:
Risk of cavitation!
Cavitation leads to early pump wear. Symptoms of cavitation include knocking
sound in the pump and/or excessive vibrations of the entire unit.
Remedy the cause for the excessive pressure resistance in the suction line.f
Clear a plugged pipe socket and/or a plugged suction line from the plugging.f
If the oil viscosity is too high or the oil temperature is too low, the operating con-f
ditions (chapter "15 Technical data") have not been complied with. In this case,
precautions have to be taken in order to comply with the operating conditions.
Renew or clean a contaminated filter (chapter "9.5 Exchanging the filter element").f
CAUTION!

RE 51433-B/04.10 | 30, 50, 80 NFF2 Bosch Rexroth AG 19/30
Maintenance and repair
Maintenance and repair9
Cleaning and care9.1
Penetrating dirt and penetrating liquids will cause faults!
Safe function of the off-line filter system is no longer ensured.
Always provide for utmost cleanness when working at the hydraulic system.f
Do not use a pressure washer.f
Damage to the surface from solvents and aggressive cleaning agents!
Aggressive cleaning agents may damage the seals of the off-line filter system and
make them age faster.
Never use solvents or aggressive cleaning agents.f
Do not use pressure washers for cleaning.f
Damage to the hydraulic system and seals!
The water pressure of a pressure washer can damage the hydraulic system and
seals of the off-line filter system. The water displaces the oil from the hydraulic
system and seals.
Do not use pressure washers for cleaning.f
Cover all openings with the appropriate protective caps / devices.f
Check that all seals and caps of the plug-in connections are firmly fitted sof
that no humidity can penetrate the off-line filter system.
Only clean the off-line filter system using a damp, lint-free cloth. Only usef
water and a mild cleaning agent, if necessary, to do so.
Maintenance9.2
If used as intended, the off-line filter system is maintenance-free.
Replacing wear parts9.3
The wear parts of the off-line filter system are shown in the following figure.
Use the material numbers specified in this table for ordering the wear partsf
from Bosch Rexroth.
CAUTION!
CAUTION!
CAUTION!

20/30 Bosch Rexroth AG 30, 50, 80 NFF2 | RE 51433-B/04.10
Maintenance and repair
Wear partsTable 3:
Wear part Material number
Main filter element Rating see name plate
Protective pump filter Rating see name plate
For the addresses of foreign subsidiary please refer to
www.boschrexroth.com and chapter "16.1 Address directory".
Exchanging the suction filter (protective pump filter)9.4
Switch off the off-line filter system at the on/off switch and separate the off-line
filter system from the voltage supply.
Unscrew the filter bowl (3) and pull the filter element (2) off the centeringf
spigot on the filter head (1).
Replace the filter element by putting the new filter element onto the centeringf
spigot (it may be necessary to remove the protective foil in advance).
Screw on the filter bowl again and fasten it hand-tight (fig. 7).f
Protective pump filter set-upFig. 7:
Filter head1
Filter element2
Filter bowl3
Exchanging the filter element9.5
During operation, the pressure differential is monitored at the maintenance indica-
tor at the main filter. If the pressure differential exceeds the value of 2.5 bar, the
pressure resistance in the suction line is too high.
This may be due to the following causes:
Plugged pipe socket and/or plugged suction line;•
Oil viscosity too high / oil temperature too low;•
Contaminated filter.•