Bosch Rexroth VPV and SV Variable Volume Vane Pumps: Installation Manual

INSTALLATION MANUAL Industrial Hydraulics
Bosch Rexroth VPV

and SV Variable
Volume Vane Pumps The satisfactory operation of your Bosch hydraulic pump depends on certain
precautions that should be taken during installation. The pump should only be
installed by qualified personnel. Please read this bulletin carefully for detailed steps to
install this equipment.
Suggestions for System Plumbing 15. On VPV16 / VPV25 / VPV32 models, there is an external shock
1. A large diameter suction line with a minimum amount of elbows and clipper that can optionally be plumbed to tank. The shock clipper
sharp turns is recommended to prevent pump cavitation. As a can limit the extent of dynamic pressure spikes that are imposed on
guide, the size of the suction line should be as large or larger than the pump and circuit. It will also minimize pressure overshoot
the inlet connection on the pump. The suction line should be (spikes) and undershoot to improve pump stability and pressure
designed without strainers and should avoid screwed pipe joints or decay times. The connection for the shock clipper is located on the
other poor fitting connections that may allow air into the fluid. side of the compensator (control) housing, and if enabled, must be
Cavitation and aeration in the fluid can cause the pump to be individually plumbed to tank.
damaged, unstable, and noisy. IMPORTANT: When enabled, the shock clipper can create additional
2. The outlet line should be properly supported to resist the loading control leakage that may decrease pump efficiency. On certain smaller
from changes in the system pressure. Vibration dampening supports systems with limited cooling capability, this could result in higher fluid
should be located as close as possible to the pump outlet. temperatures than desired. In these cases, pump efficiency will be
maximized by not connecting the shock clipper.
3. The case drain line should be less than 10 ft. [3 meters] long and
lead directly back to the reservoir in a location that is always below 16. For VPV45 – 164 models, the shock clipper is internal to the
the fluid level but away from the suction line. As a guide, use a compensator design and does not need to be externally plumbed.
pipe/hose size for the case drain line as large as the case drain Pump Alignment
connection size in the pump. 17. Obtaining proper shaft alignment is necessary to minimize
4. Do not use manual positive shut off valves in the case drain line. equipment noise, vibration, and internal pump wear. Alignment
Do not use spring loaded check valves in the case drain line. should be less than 0.006" [0.152mm] by the methods shown in
5. Restrictions in the case drain line should be avoided if possible, but Illustrations 1 and 2.
certain swing style (low mass) check valves and heat exchangers
sized for low pressure drops may be installed in the case drain line
of VPV and SV pumps.
6. Shaft seal failures or reduced shaft seal life will occur if the Illustration 1
Dial Indicators
maximum case pressure of 10 psig [0.7 bar] is exceeded.
7. Do not connect case drain lines of multiple pumps into one
common line or header. This can lead to excessive pump case
pressures and/or pressure spikes that could damage the shaft seal
and other internal pump seals. Dynamic pressure variations in the
case pressure can cause pump instability to occur.
Electric Motor Shaft
8. The case drain lines and main return line in the reservoir should be
separated from the pump inlet line by a baffle system. This insures
maximum heat dissipation and de-aeration of the fluid before re-
entering the pump.
9. To minimize noise and vibration energy that could be transmitted to Illustration 2
Dial Indicators
the hydraulic system, dampening flanges and supports should be
used between the pump motor group and the rest of the hydraulic
system. When possible, use flexible hoses in place of hard pipe to
prevent un-necessary vibrations. Hoses must eventually be
replaced, so the layout of the hydraulic system should reflect this
future maintenance requirement.
Electric Motor Shaft
10. It is recommended that a low resistance check valve be installed in
the hydraulic circuit downstream of the pump to prevent back-flow
through the pump on system shutdowns. This in-line check valve can
also prevent possible pump stability problems in circuits with large
system capacitance (hoses, accumulators, large cylinders, etc.).
Pump Installation
ILLUSTRATION1 – Two precision dial indicators must be used in order
11. Bosch Rexroth hydraulic vane pumps should only be installed in a to insure proper alignment in the vertical, horizontal and parallel planes.
new hydraulic system after the system has been flushed of
contaminants that could damage the pump (for filtration The coupling halves can be either engaged or disengaged. If
requirements, see paragraph 22). Verify fluid cleanliness prior to disengaged, the outside diameter of the pump coupling must be smooth
installing the pump in the hydraulic system. and machined true in respect to the coupling bore.
12. Mount the pump to a rigid base or bell housing, such that the pump Proper alignment is achieved when neither indicator varies more than
is no more than 3 ft. [1 meter] vertically above the fluid level in the 0.006 inches (0.152 mm) during one complete revolution of the shaft.
system reservoir. The VPV and SV pumps can be mounted in any ILLUSTRATION 2 – One indicator rides on the inside face of the pump
orientation. coupling. MeasuRIng parallel offset alignment, as in illustration #1,
13. After the pump has been secured, remove all plastic protective cap proper alignment is achieved when neither indicator varies more than
plugs and port covers just prior to attaching the fluid lines. 0.006 inches (0.152 mm) during one complete revolution of the shaft.
14. Carefully connect the inlet, outlet, and case drain plumbing to the CAUTION: – The coupling selected should provide a clearance fit on the
pump while paying special attention not to introduce any foreign pump and motor shafts. never use couplings with interference or sweat fits.
material inside the pump. Do not force hard or rigid piping to Do not press jaw coupling hub together tightly. Allow air gap between hub
align with the pump ports. This could potentially cause mis- and insert to prevent end thrust into pump rotor which will damage pump.
alignment of the pump motor group or damage the pump internals. No external forces (other than rotational) should be applied to the shaft.
2 Installation Manual VPV and SV Variable Volume Vane Pumps Bosch Rexroth
Fluid Recommendations and Filtration Pump and System Settings

18. Bosch Rexroth recommends the use of premium quality grade 28. Once the pump is primed and operating properly, pressure
hydraulic fluids with anti-wear additives, although anti-wear additives adjustments can be made by placing the pump in deadhead
are not required. Please refer to Bosch publications “Petroleum (blocked circuit, no pump flow) and turning the adjustment knob on
Hydraulic Fluids” (9 535 233 456) and “Fire Resistant Fluids” (9 the compensator. Each pump is factory set to a maximum pressure
535 233 457) for additional information. Bosch Rexroth supports of approximately 500 psi [35 bar] for shipment purposes. Turning
the fluid products of most major fluid suppliers, but contact the the adjustment knob in a clockwise direction will increase maximum
factory with specific questions. pump pressure (compensator setting). Once the desired
19. When using hydraulic hoses, always consider the compatibility of compensator setting is reached, tighten the locknut on the
the hose material to the hydraulic fluid and design accordingly. adjustment stem to lock the adjustment in place.
20. The optimum viscosity range for VPV and SV pumps are as follows: 29. The compensator setting of the pump should be adjusted as low as
possible, but high enough to meet all system demands. Keeping the
VPV Models SV Models Optimum Operating Viscosity maximum pressure as low as possible extends the pump life, reduces
the amount of thermal energy generated in the hydraulic system, and
VPV16/25/32 SV10/15/20/25 150–250 SUS (32–54 cSt) decreases energy consumption of the motor.
VPV45/63/80 SV40 200 – 300 SUS (43–65 cSt) 30. The maximum pressure setting of the pump (compensator setting)
VPV100/130/164 SV80/100 200 – 300 SUS (43–65 cSt) needs to be a minimum of 100 psi [7 bar] or greater above the
maximum peak full flow operating pressure in the system. If this
21. The maximum inlet fluid temperature for all VPV pumps is 140°F pressure differential is not great enough, pressure spikes in the
[60°C]. Always select the hydraulic fluid for optimum viscosity at system can cause the pump to become unstable or lose output
operating temperature. flow.
22. The Bosch Rexroth requirements for filtration according to ISO/DIS 31. The pressure differential between the maximum pump pressure and an
4406 is 18/15 or better for pressures up to 2000 psi [140 bar]. inline relief valve should also be set to a minimum of 100 psi or more.
For continuous operating pressures between 2000 psi and 3000 Adjusting the relief valve setting too close to the pump compensator
psi [210 bar], fluid cleanliness should be 17/14 or better. setting can cause the pump to become unstable.
23. In addition to pump wear, some of the known effects of system 32. If the VPV or SV pump is equipped with a mechanical stroke limiter
contamination are pump instability or the inability of the pump to (sometimes referred to as a volume control), adjust the output flow
build full pressure due to sticking compensator spools, increased to the desired value. Adjustments of the stroke limiter should only
friction, or clogged orifice-type passageways. Regular maintenance be done while the pump is running at full flow and low pressure.
and proper filtering of the hydraulic system can prevent these Clockwise rotation of the stroke limiter adjustment will cause the
problems from occurring. pump flow to decrease. Once the desired flow is reached, tighten
Pump and Motor Start-Up the locknut on the stroke limiter adjustment stem to lock the
24. VPV and SV pump casings do not need to be full of oil for the adjustment in place.
pump to operate properly. This means that for the VPV and SV Thank you for choosing Bosch Rexroth products, and if you need
pumps, case pre-filling is not required. further information or assistance, please contact your local Bosch
25. If the VPV or SV pump has a mechanical stroke limiter (sometimes Rexroth distributor.
called volume control), the stroke limiter should be adjusted to IMPORTANT REFERENCES:
provide at least 50% of the maximum flow on start-up (pump flow is VPV Service and Repair Guide, document number 9 535 233 872
increased by turning the adjustment screw counter-clockwise). This VPV Whisper™ pump catalog, document number 9 535 233 724
is a precaution that will insure that the pump primes when started.
26. With no load on the system (i.e. open center valve), jog the electric
motor a few times and observe the hydraulic system for leaks. Re-
start the motor and insure that the pump primes before making any
further adjustments. The audible tone of the pump should change
as the pump begins to prime. Do not operate the pump for more
than 10 seconds without the pump priming or the pump may
be damaged.
27. There should be a provision in the design of the hydraulic system
that allows the trapped air in the system to vent at start-up. Any air
that remains trapped in the hydraulic system may cause pump
instability or unwanted noise problems. If necessary, incorporate an
automatic bleed valve in the hydraulic circuit near the pump outlet
to purge the air from the system.
Bosch Rexroth Corporation

Industrial Hydraulics Division
7505 Durand Avenue
Sturtevant, Wisconsin 53177
Phone: (262) 554-7100
Fax: (262) 554-7117
www.boschrexroth-us.com
9 535 233 783 11/01

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INSTALLATION MANUAL Industrial Hydraulics

Bosch Rexroth VPV

Fluid Recommendations and Filtration Pump and System Settings

Bosch Rexroth Corporation

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