HPSU Rexorth

Bosch Rexroth AG
Industrial Hydraulics
Hydraulics for Energy Technology, Turbine Control
Zum Eisengießer 1
97816 Lohr am Main
AMRAVATI
BHARAT HEAVY ELECTRICALS LTD.
BHEL Purchase Order No. B0V7060 ( 4500201006 / I18 )
Rexroth Sales Order No. 1005335855

reg. naming data sheet
Documentation
Actuators "AMRAVATI"
1 General description
2 Instruction manual
3 Circuit diagram HS-A11-P295-2-B

4 Parts list PL_1005335855_Amravati_A
5 Actuator drawings D901272_EBZ_E
D901272_EBZ_E
D901273_EBZ_E
D901274_EBZ_E
D901275_EBZ_E
6 Spare parts drawings and -lists D901272_TLL_E
D901273_TLL_E
D901274_TLL_F
D901275_TLL_G
7 Junction box diagrams for Bosch Rexroth hydraulic actuators ES-A11-P295-4-B
8 Test report for actuators D901272_1042A
D901272_1043A
D901272_1046A
D901272_1047A
D901272_1050A
D901272_1051A
D901272_1054A
D901272_1055A
D901272_1056A
D901272_1057A
D901273_1038A
D901273_1039A
D901273_1042A
D901273_1043A
D901273_1046A
D901273_1047A
D901273_1050A
D901273_1051A
D901273_1052A
D901273_1053A
D901274_1038A
D901274_1039A
D901274_1042A
D901274_1043A
D901274_1046A
D901274_1047A
D901274_1050A
D901274_1051A
D901274_1052A
D901274_1053A
D901275_1038A
D901275_1039A
D901275_1042A
D901275_1043A
D901275_1046A
D901275_1047A
D901275_1050A
D901275_1051A
D901275_1052A
D901275_1053A
Documentation
9 Inspection certificate B for actuators D901272_1042

D901272_1043
D901272_1046
D901272_1047
D901272_1050
D901272_1051
D901272_1054
D901272_1055
D901272_1056
D901272_1057
D901273_1038
D901273_1039
D901273_1042
D901273_1043
D901273_1046
D901273_1047
D901273_1050
D901273_1051
D901273_1052
D901273_1053
D901274_1038
D901274_1039
D901274_1042
D901274_1043
D901274_1046
D901274_1047
D901274_1050
D901274_1051
D901274_1052
D901274_1053
D901275_1038
D901275_1039
D901275_1042
D901275_1043
D901275_1046
D901275_1047
D901275_1050
D901275_1051
D901275_1052
D901275_1053
10 2- way cartridge valves RE21010
type LC 32 A40E7X/V
type LFA 32 WEA27-7X/V
11 Poppet direct valve direct operated RE22058
type M-3SEW6U3X/420MG24N9K4/V
type M-3SEW6C3X/420MG25N9Z2/B08V SO214
12 Servo directional valve in 4- way design RE29583
type 4WS2EM10-5X/30B11T315K31CV-114
type 4WS2EM10-5X/60B11T315K31CV-114
Documentation
13 Displacement transducer Sensor BTL5…

type BTL5…
14 Assembly, commissioning and maintenance of industrial valves RE07300
15 Installation, commissioning and maintenance of electro-hydraulic RE07700

servo and high response control valves
16 Assembly, commissioning and service of hydraulic systems RE07900
17 High pressure filters mfr Fa. Hydac
type DFP E 060 QB 25BM1.X/-V-W

type DFP BH/HC 060QB 10BM1.X/-V-W
Description
Electro-hydraulic drives (EHA3)
Control and trip actuators
General
The electro-hydraulic drive consists of an actuator, a directly attached disk spring column, a flanged-on
control block and an integrated position transducer.
The pilot oil is supplied externally from a central supply power unit.
The electric power supply and the signal transmission are realized via a loom of cables with plug-in
connectors.
Control actuator
The drive consists of a double rod cylinder (piston rod on both sides). The piston which is pressurized in
the opening direction and depressurized in the opposite direction is guided in the cylinder. The
depressurized chamber behind the piston is sufficiently large to accommodate the fluid quantity involved in
closing processes.
A position transducer made by Balluff is provided for position sensing.
The connection to the central pilot oil supply is via a pressure port (P) and a tank port (T).
Control block
Depending on the version, the control block includes a servovalve of special design (ground on one side)
for the control functions or a directional valve for actuating the valve for the tripping function. Filters are
installed to prevent dirt from entering the system.
Both, control and trip actuators are provided with a superimposed emergency tripping feature consisting of
two redundantly arranged 2-way poppet valves including two directional seat valves for their pilot control.
All the control components are connected by a control plate via internal channels to the cylinder (no
pipework).
Operating principle
As for the control actuator, the actuator piston is controlled by the servovalve, which in turn receives its
control signals from a controller according to a preselected position command value. The actuator is
controlled by moving it on one side against the disk spring column. The actual value is continuously
checked by means of a command/actual value comparison that is realized through the position transducer
on the actuator.
With the trip actuator, the actuator piston is controlled by the directional valve which is energized or de-
energized, respectively, for the slow opening or closing of the associated valve during normal extending or
retracting of the actuator.
In the case of an emergency trip, the directional seat valves, which operate according to the closed-circuit
principle, are de-energized, with the pressure being reduced via the poppets of the 2-way poppet valves.
The valves are opened by the pressure applied by the control actuator below the poppets, thus introducing
the emergency trip process.
The actuating time of the drive in the closing direction is determined by the throttle VM.
A dampening feature provides a smooth closing sequence. The closing characteristics are determined by
the opening of the gap and the throttle.
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
Steam Energy Cylinder

Type: CXE1...2X/...
Operating Instructions
These instructions must be read and applied by every person au-
thorized to work on the energy cylinder.
The safety regulations in Chapter 3 in particular must be read and

observed.
A copy of these instructions must always be kept at the energy

cylinder location.
Publisher Bosch Rexroth AG
Systems & Engineering
Zum Eisengießer 1
D-97816 Lohr am Main
Tel.: +49 (0) 9352/18-1178

Fax: +49 (0) 9352/18-1054
Doc No. CCE_ANTRIEBE-GE-CXE1-2X_BAL_V10_EN.doc
Issue date 07.06.
Copyright © Bosch Rexroth AG 2006
The contents of this publication—including extracts thereof—must

not be disclosed to third parties without written permission from
Bosch Rexroth. All technical specifications, drawings etc. are gov-
erned by copyright law.
2 / 44 CCE_ANTRIEBE-CXE1-2X_V11_EN.doc
Content
Content
1 Identifying the product..............................................................................................6
1.1 Checking delivery................................................................................................6

Scope ..............................................................................................................................6
Delivery condition ............................................................................................................6
1.2 Identifying the energy cylinder ............................................................................7

Rating plate .....................................................................................................................7
1.3 Proper use ..........................................................................................................7
1.4 Improper use.......................................................................................................8
2 Product documentation ............................................................................................9
2.1 About the Operating Instructions.........................................................................9

Characters and icons used..............................................................................................9
Safety and warning instructions ....................................................................................10
2.2 Technical drawing ............................................................................................. 11
2.3 Parts list/spare parts list.................................................................................... 11
3 General safety regulations ..................................................................................... 13
3.1 Basic principles ................................................................................................. 13
3.2 Key installation instructions............................................................................... 13
3.3 Safe operation................................................................................................... 14
3.4 Working on the energy cylinder.........................................................................14

Qualification of personnel..............................................................................................14
Personal protection equipment......................................................................................15
Installation, maintenance, repair ...................................................................................15
3.5 Structural modifications..................................................................................... 17
3.6 Residual hazards posed by the energy cylinder................................................ 17
CCE_ANTRIEBE-CXE1-2X_V11_EN.doc 3 / 44
Content
4 Technical description ............................................................................................. 19
4.1 Possible applications ........................................................................................ 19
4.2 Energy cylinder ................................................................................................. 19

Components ..............................................................................................................19
Function of actuator and switching drive .......................................................................21
5 Transportation and storage.................................................................................... 24
5.1 Storing/conserving the energy cylinder ............................................................. 24

Storage method .............................................................................................................24
Conservation method ....................................................................................................24
5.2 Lifting and transporting the energy cylinder ...................................................... 25

Weight data ................................................................................................................. 25
Lifting gear and fastening equipment/fastening points ..................................................25
6 Installation and commissioning............................................................................. 28
6.1 Preparing for mounting ..................................................................................... 28
6.2 Mounting the energy cylinder onto fitting .......................................................... 29

Installation, positioning and fastening the cylinder to the "yoke". ..................................29
6.3 Connecting the energy cylinder to the pressure line ......................................... 30
6.4 Electrical connection for the energy cylinder..................................................... 31
6.5 Commissioning the energy cylinder .................................................................. 32
7 Operation ................................................................................................................. 34
7.1 Normal operation .............................................................................................. 34
8 Inspection and maintenance activities.................................................................. 36
8.1 General ............................................................................................................. 36
8.2 Inspection and maintenance chart .................................................................... 38
8.3 Maintenance activities on the energy cylinder................................................... 40
9 Service addresses................................................................................................... 42
9.1 Service locations in Europe............................................................................... 42
4 / 44 CCE_ANTRIEBE-CXE1-2X_V11_EN.doc
Content
9.2 Service locations in America ............................................................................. 42
9.3 Service locations in Asia ................................................................................... 42
10 Disposal ................................................................................................................... 43
Personal notes
1 Identifying the product

These Operating Instructions are applicable for type
"CGE1 …2X /…" and "CXE1...2X/..." electro-hydraulic drives
manufactured by Bosch Rexroth AG, Lohr am Main.
1.1 Checking delivery
Scope
Before mounting the energy cylinder onto the fitting, confirm that
the following components are contained in the transport packaging:
• Energy cylinder
• Accessories as per packing list
• Supply of documentation:
o Where contractually agreed, the documentation and Op-
erating Instructions will be supplied separately on CD. In
the absence of an agreement for a separate CD, the
documentation and Operating Instructions will be sup-
plied with the drive.
• Documentation:
o Scope as per table of contents
Delivery condition
The energy cylinder is delivered with piston rods retracted or ex-

tended to limit stop, depending on design. The design concerned is
specified in the type designation and/or the installation drawing.
The energy cylinder contains a residual amount of hydraulic oil on
delivery.
Supplied accessories are mounted as stated on the packing list or

have to be mounted onto the energy cylinder.
Check conformity of A name plate is affixed to the energy cylinder housing. It contains
delivered parts the precise type designation, serial number/commission number
and other key data.
6 / 44 CCE_ANTRIEBE-GE-CXE1-2X_BAL_V11_EN.doc
Identifying the product 1
Compare the serial number/commission number on the name plate

with those in the test report log supplied as an attachment to these
Operating Instructions (see Chapter 1 and documentation).
Notify Bosch Rexroth immediately if,

• the delivery is not complete
• the delivery differs from the delivery note or the packing list
• the data on the rating plate is inconsistent with that in the
technical drawing or parts list
• the serial number/commission number on the energy cylin-
der is inconsistent with the number in the test report.
Operating Instructions, technical drawings, test reports and parts
lists must always be stored together.
1.2 Identifying the energy cylinder
Name plate
Type "CGE1...2X/..." (extending) and "CXE1…2X/…" (retracting)

energy cylinders are clearly identifiable by their name plates.
1.3 Proper use
The energy cylinders serve as control – or trip actuators for control

or trip valves on steam turbines.
Their use is reserved for:

• Locations for which the energy cylinder was designed as a
drive
• Forces (on spring assembly) described in the manufac-
turer's documentation
• Temperatures described in the manufacturer's documenta-
tion
• Use in suitable rooms
• Valves for which the energy cylinder is designed as per the
project planning.
1.4 Improper use
Any application that does not conform to the defined specifications

is considered improper use.
This comprises:
• Locations for which the energy cylinder was not designed
• Forces (on spring assembly) that do not satisfy the speci-
fied requirements
• Temperatures that deviate from those in the manufacturer's
documentation
• Valves for which the energy cylinder is not designed as per
the project planning
Improper use may result in physical injury to the user or other third
parties. The energy cylinder itself or other materials may also be-
come damaged.
Product documentation 2
2 Product documentation
The following documents are supplied with the energy cylinder:
• Scope as per table of contents
2.1 About the Operating Instructions
The Operating Instructions contain important notes on how to use

the energy cylinder safely for its intended purpose. Observing the-
se notes will help to:
• avoid risks
• minimize repair and outage costs
• increase the reliability and the service life of the drive
The Operating Instructions contain information on

• Installation/dismantling
• Operation
• Maintenance
• Repair
• Transportation
• Disposal
Characters and icons used
Î The text after this character describes activities that are to be

carried out from top to bottom in the sequence indicated.
9 The text after this character describe the result of an action.
Note: The word "Note" is followed by notes and useful tips on

optimized use of the energy cylinder.
Safety and warning instructions
Special safety regulations could be necessary for individual work.

These safety instructions for the respective activity can be found in
the Operating Instructions. They are clearly highlighted with a
warning character (pictograph). Different signal words are used,
depending on the severity of the hazard.
Signal word Possible consequences if the safety instructions are

not observed:
DANGER Fatal or severe injuries.
WARNING Possibly fatal or severe injuries.
IMPORTANT Minor or slight injuries.
NOTE Material damage to the energy cylinder or the surrounding
area.
Tab. 2.1: Signal words and their use
Warning character Special safety information is given at the relevant positions. It is

identified with the symbol below.
General hazard zones
This character precedes activities that pose a risk of general per-

sonal injury.
Risk of crushing
This character precedes activities that pose a risk of fingers or

hands being crushed.
Suspended loads
This character precedes activities during which raised loads may

drop and cause personal injury.
Material damage
This character precedes activities that pose a risk of extensive

property damage.
Product documentation 2
2.2 Technical drawing
The following technical drawings are supplied:
• General arrangement drawing with dimensions

A full illustration of the energy cylinder is shown on the
General Arrangement (GA) drawing. It contains all dimen-
sional, weight and technical data on the cylinder. All dimen-
sions relate to the "zero system" position (valve closed) for
the cylinder. These may deviate from the delivery condition
(cylinder fully extended/retracted).
• Hydraulic circuit diagram

• The hydraulic circuit diagram explains the energy cylinder
function.
• The indicated component numbers are explained in the cor-

responding parts lists.
• Terminal diagram
• The terminal diagram explains the terminal assignment in
the terminal box.
• Spare parts list
• (see Item 2.3)
2.3 Parts list/spare parts list
The parts list is a separate list supplied with the energy cylinder.
It contains the components used on the energy cylinder concerned.
Replacement components can be re-ordered as per the replace-

ment parts list. We recommend keeping an adequate supply of
spare parts in stock.
Personal notes
General safety regulations 3
3 General safety regulations

This Chapter contains a summary of all the relevant safety regula-
tions.
All persons engaged in activities on the energy cylinder must

read and observe this Chapter.
3.1 Basic principles
The energy cylinder is built to state-of-the-art technology and com-

plies with the recognized safety-related regulations. Nevertheless,
their use can pose danger for life and limb of the user or a third
party, as well as extensive property damage, if:
• the energy cylinder is not used for its intended purpose
• the energy cylinder is inappropriately modified or converted
• the safety regulations and instructions are not observed.
The energy cylinder may be operated only when technically sound,
for its intended purpose and with regard for the safety and hazard
issues described in these Operating Instructions!
3.2 Key installation instructions
Employ suitable measures (e.g. pressure relief valves) to guaran-

tee maximum hydraulic pressure for the energy cylinder.
Provide equipotential bonding (electrical grounding) mechanism!
3.3 Safe operation
When the energy cylinder is in operation, do not reach into the area
around the piston rods or into the area in which the drive can be
coupled to a steam valve. Risk of injury from crushed fingers if the
drive is actuated.
Never actuate the energy cylinder at a hydraulic pressure higher

than that indicated (normal operating pressure 110 bar or 165 bar
depending on design).
Do not touch the energy cylinder; the system transports hot media.
If touching the cylinder element or ancillary components cannot be
avoided, wear heat-resistant gloves.
Connectors (e.g cable sockets) may only be plugged in or un-

plugged when the electrical power supply is disconnected.
3.4 Working on the energy cylinder
Qualification of personnel
Installation, Installation, maintenance, repair and troubleshooting activities re-

maintenance quire specific knowledge and may only be carried out by qualified,
and repair specially trained personnel who are instructed to do so.
• Work on electrical equipment must only be carried out by a

trained electrician or by supervised persons under the direction
and supervision of a trained electrician in accordance with elec-
tro-technical regulations.
A trained electrician is that person who can evaluate work
transferred to him, recognize possible dangers, and take suit-
able safety measures because of his technical training, knowl-
edge and experience, as well as knowledge of pertinent regula-
tions.
• Work on hydraulic components may only be carried out by

qualified personnel with special knowledge and experience of
hydraulics.
Transportation, Transportation, assembly, installation, commissioning and disposal

assembly, installation, may be carried out only be qualified personnel instructed to do so.
commissioning,
disposal
Personal protection equipment
Where necessary, use suitable personal protection equipment, e.g.

safety gloves, hard hat, protective suit, goggles, safety shoes etc.
to carry out work.
Installation, maintenance, repair
Carrying out work that has not been authorized by Bosch Rexroth
will invalidate the warranty.
Repairs may only be carried out by qualified personnel of the

manufacturer. Before units and/or components are opened, they
and the entire energy cylinder must be disconnected from the
mains, depressurized and secured to prevent unauthorized recon-
nection
Prior to commencing Only carry out service work (maintenance and repair) on an energy
work cylinder installed in a system if this has been explicitly approved by
an individual in charge.
System sections and pressure lines to be opened must be depres-

surized and the medium removed prior to starting work.
Work may only be carried out on electrical components when the

power supply has been disconnected.
Shut-off the power supply to electrical connections prior to installa-

tion and dismantling.
Electrical connectors: DO NOT SEPARATE WHEN ENERGIZED!
If maintenance and repair work necessitate dismantling protective

devices or safety equipment, the parts must be reinstalled directly
after the maintenance and repair work is finished and their function
must be checked.
Ensure that the drive is separated from the hydraulic supply prior to
working on the energy cylinder.
Allow energy cylinder components to cool down. If touching the

energy cylinder cannot be avoided, wear heat-resistant gloves.
Prevent the energy cylinder from being unintentionally pressurized

or energized.
During work Never stand under a suspended load when transporting or disman-
tling the energy cylinder.
Ensure appropriate use of lifting gear and tools.
Use only transporting and fastening equipment that can reliably

support the weight of the load.
Route and install hydraulic lines properly. Do not interchange con-

nections. The length and quality of the lines must satisfy the re-
quirements.
Only welding nipples or reforming threaded joint systems with soft
seals or flanges are permitted.
The use of cutting ring bolts or hydraulic hoses is not permitted!
The springs on the energy cylinder are pre-tensioned. Risk of in-

jury. Housing can and may only be opened by qualified personnel
of the manufacturer using special accessories.
Replacement parts must meet the technical specifications defined

by the manufacturer. This is guaranteed by the use of genuine re-
placement parts. Only genuine replacement parts may be used.
Ensure warning signs on the energy cylinder are legible at all ti-
mes. Damaged or illegible signs must be replaced.
The periods for maintenance and monitoring work specified in the-

se Operating Instructions must be respected and such activities
recorded.
Observe applicable safety regulations when working with oils,

grease and other chemical substances.
Never use benzene or other highly flammable substances for

cleaning.
Use only lint-free cleaning cloths.
On completion of the Refit dismantled protection devices immediately on completion of

work the maintenance and repair work and check they function correctly.
On commissioning, examine the energy cylinder for leaks, loose

connections and outwardly visible damage. Rectify any obvious
defects immediately.
Dispose of operational and process materials in a safe and envi-

ronmentally friendly manner. Dispose of hazardous substances in
accordance with the Operating Instructions applicable to them.
On completion of all work, check all connections and threaded

joints for leaks.
On completion of all work, the threaded joints on all components

must be checked for correct fit.
3.5 Structural modifications
Arbitrary modifications to the energy cylinder are not permitted for

safety reasons.
Likewise, for EMC reasons, no modifications may be made to the

installation (cable, connections, shielding).
Parts and components are designed specifically for the energy cyl-
inder. We would like to expressly bring to your attention that parts
and special equipment not supplied by us are not released by us.
The mounting and/or use of such products can affect safety.
3.6 Residual hazards posed by the energy cylinder
Risk of accident during transportation, installation and dismantling

of the energy cylinder caused by uncontrolled movements (e.g.
dropping) during lifting operations. Observe standard safety and
UV rules for accident prevention.
Risk of injury posed by contact with hot media or toxic vapors.
Risk of injury caused by unintentional extension or retraction of

piston rod ⇒ opening/closing of valve (armature) during commis-
sioning, maintenance, repair or operation.
Risk of fingers or hands being crushed if they become trapped be-

tween energy cylinder and valve as the energy cylinder is being
lowered. General risk of crushing when the drive is being installed
on and dismantled from the fitting.
Risk of scalding if hot oil comes into contact with skin when the
energy cylinder is being removed.
Risk of being burned by hot solenoids during operation.
Only work on the energy cylinder under adequate lightning
Environmental risks caused by leaks on the energy cylinder and

escaping toxic or damaging media (e.g. hydraulic oil, HFD phos-
phate ester) penetrating soil or ground water.
Accident and environmental risk caused by residual oil escaping

when the energy cylinder is installed and dismantled.
WARNING: The energy cylinder comprises a pre-tensioned spring

assembly. Near fatal or fatal injuries if the spring assembly sud-
denly releases during dismantling.
Caution! The maintenance intervals must be respected. The warn-
ing signs must be checked, cleaned and where necessary re-
placed. Special tools and qualified personnel are required for dis-
mantling and installation activities. The manufacturer must be con-
tacted.
Electric shock! Only qualified electricians may work on the

cabling in compliance with the standard safety guidelines.
Caution:
Faulty connections may destroy the high-quality electronics or trig-
ger uncontrolled movements within the hydraulic system.
Î Control loops may only be commissioned by appropriately
qualified personnel.
Faulty connections may cause excessive housing voltage and high

leakage current.
Î Risk of fatality through shock currents
Î Risk of injury through electric shock
Î Risk of injury through burning
Technical description 4
4 Technical description
4.1 Possible applications
Type "CGE1 …2X /…" and "CXE1...2X/..." energy cylinders are

used as control or trip actuators for control or trip valves on steam
turbines.
4.2 Energy cylinder
Energy cylinders are electro-hydraulic drives and comprise a pre-

tensioned spring assembly. They are classified as double rod cyl-
inders.
The spring's direction of action is always towards valve close
(mech. fail safe).
The energy cylinder is mounted to the valve such that the valve
remains completely tight should the hydraulic pressure fail.
Components The principle structure of an energy cylinder with its most important
components is shown in Fig. 4.1
Fig. 4.1: Components of the energy cylinder (example figure is a control actuator)
Cylinder The energy cylinder is designed as a double rod cylinder with pis-
ton rods on both sides. A coupling half is located at the end of the
piston rod. The cylinder housing accommodates three separate
ports for pressure (FRS and FSS) and tank (FRD).
Hydraulic controller The cylinder is hydraulically controlled via the housing, which con-
siders the functions required to control the cylinder.
Spring column The drives contain a spring column comprising disk springs grou-
ped together to form an assembly. The spring assembly is de-
signed in accordance with the customer's specification. It is located
in the front part of the cylinder and guarantees safe closure (of the
valve) in the event of a pressure drop.
The spring column is safeguarded from external influences by a
protective housing. Any condensate forming in the housing is
largely dissipated through special structures. The customer must
also arrange further protection measures to prevent the ingress of
moisture and vapor.
Anti-rotation In contrast to the control valve the trip valve actuator does not fea-
mechanism ture an anti-rotation mechanism.
Coupling The connection between energy cylinder and valve is provided by

the mounted coupling half. The counterpiece must be provided by
the customer.
Transport device 2 transport profiles are mounted to the energy cylinder housing and
the flange also carries 4 eyebolts suitable for supporting the weight
of the cylinder.
The cylinder can be lifted and transported by a suitable hoist using
these transport profiles and/or eyebolts.
Displacement The DT report the position of the piston rods to the control-
fransducer ler/regulator. The valve opening can be determined by the position
of the piston. For DT used, see parts list. Further information is
contained in the Operating Instructions of the DT = Displacement
transducer.
Limit switches The limit switches indicate the position of the cylinder piston at an
(optional) upper and/or lower end point.
Further information on the optional limit switches is contained in the

parts list and in the description of the limit switches.
Function of control - and trip actuator
General The electro-hydraulic drive consists of positioning cylinder, directly

mounted disk spring columns, built-on hydraulic function and inte-
grated or mounted displacement transducer.
The control oil is supplied externally from a central supply unit.
The electrical power is supplied and signals are transferred via a

terminal box.
Cylinders The drive consists of a double rod cylinder (piston rods on both
sides).
Inside the cylinder housing, the piston rod is moved in the direction
of the steam opening valve through hydraulic pressurization and
the spring column is tensioned at the same time. The piston is
moved in closing direction of the steam valve only by spring force,
where the liquid from the pressure chamber is pushed into the tank
chamber through internal bore holes in the cylinder housing.
Displacement transducers (ultrasonic and/or inductive) and optional

limit switches are integrated or mounted for position recording. The
connection to the central control oil supply is made by three sepa-
rate ports for pressure (FRS and FSS) and tank (FRD).
Hydraulic function Depending on its design, the hydraulic function contains

• a special type of servo valve (e.g. 3-coil and biased) for the
control function or
• the directional control valve for driving the fitting for the switch-
ing function.
To prevent the ingress of dirt, a filter is installed in the control oil
supply of the servo valve at the pressure connection (FRS) for the
actuator. Actuator and switching drive also feature a filter for pre-
venting spontaneous failure through coarse impurities in the hy-
draulic medium.
Control and trip actuator both have a superimposed trip consisting

of a 2-way integrated valve actuated via an external hydraulic sig-
nal. An upstream directional control valve provides the venting
function and permits a drive stroke test.
All control components are connected to the cylinder chambers via
internal channels in the housing (no piping).
Mode of operation The control actuator is controlled via the servo valve, which is
actuated to a preset position value by the controller. The displace-
ment transducer on the actuating cylinder continuously checks the
actual value by means of a reference/actual comparison. The con-
trol equipment required is provided by the customer.
The trip actuator is controlled via the directional control valve,

which is de-energized and energized for slow opening and closing
of the corresponding valve during normal run-up and shut-down of
the system.
On both the actuator and switching drive, the two-way cartridge

valve is held shut by an external hydraulic signal.
The turbine trip function involves the two-way cartridge valve being
opened by the directional switching of an external, hydraulic signal.
This occurs by means of the associated pressure drop over the
cone of the two-way valve. The pressure present on the cone
(caused by the force of the spring assembly on the drive) opens the
two-way valve and initiates the trip action.
The actuation time for the drive to close is determined by the VM

orifice(s).
The permitted closing speed shortly before the final position of the
steam valve is guaranteed by a hydraulic damping. This is deter-
mined by a VD orifice.
Further information is contained in the attached hydraulic circuit

diagram.
An additional spool valve (FASV) in the line of the external hydrau-

lic trip signal allows to check the fast closure feature works on test.
Personal notes
5 Transportation and storage
5.1 Storing/conserving the energy cylinder
Storage method
The energy cylinders must be stored as follows:

• Do not store outdoors, but rather under a roof or in a well-
ventilated room. The energy cylinders must be protected from
direct sunlight.
• Protect from ground moisture: store on a shelf or wooden pallet.
• Cover to protect from dust and dirt.
• All connections on the energy cylinder must be suitably sealed.
• Once the transport packaging has been opened, it must be
sealed again properly ready for storage.
• Attach an oil collector below the mounting point, as the energy
cylinders are always delivered containing residual oil.
• Leave sufficient space between the individual energy cylinders.
Observe the following for the storage period:
• Longer than 1 year
o Renew the inner and outer conservation
• Longer than 2 years
o Additional function test required
Conservation method
There is a difference between internal and external conservation

(corrosion protection).
Internal conservation The energy cylinders are delivered partially filled (walls and inside
parts covered with test medium). This means that internal conser-
vation is provided by the residual test oil in the cylinder, as long as
the cylinder remains air-tight.
Note: Residual protective agents are only permitted to be a

maximum of 0.1% concentration in the pressure fluid.
Transportation and storage 5
Further information on internal conservation can be obtained from

the manufacturer if required.
External conservation The following applies for external conservation of the energy cylin-
der:
• External conservation is provided by coatings to the customer's
specification.
• Storage periods exceeding 6 months require a suitable finish-
ing-coating. The type of coating system (1 or 2 component sys-
tem) depends on the agents that attack the surface to be pro-
tected.
Further information on external conservation can be obtained from

the manufacturer if required.
5.2 Lifting and transporting the energy cylinder
The energy cylinder packaging varies depending on its dimensions.

They are delivered in boxes on pallets. The load must be secured
for transportation.
The packaging contains information on

• lifting the load (fastening points and weight)
• recognizing the top and bottom of the packaging
Weight data The weight of the energy cylinder is stated, e.g. on the installation
drawing.
Lifting gear and fastening equipment/fastening points
Suitable lifting gear and fastening equipment must be selected and

provided (e.g. crane, fork lift, rope, belt) depending on the installa-
tion site and energy cylinder weight.
Use only lifting gear and fastening equipment that will reliably sup-
port the weight of the load.
Lifting the energy cylinder using a crane:
Î Fasten the rope or lifting strap to the transport profiles on the

cylinder. The maximum load of the transport profiles must be
observed. Ensure the transport bolts and stop profiles are cor-
rectly seated and check for corrosion.
NOTE:
Risk of damage to the energy cylinder if it is raised together
with the valve steam parts.
Î Only raise or transport the cylinder at the transport profiles.
Î Ensure that no add-on parts or cables are trapped.

Î Carefully raise the energy cylinder.
WARNING!
Suspended loads!
Fatal or severe injuries if a person is hit by a falling load.
Î Never stand under a suspended load.
Î Use only lifting gear and fastening equipment that will support
the full weight of the load securely.
Î Use protective equipment (hard hat, safety shoes)
9 You can now carefully transport the energy cylinder to its moun-
ting position. Protect the energy cylinder from impact and vibra-
tion as you do so.
Transportation and storage 5
Personal notes
6 Installation and commissioning
6.1 Preparing for mounting
Preparing to mount the energy cylinder:
Î Have the technical drawing and hydraulic circuit diagram to

hand: check whether type designation and serial num-
ber/commission number on the rating plate are consistent with
the drawing data.
Î Have the tool and implements on hand
Î Carefully raise the energy cylinder from its transport packaging
Î Check that all accessory parts are present.
Î Mount the accessories if it has not already been mounted by
the manufacturer.
Information on mounting the accessories is contained in the
corresponding instructions.
Î Clean the connection surfaces.
The connection surfaces must be completely clean.
Î Check that all threaded joints on the energy cylinder are tight.
9 You can now start mounting the energy cylinder.
Installation and commissioning 6
6.2 Mounting the energy cylinder onto valve steam parts
Installation, positioning and fastening the cylinder to the "yoke"
The energy cylinder must be mounted in accordance with the

specified installation position, the piston rod and valve spin-
dle must be aligned.
This design of energy cylinder can and may only be installed

in accordance with the customer's installation, coupling and
adjustment instructions (e.g. turbine manufacturer).
Installation, coupling and adjustment work must be carried out

by the manufacturer or qualified personnel specially trained by
the manufacturer (e.g. turbine manufacturer).
NOTE:
Material damage if the energy cylinder is installed mis-
aligned!
Mounting the extending drive version:
Î Customer to mount coupling part on valve spindle and align

towards drive coupling as per the turbine manufacturer's mount-
ing instructions.
Î Insert drive into place/fit.
Î Tighten flange bolts evenly (cross-wise), further tensioning the
springs.
Î This fastens the actuator to the valve and moves it from the
uncoupled stroke position (see over-stroke) into the "system 0"
position (fitting closed).
Î Tighten screws at coupling.
Î Respect the tightening torque values in the turbine manufac-
turer's mounting instruction.
9 This completes the mechanical mounting onto the fitting.
Mounting the retracting drive version:
Î Customer to mount coupling part on valve spindle and align

towards drive coupling as per the turbine manufacturer's mount-
ing instructions.
Î Insert drive into place/fit and screw down.
Î Tighten coupling bolts evenly (cross-wise), further tensioning
the springs.
Î This moves the actuator from the uncoupled stroke position
(see over-stroke) into the "system 0" position (fitting closed).
Î Respect the tightening torque values in the turbine manufac-
turer's mounting instruction.
9 This completes the mechanical mounting onto the fitting.
6.3 Connecting the energy cylinder to the pressure line
When connecting the energy cylinder to the pressure line, ensure

that the connections are not crossed on the drive housing.
NOTE:
The pipes must be cleaned before the energy cylinder is actu-
ated for the first time.
Impurities may penetrate the cylinder chambers, damage the seals
or valves and thus cause malfunction.
The drive may only be connected when the supply lines are clean.
Hydraulic fluid: fire resistant fluid (HFDR)

depending on design specification
Maximum permitted degree of contamination
of pressure fluid to ISO/DIN 4406 (C): 18 / 16 / 13
Note: The supply lines must be flushed to be cleaned (see

separate flushing procedure)
Connecting the energy cylinder to the hydraulic lines:
Î Attach the connections to the cylinder using the appropriate

hydraulic lines.
Note: Pressure connection: FRS

Control oil connection: FSS
Tank connection: FRD
Î Tighten the connections as per the applicable instruction.

9 The energy cylinder is connected to the hydraulic lines. You can
now pressurize the cylinder.
6.4 Electrical connection for the energy cylinder
The electrical connection is made solely at the factory-fitted termi-

nal box.
The energy cylinder is delivered with a fitted terminal box that con-
tains the wiring for all the electrical components of the Bosch Rex-
roth energy cylinder.
All connectors and contact points must be checked for secure fit
and safe electrical connection after transportation. The existing
terminal diagram and the machine/system documentation must be
checked for plausibility. Alternatively: The customer's specified
terminal diagram and existing machine /system documentation
must be checked for plausibility.
The terminals area are suitable for connecting to copper wire with a
cross section of 0.34 to 2.5 mm2. Alternative wire cross-section
areas and conductor material must not be used.
The cable material must be modified to suit the environmental con-

ditions. The cable sheath must be resistant to the expected ambi-
ent temperatures and the used hydraulic oil. To guarantee the re-
quired protection, the cables must be inserted into the terminal
housing through suitable screw-in cable glands. The cable must be
correctly routed in accordance with the requirements.
The equipotential bonding (electrical grounding) of the ma-

chine/system must be guaranteed. A suitable connection is pro-
vided and marked with a symbol accordingly. The protective con-
ductor must be installed.
Cabling connecting to terminal housing needs to be properly se-

lected and installed to satisfy EMC requirements.
EN 60204-1 must be observed. The local statutory regulations and

standards, as well as other special regulations must also be ob-
served. (Sequence/priority for application of the regulations to be
clarified)
WARNING!
Electric shock! Only qualified electricians may work on the
cabling in compliance with the standard safety guidelines.
Caution:
Faulty connections may destroy the high-quality electronics or trig-
ger uncontrolled movements within the hydraulic system.
Î Control loops may only be commissioned by appropriately
qualified personnel.
Faulty connections may cause excessive housing voltage and high

leakage current.
Î Risk of fatality through shock currents
Î Risk of injury through electric shock
Î Risk of injury through burning
Risks posed by electrical current must be avoided by observing, as

a minimum, the following safety regulations:
1. Establish safety isolation
2. Secure against reconnection
3. Establish that it is de-energized
4. Cover or establish barriers between neighboring parts that
are under voltage
5. Earth and short-circuit
6.5 Commissioning the energy cylinder
The safety regulations in Chapter 3 "General safety regula-

tions" must be read prior to commissioning. Follow the in-
structions printed out there.
Work on hydraulic components may only be carried out by qualified

personnel with special knowledge and experience of hydraulics.
Work on electrical components may only be carried out by qualified

personnel with special knowledge and experience of electrics.
Putting the energy cylinder into operation:
Î Check that all lines and/or units are correctly connected as

shown on the installation drawing/circuit diagram.
Î Check that all flanges and threaded joints on the energy cylin-
der are tight.
WARNING!
Spurting hydraulic oil caused by incorrect hydraulic line con-
nection.
Hydraulic oil escaping under high pressure and flying parts can
cause serious injury.
Î Before starting the test, check that the hydraulic lines are cor-
rectly connected.
Î Make sure no persons are in the direct vicinity of the energy
cylinder during the test.
Î Instruct any persons in the hazard zone to leave. If necessary
stop the test.
Î Pressurize the pressure connections on the supply lines (FRS

and FSS connections). Start with low pressure.
Î Check that energy cylinder, mounted parts, hydraulic connec-
tion and hydraulic lines are tight.
Î Rectify any defect immediately.
Î Connect the electrical control accessory where necessary.
Î Vent the cylinder. The cylinder chambers can, if required, be
vented through the mini-meas connections at the two cylinder
chambers. Work carefully.
Î Check the cylinder function.
See the hydraulic circuit diagram for potential functions.
Î Rectify any defect immediately.
Î If necessary repeat the function check
Î Adjust the final switch position if necessary. Protective guards
must not be removed. Exception: Extending type control drive
(displacement transducer on side and GO switch). Work care-
fully!
Î Ensure that the mounted steam control valve and/or steam trip
valve are absolutely tight and that no leaks are present. This
must be checked using a suitable leak test and the result docu-
mented.
9 If no defects occur and the valve closes tight, the energy cylin-
der can be commissioned.
7 Operation
7 Operation
7.1 Normal operation
In normal operation, no operating activities are required on the en-

ergy cylinder itself.
The energy cylinder is controlled and regulated via the customer's

control equipment.
Note: The servo valve requires a superimposed dither signal.

Recommendations for frequency and amplitude are pro-
vided in the servo valve datasheet.
Frequency and amplitude must be optimized to the appli-
cation concerned.
The servo valve (excluding control function) must not
provide a safety function.
Operation 7
Personal notes
8 Inspection and maintenance activities

This Chapter describes the inspection and maintenance activities
that may only be carried out by suitably trained and qualified
personnel.
8.1 General
The safety regulations in Chapter 3 “General safety regula-

tions" must be read prior to carrying out maintenance work.
Follow the instructions printed out there.
Work on hydraulic components may only be carried out by qualified

personnel with special knowledge and experience of hydraulics.
Work on electrical components may only be carried out by qualified

personnel with special knowledge and experience of electrics.
DANGER!
Spurting hydraulic oil!
Hydraulic oil escaping under high pressure and flying parts can
penetrate the skin and cause serious injury.
Î If system sections have to be opened, switch off and depres-
surize the system and secure to prevent being switched back
on before doing so.
Setting instructions Setting values for pressure switches and pressure relief valves are
indicated in the corresponding hydraulic circuit diagrams and/or
drawings.
Report all detected defects immediately, so that they can be

swiftly rectified. Please note that minor defects can turn major
if not rectified in time.
Inspection and maintenance activities 8
Never use the following for cleaning:

Benzene or other highly flammable substances
• Compressed air (dirt penetrates the energy cylinder's sensitive
components)
• High pressure cleaner (dirt and moisture penetrate the energy
cylinder's sensitive components)
• Copious volumes of water and cleaning agent
Cleaning equipment • Clean, lint-free cleaning cloths (damp if necessary)

• Standard detergents
8.2 Inspection and maintenance chart
The following table indicates the individual tasks by maintenance

intervals and then by component/assembly.
All maintenance and repair work must be documented.
When? Where? What? Comments

Every 3 Hydraulic components Visual inspection Leaks must be repaired without
months on the energy cylinder delay.
Remove surrounding parts.
Hydraulic lines and
threaded joints Clean up fluid spillages immedi-
ately. Danger of slipping.
Electric connections, Visual inspection If damaged, have replaced without
cables, delay. Check they are fitted cor-
plugs and sockets, elec- rectly.
trical cables
Visual contamination Visual inspection If the visual contamination display
display on the filters on a filter is triggered, the filter
element is contaminated and must
be replaced.
Every 6 Hydraulic components Visual inspection Leaks must be repaired without
months on the energy cylinder delay.
Hydraulic lines and Remove surrounding parts.
threaded joints
Clean up fluid spillages immedi-
Terminal boxes, electri- Visual inspection If damaged, have replaced without
cal connections, cables, delay.
plugs and sockets, elec-
Check they are fitted correctly.
trical cables
Visual contamination Visual inspection If the visual contamination display
display on the filters on a filter is triggered, the filter
element is contaminated and must
be replaced.
All components Clean contaminated parts This makes it easier to spot and
(remove any dust deposits) monitor leaks.
Wipe away escaping oil with a
cloth immediately.
Continued on next page
When? Where? What? Comments

Every 24 Filter Replace filter elements
months
(every 36
months at the
latest)
Poppet valve, directional Check
and/or servo valves - switching times
(where fitted) - function
Displacement Check operation
transducer
Limit switches Check operation
Hydraulic lines Check all lines and threaded Arrange for immediate replace-
joints for leaks and visible ment of hydraulic lines if any of the
damage. following are found:
Have any damage repaired - damage
immediately.
- leaks
Spurting hydraulic oil can cau-
se injury.
Hydraulic components Visual inspection Leaks must be repaired without
on the energy cylinder delay.
Remove surrounding parts.
Clean up fluid spillages immedi-
Electric connections, Visual inspection Have damage (or visible signs of
cables, ageing) repaired immediately.
plugs and sockets, elec-
Check they are fitted correctly.
trical cables, all electri-
cal devices
Disk spring columns, Check for sound functioning Look for signs of corrosion. Re-
spring forces and gui- place heavily corroded parts.
deways (where fitted)
Inspection and maintenance The spring assembly may only be
replaced by the manufacturer.
Contamination Visual inspection
indicator (on filter)
Check operation if necessary
Every 5 years, All seals Replace seals Seals may only be replaced by
every 6 years the manufacturer.
at the latest
Additionally same In addition, same scope as In addition, same scope as every
scope as every 24 months 24 months
Every 24 months
Tab. 8.1: Inspection and maintenance chart
8.3 Maintenance activities on the energy cylinder
All maintenance and repair work must be undertaken by the manu-

facturer or by specially trained personnel (trained by the manufac-
turer) and all work undertaken must be documented
(see Chapter 8.2).
Spare parts Spare parts must meet the technical specifications defined by the
manufacturer. This is guaranteed by the use of genuine replace-
ment parts.
Only the installation of original spare parts and verified parts (i.e.
with documentation) is permissible.
Replacement parts can be ordered from Bosch Rexroth AG using

the data in the parts list and replacement parts list.
Equipment required The following are required to carry out the work:
• standard mechanics tools
• cleaning cloths
Personal notes
9 Service addresses
9 Service addresses
9.1 Service locations in Europe
Bosch Rexroth AG
Service Automation
Bürgermeister-Dr.-Nebel-Str. 8
Tel.: +49 (9352) 18-1164

Fax: +49 (9352) 18-3363
9.2 Service locations in America
Bosch Rexroth Corp.
Service Automation
2315 City Line Road
Bethlehem, PA 18017-2131
Tel.: +1 (610) 694- 8453

Fax: +1 (610) 654- 8670
9.3 Service locations in Asia
Bosch Rexroth Corporation
Service Department
Tsuchiura Head Office and Plant
5 – 1, Nakanuki-machi,
Tsuchiura-shi, Ibaraki-ken, 300-8588, Japan
Tel.: +81-(0)29-834-8151
Fax: +81-(0)29-834-8150
Disposal 10
10 Disposal
The springs on the energy cylinder are pre-tensioned. Risk of in-

jury: Housing can and may only be opened using a special tool.
Contact the manufacturer for further information if necessary.
The drives should be disposed of by means of a certified disposal

operation in accordance with the applicable laws and guidelines.
Note: Residual oil may escape!

Waste/residues/hazardous substances must be disposed
off separately in the containers provided.
Bosch Rexroth AG
Zum Eisengießer 1
Tel +49 (0) 93 52/18-0
Fax +49 (0) 93 52/18-1040
www.boschrexroth.de
T.No. E Mat-No Q. Description Type Manufacturer N.-Sheet
SET 1
Part list for circuit diagram : HS-A11-P295-0 Project: Amravati

Offer Nr.: Name Date Index
Commissionsnr.: 1005335855 Checked.: Frank Weis 20.12.2010 A
Customer: BHEL Drawn.: Frank Weis 20.12.2010
Rexroth
Adr Zum Eisengießer 1; 97813 Lohr Page 1 / 45
Electrohydraulic actuator EHA4 for

HPCV STV 160-177
100. 0 R901186386 1 HYDRAULIC CYLINDER CGE1MF3/140/ 60/..65F20/G5GASSTC-D901274

.020 1 R900058865 1 FILTER FILTER DFP W 060 QB 25BM1.X/-V-W
.030 1 R900058864 1 FILTER FILTER DFP BH/HC 060 QB 10BM1.X/V-W
.040 1 R900772317 1 HY-SERVOWEGEVENTIL 4WS2EM10-5X/60B11T315K31CV-114 RD29583
1 R900223890 1 PLUG-IN CONNECTOR LEITUNGSDOSE 07POL Z31 BF6-3PG11(M)SPEZ* DIN43563
.050 1 R900929926 1 HY-LOGIC CARTRIDGE VALVE LC 32 A40E7X/V RD21010
.051 1 R900965932 1 HY-LOGIC COVER LFA 32 WEA27-7X/V RD21010
.052 1 R900212093 1 HY-POPPET DIRECT VALVE DIRECT OPERATED M-3SEW 6 C3X/420MG25N9Z2/B08V SO214 RD22058
.070 1 R900012297 1 SCREW PLUG VERSCHLUSSSCHRAUBE G 1/4-A3C-FKM 143.21 RN143.21
118. 0 R901186259 1 ASSEMBLY KIT ASSEMBLY KIT CXE1-2X/ ZUBE.D901593

Rexroth

HPCV STV 160-177


Rexroth

IPCV STV 360-45
300. 0 R901186387 1 HYDRAULIC CYLINDER CGE1MF3/140/ 60/.125F20/G5GASSTC-D901275

.040 1 R900711077 1 HY-SERVOWEGEVENTIL 4WS2EM10-5X/90B11T315K31CV-114
318. 0 R901186261 1 ASSEMBLY KIT BAUSATZ CGE1-2X/ ZUBE.D901275

Rexroth

IPCV STV 360-45


Rexroth

HP - SSV 200-177
500. 0 R901186383 1 HYDRAULIC CYLINDER CGE1MF3/140/ 60/.100F20/G5GASSEW-D901272

.030 1 R900767230 1 COVER PLATE HSA 99-28086-ZA/V00-DF60P
.040 1 R900570174 1 HY-POPPET DIRECT VALVE DIRECT OPERATED M-3SEW 6 U3X/420MG24N9K4/V RD22058
1 R901017010 1 PLUG-IN CONNECTOR LEITUNGSDOSE 03POL Z4 M GR SPEZ* DIN EN 175

Rexroth

HP - SSV 200-177


Rexroth

IPSV SSV 400-45


Rexroth

IPSV SSV 400-45


Rexroth
SET 2

Rexroth

HPCV STV 160-177


Rexroth

HPCV STV 160-177


Rexroth

IPCV STV 360-45


Rexroth

IPCV STV 360-45


Rexroth

HP - SSV 200-177


Rexroth

HP - SSV 200-177


Rexroth

IPSV SSV 400-45


Rexroth

IPSV SSV 400-45


Rexroth
SET 3

Rexroth

HPCV STV 160-177


Rexroth

HPCV STV 160-177


Rexroth

IPCV STV 360-45


Rexroth

IPCV STV 360-45


Rexroth

HP - SSV 200-177


Rexroth

HP - SSV 200-177


Rexroth

IPSV SSV 400-45


Rexroth

IPSV SSV 400-45


Rexroth
SET 4

Rexroth

HPCV STV 160-177


Rexroth

HPCV STV 160-177


Rexroth

IPCV STV 360-45


Rexroth

IPCV STV 360-45


Rexroth

HP - SSV 200-177


Rexroth

HP - SSV 200-177


Rexroth

IPSV SSV 400-45


Rexroth

IPSV SSV 400-45


Rexroth
SET 5

Rexroth

HPCV STV 160-177


Rexroth

HPCV STV 160-177


Rexroth

IPCV STV 360-45


Rexroth

IPCV STV 360-45


Rexroth

HP - SSV 200-177


Rexroth

HP - SSV 200-177


Rexroth

IPSV SSV 400-45


Rexroth

IPSV SSV 400-45


Rexroth
Prüfung Nr. / Test Nr.:
Prüfbericht / Test report D901272-1042A
Hydrozylinder / Hydraulic actuator Datum / date 05.10.2011
D-97813 Lohr a. Main Baureihe CGE1 / Range CGE1 Seite / side 1 von / from 3
1. Allgemeine Angaben / General information

Hersteller / Supplier Bosch Rexroth AG
Auftrags Nr. / Contract Nr.: 1005335855
Auftragsposition / Positon in contract 150
Stückzahl / Quantity 1
Kunde / Customer Bosch Rexroth ( India ) Ltd.
Bestell Nr. / Order No.
Bestelldatum / Date of order 12.10.2010
Projektname / Name of project Amravati
Ventil Nr./ Valve No. ssv 1
Turbinen Nr. / Turbine No.
Baugruppe-Nr. / Assembly No.
Spezifikation-Nr. / Specification No. SD901272
Prüfanweisung / Test instructions RNI 50387
2. Prüfergebnisse / Test results

2.1 Prüfling / Test piece
Zylinder Nr. / Actuator No. D901272

Zylinder Material Nr. / Actuator part No. R901186383
Serien Nr. / Production No. 1042
PrüfIndex / Text index A
Ventil Hub / Valve stroke 92 mm
Überhub / Over stroke 8 mm [Üh1] 8 mm [Üh2]
Steuerblocktyp. / Control block type -
Block Material Nr. / Block part No. -
2.2 Prüfbedingungen / Test conditions
Prüfmedium / Test medium Pyrotec

Kin. Viskosität / Kin. viscosity 44 mm^2/s
Öltempertur / Oil Temperature 40 °c
Systemdruck / System pressure 160 bar
2.3 Kontrolle Typenschlüssel / Ordering code control
Zylinder Typ / Actuator type CG E1 MF3 / 140 / 60 - 100 F 20 - G 5 G A S S E W

Wirkungsweise / operation mode CG Gleichgang Standard / Double ended standard
Baureihe / Range E1 Energie / Energy
Befestigungsart / Type of mounting MF3 Rundflansch am Kopf / Round front flange
Kolbendurchmesser / Piston dia. 140 mm
Stangendurchmesser / Piston rod dia. 60 mm
Arbeitshub / Actuator stroke 100 mm
Stangenlagerung / Piston rod guidance F Führungsbände / Wear rings
Serie / Serie 20
Anschluß / Connection block G
Ventil NG / Valve size 32
Stangenausführung / Rod construction G Geteilt / Assembly
Kolbenstangenende / Piston rod end A Außengewinde / Male thread
Dämpfung / Cushioning S Kopfseitig / front end
Dichtungsausführung / Sealing system S Druckbelastet (HF) / pressure loaded (HF)
Wegmeßsystem / Displacement transd. E Endschalter / limit switches
Ausgangsignal / Output signal W Ohne / without
2.4 Funktion- und Maßkontrolle / Function and dimensional control
2.4.1 Einbaumaße / Overall dimensions geprüft / checked Zeichn. Nr./Drg. No. R901195475
Druckprüfung / Pressure test durchgeführt / carried out 300 bar
Dichtheitsprüfung / Leakage test durchgeführt / carried out
Funktionsprüfung / Function test durchgeführt / carried out
Mindestspannung / minimum voltage geprüft / checked
2.4.2 Weg / Displacement soll / required ist / actual
Wegmeßsystemausgang / Displacement 0,00 19,99 Grundstellung / Basis position

transducer output [V] 18,90 Systemnull / System zero
4,12 Endstellung / End position
Empfindlichkeit / Sensitivity [V / mm] 0,000 0,137
Gesamthub / Total stroke [mm] 116 +-1mm 115,9
2.4.3 Federkräfte / Spring forces soll / required ist / actual
F1 bei Ventilhub 0 / at valve stroke 0 [kN] 61,37 - 2,5 min. 64,65

F2 bei Ventilhub max. / at max. valve stroke [kN] 122,6 + 2,5 max. 116,7
Gesamtreibung / total friction [N] 3500 max. 2331
2.4.4 Kontrollmaße bei Antriebs-Nullstellung / Control dimensions at actuator 0
siehe diag. Seite 3 / see diag. on page 3 X Y Z

Kontrollmaße / Control dimensions [mm] 108 12,8 132,2
2.4.5 Schalt- und Verzugszeiten / switching and delay times Schaltantrieb / Stop actuator T
soll / required Ist / actual
Stellzeit (offen) / opening time [s] 1,5 ...... 25 3,728
Stellzeit (schließen) / closing time [s] 1,5 ...... 25 4,416
Driftzeit (Servoventil bias) / drift time [s] 0 +-50% 0
Blendendurchmesser / orifice dia. [mm] Bl.1: 7 Bl.2: 6,5
Gesamtschaltzeitdef. / Def. of total trip time ts
L1+L2 L1 L2
Verzugszeiten (tv) / delay times (tv) [ms] 55 max. 33 38 35
Gesamtschaltzeit / Total trip time [ms] 170 +10% -10% 169 172 171
2.4.6 Endlagendämpfung / Cushioning soll / required ist / actual
Blendendurchmesser / orifice dia. [mm] 3

Dämpfungslänge / cushioning length [mm] 10
Endgeschwindigkeit / end velocity [m/s] 0,3 max. 0,152
L1+L2 L1 L2
Dämpfungszeit (td) / cushioning time (td) [ms] 25 24 24
2.4.7 Sprungantwort / step response
Regelverstärkung / controller amplification
Überschwingdauer / overshoot period [ms]

Überschwingweite / maximum overshoot [mm]
Anstiegzeit / [ms]
2.4.8 Endkontrolle / final control
Verschmutzungsanzeige / clogging indicator geprüft / checked
Flanschanschlüsse / flanges montiert / assemblied
Schilderliste / identification plates nicht kontrolliert / not checked
Daten im Typenschlid / data in nameplate eingetragen / entered
Optische Hubanzeige / Stroke indicator eingestellt / adjusted
Hubeinstellung / stroke adjustment nicht eingestellt / not adjusted
Endschaltereinstellung/limit switch adjustment eingestellt / adjusted
2.5 Anstrich / paint finish
1. Grundierung / prime coat 7032 PUR/AC-2K

2. Grundierung / undercoat -
Deckanstrich / final coat 8001 PUR-2K
2.6 Prüfzeugnisse / test cerificates
Zylinder / actuator 3.1

Servoventil / servo-valve keine / none
2.7 Art Material Nr. Hesteller Type Serien-Nr.

Item Material No. Supplier Type Serie No.
2.8 Hübe und Kontrollmaße Definition / stroke and control dimension definition
Gh = Gesamthub / total stroke

Vh = Ventilhub / valve stroke
Ah = Zylinderhub / actuator stroke
Üh = Überhub / over stroke
Dl = Dämpfungslänge / cushioning length
0 = system null / zero ( Ventil zu / valve closed)
Bph = By.pass Hub / By-pass stroke
SV = Servoventil / servo-valve
WA = Wegaufnehmer / displacement transducer
tv = Verzugszeit / Delay time
ts = Schaltzeit / tripl time
td = Dämpfungszeit / cushioning time
Bl. = Blende / orifice
L1, L2 = Logiks / Cartridge valves
bei Antriebs-Nullstellung (0) / at system zero (0)

H. Götz(Z26) 05.10.2011 LoP1/MOE51
Prüfer / tester Datum / date Abt. / Dpt.
Der Prüfbericht wurde elektronisch hergestellt und ist ohne Unterschrift gültig./This report was
electronically produced and is valid without signature.





Serie / Serie 20



Kontrollmaße / Control dimensions [mm] 108,3 12,4 132,6
L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]





H. Götz(Z26) 01.10.2011 LoP1/MOE51





Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]





H. Siebert(Z45) 17.10.2011 LoP1/MOE51





Serie / Serie 20



Kontrollmaße / Control dimensions [mm] 108,1 13 132,2
L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]





H. Rambacher(Z28) 26.10.2011 LoP1/MOE51

Ventil Nr./ Valve No. ssv -




Serie / Serie 20

Gesamthub / Total stroke [mm] 116 +-1mm 116


L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20


F2 bei Ventilhub max. / at max. valve stroke [kN] 122,6 + 2,5 max. 118

L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]





H. Grabosch(Z39) 13.01.2012 LoP1/MOE51





Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



Blendendurchmesser / orifice dia. [mm] Bl.1: 9 Bl.2: 8
L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]





H. Götz(Z26) 06.10.2011 LoP1/MOE51





Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]





H. Hauk(Z36) 20.10.2011 LoP1/MOE51





Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



Blendendurchmesser / orifice dia. [mm] Bl.1: 9,5 Bl.2: 8
L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]










Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2

Anstiegzeit / [ms]






Ventil Nr./ Valve No. STV 1



Zylinder Typ / Actuator type CG E1 MF3 / 140 / 60 - 65 F 20 - G 5 G A S S T C

Serie / Serie 20
Wegmeßsystem / Displacement transd. T Ultraschall / Ultrasonic
Ausgangsignal / Output signal 4..20 mA

transducer output [mA] 5,86 Systemnull / System zero
Empfindlichkeit / Sensitivity [mA / mm] 0,160 0,160


2.4.5 Schalt- und Verzugszeiten / switching and delay times Stellantrieb / Control Actuator S
Stellzeit (offen) / opening time [s] 0 ...... 1,65 0,837
Stellzeit (schließen) / closing time [s] 0 ...... 1,65 0,654
Driftzeit (Servoventil bias) / drift time [s] 6,54 +-50% 5,82
L1+L2 L1 L2

L1+L2 L1 L2
Regelverstärkung / controller amplification 130 V/V Ist / actual
Soll / required Aus / ext Ein / ret
Überschwingdauer / overshoot period [ms] 180 max. 26 25
Überschwingweite / maximum overshoot [mm] 0,512 max. 0,387 0,403
Anstiegzeit / [ms] 75 63
Endschaltereinstellung/limit switch adjustment nicht eingestellt / not adjusted



SV R900772317 BR 4WS2EM10-5X/60B11T315K31CV-114 3/123070107

WA R901056201 Balluff BTL5-E10-M0100-K-K02 113106193HU







Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2






H. Götz(Z26) 17.10.2011 LoP1/MOE51





Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2







Ventil Nr./ Valve No. STV -




Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2
Überschwingweite / maximum overshoot [mm] 0,96 max. 0,483 0











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2






H. Götz(Z26) 20.10.2011 LoP1/MOE51





Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



Kontrollmaße / Control dimensions [mm] 108 12,7 132,3
L1+L2 L1 L2

L1+L2 L1 L2











Serie / Serie 20



L1+L2 L1 L2

L1+L2 L1 L2






Industrial Applications
Abnahmeprüfzeugnis 3.1
Inspection certificate 3.1
Bosch Rexroth (India) Ltd. In Anlehnung an EN 10204 (DIN 55350 Teil 18)
Near Vatva Railway Station Following EN 10204 (DIN 55350 part 18)
Nr. Datum
382445 Ahmedabad No.
954/2011 19.10.2011
Date
INDIEN
Mat. Nr.: R900259791
Lieferbedingung: Siehe Auftrag
Terms of delivery See order
Projektname: AMRAVATI
Project name
Ihre Bestell-Nr.: 4500201006 vom 28.01.2011 Unsere Auftrags-Nr. 1005335855
Your order No.: from Our order No.:
Pos.: Anzahl: Typenbezeichnung: Mat.-Nr.
Item: Quantity: Classification: Mat. No.:
150 1 CGE1MF3/140/ 60/.100F20/G5GASSEW-D901272 R901186383

Prüfbedingungen Prüfstempel: Z 26
Test conditions Test stamp
Prüfanweisung: RNI 50387
Test instruction No.
Prüfmedium: PYROTEC Einbauzeichnung/KatalogNr.: D901272
Test medium Assembly drawing/ Catalogue No.
kin. Viskosität: 44 mm2/s bei 40 °C Kundenzeichnung:
kin. Viscosity Customer drawing
Öltemperatur: 40 °C Serien Nr. 1042
Temperature of oil serial number
Betriebsdruck: 160 bar Hub: 100 mm
Working pressure Stroke
Prüfungen (alle Prüfungen entsprechend Prüfanweisung): Ergebnis:
Tests (all test agree with the test instruction) Result
Funktion bei
x Function at 160 bar i.O.
Druckprüfung und Dichtheit bei
x pressure and tightness at 300 bar i.O.
Einbaumaße nach Einbauzeichnung/KatalogNr.
x Installation dimensions according to the assembly drawing/ Catalogue No. i.O.
Chromschichtdicke der Kolbenstange (C/H/N) soll:
x Chrome plating thickness on piston rod setpoint min. 20 m i.O.
Beschichtung der Kolbenstange: Ceramax
Coating of the piston rod: Ceramax
Bestätigung:
Die vorstehend angekreuzten Prüfungen wurden an der Lieferung durchgeführt. Die Lieferung entspricht den Vereinbarungen bei Bestellannahme.
Confirmation:
All tests - marked with a cross - have been accomplished. The delivery is equivalent to declaration at acceptance of booking.
Hersteller Werksachverständiger / Manufacturer authorized inspector Bemerkungen:
Remarks
Dieses Zeugnis wurde maschinell erstellt und ist gemäß

DIN EN 10204 auch ohne Unterschrift gültig.
This certificate has been generated by data system and need not to be
signed for validity according to DIN EN 10204.
Name: Harald Beck Abt.: LoP1/QMM15 Tel.: +49 9352 18-6265 Anlagen:
Enclosures
Firmensitz: Stuttgart, Registrierung: Amtsgericht Stuttgart HRB 23192

Vorstand: Dr. Karl Tragl (Vorsitzender), Dr. Georg Hanen; Reiner Leipold-Büttner; Dr. Stefan Spindler
Vorsitzender des Aufsichtsrats: Dr. Siegfried Dais
Nr. Datum
921/2011 11.10.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1032/2011 14.11.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1000/2011 07.11.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1207/2011 14.12.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1175/2011 09.12.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
118/2012 03.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
119/2012 03.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
120/2012 03.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
122/2012 03.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
932/2011 13.10.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
961/2011 21.10.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1024/2011 11.11.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1002/2011 07.11.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1177/2011 12.12.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1178/2011 12.12.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
98/2012 27.01.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
121/2012 03.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
107/2012 01.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
108/2012 01.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
944/2011 17.10.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name
30 1 CGE1MF3/140/ 60/..65F20/G5GASSTC-D901274 R901186386

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
941/2011 14.10.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1037/2011 15.11.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1001/2011 07.11.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1208/2011 14.12.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1206/2011 14.12.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
115/2012 03.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
95/2012 27.01.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
93/2012 26.01.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
94/2012 26.01.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
950/2011 19.10.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name
90 1 CGE1MF3/140/ 60/.125F20/G5GASSTC-D901275 R901186387

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
931/2011 13.10.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1038/2011 15.11.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1003/2011 07.11.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1185/2011 13.12.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
1176/2011 12.12.2011
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
116/2012 03.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
117/2012 03.02.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
96/2012 27.01.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

Nr. Datum
97/2012 27.01.2012
Date
INDIEN
Mat. Nr.: R900259791
Project name

Funktion bei
Bestätigung:
Confirmation:
Remarks

Enclosures

2-way cartridge valves RE 21010/03.05
Replaces: 02.03
1/68
Directional functions
Cartridge valves and control covers
Types LC and LFA
H5591 H5455
Sizes 16 to 160 Control cover type LFA 25 WEA-7X/… Cartridge valve type LC 25 A40E7X/…
Component series 2X; 6X; 7X with directional valve type 4WE 6
Maximum operating pressure 420 bar D6X/EG24N9K4 and cable socket
Maximum flow 25000 L/min
Table of contents Features

Contents see page 2 – Valve poppet with or without damping nose
– 2 area ratios
– 4 different springs
– 4 stroke limiters
– Control cover with integrated poppet valve
– Control cover with integrated shuttle valve
– Control cover for mounting directional spool valves with or
without integrated shuttle valve
– Control cover with or without limit switch monitoring
– Further information:
Pilot control valves Size 6 Size 10
Directional spool valve type WE RE 23178 RE 23327
Directional poppet valve type SEW RE 22058 RE 22075
Directional poppet valve type SED RE 22049 RE 22045
2/68 Bosch Rexroth AG Hydraulics LC; LFA RE 21010/03.05
Table of contents
Contents Page Contents Page
Features 1 Control cover type LFA
Function, sections, symbol 3 General notes on the ordering code 10, 11, 16
Mounting cavity and connection dimensions 4, 5 Preferred types 11
Technical data 6 Basic symbols 12, 13
Characteristic curves for the selection of nozzles 14
Cartridge valve type LC Material numbers of nozzles and plug screws 15
Ordering code 7 Fixing screws 16
Preferred types 7 Symbols and unit dimensions:
Symbols 7 – Type ..D… 17, 18
Technical data 8 – Type ..H… 19 to 21
Characteristic curves 9 – Type ..G… 22, 23
– Type ..R…; ..RF… 24, 25
– Type ..R…; ..R2… 26, 27
– Type ..WEA…, ..WEB… 28 to 33
– Type ..WEMA…, ..WEMB… 34 to 37
– Type ..WEA8…, ..WEB8… 38, 39
– Type ..WECA… 40 to 42
– Type ..WEA9… 43
– Type ..GWA…, ..GWB… 44 to 49
– Type ..KWA…, ..KWB… 50 to 55
– Type ..E… 56, 57
– Type ..EH2… 58, 59
– Type ..EWA…, ..EWB… 60 to 65
Inductive position switch type QM 66
Cable socket for inductive position switch type QM 66
RE 21010/03.05 LC; LFA Hydraulics Bosch Rexroth AG 3/68
Function, sections, symbol

2-way cartridge valves are designed as elements for insertion
into compact blocks. The power part with ports A and B is in- X X**
stalled in a mounting cavity, which is standardised according
to DlN ISO 7368, in the block and sealed by means of a cover.
X
In most cases, the cover forms at the same time the connec- Type LFA…D../FX..
tion between the control section of the power part and the pilot B
control valves. By controlling the power part with appropriate A E
Type LC.. .. ../..
B D
pilot control valves, it can perform pressure control, directional A
and throttling functions or a combination of these. Particularly
economic solutions can be achieved by adapting the sizes to
the different flows in the individual channels of an actuator. A 1
very cost-efficient solution can be obtained, if several functions
are assigned to the power part of an element.
4
Directional function X
2-way cartridge valves mainly consist of a control cover (1) and 3
a cartridge element (2). The control cover is provided with pi-
lot bores and, depending on the required overall function, op- 2
tionally a stroke limiter, a hydraulically controlled directional
poppet valve or a shuttle valve. Moreover, electrically oper- 8
ated directional spool valves or directional poppet valves can B
be mounted onto the control cover. The cartridge consists of a 6
bushing (3), a ring (4) (up to size 32 only), a valve poppet (5),
optionally with damping nose (6) or without damping nose (7) A
and a closing spring (8).
Function 5; 7
A1 ↑ 100%
2-way cartridge valve operate in dependence upon pressure.
Sizes 16 to 32
Three pressurised areas are essential for the function: A1, A2,
A3. The area of the valve seat is always taken as 100%. As a A2 ↑ 7% (50%)
result of the stepping, the annulus area A2 is 7% or 50% of
area A2, depending on the version. Consequently, the area ra-
tio A1: A2 is either 14.3:1 or 2:1. Area A3 is equal to the sum
of areas A1 + A2. Due to the different area ratios A1: A2 and A3 ↓ 107% (150%)
the resulting different annulus areas (A2), area A3 is either
107% or 150% of area A1 on the seat that is assumed to be
100%.
The following is generally valid: 1
Areas A1 and A2 act in the direction of opening. Area A3 and
the spring act in the direction of closing. The effective direction
of the force resulting from the opening and closing forces de- X
termines the spool position of the 2-way cartridge valve.
3
The medium can flow through 2-way cartridge valves from A to
B or from B to A. When area A3 is pressurised due to the pilot 2
oil flow from channel B or external pilot oil supply, channel A is
leak-free closed. 8
B
6
A
5; 7
A1 ↑ 100%
Sizes 40 to 160
A2 ↑ 7% (50%)
A3 ↓ 107% (150%)
Mounting cavity and connection dimensions to DIN ISO 7368 (except for sizes 125 and 160)
(nominal dimensions in mm)
T
W 7 1
ØD1H7 X = Rz1max 4
Z
A
15
Y
H8
H7
X Y = Rz1max 8
H1(H1*)
Z = Rz1max 10
Y
H3±0,1
ØD3(D3*)
H2+0,1
H6
B 6
15
Size 16 to 63 L1
Z
H9
L2±0,2
A
H5
ØD7H13; 10 L5±0,2 4 x D5; H4

ØD2
5
3 2 4 7 1
ØD4H7 Z1
0,05 A
L4±0,2
L3±0,2
x Y
L2±0,2
For indication of dimensions and explanation of positions,
L1
see page 9! L4±0,2
Sizes 80 and 100 Z2

22,5
35 L4±0,2 L4±0,2 ØD6 max.
ØD7H13; 10 (X, Y, Z1, Z2)
45
5
8 x D5; H4 Z1
Ptmax 20
Ø62H11
L2±0,3
L1
R0,2 max.
ØD6 max. X Y U Rz 20
R1
(X, Y, Z1, Z2) Rz1max 8

L Rz 12
Z2
4,5+0,1
Ø40 max.
(X, Y, Y1)
Size 125 22,5 Size 160 45±0,2

30±0,2 Ø9; 10
Ø9; 10 5
5
45
45
Z1 Y1
45
165±0,2
215±0,2
45
Y1
22,5
48
0
X
300±0,3
380
Y Y
0,3
X
22,5
0±
165±0,2
40
215±0,2
Ø32 max.
Z2
45
(X, Y, Y1)
45
45±0,2 Ø9; 10 8 x M36; 62

5 12 x M42; 74 60±0,2 Ø9; 10
5
Mounting cavity and connection dimensions to DIN ISO 7368 (except for sizes 125 and 160)
Size 16 25 32 40 50 63 80 100 125 160

ØD1 32 45 60 75 90 120 145 180 225 300
ØD2 16 25 32 40 50 63 80 100 150 1) 200 1)
ØD3 16 25 32 40 50 63 80 100 125 200
(ØD3*) 25 32 40 50 63 80 100 125 150 250 1)
ØD4 25 34 45 55 68 90 110 135 200 270
ØD5 M8 M12 M16 M20 M20 M30 M24 M30 – –
ØD6 1) 4 6 8 10 10 12 16 20 – –
ØD7 4 6 6 6 8 8 10 10 – –
H1 34 44 52 64 72 95 130 155 192 268
(H1*) 29.5 40.5 48 59 65.5 86.5 120 142 180 243
H2 56 72 85 105 122 155 205 245 300+0.15 425+0.15
H3 43 58 70 87 100 130 175±0.2 210±0.2 257±0.5 370±0.5
H4 20 25 35 45 45 65 50 63 – –
H5 11 12 13 15 17 20 25 29 31 45
H6 2 2.5 2.5 3 3 4 5 5 7±0.5 8±0.5
H7 20 30 30 30 35 40 40 50 40 50
H8 2 2.5 2.5 3 4 4 5 5 5.5±0.2 5.5±0.2
H9 0.5 1 1.5 2.5 2.5 3 4.5 4.5 2 2
L1 65/80 85 102 125 140 180 250 300 – –
L2 46 58 70 85 100 125 200 245 – –
L3 23 29 35 42.5 50 62.5 – – – –
L4 25 33 41 50 58 75 – – – –
L5 10.5 16 17 23 30 38 – – – –
W 0.05 0.05 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.2
1) Maximum dimension
1 Depth of fit
2 Reference dimension
3 For diameters other than ØD3 or (ØD3*) for port B, the
distance from the cover support surface to the centre
of the bore must be calculated.
4 Port B can be arranged around the central axis of port
A. However, care must be taken to ensure that the
mounting cavities and the pilot bores are not damaged.
5 Drilling for locating pin
6 Note on porting patter for size 16: Length L1 (x–y axis
of bores) for control cover with built-on directional
valve is 80 mm.
7 For Ø ≤ 45 mm → fit H8 permitted!
Technical data (for applications outside these parameters, please consult us!)
Ambient temperature range °C – 20 to + 70
Maximum operating – Without directional valve bar 420
pressure
– Ports A, B, X, Z1, Z2 bar 315; 350: 420 (according to the maximum operating pressure
of built-on valves)
– Port Y bar corresponds to maximum tank pressure of built-on valves
– With monitored spool bar 400
position
Maximum flow L/min 25000 (size-dependent; see characteristic curves on page 9)
Hydraulic fluid Mineral oil (HL, HLP) to DIN 51524 1); fast bio-degradable
hydraulic fluids to VDMA 24568 (see also RE 90221); HETG
(rape seed oil) 1); HEPG (polyglycols) 2); HEES (synthetic
esters) 2); other hydraulic fluids on enquiry
Hydraulic fluid temperature range °C – 20 to + 80
Viscosity range mm2/s 2.8 to 500
Max. permissible degree of contamination of the Class 20/18/15 3)
hydraulic fluid - cleanliness class to ISO 4406 (c)
1) Suitable for NBR and FKM seals malfunction and, at the same time, increases the service life
2) Suitable for FKM seals only of components.
3) The cleanliness classes specified for components must be For the selection of filters, see data sheets RE 50070,
adhered to in hydraulic systems. Effective filtration prevents RE 50076, RE 50081, RE 50086 and RE 50088.
Ordering code: Cartridge valve (without control cover)
LC
Size 16 (series 7X) = 16 No code = NBR seals
Size 25 (series 7X) = 25 V= FKM seals
Size 32 (series 7X) = 32 (Other seals on enquiry)
Size 40 (series 7X) = 40 Caution!
Size 50 (series 7X) = 50 Observe compatibility of seals with hydraulic
Size 63 (series 7X) = 63 fluid used!
Size 80 (series 6X) = 80 7X = (Sizes 16 to 63) component series 70 to 79
Size 100 (series 6X) = 100 (70 to 79: unchanged installation and connection dimensions)
Size 125 (series 2X) = 125 6X = (Sizes 80 and 100) component series 60 to 69
Size 160 (series 2X) = 160 (60 to 69: unchanged installation and connection dimensions)
Area ratio 2:1 (annulus area = 50%) =A 2X = (Sizes 125 and 160) component series 20 to 29
(20 to 29: unchanged installation and connection dimensions)
Area ratio 14x3:1 (annulus area = 7%) =B
E= Valve poppet without damping nose
Cracking pressure approx. 0 bar (without spring) = 00
D= Valve poppet with damping nose
Cracking pressure approx. 0.5 bar = 05
Cracking pressure approx. 1.0 bar = 10
Cracking pressure approx. 2 bar = 20
Cracking pressure approx. 3 bar (size 125 only) = 30
Cracking pressure approx. 4 bar (not with sizes 125 and 160) = 40
For exact values, see page 8.
Preferred types
Type LC (cartridge vavle) Material number Type LC (cartridge vavle) Material number
LC 16 A20D7X/ R900912572 LC 40 A20D7X/ R900937999
LC 16 A20E7X/ R900910269 LC 40 A20E7X/ R900938000
LC 16 A40D7X/ R900912573 LC 40 A40D7X/ R900935732
LC 16 A40E7X/ R900912568 LC 40 A40E7X/ R900927973
LC 16 B20E7X/ R900912595 LC 40 B20E7X/ R900938007
LC 25 A20D7X/ R900912580 LC 50 A20D7X/ R900938026
LC 25 A20E7X/ R900910270 LC 50 A20E7X/ R900920273
LC 25 A40D7X/ R900912581 LC 50 A40D7X/ R900938027
LC 25 A40E7X/ R900912574 LC 50 A40E7X/ R900929935
LC 25 B20E7X/ R900912604 LC 50 B20E7X/ R900929665
LC 25 B40D7X/ R900912609 LC 63 A20D7X/ R900938058
LC 25 B40E7X/ R900912601 LC 63 A20E7X/ R900928826
LC 32 A20D7X/ R900912589 LC 63 A40D7X/ R900938059
LC 32 A20E7X/ R900906337 LC 63 A40E7X/ R900933230
LC 32 A40D7X/ R900909665 LC 63 B20E7X/ R900938064
LC 32 A40E7X/ R900909662
LC 32 B20E7X/ R900912613 Further preferred types and standard components
LC 32 B40D7X/ R900912617 can be found in the EPS (standard price list).
LC 32 B40E7X/ R900912610
Symbols: Cartridge valve (for versions, see ordering code)

Without damping nose With damping nose
X Area ratio X Area ratio X Area ratio X Area ratio
A1 : A2 = 2 : 1 A1 : A2 = 14.3 : 1 A1 : A2 = 2 : 1 A1 : A2 = 14.3 : 1
Version Version Version Version
B B B B
…A..E../… …B..E../… …A..D../… …B..D../…
A A A A
2-way cartridge valves for directional function
Size
16 25 32 40 50 63 80 100 125 160
LC..A.. 1.89 4.26 6.79 11.1 19.63 30.2 37.9 63.6 95 160.6
Area A1 in cm2
LC..B.. 2.66 5.73 9.51 15.55 26.42 41.28 52.8 89.1 133.7 224.8
LC..A.. 0.95 1.89 3.39 5.52 8.64 14.0 18.84 31.4 48 79.9
Area A2 in cm2
LC..B.. 0.18 0.43 0.67 1.07 1.85 2.90 3.94 5.9 9.3 15.7
LC..A.. 2.84 6.16 10.18 16.62 28.27 44.2 56.74 95 143 240.5
Area A3 in cm2
LC..B.. 2.84 6.16 10.18 16.62 28.27 44.2 56.74 95 143 240.5
LC..E.. 0.9 1.17 1.4 1.7 2.1 2.3 2.4 3.0 3.8 5.0
Stroke in cm
LC..D.. 0.9 1.17 1.4 1.9 2.3 2.8 3.0 3.8 4.8 6.5
LC..E.. 2.56 7.21 14.3 28.3 59.4 102 136 285 544 1203
Pilot oil volume in cm3
LC..D.. 2.56 7.21 14.3 31.6 65.0 124 170 361 687 1563
Theoretical pilot flow in LC..E.. 15.4 43.3 86 170 356 612 816 1710 3264 7218
L/min 1) LC..D.. 15.4 43.3 86 190 390 744 1020 2166 4122 9378
Cartridge valve 0.25 0.5 1.1 1.9 3.9 7.2 13.0 27.0 44.0 75.0
Weight in kg
Control cover 1.2 2.3 4.0 7.4 10.5 21.0 27.0 42.0 80.0 150.0
Cracking pressure in bar
LC..A 00.. 0.02 0.025 0.05 0.05 0.05 0.07 0.07 0.1 0.15 0.15
LC..A 05.. 0.35 0.35 0.36 0.35 0.37 0.31 0.44 0.43 0.43 0.45
LC..A 10.. 0.70 0.68 0.72 0.71 0.67 0.64 0.88 0.88 0.88 –
LC..A 20.. 2.03 2.18 2.12 2.02 2.01 2.0 1.75 1.75 1.76 1.94
LC..A 30.. – – – – – – – – 2.05 –
Direction of flow from LC..A 40.. 3.50 3.90 3.80 4.0 4.11 3.8 3.13 3.04 – –
A to B LC..B 00.. 0.014 0.02 0.035 0.035 0.035 0.05 0.05 0.07 0.1 0.1
LC..B 05.. 0.25 0.26 0.26 0.25 0.28 0.23 0.31 0.31 0.31 0.32
LC..B 10.. 0.49 0.50 0.51 0.51 0.48 0.47 0.63 0.63 0.62 –
LC..B 20.. 1.44 1.62 1.52 1.44 1.5 1.5 1.26 1.25 1.25 1.4
LC..B 30.. – – – – – – – – 1.45 –
LC..B 40.. 2.48 2.90 2.70 2.86 3.05 2.8 2.25 2.17 – –
LC..A 00.. 0.04 0.05 0.1 0.1 0.1 0.14 0.14 0.2 0.30 0.33
LC..A 05.. 0.69 0.78 0.72 0.7 0.84 0.68 0.88 0.88 0.86 0.91
LC..A 10.. 1.38 1.53 1.42 1.43 1.47 1.37 1.77 1.78 1.73 –
LC..A 20.. 4.05 4.91 4.25 4.06 4.57 4.33 3.53 3.54 3.50 3.9
LC..A 30.. – – – – – – – – 4.0 –
Direction of flow from LC..A 40.. 6.96 8.74 7.6 8.05 9.34 8.15 6.3 6.2 – –
B to A LC..B 00.. 0.24 0.25 0.5 0.5 0.5 0.8 0.7 1.0 1.5 1.5
LC..B 05.. 3.69 3.40 3.64 3.64 3.95 3.27 4.2 4.6 4.4 4.6
LC..B 10.. 7.43 6.69 7.24 7.37 6.88 6.62 8.4 9.4 8.9 –
LC..B 20.. 21.3 21.5 21.6 20.9 21.4 20.9 16.9 18.7 17.9 20
LC..B 30.. – – – – – – – – 20.7 –
LC..B 40.. 36.6 38.3 38.6 41.5 43.6 39.4 30.2 32.5 – –
1) with a switching time of 10 ms
Characteristic curves (measured with HLP46, ϑoil = 40 °C ± 5 °C)

With damping nose Without damping nose
10 10
NG16 NG25 NG32 NG16 NG25
NG32
Pressure differential in bar →

8 8
6 6
4 4
2 2
0 200 400 600 800 1000 1200 0 200 400 600 800 1000 1200
Flow in L/min → Flow in L/min →
10 10
NG40 NG50 NG40
8
8
NG50
6 6
NG63
4 4
NG63
2 2
0 500 1000 1500 2000 2500 3000 0 500 1000 1500 2000 2500 3000
10 10
NG80 NG100 NG125 NG80 NG100 NG125
NG160
8 8
6 6
NG160
4 4
2 2
0 4000 8000 12000 16000 20000 0 4000 8000 12000 16000 20000
General notes on the ordering code for control covers

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
x = available
• = on enquiry LFA 1) 2) 3) 4)
Component series
control port
El. monitor
for closed
Area ratio
Damping
pressure
Cracking
material
position
Remote
Size Nozzles in channel 5)
Seal
Type
16 25 32 40 50 63 80 100 125 160 A B P T X F Z1

x x x x x x 7X
The ordering code can be found on the relevant pages of the individual control cover variants
x x 6X
x x 2X
x x x x x x x x x x D F x
x x x x H1 F x
x x x x x x x x x x H2 F x
x x x x H3 F x
x x x x x x x x H4 F x
x x x x x x x x G x x
x x x x x x x R x
x x x x x RF x
x x R2 x
x x x x x x x x • • WEA x x x
x x x x x x x x • • WEB x x x
x x x x x x WEMA x x x
x x WEA8 x x x
x x x x x x WEMB x x x
x x WEB8 x x x
x x x x x x WECA x x x x
x x WEA9 x x x x
x x x x x x x x GWA x x x
x x x x x x x x GWB x x x
x x x x x x x x KWA x
x x x x x x x x KWB x
x x x x x x • • • • E x x D QMG24 F x
x x x x x x • • EH2 x x D QMG24 F x
x x x x x x EWA x x D QMG24 x x x
x x x x x x EWB x x D QMG24 x x x
1) 7X = component series 70 to 79, 3) 10 = 1.0 bar cracking pressure

6X = component series 60 to 69 and 20 = 2.0 bar cracking pressure
40 = 4.0 bar cracking pressure
2X = component series 20 to 29: (unchanged installation
4) D = valve poppet of the cartridge with damping nose
and connection dimensions)
2) 5) Order of nozzles for the purchase order and representation
CA = 2 : 1 (area ratio A1:A2)
CB = 14.3 : 1 (area ratio A1:A2) in symbols and circuit diagrams.
CD = 0 % Further details can be found on the relevant pages of the
For the control cover with electrical monitor of the closed individual control cover variants and on page 14 (nozzle
position (including position switch), the type designation characteristic curves).
includes the version of the control cover and the cartridge
valve).
Preferred types, see page 11,

are available at short notice!
General notes on the ordering code for control covers
Symbol in the ordering Symbol in the ordering

Nozzle symbol Nozzle symbol
code code
A** A** Ø1,2
This nozzle is designed as screw-in nozzle. If a nozzle is to be This nozzle is designed as a drilling; no entries are required
installed, the relevant code letter must be entered in the type in the type designation. (Nozzle Ø in mm)
designation together with the nozzle Ø in 1/10 mm.
Symbol in the ordering
Examle: A12 = nozzle with Ø1.2 mm in channel A. Nozzle symbol
code
Z12
This nozzle is designed as threaded nozzle. It is a standard

nozzle, for which no entries are required in the type designa-
For pilot control valves, see page 16! tion. (Nozzle Ø in 1/10 mm)
Preferred types
Type LFA (control cover) Material number Type LFA (control cover) Material number
LFA 16 D-7X/F R900912625 LFA 40 D-7X/F R900938073
LFA 16 H2-7X/F R900912655 LFA 40 H2-7X/F R900938122
LFA 16 WEA-7X/ R900910271 LFA 40 WEA-7X/ R900931581
LFA 16 GWA-7X/ R900912636 LFA 40 GWA-7X/ R900938114
LFA 16 E-7X/CA40DQMG24F R900912619 LFA 40 E-7X/CA40DQMG24F R900938107
LFA 25 D-7X/F R900905302 LFA 50 D-7X/F R900938150
LFA 25 H2-7X/F R900912694 LFA 50 H2-7X/F R900938205
LFA 32 D-7X/F R900905303 LFA 63 D-7X/F R900938225
LFA 32 H2-7X/F R900912728 LFA 63 H2-7X/F R900938250
Further preferred types and standard components

can be found in the EPS (standard price list).
Symbols (basic symbols)

The symbols used in the description of types below are binding!
LFA . D-../F… LFA . H.-../F… LFA . G-../…

Control cover with remote control port Control cover with stroke limiter, Control cover with integrated shuttle
Sizes 16 to 160 with remote control port valve
Pages 17 and 18 Sizes 16 to 160 Sizes 16 to 100
Pages 19 to 21 Pages 22 and 23
X X** X X** X.. Z..
X X X Z1 Z2
B B B
A A A
LFA . R-../… LFA . WEA-../… LFA . WEMA-../…; LFA . WEA8-../…

Control cover with integrated pilot oper- Control cover for mounting a directional Control cover for mounting a directional
ated pilot control valve (directional pop- spool or poppet valve spool or poppet valve with pilot ports for
pet valve) Sizes 16 to 160 operating a 2nd valve
Sizes 25 to 100 Pages 28 to 33 Sizes 16 to 100
Pages 24 to 27 Pages 34 to 39
A B
A B
P T
P T
P** T**
X.. Z12 P** A** T** F**
F**
X Z1 Y X Y X Z1 Z2 Y
B B B
A A A
LFA . WECA-../…; LFA . WEA9-../… LFA . GWA-../… LFA . KWA-../…

Control cover for mounting a directional Control cover for mounting a directional Control cover for mounting a directio-
spool valve as check valve circuit spool or poppet valve, with integrated nal spool or poppet valve, with integrated
Sizes 16 to 100 shuttle valve shuttle valve as check valve circuit
Pages 40 to 43 Sizes 16 to 100 Sizes 16 to 100
Pages 44 to 49 Pages 50 to 55
A B A B
A B
P T P T
P T P.. A**
P** A** T**
A** P** T**
B** X..
X Z1 Y X Z1 Y X Z1 Y
B B B
A A A
Symbols (basic symbols)

The symbols used in the description of types below are binding!
LFA . E-../..DQMG24F… LFA . EH2-../..DQMG24F… LFA . EWA-../..DQMG24…

Control cover with electrical monitor for Control cover with electrical monitor for Control cover with electrical monitor for
the closed position, including cartridge the closed position and stroke limiter, in- the closed position, for mounting a di-
insert cluding cartridge insert rectional spool or poppet valve, including
Sizes 16 to 160 Sizes 16 to 100 cartridge insert
Pages 56 and 57 Pages 58 and 59 Sizes 16 to 63
Pages 60 to 65
A B
P T
P** T** A**
X X** X X**
X X X Y
B B B
A A A
Characteristic curves for the selection of nozzles

Nozzle Ø in mm (possible nozzle Ø depends on thread
dimensions)
0,5 0,6 0,7 0,8 1,0 1,2 1,5 1,8 2,0 2,5 3,0
400
300 3,5
200 4,0
100
5,0
50
40
30 6,0
20
10 8,0
5
4
3
2
1,4
1
0,7
0,5
0,35
0,25
0,05 0,1 0,2 0,5 2 3 4 5 10 15 20 30 40 50 100
Flow in L/min →
Thread Nozzle Ø in mm
M6 tap. 0.5 to 3.0
M8 x 1 tap. 0.5 to 4.0
G3/8 0.8 to 6.0
G1/2 1.0 to 8.0
Material numbers of nozzles and plug screws

Standard nozzle Nozzle Ø Material number
for size in mm M6 tap. M8 x 1 tap. G3/8 G1/2
0.5 R900157933 R900157930 – –
0.6 R900157934 R900149430 – –
0.7 R900157931 R900143957 – –
16 0.8 R900152276 R900136843 R900159043 –
25 1.0 R900149335 R900136842 R900159033 R900139115
32 1.2 R900152286 R900139101 R900159032 R900150714
40 1.5 R900148823 R900133712 R900159031 R900139117
50 1.8 R900157932 R900150953 R900159030 R900159026
63 and 80 2.0 R900156650 R900137299 R900159029 R900148352
100 2.5 R900157929 R900137445 R900146259 R900148353
3.0 R900181894 R900144761 R900149044 R900148361
3.5 – R900136079 R900146258 R900159027
4.0 – R900802480 R900149052 R900149939
5.0 – – R900152287 R900143775
6.0 – – R900135774 R900147875
8.0 – – – R900159028
Plug screw R900023986 R900003443 R900006325 R900006445
General notes on the ordering code for control covers (pilot control valves)
Pilot control valve Size Data Control cover Size (control

Type sheet no. type cover)
WEA, WEB, GWA, GWB, KWA, KWB, 16 to 50

4WE 6 D…6X/E 6 23178
EWA, EWB, WEMA, WEMB
Directional
spool valve 3WE 6 A…6X/E 6 23178 WECA 16 to 50
(wet pin) 4WE 10 D…3X/E 10 23327 WEA, WEB, GWA, KWA, KWB, EWA, EWB 63 to 100
4WE 10 A…3X/E 10 23327 WEA 9, WECA 63 to 100
M-3SED 6 UK../350 16 to 50
6 22049 WEMA, WEA, GWA, KWA
M-3SED 6 CK../350
M-3SEW 6 U../420 16 to 50
6 22058 WEA, GWA, KWA, EWA, WEMA
Diretional pop- M-3SEW 6 C../420
pet valve M-3SED 10 UK../350 63 to 100
10 22045 WEA, GWA, KWA
M-3SED 10 CK../350
M-3SEW 10 U../420 63 to 100
10 22075 WEA, GWA, KWA, EWA
M-3SEW 10 C../420
Pilot control valves must be ordered separately. Note!

For more details, see data sheet. By combining a 2-way cartridge valve with a pilot control valve,
Valve fixing screws are included in the scope of supply of the various valve functions can be realised. In particular, the follow-
control cover. ing components with porting patter to ISO 4401-03-02-0-94
(up to size 50) and ISO 4401-05-04-0-94 (sizes 63 to 100)
are suitable for this purpose.
Fixing screws 1) (included in the scope of supply)
Control cover Tightening Control cover Tightening

Dimen- Dimen-
Size Qty torque MT Size Qty torque MT
type sions type sions
in Nm 3) in Nm 3)
WE., GW. M8 x 45 H2, H4 M20 x 120
WEM. M8 x 70 E, EW. M20 x 130
50 4 520
E M8 x 60 EH2 M20 x 210
16 4 32 2) M20 x 80
EH2 M8 x 80
H2, H4 M30 x 150
EW. M8 x 85
2)
E, EW. M30 x 180
M8 x 40 63 4 1800
EH2 M30 x 250
E M12 x 60 2) M30 x 100
25 EH2, EW. 4 M12 x 90 110 H2, H4 M24 x 120
2) M12 x 50 80 2)
8 900
M24 x 100
H1, H2, E M16 x 80 D, WE. M30 x 120
100 2)
8 1800
H3, H4 M16 x 70 M30 x 140
32 4 270
EH2, EW. M16 x 110 All control cov-
125 8 M36 x 160 3100
2) M16 x 60 ers available
All control cov-
E, EW. M20 x 120 160 12 M42 x 220 5000
ers available
EH2 M20 x 200
40 4 520 1) Hexagon socket head cap screws to ISO 4762 - 10.9
H1, H2 M20 x 110
2) Other available standard control covers
2) M20 x 70
3) Calculated with a total coefficienct of friction µ = 0.14; must
be adjusted for other surfaces
Control cover with or without remote control port: Type ..D… (nominal dimensions in mm)
Sizes 16 to 63 1 2 3 4 9 14 17
LFA D 7X F
Size Remote Nozzle in channel No code = NBR seals

16 25 32 40 50 63 control port (Ø in 1/10 mm) V= FKM seals
(other seals on enquiry)
x x x x x x F X**
Caution!
Nozzle possible; indicate, if required Observe compatibility of seals with the hydraulic
fluid used!
Type LFA . D…/F Type LFA . D…/FX**

X X X**
X X
B B
A A
H4
Size 16 25 32 40 50 63
D2
D1 G1/8 G1/4 G1/4 G1/2 G1/2 G3/4
D1; T1
D2 1) M6 M6 M6 M8 x 1 M8 x 1 G3/8
X** H1 27 30 35 60 68 82
H1
H2 12 16 16 30 32 40
H2
X H3 15 24 28 32 34 50
H3
H4 8 12 16 – – –
4 L1 65 85 100 125 140 180

L2 32,5 42,5 50 72 80 90
2 T1 8 12 12 14 14 16
2
1) For ordering codes for nozzles, see pages 14 and 15.
1 Nameplate for sizes 16, 25

2 Nameplate for size 32
L1
X 3 Nameplate for sizes 40, 50, 63

4 Port X optionally as threaded connection
L2
4 3 1
Control cover with or without remote control port: Type ..D… (nominal dimensions in mm)
Sizes 80 to 160 1 2 3 4 9 14 17
LFA D 1) F
Size Remote Nozzle in channel No code = NBR seals

80 100 125 160 control port (Ø in 1/10 mm) V= FKM seals
(Other seals on enquiry)
x x x x F X**
Caution!
Nozzle possible; indicate, if required Observe compatibility of seals with
hydraulic fluid used!
1) 6X = series 6X (sizes 80, 100)
2X = series 2X (sizes 125, 160)
Type LFA . D…/F Type LFA . D…/FX**

X X X**
X X
B B
A A
D2 Size 80 100 125 160

D1 250 300 380 480
H4
D3; T1
D2 G3/8 G1/2 G1 G1
D3 2) G3/4 G1 G1 1/4 G1 1/4
X**
H1
H1 70 75 105 147
H2
H2 35 40 50 70
H3
H3 45 52,5 61 74
4 H4 – 24 31 42
T1 16 18 20 20
2) For ordering codes for nozzles, see page 14 and 15.
2 1 Nameplate
X
D1
1
Control cover with stroke limiter and remote control port: Type ..H… (nominal dimensions in mm)
Size 16 to 40 1 2 3 4 9 14 17
LFA 7X F
No code = NBR seals

Size Control Remote Nozzle in channel
control port (Ø in 1/10 mm) V= FKM seals
16 25 32 40 (Other seals on enquiry)
x x x x H1 F X** Caution!
Observe compatibility of seals with
x x x x H2 F X**
x x x x H3 F X** Nozzle possible; indicate, if required
x x x x H4 F X**
Type LFA . H…/F Type LFA . H…/FX**
X X X**
X X
B B
A A
Control Control
"H3" "H4"
18
Ø46 Ø46
Control "H1" Control "H2"
Sizes 16 and 25 Sizes 32 and 40
ØD3
SW1
SW1 6 5 4 6 5 4
SW2 SW2
SW2
H6
H7
H4
D1; T1
D2
H5
Ø38
H5
X**
H1
X
H2
H3
4 Size 16 25 32 40
1 D1 G1/8 G1/4 G1/4 G1/2
2
D2 1) M6 M6 M6 M8 x 1
1) For ordering codes ØD3 52 80 80 100
for nozzles, see H1 35 40 75 (60 2)) 95 (100 2))
page 14 and 15. H2 12 16 16 30
L1
2) Dimensions () valid H3 15 24 28 32
X only for controls H4 max 90 95 120 160
"H3" and "H4"
H5 max 76 80 100 146
L2
3) Hexagon socket H6 max 155 160 180 234

H7 max 130 135 155 209
L1 65 85 100 125
3 2
L2 32.5 42.5 50 72
1 Nameplate for sizes 16, 25, 32 T1 8 12 12 14
2 Nameplate for size 40 A/F1 3) 6 6 10 14
3 Port X optionally as threaded connection A/F2 21 22 27 46
Sizes 50 and 63 1 2 3 4 9 14 17
LFA 7X F
No code = NBR seals

50 63 (Other seals on enquiry)
x x H2 F X** Caution!
x x H4 F X**
Nozzle possible; indicate, if required
X X X**
X X
B B
A A
Control "H4"
3 Ø40 SW3
Control "H2"
SW4
4
SW1
63
SW2
H5
28
D1; T1
D2 1 Ø70
H4
X**
H1
X
H2
H3
4 Size 50 63
D1 G1/2 G3/4
D2 1) M8 x 1 G3/8
H1 110 125
H2 32 40
H3 34 50
1 Nameplate H4 max 156 175
L1
X 2 Port X optionall as H5 max 200 220

threaded connection
L2
L1 140 180
3 Scale
L2 80 90
4 Secured by means of locknut
T1 14 16
A/F1 2) 17 24
2 1 1) For ordering codes for nozzles, see A/F2 55 65
page 14 and 15. A/F3 2) 19 19
2) Hexagon socket
A/F4 5 5
Sizes 80 to 160 1 2 3 4 9 14 17
LFA 1) F
No code = NBR seals

80 100 125 160 (Other seals on enquiry)
x x x x H2 F X** Caution!
x x H4 F X**
1) 6X = series 6X (sizes 80, 100)
2X = series 2X (sizes 125, 160)
X X X**
X X
B B
A A
H7 5)
SW4
SW3
Control "H2" – sizes 80 to 125
SW3 3
H7 5)
SW2 SW4
3
2 1 0 9 8
SW1
H6
D3; T1
H5
Control "H2" Control "H4"

H5
size 160 sizes 80 and 100

H1
X**
H4
D2
H2
X
H3
4
Size 80 100 125 160
D1 250 300 380 480
D2 G3/8 G1/2 G1 G1
2 D3 2) G3/4 G1 G1 1/4 G1 1/4
H1 114 132 170 225
X
D1
H2 35 (24 3)) 35 50 70
H3 45 52.5 61 74
H4 76 88.5 100 147
H5 137 157 195 340
1 H6 229 247 – –
H7 30 38 48 –
T1 16 18 20 20
2) For ordering codes for A/F1 75 75 95 –
1 Nameplate
nozzles, see page 14 and 15. A/F2 4) 24 27 27 –
2 Port X optionally as 3) Dimension () valid only for A/F3 4) – – – 32
threaded connection
control "H4" A/F4 4) – – – 8
3 Secured by means of 4) Hexagon socket A/F5 4) 5 5 – –
locknut 5) Maximum dimension A/F6 4) 14 14 – –
Control cover with integrated shuttle valve: Type ..G… (nominal dimensions in mm)
Sizes 16 to 63 1 2 3 4 14 16 17
LFA G 7X
No code = NBR seals

Size Nozzle in channel
V= FKM seals
X Z1 (Other seals on enquiry)
16 Ø1,2 Ø1,2 Caution!
25 Ø1,5 Ø1,5 Observe compatibility of seals with
32 Ø2,0 Ø2,0
40 X15 Z15 Nozzle drilled (Ø in mm) 1)
Standard nozzle (Ø in 1/10 mm) 1)
50 X18 Z18
1) Not shown in the type designation
63 X20 Z20
For ordering codes for nozzles, see page 14 and 15.
LFA . G… LFA . G… LFA . G…

sizes 16 to 32 size 40 sizes 50 and 63
Z..
Z1
X15 Z2
Ø.. Ø.. Z15 X..
X Z1 Z2 X Z1 Z2 X Z1 Z2
B B B
A A A
D1 L4 D3; 14
3
H4
Size 16 25 32 40 50 63
D1 Ø1.2 Ø1.5 Ø2.0 M6 M8 x 1 M8 x 1
D2 Ø1.2 Ø1.5 Ø2.0 M6 M8 x 1 M8 x 1
D3 – – – – G1/2 G1/2
H1
H1 35 30 35 60 68 82
H5
X
H2
Z1
H2 17 17 21.5 30 32 42
H3
H3 15 24 28 32 34 50
H4 – 12 16 – – –
D2
4 5 H5 – – – – 32 40
1 L1 65 85 100 125 140 180
L5 L3 D3; 14 L2 36.5 45.5 50 62.5 74 90

4
2
L3 – – – – 72 81
L4 – – – – 72 90
Z1
L5 4.5 4 1 – 6 4
L1
1 Nameplate for sizes 16, 25, 32

X D2
6 2 Nameplate for sizes 40, 50, 63
L2
3 Ports Z1 and Z2 optionally as threaded connection for

Z2 sizes 50 and 63
4
4 Shuttle valve
5 D2 for sizes 16 to 40
2 6 D2 for sizes 50 and 63
Control cover with integrated shuttle valve: Type ..G… (nominal dimensions in mm)
Sizes 80 to 100 1 2 3 4 14 15 16 17
LFA G 6X
No code = NBR seals

Size Nozzle in channel (Ø in 1/10 mm)
V= FKM seals
X F Z1 (Other seals on enquiry)
80 X20 F** Z20 Caution!
100 X20 F** Z20 Observe compatibility of seals with
Standard nozzle – not shown in the type designation

LFA . G… For ordering codes for nozzles, see page 14 and 15.
M F** Z2
Z1
X20 Z20
X Z1 Z2
B
M8 x 1
H4
H1
X
H3
Size 80 100
H2
D1 250 300
Ø34; 3
L1
3 H1 80 75
G1/2; 14
3
H2 45 43
M8 x 1 H3 45 52,5
H4 4 23,5
Z1 Z1 L1 73 96.5
X M
D1
1 Nameplate
G1/4; 12 5
2 2 Measuring port
M8 x 1
3 Port Z1 optionally as
Z2 threaded connection
1 Z2
3
4 Port Z2 optionally as
threaded connection
G1/2; 14
5 Shuttle valve
Ø34; 3
4
H2
Control cover with integrated directional poppet valve: Type ..R…; ..RF…
Sizes 25 to 63 1 2 3 4 14 15 16 17
LFA 7X
No code = NBR seals

Size Type Nozzle in channel
V= FKM seals
(Ø in 1/10 mm)
X F Z1 Caution!
25 R X10 F** Z12 Observe compatibility of seals with
32 R X12 F** Z12 hydraulic fluid used!
40 R X15 F** Z12 Standard nozzle – not shown in the type designation
50 R X15 F** Z12 Nozzle possible; indicate, if required
63 R X18 F** Z12 1) Directional poppet valve with spring return
25 RF 1) X10 F** Z12
32 RF 1) X12 F** Z12
40 RF 1) X15 F** Z12
50 RF 1) X15 F** Z12
63 RF 1) X18 F** Z12
LFA . R… LFA 63 R…
sizes 25 to 50 size 63
Z1 Z12
Y
X.. Z12 X18

F** F**
X Z1 Y 2) X Z1 Y 2)
B B
A A
LFA . RF… LFA 63 RF…

sizes 25 to 50 size 63
Z1 Z12
Y
X.. Z12 X18

F** F**
X Z1 Y 2) X Z1 Y 2)
B B
A A
2) Max. pressure in port Y 5 bar

Control cover with integrated directional poppet valve: Type ..R…; ..RF… (nominal dimensions in mm)
Sizes 25 to 63
AZ1 3
Area ratio =
AX 1
H1
F
H2
X Z1
40
H3
Size Type 25 32 40 50 63
D1 D2 D1 3) M6 M6 M8 x 1 M8 x 1 M8 x 1
5
D2 3) M6 M6 M8 x 1 M8 x 1 M8 x 1
H1 40 50 60 68 82
1
90 H2 20 26 33 32 40
D1 H3 24 28 32 34 50
6 3
4
2
L1 85 100 125 140 180

R 2 1 4 3 –
Z1 L2
RF 18.5 17.5 25 24 16
4
L1
X Y 4 3) For ordering codes for nozzles, see page 14 and 15.

78,5

L2
3 Port Z1 optionally as threaded connection for size 63

2 – G1/4; 12
4 Port Y optionally as threaded connection for
size 63 – G1/2; 14
5 D1 for sizes 16 to 50
6 D1 for size 63
Control cover with integrated directional poppet valve: Type ..R…; ..R2…(nominal dimensions in mm)
Sizes 80 and 100 1 2 3 4 14 15 16 17
LFA 6X
No code = NBR seals

Size Type Nozzle in channel
V= FKM seals
(Ø in 1/10 mm)
X F Z1 Caution!
80 R X20 F** Z12 Observe compatibility of seals with
100 R X25 F** Z12 hydraulic fluid used!
80 R2 1) X20 F** Z12 Standard nozzle – not shown in the type designation
100 R2 1) X25 F** Z12 Nozzle possible; indicate, if required
1) Directional poppet valve with spring return
LFA . R… LFA . R2…
Z1 Z12 Z1 Z12
Y Y
X.. X..
F** F**
X Z1 Y 2) X Z1 Y 2)
B B
A A
2) Max. pressure in port Y 5 bar
Control cover with integrated directional poppet valve: Type ..R…; ..R2… (nominal dimensions in mm)
Sizes 80 and 100
AZ1 3
Area ratio =
AX 1
M8 x 1 3) Size 80 100
4
D1 250 300
F** D2 G1/4; 12 G1/2; 14
H1
H1 80 100
H2
X Y
H2 36 45
H3
H3 45 52
L2 L1 52 74
M8 x 1 3) L2 21 18
L3 6 5
3) For ordering codes for nozzles, see page 14 and 15.
G1/4; 12
2
D2 1 Nameplate
2 Port Z1 optionally as threaded connection
Z1 3 Port Y optionally as threaded connection
M8 x 1 3)
6
Y Y
D1
G1/4; 12
L1
3 1
Control cover for mounting a directional spool or poppet valve: Type ..WEA…, ..WEB…
Sizes 16 to 50 1 2 3 4 10 11 12 13 17
LFA 7X
No code = NBR seals

V= FKM seals
Size Type Nozzle in channel (Other seals on enquiry)
(Ø in 1/10 mm)
Caution!
16 25 32 40 50 A B P T Observe compatibility of seals with
x x x x x WEA A** P** T** hydraulic fluid used!
x x x x x WEB B** P** T** Nozzle possible; indicate, if required

M-3SED 6 UK../350…
M-3SEW 6 C../420… M-3SED 6 CK../350…
M-3SEW 6 U../420…
A A A
P T P T P T
LFA . WEA… LFA . WEB…

sizes 16 to 32 sizes 16 to 32
(with directional spool valve type 4WE 6 D…) (with directional spool valve type 4WE 6 D…)
A B A B
P T P T
P** A** T** P** B** T**
X Y X Y
B B
A A

sizes 40 and 50 sizes 40 and 50
A B A B
P T P T
P** A** T** P** B** T**

X Y X Y
X Y X Y
B B
A A
Sizes 16 to 50
4 5 6
M6
D1; 14
B A
H1
X
H2
Y D1; 14
H3
4
3 4
L2
1
2
M6
P
F4
F3
B
L1
X A Y
F2 F1
T
L3
L4
L5
L6
7 2
1 Nameplate for sizes 16, 25, 32 Size 16 25 32 40 50

2 Nameplate for sizes 40 and 50 D1 – – – G1/2 G1/2
3 Ports X and Y optionally as threaded connection for H1 40 40 50 60 68
sizes 40 and 50 H2 – – – 30 32
4 Valve fixing scews included in the control cover‘s H3 15 24 28 32 34
scope of supply
L1 65 85 100 125 140
5 Directional spool valve type 4WE 6 D…
L2 80 85 100 125 140
6 Directional poppet valve type M-3SEW 6 …
L3 – – – 72 80
7 Position of ports according to ISO 4401-03-02-0-94
L4 – – – 53 60
L5 17 27 34.5 47 54.5
L6 47.5 64 71.5 84 91.5
Size 63 1 2 3 4 10 11 12 13 17
LFA 63 7X
No code = NBR seals

V= FKM seals
Type Nozzle in channel (Other seals on enquiry)
(Ø in 1/10 mm)
Caution!
A B P T Observe compatibility of seals with
WEA A** P** T** hydraulic fluid used!
WEB B** P** T** Nozzle possible; indicate, if required

M-3SED 10 UK../350…
M-3SEW 10 C../420… M-3SED 10 CK../350…
M-3SEW 10 U../420…
A A A
P T P T P T
LFA 63 WEA… LFA 63 WEB…

A B A B
P T P T
P** A** T** P** B** T**

X Y X Y
X Y X Y
B B
A A
Size 63
3 4 5
M8 x 1
G1/2; 14
B A
82
X Y
40
G1/2; 14
50
4 2 4
6
180
M8 x 1
F3 F4
T
180
X Y
B A
F2 P F1
101
79
78
84
1
1 Nameplate
2 Ports X and Y optionally as threaded connection
3 Valve fixing screws are included in the control cover‘s
scope of supply
6 Position of ports to ISO 4401-05-04-0-94
Sizes 80 and 100 1 2 3 4 10 11 12 13 17
LFA 6X
No code = NBR seals

V= FKM seals
(Ø in 1/10 mm)
Caution!
80 100 A B P T Observe compatibility of seals with
x x WEA A** P** T** hydraulic fluid used!
x x WEB B** P** T** Nozzle possible; indicate, if required

M-3SED 10 UK../350…
M-3SEW 10 C../420… M-3SED 10 CK../350…
M-3SEW 10 U../420…
A A A
P T P T P T

A B A B
P T P T
P** A** T** P** B** T**

X Y X Y
X Y X Y
B B
A A
Sizes 80 and 100
3 6 7
M8 x 1
G1/2; 14
G1/2; 14
Ø34; 4
Ø34; 4
H1
H4
H2
X Y
H3
2 2
8 2
4 L3
F3 F4
L3
X B T Y
D1
A
L4
F2 P F1
M8 x 1
1
27
1 Nameplate Size 80 100

2 Ports X and Y optionally as threaded connection D1 250 300
3 Valve fixing screws are included in the control cover‘s H1 80 100
scope of supply H2 30 24
4 Plug screw for type .. WEB.. H3 45 52.5
5 Plug screw for type .. WEA.. H4 45 55
6 Directional spool valve type 4WE 10 D… L3 10 13
7 Directional poppet valve type M-3SEW 10 … L4 16 18
Control cover for mounting a directional spool or poppet valve: Type ..WEMA…, ..WEMB…
Sizes 16 to 50 1 2 3 4 12 13 15 17
LFA 7X
No code = NBR seals

V= FKM seals
(Ø in 1/10 mm)
Caution!
16 25 32 40 50 P T F Observe compatibility of seals with
x x x x x WEMA P** T** F** hydraulic fluid used!
x x x x x WEMB P** T** F** Nozzle possible; indicate, if required

M-3SED 6 UK../350…
M-3SEW 6 C../420… M-3SED 6 CK../350…
M-3SEW 6 U../420…
A A A
P T P T P T
LFA . WEMA… LFA . WEMB…

A B A B
P T P T
P** T** P** T**

F** F**
X Z1 Z2 Y X Z1 Z2 Y
B B
A A
LFA . WEMA… LFA . WEMB…
A B A B
P T P T
P** T** P** T**

Z1 Z2 Z1 Z2
X F** Y X F** Y
X Z1 Z2 Y X Z1 Z2 Y
B B
A A
Sizes 16 to 50
4 7 5 8
6
D1; 14
D1; 14
B A
H1
X
Y
H4
H2
H2
H3

4 4 2 Nameplate for sizes 40 and 50
3 9
1 3 Ports X, Y, Z1 and Z2 optionally
L2 as threaded connection for sizes
40 and 50
L6
4 Valve fixing screws are included
G1/2; 14
in the control cover‘s scope of
4
2
supply
M6 5 Plug screw M6 for type

Z1 ..WEMB…
6 Plug screw M6 for type
..WEMA….
F3 P F4
7 Directional spool valve
L1
X B A Y type 4WE 6 D…
F2 T F1 8 Directional poppet valve
type M-3SEW 6 …
L6
9 Position of ports to
L4
L3
ISO 4401-03-02-0-94
4
G1/2; 14 Size 16 25 32 40 50
L3 D1 – – – G1/2 G1/2
2 L5 H1 65 40 50 60 68
H2 – – – 30 32
H3 15 24 28 32 34
H4 – – – 30 32
L1 65 85 100 125 140
L2 80 85 100 125 140
L3 – – – 53 60
L4 17 27 34.5 47 54.5
L5 47.5 64 71.5 84 91.5
L6 – – – 72 80
Size 63 1 2 3 4 12 13 15 17
LFA 63 7X
No code = NBR seals

V= FKM seals
(Ø in 1/10 mm)
Caution!
P T F Observe compatibility of seals with
WEMA P** T** F** hydraulic fluid used!
WEMB P** T** F** Nozzle possible; indicate, if required

M-3SED 10 UK../350…
M-3SEW 10 C../420… M-3SED 10 CK../350…
M-3SEW 10 U../420…
A A A
P T P T P T
LFA 63 WEMA… LFA 63 WEMB…

A B A B
P T P T
P** T** P** T**

Z1 Z2 Z1 Z2
X F** Y X F** Y
X Z1 Z2 Y X Z1 Z2 Y
B B
A A
Size 63
3 6 4 7
5
G1/2; 14
B A
82
X Y
60
35
40
G1/2; 14
50
4 4
2
2 180 8
100
G1/2; 14
4
M8 x 1
F3 F4
T
180
X Y
B A
F2 P F1
101
78
67
4
G1/2; 14
78
1 117
1 Nameplate 5 Plug screw M8 x 1 for type ..WEMA….

2 Ports X, Y, Z1 and Z2 optionally as threaded connec- 6 Directional spool valve type 4WE 10 D…
tion 7 Directional poppet valve type M-3SEW 10 …
3 Valve fixing screws are included in the control cover‘s 8 Position of ports to ISO 4401-05-04-0-94
scope of supply
4 Plug screw M8 x 1 for type ..WEMB…
Control cover for mounting a directional spool or poppet valve: Type ..WEA8…, ..WEB8…
Sizes 80 and 100 1 2 3 4 12 13 15 17
LFA 6X
No code = NBR seals

V= FKM seals
(Ø in 1/10 mm)
Caution!
80 100 P T F Observe compatibility of seals with
x x WEA8 P** T** F** hydraulic fluid used!
x x WEB8 P** T** F** Nozzle possible; indicate, if required

M-3SED 10 UK../350…
M-3SEW 10 C../420… M-3SED 10 CK../350…
M-3SEW 10 U../420…
A A A
P T P T P T
LFA . WEA8… LFA . WEB8…

A B A B
P T P T
P** T** P** T**

Z1 Z2 Z1 Z2
X F** Y X F** Y
X Z1 Z2 Y X Z1 Z2 Y
B B
A A
Control cover for mounting a directional spool or poppet valve: Type ..WEA8…, ..WEB8…
Sizes 80 and 100
2
G1/2; 14 3 6 7
G1/2; 14
Ø34; 4
Ø34; 4
H1
H2
H2
H4
H3
2 2
L4 2
Z2
4
F3 F4
L3
L3
X B T
Y
D1
A
L5
F2 P F1
5
8
M8 x 1
1 Z1
L4
L6
1 Nameplate Size 80 100

2 Ports X, Y, Z1 and Z2 optionally as threaded connec- D1 250 300
tion H1 80 100
3 Valve fixing screws are included in the control cover‘s H2 42 55
scope of supply
H3 45 52.5
4 Plug screw M8 x 1 for type .. WEB8..
H4 26 35
5 Plug screw M8 x 1 for type .. WEA8..
L3 10 13
L4 10 9.5
L5 16 27
L6 27 26
Control cover for mounting a directional spool valve: Type ..WECA…

Sizes 16 to 50 1 2 3 4 10 11 12 13 17
LFA WECA 7X
No code = NBR seals

V= FKM seals
Size Nozzle in channel (Ø in 1/10 mm) (Other seals on enquiry)
16 25 32 40 50 A B P T Caution!
x x x x x A** B** P** T** Observe compatibility of seals with

LFA . WECA… LFA . WECA…

size 16 sizes 25 and 32
(with directional spool valve type 3WE 6 A…) (with directional spool valve type 3WE 6 A…)
A B A B
P T P T
A** P** T** A** P** T**

B** B**
X Z1 Z2 Y X Z1 Y
B B
A A
LFA . WECA…
sizes 40 and 50
(with directional spool valve type 3WE 6 A…)
A B
P T
B** A** P** T**

Z1
X Y
X Z1 Y
B
A
Control cover for mounting a directional spool valve: Type ..WECA… (nominal dimensions in mm)
Sizes 16 to 50
4 5
M6
Size 16 25 32 40 50
D1 – – – G1/2 G1/2
D1; 14
B A H1 40 40 50 60 68
H2 – – – 30 32
H1
H3 15 24 28 32 34
H4
H2
H2
X Y
D1; 14 H4 – – – 30 32
H3
L1 65 85 100 125 140

4
L2 80 85 100 125 140
3 4
L3 – – – 53 60
L2 3 L4 17 27 34.5 47 54.5
1
L7 L5 47.5 64 71.5 84 91.5
G1/2; 14 L6 – – – 62.5 70
4
2
L7 – – – 72 80
M6
Z1
F3 P F4 2 Nameplate for sizes 40 and 50
B A
L1
Y
X F2 T F1
3 Ports X, Y and Z1 optionally as threaded connec-
tion for sizes 40 and 50
L6
L3
4 Valve fixing screws are included in the control

L4
cover‘s scope of supply

5 Directional spool valve type 3WE 6 A…
L5
6 2
Control cover for mounting a directional spool valve: Type ..WECA… (nominal dimensions in mm)
Size 63 1 2 3 4 10 11 12 13 17
LFA 63 WECA 7X
No code = NBR seals

V= FKM seals
Nozzle in channel (Ø in 1/10 mm) (Other seals on enquiry)
A B P T Caution!
A** B** P** T** Observe compatibility of seals with

LFA 63 WECA…
A B
P T
B** A** P** T**

Z1
X Y
3 4 X Z1 Y
M8 x 1 B
A
G1/2; 14
B A
82
X
60
Y
40
40
G1/2; 14
50
4 4
2
180
2 100
G1/2; 14
4
M8 x 1
Z1
F3 F4
180
X T Y 1 Nameplate
B A
P 2 Ports X, Y and Z1 optionally as threaded connection
101
F2 F1
90
68,5

scope of supply
4 Directional spool valve type 3WE 6 A…
117
5 1
Control cover for mounting a directional spool valve: Type ..WEA9… (nominal dimensions in mm)
Sizes 80 and 100 1 2 3 4 10 11 12 13 17
LFA WEA9 6X
No code = NBR seals

V= FKM seals
Size Nozzle in channel (Ø in 1/10 mm) (Other seals on enquiry)
80 100 A B P T Caution!
x x A** B** P** T** Observe compatibility of seals with

LFA . WEA9…
sizes 80 and 100
A B
P T
B** A** P** T**

Z1
X Y
X Z1 Y
3 4
B
M8 x 1 A
G1/2; 14
Ø34; 4
Ø34; 4
Size 80 100
D1 250 300
H1 80 100
H1
H2
H2
H4
X Y H2 30 40
G1/2; 14
H3 45 52.5
H3
H4 30 70
2 L4 2
2 L2 0 6
L3 6 6
Z1 L4 6 6
L5 23 19
L6 27 26
L3
L2
L5
F3 F4
X T Y
D1
B A
F2 P F1 1 Nameplate
1 2 Ports X, Y, Z1 and Z2 optionally as threaded con-
nection
M8 x 1 3 Valve fixing screws included in the control cover‘s
scope of supply
L6 4 Directional spool valve type 3WE 10 A…
5
Control cover for mounting a directional spool valve: Type ..GWA…, ..GWB…
Sizes 16 to 50 1 2 3 4 10 11 12 13 17
LFA 7X
No code = NBR seals

V= FKM seals
(Ø in 1/10 mm)
Caution!
16 25 32 40 50 A B P T Observe compatibility of seals with
x x x x x GWA A** P** T** hydraulic fluid used!
x x x x x GWB B** P** T** Nozzle possible; indicate, if required

M-3SED 6 UK../350…
M-3SEW 6 C../420… M-3SED 6 CK../350…
M-3SEW 6 U../420…
A A A
P T P T P T
LFA . GWA… LFA . GWB…

A B A B
P T P T
P** A** T** P** B** T**
X Z1 Y X Z1 Y
B B
A A
A B A B
P T P T
P** A** T** P** B** T**
Y Y
Z1 Z1
X Z1 Y X Z1 Y
B B
A A
Control cover for mounting a directional spool valve: Type ..GWA…, ..GWB… (nominal dimensions in mm)
Sizes 16 to 50
4 6 5 8 7 9
B A
D1; 14
H1
Y
H4
H2
X
H3
4 4
3
L2
1 Size 16 25 32 40 50
L5
D1 – – – G1/2 G1/2
D1; 14
H1 40 40 50 60 68
4
2
H2 – – – 30 32
M6 H3 15 24 28 32 34
Z1
H4 17 17 21.5 30 32
L1 65 85 100 125 140
F3 P F4
B A Y L2 80 85 100 125 140
L1
X L3 36.5 45.5 50 62.5 72

F2 T F1 L4 – – – 53 60
L3
L5 – – – 62.5 70
L4
L7
L6 47.5 64 71.5 84 91.5

L7 17 27 34.5 47 54.5
L6
10 2
1 Nameplate for sizes 16, 25, 32 6 Plug screw M6 for ..GWA…

2 Nameplate for sizes 40 and 50 7 Plug screw M6 for ..GWB…
3 Ports Y and Z1 optionally as threaded connection for 8 Directional spool valve type 4WE 6 D…
sizes 40 and 50 9 Directional poppet valve type M-3SEW 6 …
4 Shuttle valve 10 Position of ports to ISO 4401-03-02-0-94
scope of supply
Control cover for mounting a directional spool or poppet valve: Type ..GWA…, ..GWB…
Size 63 1 2 3 4 10 11 12 13 17
LFA 63 7X
No code = NBR seals

V= FKM seals
(Ø in 1/10 mm)
Caution!
A B P T Observe compatibility of seals with
GWA A** P** T** hydraulic fluid used!
GWB B** P** T** Nozzle possible; indicate, if required

M-3SED 10 UK../350…
M-3SEW 10 C../420… M-3SED 10 CK../350…
M-3SEW 10 U../420…
A A A
P T P T P T
LFA 63 GWA… LFA 63 GWB…

A B A B
P T P T
P** A** T** P** B** T**
Y Y
Z1 Z1
X Z1 Y X Z1 Y
B B
A A
Size 63
5 3 7 4 8
B A
82
X Y
42
40
G1/2; 14
50
4 4
6 2
2 180
78
G1/2; 14
4
M8 x 1
Z1
F3 F4
T
180
X Y
B A
F2 P F1
101
90
69,5
84
1 9
1 Nameplate 5 Plug screw M8 x 1 for type ..GWA….

2 Ports Y and Z1 optionally as threaded connection 6 Shuttle valve
3 Valve fixing screws are included in the control cover‘s 7 Directional spool valve type 4WE 10 D…
scope of supply 8 Directional poppet valve type M-3SEW 10 …
4 Plug screw M8 x 1 for type ..GWB… 9 Position of ports to ISO 4401-05-04-0-94
Sizes 80 and 100 1 2 3 4 10 11 12 13 17
LFA 6X
No code = NBR seals

V= FKM seals
(Ø in 1/10 mm)
Caution!
80 100 A B P T Observe compatibility of seals with
x x GWA A** P** T** hydraulic fluid used!
x x GWB B** P** T** Nozzle possible; indicate, if required

M-3SED 10 UK../350…
M-3SEW 10 C../420… M-3SED 10 CK../350…
M-3SEW 10 U../420…
A A A
P T P T P T

(with directional spool valve type 4WE 10 D…) (wth directional spool valve type 4WE 10 D…)
A B A B
P T P T
M P** A** T** M P** B** T**
X Y X Y
X Z1 Y X Z1 Y
B B
A A
Sizes 80 and 100
6
G1/2; 14 5 3 8 4 9
G1/2; 14
Ø34; 4
Ø34; 4
H1
X
H2
H4
H3
2 2
7 G1/4 2 10
Z1
M
L1
F3 F4
L5
X T
B
D1
A Y
L4
P
L3
F2 F1
1
M8 x 1
27
1 Nameplate
2 Ports X and Y optionally as threaded connection Size 80 100
3 Valve fixing screws are included in the control cover‘s D1 250 300
scope of supply 80 100
H1
4 Plug screw M8 x 1 for type ..GWB.. 26 40
H2
5 Plug screw M8 x 1 for type ..GWA.. 45 52.5
H3
6 Shuttle valve 26 55
H4
7 Measuring port 74 96.5
L1
8 Directional spool valve type 4WE 10 D… 9.5 13
L3
9 Directional poppet valve type M-3SEW 10 … 17 18
L4
10 Position of ports to ISO 4401-05-04-0-94 10.5 13
L5
Control cover for mounting a directional spool or poppet valve: Type ..KWA…, ..KWB…
Sizes 16 to 50 1 2 3 4 10 11 12 14 17
LFA 7X
No code = NBR seals

V= FKM seals
Size Type Nozzle in channel (Ø in 1/10 mm) (Other seals on enquiry)
A B P X Caution!
16 KWA A** P15 X15 Observe compatibility of seals with
25 KWA A** P15 Ø2,0
32 KWA A** P20 Ø2,5 Nozzle drilled (Ø in mm) 1)
40 KWA A** P20 X30 Standard nozzle (Ø in 1/10 mm) 1)
50 KWA A** P20 X30
(Ø in 1/10 mm)
16 KWB B** P15 X15
1) Not shown in the type designation
25 KWB B** P15 Ø2,0
32 KWB B** P20 Ø2,5 For ordering codes for nozzles, see page 14 and 15.
40 KWB B** P20 X30

50 KWB B** P20 X30
M-3SED 6 UK../350… 4WE 6 D… 4WE 6 D…

M-3SEW 6 C../420… M-3SED 6 CK../350…
M-3SEW 6 U../420… (for type LFA . KWA only) (for type LFA . KWB only)
A A A A B A B
P T P T P T P T P T
LFA . KWA… LFA . KWA… LFA . KWA…

size 16 sizes 25 and 32 sizes 40 and 50
(for directional valve, see above) (for directional valve, see above) (for directional valve, see above)
P15 A** P.. A** P.. A**
Z1
Y
X15 Ø.. X..
B B B
A A A
LFA . KWB… LFA . KWB… LFA . KWB…

size 16 sizes 25 and 32 sizes 40 and 50
(for directional valve, see above) (for directional valve, see above) (for directional valve, see above)
P15 B** P.. B** P.. B**
Z1
Y
X15 Ø.. X..
B B B
A A A
Sizes 16 to 50
7 4 M6 9
B A
D1; 14
10
H1
X H5 Y
H4
H2
H3
8
4 4 3
L2 1
L7
D1; 14
2
Z1 5
M6
F3
P F4
L1
B A
X Y
F2 F1
T
L3
L4
L5
L6
6 2 11
Size 16 25 32 40 50
D1 – – – G1/2 G1/2
1 Nameplate for sizes 16, 25 and 32
H1 40 40 50 60 68
2 Nameplate for sizes 40 and 50
H2 17 17 21.5 30 32
3 Ports Y and Z1 optionally as threaded connection for
sizes 40 and 50 H3 15 24 28 32 34
4 Valve fixing screws are included in the control cover‘s H4 – – – 30 32
scope of supply H5 – – – 30 50
5 Plug screw ..KWB… L1 65 85 100 125 140
6 Plug screw ..KWA… L2 80 85 100 125 140
7 Shuttle valve L3 36.5 45.5 50 62.5 72
8 M6 for sizes 16 and 40, M8 x 1 for size 50 L4 – – – 53 60
9 Directional spool valve type 4WE 6 D… L5 17 27 34.5 47 54.5
10 Directional poppet valve type M-3SEW 6 … L6 47.5 64 71.5 84 91.5
11 Position of ports to ISO 4401-03-02-0-94 L7 – – – 62.5 70
Size 63 1 2 3 4 10 11 12 14 17
LFA 63 7X
No code = NBR seals

V= FKM seals
(Ø in 1/10 mm)
Caution!
A B P X Observe compatibility of seals with
KWA A** P25 X** hydraulic fluid used!
KWB B** P25 X** Standard ozzle (Ø in 1/10 mm) – is not shown in the
type designation
(Ø in 1/10 mm)
For ordering codes for nozzles, see pages 14 and 15.
M-3SED 10 UK../350…
M-3SEW 10 C../420… M-3SED 10 CK../350…
M-3SEW 10 U../420…
A A A
P T P T P T
LFA 63 KWA… LFA 63 KWB…

A B A B
P T P T
P25 A** P25 B**

Z1 Z1
Y Y
X** X**
X Z1 Y X Z1 Y
B B
A A
Size 63
5 3 7 4 8
B A
82
X Y
42
27
28
G1/2; 14
50
4 6 2 4
2 180
90
G1/2; 14
4
M8 x 1
Z1
180
F3 F4
X T Y
B A
F2 P F1
90
101
69
9 117 1
1 Nameplate 5 Plug screw M8 x 1 for type ..KWA…

2 Ports Y and Z1 optionally as threaded connection 6 Shuttle valve
4 Plug screw M8 x 1 for type ..KWB… 9 Position of ports to ISO 4401-03-02-0-94
Sizes 80 and 100 1 2 3 4 10 11 12 13 14 17
LFA 6X
No code = NBR seals

V= FKM seals
Size Type Nozzle in channel (Ø in 1/10 mm) (Other seals on enquiry)
80 100 A B P T X Caution!
x x KWA A** P25 T** X20 Observe compatibility of seals with
x x KWB B** P25 T** X20
Standard nozzle – is not shown in the type designation
M-3SED 10 UK../350…
M-3SEW 10 C../420… M-3SED 10 CK../350…
M-3SEW 10 U../420…
A A A
P T P T P T
LFA . KWA… LFA . KWB…

A B A B
P T P T
P25 A** P25 B**

Z1 Y Z1 Y
X20 M X20 M
X Z1 Y X Z1 Y
B B
A A
Sizes 80 and 100
3 7 8
G1/2; 14 G3/8
G1/2; 14
B A
Ø34; 4
Ø34; 4
H1
H5
H4
H2
X Y
H3
2
G1/2; 14
2 2
2 L6 M8 x 1
Ø34; 4 4
9
Z1
M
F3 F4
L3
X T Y
B
D1
A
31
F2 P F1
6
M8 x 1
M8 x 1
5
27
L1 Size 80 100
D1 250 300
1
H1 100 110
1 Nameplate 6 Shuttle valve
H2 19.5 27
2 Ports Y and Z1 optionally as 7 Directional spool valve
threaded connection type 4WE 10 D… H3 45 52.5
3 Valve fixing screws are included 8 Directional poppet valve H4 60 70
in the control cover‘s scope of type M-3SEW 10 … H5 52 62
supply 9 Position of ports to L1 55 62
4 Plug screw ..KWB… ISO 4401-05-04-0-94
L3 6.5 5
5 Plug screw ..KWA…
L6 6.5 2
Control cover with electrical monitor of the closed position: Type ..E…
(monitoring of the closed position)
Technical data and notes are valid for all listed control cov- Position switch
ers with electrical monitor (E, EH2, EWA and EWB). For connection, functions, pin assignment, see page 66.
The contact-free position switch with integrated amplifier Caution!
switches after having reached the switching position. This posi- Outputs of the position switch protected only from load
tion switch offers the following advantages: short-circuit.
– No dynamic seals Prevent short-circuit of the outputs against +24 V.
– Direct monitoring of the closed position of the valve
– Long service life
– Control cover and cartridge valve included completely in
this type
– pmax = 400 bar
Sizes 16 to 63
1 2 3 4 5 6 7 8 9 14 17
LFA E 7X D QMG24 F
Size Area ratio A1: Cracking Nozzle in channel No code = NBR seals
A2 pressure pÖ (Ø in 1/10 mm) V= FKM seals
16 25 32 40 50 63
x x x x x x CA = 2:1 1) 10 = 1.0 bar X**
Caution!
CB = 14.3:1 2) 20 = 2.0 bar
40 = 4.0 bar hydraulic fluid used!
QM = Inductive position switch, see page 66

G24 = 24 V DC voltage
1) Annulus area = 50% (standard version)

2) Annulus area = 7%
LFA . E…
sizes 16 to 63
X X**
X
B
A
Control cover with electrical monitor of the closed position: Type ..E…
(monitoring of the closed position) (nominal dimensions in mm)
48
10
Size 16 25 32 40 50 63
5 4 D1 G1/8 G1/4 G1/4 G1/2 G1/2 G3/4
3 D2 M6 M6 M6 M8 x 1 M8 x 1 M8 x 1
H1 50 50 70 110 120 150
H2 12 16 16 83 93 113
H5
H3 15 24 28 32 34 50
H4
6 H4 78 78 78 98 98 98
H5 105 105 105 123 123 123
D2
L1 65 85 100 125 140 180
T1 8 12 12 14 14 16
X** 1
H1
H2
X
1 Nameplate
H3
3 Position switch type QM (included in the type, see

page 66)
4 Cable socket Z24 (separate order, see page 66)
D1; T1 4
2 5 Space required to remove cable socket
6 Protective cap
L1
Control cover with electrical monitor of the closed position and stroke limiter: Type ..EH2…
(monitoring of the closed position)
Sizes 16 to 40
1 2 3 4 5 6 7 8 9 14 17
LFA EH2 7X D QMG24 F
Size Area ratio A1: Cracking Nozzle in channel No code = NBR seals
16 25 32 40
x x x x CA = 2:1 1) 10 = 1.0 bar X**
Caution!
CB = 14.3:1 2) 20 = 2.0 bar
40 = 4.0 bar hydraulic fluid used!


LFA . EH2… LFA . EH2…

sizes 16 and 32 size 40
X X**
X X**
X X
B B
A A
Control cover with electrical monitor of the closed position and stroke limiter: Type ..EH2…
(monitoring of the closed position) (nominal dimensions in mm)
Sizes 16 to 32
SW1
D1; T1
SW2 7 3 4
X** M6
H1
H5
H6
H2
H4
X
H3
105 10
4
6
2 1 5
80
2
78 48
X
L1
Size 16 25 32 40
L2
D1 G1/8 G1/4 G1/4 G1/2

H1 35 40 50 182
H2 50 50 50 –
Size 40 H3 15 24 28 32
H4 25 25 25 25
SW1
H5 126 130 150 3) 233 3)
SW2 H6 62 66 66 88
7 3
L1 65 85 100 125
D1; T1 L2 32.5 42.5 50 62.5
H5
M8 x 1
X** T1 8 12 12 14
H1
A/F1 6 6 10 14
H6
H4
A/F2 21 21 27 46
X 3) Maximum dimension
H3
1 Nameplate
4 2 Port X optionally as threaded connection
3 Position switch type QM (included in
78 type, see page 66)
4 Cable socket Z24 (separate order, see
page 66)
5 Space required to remove cable socket
X
48
L1
6 For size 16 (lower cover only)

L2
7 Protective cap
1
Control cover with electrical monitor of the closed position for mounting a directional spool
or poppet valve: Type ..EWA…, ..EWB… (monitoring of the closed position)
Sizes 16 to 32
1 2 3 4 5 6 7 8 10 11 12 13 17
LFA 7X D QMG24
Size Type Area ratio A1: Cracking Nozzle in channel No code = NBR seals
16 25 32
x x x EWA CA = 2:1 1) 10 = 1.0 bar A B P T
Caution!
x x x EWB CB = 14.3:1 2) 20 = 2.0 bar A** P** T**
40 = 4.0 bar B** P** T** hydraulic fluid used!


M-3SED 6 UK../350…
M-3SEW 6 C../420… M-3SED 6 CK../350…
M-3SEW 6 U../420…
A A A
P T P T P T
LFA . EWA… LFA . EWB…

A B A B
P T P T
P** T** A** P** T** B**
X Y X Y
B B
A A
or poppet valve: Type ..EWA…, ..EWB… (monitoring of the closed position) (nominal dimensions in mm)
Sizes 16 to 32
2 8 9
M6
4
B A
M6
3 5 6
H1
X Y
H2
H4
H3
105 10
11
M6
L2 1 10 7
2
F3
P F4
X B A Y
48
L1
T F1
F2
L4
L3 M6 78
1 Nameplate 6 Cable socket Z24 (separate or-

Size 16 25 32
2 Valve fixing screws are included der, see page 66)
H1 40 40 50
in the control cover‘s scope of 7 Space required to remove cable
supply socket H2 50 50 50
3 Plug screw M6 for 8 Directional spool valve H3 15 24 28
type ..EWB... type 4WE 6 D… H4 25 25 25
4 Plug screw M6 for 9 Directional poppet valve L1 65 85 100
type ..EWA... type M-3SEW 6 …
L2 80 85 100
5 Position switch type QM (includ- 10 Protective cap
ed in type, see page 66) L3 47.5 64 71.5
11 Position of ports to
ISO 4401-03-02-0-94 L4 17.25 27.25 34.75
Sizes 40 and 50
1 2 3 4 5 6 7 8 10 11 12 13 17
LFA 7X D QMG24
Size Type Area ratio A1: Cracking Nozzle in channel No code = NBR seals
40 50
x x EWA CA = 2:1 1) 10 = 1.0 bar A B P T
Caution!
x x EWB CB = 14.3:1 2) 20 = 2.0 bar A** P** T**


M-3SED 6 UK../350…
M-3SEW 6 C../420…
M-3SEW 6 U../420…
A A
P T P T
LFA . EWA… LFA . EWB…

A B A B
P T P T
P** T** A** P** T** B**
X Y X Y
X Y X Y
B B
A A
Sizes 40 and 50
8 7 6
10
11
123
98
9
M6
4
A M6
X 5
H1
B
H4
H2
X Y
H3
2 3 10
3
48
Size 40 50
X
L1
H1 110 120
Y
H2 58.5 68
L4
H3 32 34
H4 77.5 87
L2
4
L3 L1 125 140
2 1 L2 62.5 70
L3 98.5 113
L4 66.5 70
1 Nameplate 6 Position switch type QM (included in type, see page

2 Ports X and Y optionally as threaded connection G1/4 66)
3 Valve fixing screws are included in the control cover‘s 7 Cable socket Z24 (separate order, see page 66)
scope of supply 8 Space required to remove cable socket
4 Plug screw M6 for ..EWB... 9 Directional spool valve type 4WE 6 D…
5 Plug screw M6 for ..EWA... 10 Directional poppet valve type M-3SEW 6 …
11 Protective cap
Size 63
1 2 3 4 5 6 7 8 10 11 12 13 17
LFA 63 7X D QMG24
Type Area ratio A1: Cracking Nozzle in channel No code = NBR seals
EWA
EWB CA = 2:1 1) 10 = 1.0 bar A B P T
Caution!
CB = 14.3:1 2) 20 = 2.0 bar A** P** T**


M-3SED 10 UK../350…
M-3SEW 10 C../420…
M-3SEW 10 U../420…
A A
P T P T
LFA 63 EWA… LFA 63 EWB…

A B A B
P T P T
P** T** A** P** T** B**
X Y X Y
X Y X Y
B B
A A
Size 63
8 7 6
10
11
123
98
9
M8 x 1
4
A M8 x 1
X 5
150
B
105
78
X Y
50
2 3 10
3 90
4
X
180
Y
90
150
48
1 Nameplate 7 Cable socket Z24 (separate order, see page 66)

2 Ports X and Y optionally as threaded connection G1/2 8 Space required to remove cable socket
4 Plug screw M8 x 1 for ..EWB... 11 Protective cap
5 Plug screw M8 x 1 for ..EWA...
6 Position switch type QM (included in type, see page
66)
Inductive position switch type QM, electrical connection

The electrical connection is made by means of a 4-pin cable 0V
+ 24 V
socket with threaded connection M12 x 1.
The cable socket must be ordered separately (see below).
Load up to
Operating voltage 24 V DC voltage + 20 %
400 mA
– 10 %
(Residual ripple content < 10%)
Current consump- Maximum 40 mA S(Ö) Ö(S)
tion:
1 4 2 3
Load-carrying capac- 400 mA (output to PNP 24 V =)
ity of outputs :
Temperature range: –20° C to +80° C PNP
Pin assignment: 1: +24V Inductive position switch type QM can be a nor-

2: Normally-closed (low-resistance– mally-closed or normally-open contact.
4 3
high-resistance)
3: 0 V Caution!
1 2 4: Normally-open (high-resistance– The position switch is not provided with a protective con-
Plug-in contacts on low-resistance) ductor connection!
position switch
Cable socket for inductive position switch type QM, separate order (nominal dimensions in mm)
Cable socket Z24-3m, 4-pin, M12 x 1
with moulded-on PVC cable, 3m long.
Cable cross-section: 4 x 0.34 mm2
Wire identification: 1: brown
Cable socket Z24, 4-pin, M12 x 1 2: white
with threaded connection, cable gland Pg 9. 3: blue
4: black
Material no. R900031155 Material no. R900064381
M12 x 1
M12 x 1
Ø14,5
Ø19,6
41,5
54
35
Cable socket Z24 – angled, 4-pin, M12 x 1

with threaded connection, cable gland Pg 9, angled.
M12 x 1
Ø19,6
Housing can be rotated through 4 x 90° in relation to the con-

tact insert.
40
Material no. R900082899

Notes
Notes
Bosch Rexroth AG © This document, as well as the data, specifications and other
Hydraulics information set forth in it, are the exclusive property of Bosch Rexroth
Zum Eisengießer 1 AG. Without their consent it may not be reproduced or given to third
97816 Lohr am Main, Germany parties.
Phone +49 (0) 93 52 / 18-0 The data specified above only serve to describe the product. No
Fax +49 (0) 93 52 / 18-23 58 statements concerning a certain condition or suitability for a certain
documentation@boschrexroth.de application can be derived from our information. The given information
www.boschrexroth.de does not release the user from the obligation of own judgement and
verification. It must be remembered that our products are subject to a
natural process of wear and aging.
2/2, 3/2 and 4/2 directional seat RE 22058/07.09
Replaces: 07.06
1/14
valve with solenoid actuation
Type M-.SEW
Size 6
Component series 3X
Maximum operating pressure 420/630 bar [6100/9150 psi]
Maximum flow 25 l/min [6.6 gpm]
H7383
Table of contents Features

Contents Page – Direct operated directional seat valve with solenoid actuation
Features 1 – Porting pattern according to DIN 24340 form A
Ordering code 2, 3 – Porting pattern according to ISO 4401-03-02-0-05 and
Function, section, symbols 4, 5 NFPA T3.5.1 R2-2002 D03 (with locating hole)
Technical data 6 – Safe switching also with longer standstill periods under pressure
Characteristic curves 7, 8 – Air-gap DC solenoids with detachable coil (AC voltage pos-
sible by means of a rectifier)
Performance limit 9
– Solenoid coil can be rotated by 90°
Unit dimensions 10 to 12
– The coil can be changed without having to open the pres-
Valve mounting screws 12
sure-tight chamber
Mating connectors 13
– Electrical connection as individual connection (for more elec-
Throttle insert 13 trical connections, see RE 08010)
Check valve insert 13 – with concealed manual override, optional
General notes 13 – Inductive position switch (contactless), see RE 24830
Information on available spare parts:

www.boschrexroth.com/spc
2/14 Bosch Rexroth AG Hydraulics M-.SEW RE 22058/07.09
Ordering code
M SEW 6 3X M
2 main ports =2
3 main ports =3
4 main ports =4
Seat valve, direct operated
Size 6 =6
Main ports 2 3 4
T
a b – – =P
a b
P
T
a b – – =N
a b
P
A
a b
– – =U
a b
Symbols
P T
A
a b
– – =C
a b
P T
A B
a
a b
b – – =D
P T
A B
a
a b
b – – =Y
P T
= Available
Component series 30 to 39 = 3X
Operating pressure 420 bar [6100 psi] = 420
Operating pressure 630 bar [9150 psi] = 630
Solenoid, air-gap, with detachable coil =M
DC voltage 24 V = G24
DC voltage 205 V = G205 1)
DC voltage 96 V = G96
For further ordering codes for other voltages, see page 6
AC voltage mains (per- Nominal voltage of the DC

Ordering
code
missible voltage toler- solenoid in case of operation

ance ±10%) with alternating voltage
110 V - 50/60 Hz 96 V G96
120 V - 60 Hz 110 V G110
230 V - 50/60 Hz 205 V G205
RE 22058/07.09 M-.SEW Hydraulics Bosch Rexroth AG 3/14
K4 *
Further details in the plain text

No code = without locating hole
/62 = with locating hole and locating pin ISO 8752-3x8-St
No code = NBR seals
V= FKM seals
(other seals upon request)
Attention!
Observe compatibility of seals with hydraulic fluid used!
No code = without check valve insert, without throttle insert
P= with check valve insert
B12 = Throttle Ø 1.2 mm [0.047 inch]
Other orifices upon request
Spool position monitoring
No code = without position switch
QMAG24 2) = Monitored spool position “a”
QMBG24 2) = Monitored spool position “b”
For further details see RE 24830
Electrical connection
K4 3) = without mating connector, individual connection with connector according to DIN EN 175301-803
N9 = with concealed manual override
No code = without manual override
Note!
For more types of actuation (e.g. pneumatic, hydraulic, rotary knob, rotary knob with lock, plunger, hand lever, roller actua-
tion), see RE 22340 or upon request!
1) For connection to the AC voltage mains, a DC solenoid must be used, which is controlled via a rectifier (see table page 3).
A mating connector with integrated rectifier can be used (separate order, see page 13).
2) Only version “420”
3) Mating connectors, separate order, see page 13.
Standard types and units are contained in the

EPS (standard price list).
Function, section, symbols: 2/2 and 3/2 directional seat valve

General Attention!
The directional valve type M-.SEW is a directional seat valve It has to be made sure that the specified maximum flow is not
with solenoid actuation. It controls start, stop and flow direction. exceeded! A throttle insert must be used for limiting the flow,
The directional valve basically comprises of the housing (1), if necessary (see page 13).
the solenoid (2), the hardened valve system (3) as well as the
ball / the spool (4) as closing element.
The seat arrangement offers the following options:
Basic principle
2/2 directional seat valve
In the initial position, the ball / the spool (4) is pressed onto
the seat by the spring (9), in spool position by the solenoid T
(2). The force of solenoid (2) acts via the angled lever (6) and
Symbol “P” a b
the ball (7) on the actuating plunger (8) that is sealed on two a b
sides. The chamber between the two sealing elements is con- P
nected to port P. Thus, the valve system (3) is pressure-com-
pensated in relation to the actuating forces (solenoid or return Initial position P and T connected
spring). Thus, the valves can be used up to 630 bar. Spool position P blocked
Notes! T
– The 3/2 directional seat valves have a “negative spool un- Symbol “N” a b
derlap”. Therefore, port T must always be connected. That a b
means that during the switching process – from the starting P
of the opening of one valve seat to the closing of the other
Initial position P blocked
valve seat – ports P–A–T are connected with each other.
This process takes, however, place within such a short time Spool position P and T connected
that it is irrelevant in nearly all applications.
– The manual override (10) allows for the switching of the
valve without solenoid energization. A
a b
Symbol “U”
a b
P T
Initial position P and A connected,

T blocked
Spool position P blocked,
A and T connected
10 A
a b
Symbol “C”
a b
2 P T
Initial position P blocked,

A and T connected
Spool position P and A connected,
T blocked
6
4 8
7 4
7
6 9
9
8
1
3 1
T P T P
Type M-3SEW 6 U … Type M-2SEW 6 N …
A
Function, section, symbols, schematic illustration: 4/2 directional seat valve

With a sandwich plate, the Plus-1 plate, under the 3/2 direc- – Spool position:
tional seat valve, the function of a 4/2 directional seat valve is P is connected to A. As the pump pressure acts via A on
achieved. the large area of the control spool (12), the ball (13) is
pressed onto the seat (16). Thus, B is connected to T, and
Function of the Plus-1 plate P to A. The ball (13) in the Plus-1 plate has a “positive
– Initial position: spool underlap”.
The main valve is not operated. The spring (9) holds the Attention!
ball (4.1) on the seat (11). Port P is blocked and A connect- To prevent pressure intensification in conjunction with
ed to T. Apart from that, one pilot line is connected from A single-rod cylinders, the annulus area of the cylinder
to the large area of the control spool (12), which is thus un- must be connected to A.
loaded to the tank. The pressure applied via P now pushes
the ball (13) onto the seat (14). Now, P is connected to B,
and A to T. The use of the Plus-1 plate and the seat arrangement offer
– Transition position: the following options:
When the main valve is operated, the spool (4.2) is shifted A B
against the spring (9) and pressed onto the seat (15). Dur-
ing this, port T is closed, P, A, and B are briefly connected Symbol “D”: a b
a b
to each other.
P T
A B
Symbol “Y”: a b
a b
P T
Schematic illustration: Initial position

4.2 4.1
4.2 15 11 4.1 9
9
A
3/2 direc-
15 11 tional seat
valve
P
T
Plus-1
plate
T B P
T P
B A
12 14 13 16
Type M-4SEW 6 Y …
Technical data (For applications outside these parameters, please consult us!)
general
Weight – 2/2 directional seat valve kg [lbs] 1.5 [3.3]
– 3/2 directional seat valve kg [lbs] 1.5 [3.3]
– 4/2 directional seat valve kg [lbs] 2.3 [5.1]
Installation position Any
Ambient temperature range °C [°F] –30 to +50 [–22 to +122] (NBR seals)
–20 to +50 [–4 to +122] (FKM seals)
hydraulic
Maximum operating pressure bar [psi] See performance limit page 9
Maximum flow l/min [gpm] 25 [6.6]
Hydraulic fluid Mineral oil (HL, HLP) according to DIN 51524 1);
fast biodegradable hydraulic fluids accord-
ing to VDMA 24568 (see also RE 90221); HETG
(rape seed oil) 1); HEPG (polyglycols) 2); HEES (syn-
thetic esters) 2); other hydraulic fluids upon request
Hydraulic fluid temperature range °C [°F] –30 to +80 [–22 to +176] (NBR seals)
–20 to +80 [–4 to +176] (FKM seals)
Viscosity range mm2/s [SUS] 2.8 to 500 [35 to 2320]
Maximum permitted degree of contamination of the hydraulic Class 20/18/15 3)
fluid - cleanliness class according to ISO 4406 (c)
electrical
Type of voltage Direct voltage Alternate voltage
Available voltages 4) V 12, 24, 42, 96, 110, 205, Only possible with recti-
220 fier (see page 13)
Voltage tolerance (nominal voltage) % ±10
Power consumption W 30
Duty cycle % 100
Switching time accord- – ON ms 25 to 40 (without rectifier)
ing to ISO 6403 30 to 55 (with rectifier)
– OFF 10 to 15 (without rectifier)
35 to 55 (with rectifier)
Maximum – Operating pressure ≤ 350 bar 1/h 15000
switching frequency – Operating pressure > 350 bar 1/h 3600
Protection class according to DIN EN 60529 IP 65 (with mating connector mounted and locked)
Maximum surface temperature of the coil 5) °C [°F] 120 [248]
1) Suitable for NBR and FKM seals 4) Special voltages upon request
2) Only suitable for FKM seals 5) Due to the temperatures occurring at the surfaces of the
3) The cleanliness classes specified for the components must solenoid coils, the standards ISO 13732-1 and EN 982
be adhered to in hydraulic systems. Effective filtration pre- need to be adhered to!
vents faults and at the same time increases the service life
of the components.
For selecting the filters, see data sheets RE 50070,
RE 50076, RE 50081, RE 50086, RE 50087 and RE 50088. When establishing the electrical connection, the protective
earthing conductor (PE ) has to be connected properly.
Characteristic curves (measured with HLP46, ϑOil = 40 ± 5 °C [104 ± 9 °F])
∆p-qV characteristic curves ∆p-qV characteristic curves

2/2 directional seat valve 3/2 directional seat valve
22 22
�� 1
20 20
Pressure differential in bar [psi] →

�� 2
16 16
2
��
1 3
12 12
��
8 8
��
��
4 ��
4
�� 0 �� 0
0 4 8 12 16 20 24 25 0 4 8 12 16 20 24 25
��
Flow in l/min [gpm] → Flow in l/min [gpm] →
U
1 M-2SEW 6 N …, P to T 1 M-3SEW 6 …, A to T
C
2 M-3SEW 6 P …, P to T 2 M-3SEW 6 U …, P to A
3 M-3SEW 6 C …, P to A
∆p-qV characteristic curves

22
��
20
1 2
��
16
��
3
12
�� D
1 M-4SEW 6 …, A to T
8 Y
��
D
2 M-4SEW 6 …, P to A
��
4 Y
D
3 M-4SEW 6 …, P to B and B to T
�� 0 Y
0 4 8 12 16 20 24 25
��

Flow in l/min [gpm] →
Characteristic curves (measured with HLP46, ϑOil = 40 ± 5 °C [104 ± 9 °F])
∆p-qV characteristic curves ∆p-qV characteristic curves

Check valve insert Throttle insert
12 �� 630
�� 600 B12
��

10
�� 500 B15
��
�� 8 ��
400
��
��
6 300
��
��
B18
�� 4 �� 200
��
2 100
�� B22
B20
�� 0 ��
0 4 8 12 10 20 24 25 0 4 8 12 16 20 24 25
��
Flow in l/min [gpm] → Flow in l/min [gpm] →
Performance limit (measured with HLP46, ϑOil = 40 ± 5 °C [104 ± 9 °F])

Maximum operating pressure in bar [psi] Flow
in l/min
Symbol Comment P A B T [gpm]
T 420/630
(2/2 directional seat valve)
100 25
P a b [6100/
a b [1450] [6.6]
9150]
2-way circuit
pP ≥ pT
T 420/630
100 25
N a b [6100/
a b [1450] [6.6]
P
9150]
A Before switching from the ini-

420/630
Only as unloading function
(3/2 directional seat valve)
a b tial position to the spool posi- 100 25

U [6100/
a b tion, pressure must be applied [1450] [6.6]
9150]
2-way circuit
P T to port A. pA ≥ pT
A
420/630
a b 100 25
C pA ≥ pT [6100/
a b [1450] [6.6]
P T 9150]
A
420/630 420/630
a b 100 25
U [6100/ [6100/
a b [1450] [6.6]
9150] 9150]
3-way circuit
P T
pP ≥ pA ≥ pT
A 420/630 420/630
a b 100 25
C [6100/ [6100/
a b [1450] [6.6]
P T
9150] 9150]
(flow only possible in the direction
A B
3/2 directional valve (symbol 420/630 420/630 420/630
100 25
D a
a b
b “U”) in connection with Plus-1 [6100/ [6100/ [6100/
[1450] [6.6]
plate: pP > pA ≥ pB > pT 9150] 9150] 9150]
4-way circuit
P T
of arrow!)
A B
3/2 directional valve (symbol 420/630 420/630 420/630
100 25
Y a
a b
b “C”) in connection with Plus-1 [6100/ [6100/ [6100/
[1450] [6.6]
P T plate: pP > pA ≥ pB > pT 9150] 9150] 9150]
Attention!
Please observe the general notes on page 13!
The performance limits were determined when the solenoids were at operating temperature, at 10% undervoltage and without
tank pre-loading.
Unit dimensions: 2/2 directional seat valve and 3/2 directional seat valve
(dimensions in mm [inch])
5 2 9 1 3 4
[2.01]
51
140 [5.51]
15 [0.59] [0.59] 15
36,5 [1.44]
23 [0.9]
[0.33] 8,5
6
SW22
[0.79] 20 72,2 [2.84]
116,5 [4.59]
125 [4.92] 14 8
64+1 [2.52+0.39] 11
13,8 [0.54]
0,01/100
F1
T F2
[0.0004/4.0]
7 [0.28]
45 [1.77]
B 3/2 directional Rzmax 4

seat valve
A Required surface quality of the
12 P
F4 F3 valve mounting face
13 10
F1 T F2
B 2/2 directional
seat valve
A
P G
F4 F3
Position explanations and valve mounting screws

see page 12.
Unit dimensions: 4/2 directional seat valve (dimensions in mm [inch])

[2.01]
5 2 9 1 3 4
51
140 [5.51]
15 [0.59] [0.59] 15
23 [0.9]
6
81 [3.19]
SW22
44,5 [1.75]
7 8
9
[0.79] 20 62,7 [2.47]

11
[0.35]
72,2 [2.84]
116,5 [4.59] 14
125 [4.92]
64+1 [2.52+0.39]
13,8 [0.54] 12, 13
0,01/100
F1
T F2
[0.0004/4.0]
45 [1.77]
7 [0.28]
B Rzmax 4
AP
Required surface quality of the
F4 G F3
valve mounting face
Position explanations and valve mounting screws

see page 12.
Unit dimensions
1 Solenoid “a” 10 Attention!

2 Concealed manual override “N9” – With 3/2 directional seat valves version “420”, port B
3 Mating connector without circuitry (separate order, is designed as blind counterbore, in version “630”, it
see page 14) is not available.
– With 2/2 directional seat valves version “420”, ports
4 Mating connector with circuitry (separate order, see
A and B are available as blind counterbore.
page 14)
11 Identical seal rings for ports A, B, and T;
5 Space required for removing the coil
Seal ring for port P
6 Space required for removing the mating connector
12 Porting pattern according to DIN 24340 form A
7 Plus-1 plate
13 Porting pattern according to ISO 4401-03-02-0-05 and
8 Nameplate NFPA T3.5.1 R2-2002 D03 (with locating hole for lo-
9 Lock nut, tightening torque MA = 4 Nm [2.95 ft-lbs] cating pin ISO 8752-3x8-St, Material no. R900005694,
included in the delivery)
14 Valve mounting screws see below
Valve mounting screws (included in the delivery)

2/2 and 3/2 directional seat valve 4/2 directional seat valve
– Version “420”: – Version “420”:
4 hexagon socket head cap screws metric 4 hexagon socket head cap screws metric
ISO 4762 - M5 x 45 - 10.9-flZn-240h-L ISO 4762 - M5 x 90 - 10.9-flZn-240h-L
(friction coefficient µtotal = 0.09 to 0.14); (friction coefficient µtotal = 0.09 to 0.14);
Tightening torque MA = 7 Nm [5.2 ft-lbs] ±10 %, Tightening torque MA = 7 Nm [5.2 ft-lbs] ±10 %,
or or
4 hexagon socket head cap screws 4 hexagon socket head cap screws
ISO 4762 - M5 x 45 - 10.9 (self procurement) ISO 4762 - M5 x 90 - 10.9 (self procurement)
Tightening torque MA = 8.1 Nm [6 ft-lbs] ±10 % Tightening torque MA = 8.1 Nm [6 ft-lbs] ±10 %
4 hexagon socket head cap screws UNC 4 hexagon socket head cap screws UNC
10-24 UNC x 1 3/4” ASTM-574 (self procurement) 10-24 UNC x 3 1/2” (self procurement)
(friction coefficient µtotal = 0.19 to 0.24 according to ASTM-574); (friction coefficient µtotal = 0.19 to 0.24 according to ASTM-574);
(friction coefficient µtotal = 0.12 to 0.17 according to ISO 4762); (friction coefficient µtotal = 0.12 to 0.17 according to ISO 4762);
– Version “630”: – Version “630”:

4 hexagon socket head cap screws metric 4 hexagon socket head cap screws metric
ISO 4762 - M6 x 45 - 10.9-flZn-240h-L ISO 4762 - M6 x 90 - 10.9-flZn-240h-L
Tightening torque MA = 12.5 Nm [9.2 ft-lbs] ±10 %, Tightening torque MA = 12.5 Nm [9.2 ft-lbs] ±10 %,
Material no. metric R913000258 Material no. R913000259
or or
4 hexagon socket head cap screws 4 hexagon socket head cap screws
ISO 4762 - M6 x 45 - 10.9 (self procurement) ISO 4762 - M6 x 90 - 10.9 (self procurement)
Tightening torque MA = 15.5 Nm [11.5 ft-lbs] ±10 % Tightening torque MA = 15.5 Nm [11.4 ft-lbs] ±10 %
4 hexagon socket head cap screws UNC 4 hexagon socket head cap screws UNC
1/4-20 UNC x 1 3/4” ASTM-574 (self procurement) 1/4-20 UNC x 3 1/2” (self procurement)
(friction coefficient µtotal = 0.19 to 0.24 according to ASTM-574); (friction coefficient µtotal = 0.19 to 0.24);
(friction coefficient µtotal = 0.12 to 0.17 according to ISO 4762); (friction coefficient µtotal = 0.12 to 0.17);
Mating connectors according to DIN EN 175301-803
Details and further mating

connectors are contained in
RE 08006
Material no.
Valve side
with indicator light

with indicator light with rectifier and Zener diode sup-
Connection Color without circuitry 12 … 240 V 12 … 240 V pression circuit 24 V
a Gray R901017010 – – –
M16 x 1.5
a/b Black R901017011 R901017022 R901017025 R901017026
1/2” NPT a Red/brown R900004823 – – –
(Pg16) a/b Black R900011039 R900057453 R900842566 –
Throttle insert Check valve insert

The use of a throttle insert is required when due to prevailing The check valve insert allows a free flow from P to A and
operating conditions, flows can occur during the switching closes A to P in a leak-free form.
processes, which exceed the performance limit of the valve.
Examples: 2/2 and 3/2 directional seat valve (see
– Accumulator operation, page 4)
– Use as pilot control valve with internal The check valve insert is inserted in port
pilot fluid tapping. P of the seat valve.
2/2 and 3/2 directional seat valve 4/2 directional seat valve (see page 5)
The throttle insert is inserted in port P The check valve insert is inserted in port
of the seat valve. P of the Plus-1 plate.
4/2 directional seat valve (see page 5)
The throttle insert is inserted in port P
of the Plus-1 plate. P P
General notes
Seat valves can be used according to the spool symbols as Plus-1 plate:
well as the assigned operating pressures and flows (see per- – When the Plus-1 plate (4/2-directional function) is used, the
formance limits page 7). following lower operating values must be taken into account:
In order to ensure safe functioning, it is absolutely necessary pmin = 8 bar; qV > 3 l/min.
to observe the following points: – The ports P, A, B and T are clearly determined according to
– In order to switch the valve safely or maintain it in its spool the tasks. They must not be optionally exchanged or closed!
position, the pressure situation must be as follows: pP ≥ pA – With 3- and 4-way spool positions, port T must always be
≥ pT (for design reasons). connected.
– Seat valves have a negative spool underlap, i.e. during the – Pressure level and pressure distribution must be observed!
switching process, leakage oil accrues. This process takes,
– The flow is only permitted in the direction of arrow!
however, place within such a short time that it is irrelevant
in nearly all applications.
– The specified maximum flow must not be exceeded (use a
throttle insert for limiting the flow, if necessary)!
Notes
Bosch Rexroth AG © This document, as well as the data, specifications and other informa-
Hydraulics tion set forth in it, are the exclusive property of Bosch Rexroth AG. It
Zum Eisengießer 1 may not be reproduced or given to third parties without its consent.
97816 Lohr am Main, Germany The data specified above only serve to describe the product. No state-
Phone +49 (0) 93 52 / 18-0 ments concerning a certain condition or suitability for a certain applica-
Fax +49 (0) 93 52 / 18-23 58 tion can be derived from our information. The information given does not
documentation@boschrexroth.de release the user from the obligation of own judgment and verification. It
www.boschrexroth.de must be remembered that our products are subject to a natural process
of wear and aging.
Notes
of wear and aging.
Notes
of wear and aging.
RE 29 583/07.03
Replaces: 10.02
Servo directional valve of 4-way design

Type 4WS.2E…
Nominal size 10
Series 5X
H/A/D 5892/97
Maximum operating pressures 315 bar
Maximum flow 180 L/min
Type 4WSE2ED 10-5X/…B…K31EV
Overview of contents
Contents Page
Features 1
Ordering details 2
Test unit 3
Preferred types, symbols 3
Function, section 4 and 5
Technical data 6 and 7
Control electronics 7
H/A/D 5893/97
Plug-in connector, electrical connections 7 and 8

Characteristic curves 9 to 15
Unit dimensions, subplates 16 to 18
Pilot oil supply and drain, flushing plate 19 Type 4WS2EM 10-5X/…B…K31EV
Features
– Valve control for closed loop position, force and speed control – Control:
– 2-stage servo valve with mechanical or mechanical and • External electronics in Eurocard or modular format (separate
electrical feedback order), see page 7
• Or with the electronics integrated into the valve
– 1st stage as jet/flapper plate amplifier
– Valve and integrated electronics are adjusted and tested
– For subplate mounting,
– Pilot oul supply and drain, internal/external can be changed
Porting pattern to DIN 24 340 form A10 with ports X and Y
without dismantiling the valve
Subplates to catalogue sheet RE 45 054 (separate order)
– Spool with flow force compensation
– Dry torque motor, no contamination of the magnetic gap by the
pressure fluid – Pressure chamnbers in the control bush have gap seals,
no O-ring wear
– Can also be used as a 3-way version
– Filter for 1st stage is externally accessible
– Wear-free spool return element
– Three control variants
© 2003
by Bosch Rexroth AG, Industrial Hydraulics, D-97813 Lohr am Main
All rights reserved. No part of this document may be reproduced or stored, processed, duplicated or circulated using
electronic systems, in any form or by any means, without the prior written authorisation of Bosch Rexroth AG.
In the event of contravention of the above provisions, the contravening party is obliged to pay compensation.
4WS.2E… 1/20 RE 29 583/07.03

Ordering details
10 –5X / B K31 E V *
Electrically actuated 7
Further details
2-stage servo valve in a in clear text
6
4-way version V= FKM seals,
For external = 4WS2E suitable for mineral oil
control electronics (HL, HLP) to DIN 51 524
With integrated = 4WSE2E 5 Spool overlap
control electronics E= 0 to 0.5 % negative
Mechanical feedback =M Electrical connections
Mechanical and =D K31 = Without plug-in connector,
electrical feedback with component plug
(only available with integrated electronics) to DIN EN 175.201-804
Nominal size 10 = 10 Plug-in connector – separate order,
see page 7
Series 50 to 59 = 5X
4 Inlet pressure range for the 1st stage
210 = 10 to 210 bar
Nominal flow 315 = 10 to 315 bar
With a valve pressure differential ∆p = 70 bar 1
5 L/min = 5 3 Pilot oil supply and drain
10 L/min = 10 – = External supply, external drain
20 L/min = 20 E = Internal supply, external drain
30 L/min = 30 T = External supply, internal drain
45 L/min = 45 ET = Internal supply, internal drain (standard)
60 L/min = 60 2 Valves for external control electronics:
75 L/min = 75 11 = Coil no. 11 (30 mA / 85 Ω per coil)
90 L/min = 90 Valves with integrated control electronics:
Control:
Com. value Act. value (only provided with 4WSE2ED…)
9= ± 10 V ± 10 V
13 = ± 10 mA ± 10 mA
1 Nominal flow 4 Inlet pressure range

The nominal flow refers to a 100 % command value signal at a valve The system pressure should be held as constant as possible.
pressure differential of 70 bar (35 bar per control land). This valve Pilot pressure range: 10 to 210 bar or 10 to 315 bar
pressure differential is to be considered as a reference value. Other With reference to the dynamics the frequency relationship within the
values cause a change to the flow. permissible pressure range has to be taken into account.
A possible nominal flow tolerance of ± 10 % (see flow signal func-
tion on page 9) must be taken into consideration. 5 Spool overlap
The spool overlap given in % relates to the nominal stroke of the
2 Electrical control data control spool.
Valves for external control electronics: The control signal has to be Further spool overlaps are available on request!
generated by a current regulated output stage. For servo amplifiers
see page 7. 6 Seal materials
Valves with integrated control electronics: For valves with integrated If a different seal material is required please consult us!
control electronics the command value can be a voltage (ordering
code „9“) or where there is extensive cabling (> 25 m between the 7 Further details in clear text
control and valve) as a current (ordering code „13“). Here special requirements should be stated in clear text. Following
the receipt of an order these requirements will be checked at the
3 Pilot oil factory and valve code supplemented with an additional number.
Care should be taken to ensure that the pilot oil supply pressure is as
constant as possible. It is therefore often advantageous to provide
an external pilot control via port X. To positively influence the dy-
namics, the valve can be operated with a higher pressure at port X
than at port P.
Ports X and Y are also pressurised with “internal” pilot oil supply.
RE 29 564/03.99
583/07.03 2/20 4WS.2E…
Test unit
Test unit (battery operated, optionally with a power supply) to The following modes of operation are possible:
catalogue sheet RE 29 681 – External operation → passing on the operating voltage and
Attention: command values from the control cabinet to the valve
– Only for valves with external control electronics – Internal/external operation → command value via the test unit;
operating voltage from the control cabinet
Test unit for proportional and servo valves with integrated – Internal operation → operating voltage via a separate power
control electronics supply; command value via the test unit
Type VT-VET-1, series 1X to catalogue sheet RE 29 685. – Command values via the BNC socket → optional operational voltage
The test unit is used for the control and for functional testing of
proportional and servo valves with integrated electronics. It is suitable
for testing valves with an operating voltage of ± 15 V or 24 V.
Preferred types (readily available)
Valves for external control electronics, Valves with integrated control electronics,
mechanical feedback mechanical feedback
Material No. Type 4WS2EM Material No. Type 4WSE2EM
R900785537 4WS2EM 10-5X/5B11ET315K31EV R901006218 4WSE2EM 10-5X/5B9ET315K31EV
Valves with integrated control electronics,

mechanical and electrical feedback
Material No. Type 4WSE2ED
Preferred types and standard components are R901006219 4WSE2ED 10-5X/5B9ET315K31EV
highlighted in the RPS (Standard Price list). R900780250 4WSE2ED 10-5X/10B9ET315K31EV
R900918001 4WSE2ED 10-5X/20B9ET315K31EV
R900918003 4WSE2ED 10-5X/30B9ET315K31EV
R900921236 4WSE2ED 10-5X/45B9ET315K31EV
R900944398 4WSE2ED 10-5X/60B9ET315K31EV
R900927674 4WSE2ED 10-5X/75B9ET315K31EV
R900918008 4WSE2ED 10-5X/90B9ET315K31EV
Symbols
Simplified
Valves for external control electronics Valves with integrated control electronics
A B A B
a, b a, b
P T P T
Detailed
Mechanical feedback Electrical and mechanical feedback
A B A B
a, b a, b
P T P T
4WS.2E… 3/20 RE 29 564/03.99

583/07.03
Function, section
4WS(E)2EM10-5X/... External control electronics, type 4WS2EM10-5X/...
The valve types 4WS(E)2EM10-5X/... are electrically actuated, 2-stage (separate order)
servo directional valves with a porting pattern to DIN 24 340 form External electronics, (servo amplifier), are used to control the valve,
A10. They are primarily used for the closed loop control of position, they so amplifiy the analogue input signal (command value) that the
force and velocity. controlled current output signal is capable of driving the servo valve.
These valves comprise of an electro-mechanical convertor (torque Integrated control electronics, types 4WSE2EM10-5X/... and
motor) (1), a hydraulic amplifier (flapper jet principle) (2) and a control 4WSE2ED10-5X/...
spool (3) in a bush (2nd stage), that is connected to the torque motor
For the amplification of the analogue input signal control electronics
via a mechanical feedback.
(10), which are specially matched to this valve, are integrated into
Via an electrical input signal at the coils (4) of the torque motor, a
the valve. They are built into the torque motor cover plate. The valve
force is generated via a permanent magnet at the armature (5), that
zero point can be adjusted by a potentiometer which is externally
in conjunction with a torque tube (6) generates a torque. Due to this
accessible.
the flapper plate (7), which is connected with the torque tube (6) via
a rod, is moved out of the central position between the control orifices 4WSE2ED10-5X/...
(8) a pressure differential now results which acts on the front face of This type of valve has in addition to the mechanical control via a
the control spool. This pressure differential causes the spool to move, feedback spring an electrical spool position acquisition and closed
whereby the pressure connection is connected to an actuator loop control. The spool position is obtained via an inductive position
connection and at the same time the other actuator connection is transducer (11). The position transducer signal is compared with the
connected to the return connection. command value via the integrated control electronics (10). Any
The control spool is connected via a feedback spring (mechanical possible control deviation is electrically amplified and then passed
feedback) (9) to the flapper pate and torque motor. The control spool onto the torque motor as a control signal. With the additional electrical
continues to change position until the torque feedback, via the feedback it is possible to obtain higher dynamic values in the small
feedback spring and the electro-magnetic torque of the torque motor signal range than the mechanical version due to the electrical closed
are balanced, and the pressure differential at the flapper jet system loop amplification. The mechanical feedback ensures that, in the case
becomes zero. of failure of the electrical power supply, the spool is positioned in the
The stroke of the control spool and thus the flow through the pilot zero range.
control valve is closed loop controlled in proportion to the electrical The valve is only available with integrated control electronics. The
input signal. It has, however to be taken into account that the flow is valve zero point can be adjusted by an externally accessible
dependent on the valve pressure differential. potentiometer.
Typ 4WS2EM 10 … 1
4
5
6
2
7
3
TA P TB
Type 4WS2EM 10 … A B
RE 29 564/03.99
583/07.03 4/20 4WS.2E…
Section
Type 4WSE2EM 10…

10
TA P TB
A B
Type 4WSE2ED 10…
10
11
TA P TB
A B
4WS.2E… 5/20 RE
RE 29
29 564/03.99
583/07.03
General
Porting pattern DIN 24 340 form A10
Installation Optional, it has to be ensured the pilot control is supplied with
adequate pressure, ( ≥ 10 bar) when starting-up the system!
Storage temperature range °C –20 to +80
Ambient temperature range °C –30 to +70 (valves with external control electronics)
–20 to +60 (valve with integrated electronics)
Weight With mechanical feedback kg 3.56
With mechanical and electrical feedback kg 3.65
and integrated electronics
Hydraulic (measured with HLP 32, ϑoil = 40 °C ± 5 °C)

Operating pressure: Pilot control stage, pilot oil supply bar 10 to 210 or 10 to 315
Main valve, ports P, A, B bar Up to 315
Return pressure: Port T Internal pilot oil drain bar Permissible pressure peaks < 100
External pilot oil drain bar Up to 315
Port Y bar Permissible pressure peaks < 100, static < 10
Pressure fluid Mineral oil (HL, HLP) to DIN 51 524,
other pressure fluids on request!
Pressure fluid temperature range °C –15 to +80; preferably +40 to +50
Viscosity range mm2/s 15 to 380; preferably 30 to 45
Cleanliness class to ISO codes Maximum permissible degree of contamination of the pressure
fluid is to ISO 4406 (C) class 18/16/13 1)
Zero flow qV,L 2) pP 4) L pP 4) L pP 4) L pP 4) L pP 4) L
measured without dither signal L/min •0,7 •0,9 •1,2 •1,5 •1,7
70bar min 70bar min 70bar min 70bar min 70bar min
Nominal flow qV nom ± 10 % 3)
with a valve pressure differential ∆p = 70 bar 5) L/min 5 10 20 30 45 60 75 90

Control spool stroke mm 0,29 0,43 0,74 0,99 1,1
Max. possible control spool stroke at mechanical end stop
referring to the nominal stroke (in the case of a fault) % 120 to 170 120 to 150 120 to 150
Feedback system mechanical (M) mech. and elektr. (D)
Hysteresis (dither optimised) % ≤ 1,5 ≤ 0,8
Reversal span (dither optimised) % ≤ 0,3 ≤ 0,2
Response sensitivity (dither optimised) % ≤ 0,2 ≤ 0,1
Pressure amplification 1 % spool stroke change
(from the hydraulic zero point) % of pP ≥ 30 ≥ 60 ≥ 80
Balance current over
the entire operating pressure range % ≤ 3, long term ≤ 5 ≤2
Zero displacement with changes to:
Pressure fluid temperature %/20 °C ≤1 ≤ 2
Ambient temperature %/20 °C ≤ 1 ≤ 2
Operating pressure 80 to 120 % of pP %/100 bar ≤ 2 ≤ 2
Return pressure 0 to 10 % of pP %/bar ≤1 ≤1
1) The cleanliness class stated for the components must be adhered too in hydraulic systems. 2) qV,L = Zero flow in L/min
Effective filtration prevents faults from occuring and at the same time increases the 3) qV nom = Nominal flow (entire valve) in L/min
component service life. 4) pP = Operating pressure in bar
For the selection of filters see catalogue sheets RE 50 070, RE 50 076 and RE 50 081. 5) ∆p = Valve pressure differential in bar
RE 29 583/07.03 6/20 4WS.2E…

Electrical
Feedback system Mechanical „M“ Mechanical and electrical „D“
Valve protection to EN 60 529 IP 65 with mounted and fixed plug-in connector
Signal type Analogue
Nominal current per coil mA 30
Resistance per coil Ω 85
Inductivity at 60 Hz
and 100% nom. current: Serial connection H 1.0
Parallel connection H 0.25
Recommended superimposed The amplitude is dependent on the hydraulic system:
dither signal: f = 400 Hz max. 5 % of the nominal current
Electrical, external control electronics (only version „M“)

Amplifier Eurocard format Analogue Type VT-SR2-1X/... to catalogue sheet RE 29 980
(separate order) Module format Analogue Type VT 11021 to catalogue sheet RE 29 743
Note: For details regarding the environmental simulation test covering EMC (electro-magnetic compatibility), climate
and mechanical loading see RE 29 583-U (Declaration regarding environmental compatibility).
Plug-in connectors
Plug-in connector to DIN EN 175.201-804
Separate order under Material No. R900223890
(metal version)
A
B F
C E
D
Ø8…Ø13,5
85
Electrical connections, external control electronics
Type 4WS2EM 10-5X… The electrical connections can be made in either series or parallel. Due to operational
safety reasons and the low coil inductivity, we recommend the parallel connection.
A The bridge E-F can be used for the electrical recognition that the plug is correctly connected
Coil A
C or for cable break recognition.
B Parallel connection: In the plug-in connector connect contact A with B and C with D.
Coil B
D Serial connection: In the plug-in connector connect contact B with C.
E Electrical control from A (+) to D (–) causes a flow direction of P to A and B to T. By
F reversing the electrical control the direction of flow is P to B and A to T.
PE
E → F = Bridge
4WS.2E… 7/20 RE 29 583/07.03

Electrical connections, integrated control electronics
Type 4WSE2EM 10-5X/…

Zero point adjustment
A Current Voltage
B Plug-in connector control control
C
allocation Control "13" Control "9"
D Power A + 15 V + 15 V
Re supply B – 15 V – 15 V
Dither E
(± 3 %) C ⊥ ⊥
signal F 1)
PE
D ± 10 mA ± 10 V
Command value
E Re = 100 Ω Re ≥ 50 kΩ
Measurement output F 1) ± 10 mA 2) ± 10 V against ⊥ 2)
for control spool max. ohmic load 1 kΩ Ri ≈ 4.7 kΩ
Type 4WSE2ED 10-5X/… 1) For valves with mechanical feedback connection F is not allocated.
Zero point adjustment 2) With spool nominal stroke
Power A max. 150 mA max. 150 mA

A
consumption B
B at plug-in connector D
C 0 to ± 10 mA ≤ 0.2 mA
connection E
D
Re
Sensitivity E
adjustment F
Ri
PE
Dither signal
adjustment
Power supply: ± 15 V ± 3 %, residual ripple < 1 %
Command value: Command value at plug-in connector connection D = positive against plug-in connector connection E
causes a flow from P to A and B to T.
Measurement output F has a positive signal against ⊥.
Command value at plug-in connector connection D = negative against plug-in connector connection E
causes a flow from P to B and A to T.
Measurement output F has a negative signal against ⊥.
Measurement ouput: The voltage signal is proportional to the control spool stroke.
Note: Electrical signals (e.g. actual value) obtained via the valve electronics must not be used to switch-off the
machine safety functions!
(Also see European standard regulations "Safety requirements of fluid technology systems and components
– hydraulics"EN 982!)
RE 29 564/03.99
583/07.03 8/20 4WS.2E…
Characteristic curves (measured with HLP 32, ϑoil = 40 °C ± 5 °C )
Flow-load function (folerance ± 10 %) Nominal flow

at 100 % command value signal 5 L/min curve 1 30 L/min curve 4 75 L/min curve 7
10 L/min curve 2 45 L/min curve 5 90 L/min curve 8
20 L/min curve 3 60 L/min curve 6
200 8
7
6
100
90 5
75 70
60 4
50
45
40 3
30
Flow in L/min →
20 2
15
10 1
8
1
10 20 30 40 50 60 70 100 200 300
Valve pressure differential in bar →
∆p = Valve pressure differential (inlet pressure pP minus load pressure pL and minus return pressure pT)
Tolerance field of the flow signal function

at a constant valve pressure differential P →A; B →T
110
100
Flow in %
90
80
60
40
20 Tolerance field
-100 -80 -60 -40 -20 -5
Typical flow 5 20 40 60 80 100

curve 20
Command
40 value in %
60
80
90
100
110
P →B; A →T
4WS.2E… 9/20 RE 29 583/07.03

Characteristic curves: types 4WS.2EM 10 and 4WSE2ED 10 (measured with HLP 32, ϑoil = 40 °C ± 5 °C )
Transient functions with the 315 bar pressure stage, step response without flow
4WS.2EM 10 4WSE2ED 10
Nominal flow 5, 10, 20 L/min Nominal flow 5, 10, 20 L/min
100 100
90 90
80 80
Spool stroke in % →
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 10 20 30 40 0 10 20 30 40
Time in ms → Time in ms →
40 bar 70 bar 140 bar 210 bar 315 bar
Frequency response with the 315 bar pressure stage, stroke frequency response without flow
5 –315 5 –315
Phase angle in ° →
Amplitude relationship in dB →
0 –270 0 –270
–5 –225 –5 –225
–10 –180 –10 –180
–15 –135 –15 –135
–20 –90 –20 –90
–25 –45 –25 –45

–30 0 –30 0
10 20 50 100 200 500 700 10 20 50 100 200 500 700
Frequency in Hz → Frequency in Hz →
5% 25 % 100 %
The relationship of the frequency f at – 90 ° to the operating pressure p and the input amplitude
100 100
90 90
Input amplitude in % →
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 50 100 150 200 250 300 325 0 50 100 150 200 250 300 325
Frequency at – 90 ° in Hz → Frequency at – 90 ° in Hz →
RE 29 583/07.03 10/20 4WS.2E…

Nominal flow 30 L/min Nominal flow 30 L/min
100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 10 20 30 40 0 10 20 30 40
5 –315 5 –315
0 –270 0 –270
–5 –225 –5 –225
–10 –180 –10 –180
–15 –135 –15 –135
–20 –90 –20 –90
–25 –45 –25 –45
–30 0 –30 0
10 20 50 100 200 500 700 10 20 50 100 200 500 700
5% 25 % 100 %
100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 50 100 150 200 250 300 325 0 50 100 150 200 250 300 325
4WS.2E… 11/20 RE 29 583/07.03

100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 10 20 30 40 0 10 20 30 40
5 5
0 0
–5 –5
–10 –10
–150 –150
–15 –15
–120 –120
–20 – 90 –20 – 90
– 60 – 60
–25 –25
– 30 – 30
–30 – 0 –30 – 0
2 10 20 50 100 200 300 700 2 10 20 50 100 200 300 700
5% 25 % 100 %
100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 50 100 150 200 250 300 325 0 50 100 150 200 250 300 325
RE 29 583/07.03 12/20 4WS.2E…

100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 10 20 30 40 0 10 20 30 40
5 5
0 0
–5 –5
–10 –10
–150 –150
–15 –15
–120 –120
–20 – 90 –20 – 90
– 60 – 60
–25 –25
– 30 – 30
–30 – 0 –30 – 0
2 10 20 50 100 200 300 700 2 10 20 50 100 200 300 700
5% 25 % 100 %
100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 50 100 150 200 250 300 325 0 50 100 150 200 250 300 325
4WS.2E… 13/20 RE 29 583/07.03

100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 10 20 30 40 0 10 20 30 40
5 5
0 0
–5 –5
–10 –10
–150 –150
–15 –15
–120 –120
–20 – 90 –20 – 90
– 60 – 60
–25 –25
– 30 – 30
–30 – 0 –30 – 0
2 10 20 50 100 200 300 700 2 10 20 50 100 200 300 700
5% 25 % 100 %
100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 50 100 150 200 250 300 325 0 50 100 150 200 250 300325
RE 29 583/07.03 14/20 4WS.2E…

100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 10 20 30 40 0 10 20 30 40
5 5
0 0
–5 –5
–10 –10
–150 –150
–15 –15
–120 –120
–20 – 90 –20 – 90
– 60 – 60
–25 –25
– 30 – 30
–30 – 0 –30 – 0
2 10 20 50 100 200 300 700 2 10 20 50 100 200 300 700
5% 25 % 100 %
100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 50 100 150 200 250 300 325 0 50 100 150 200 250 300325
4WS.2E… 15/20 RE 29 583/07.03

Unit dimensions: type 4WS2EM 10 (dimensions in mm)
Mechanical feedback / external control electronics,
Type 4WS2EM 10-5X/…
3 2 1
15 95 68
32
96
80
64
60
10
9,5
M6
10 4 6 7 5 8
3,7
9,5
P
X A B Y
46
65
TA TB
1,5
12,5 24 54
102
127
9
1 Cap 2 54
13,5
2 Plug-in connector 7,9 61,9

(separate order, see page 7) 0,006/100mm
3 Space required to remove the plug-in connector, R max 4 P
take connection cable into account! X A B Y
11,1
46
65
4 Exchangeable filter element TA TB

Material No.: R900306843 with FKM seal Required surface finish
22A/F, MA = 30 Nm of the mating piece
102
5 Profile seal for filter screw 16 x 1.5
Material No.: R900012503 (FKM seal)
6 Name plate Subplates to catalogue sheet RE 45 054 must be ordered separately.
7 Identical seal rings for ports A, B, P, TA and TB G 66/01 (G 3/8)
8 Identical seal rings for ports X and Y G 67/01 (G 1/2)
Ports X and Y are also pressurised with the option G 535/01 (G 3/4)
"internal" pilot oil. G 535/02 (M 27 x 2)
9 Machined valve contact area, position of ports to DIN 24 340 G 536/01 (G 1) With ports X
form A10, ISO 4401 and CETOP-RP121H and Y
G 536/02 (M 33 x 2)
10 Valve fixing screws
4 off M6 x 70 DIN 912-10.9 NEL, MA = 16 Nm
(are included within the scope of supply)
RE 29 583/07.03 16/20 4WS.2E…

Unit dimensions: type 4WSE2EM 10 (dimensions in mm)
Mechanical feedback / integrated control electronics
Type 4WSE2EM 10-5X/…
4 3 2 1
15 95 75
47
111
80
64
60
10
2,5
M6
11 5 7 8 6 9
3,7
9,5
P
X A B Y
46
65
TA TB
1,5
12,5 24 54
102
1 Cap with integrated control eclectronics 127
2 Electrical zero point adjustment:
After removing the 2.5A/F plug, a correction, via a potentiometer, 9
2 54
to the zero point is possible.
13,5
0,006/100mm 7,9 61,9

3 Plug-in connector
(separate order, see page 7) R max 4
4 Space required to remove the plug-in connector, P

X A B Y
11,1
take connection cable into account!

46
65
Required surface finish

5 Exchangeable filter element of the mating piece
TA TB
Material No.: R900306843 with FKM seal, 22 A/F, MA = 30 Nm
6 Profile seal for filter screw 16 x 1.5 102
Material No.: R900306843 (FKM seal)
7 Name plate
8 Identical seal rings for ports A, B, P, TA and TB
9 Identical seal rings for ports X and Y
Subplates to catalogue sheet RE 45 054 must be ordered separately.
Ports X and Y are also pressurised with the option
"internal"pilot oil. G 66/01 (G 3/8)
10 Machined valve contact area, position of ports to DIN 24 340 G 67/01 (G 1/2)
form A10, ISO 4401 and CETOP-RP121H G 535/01 (G 3/4)
11 Valve fixing screws G 535/02 (M 27 x 2) With ports X
4 off M6 x 70 DIN 912-10.9 NEL, MA = 16 Nm and Y
G 536/01 (G 1)
G 536/02 (M 33 x 2)
4WS.2E… 17/20 RE 29 583/07.03

Unit dimensions: type 4WSE2ED 10 (dimensions in mm)
Electrical and mechanical feedback / integrated control electronics
Type 4WSE2ED 10-5X/…
4 3 2 1
15 95 75
47
111
80
64
60
10
44,5 2,5 M6
159
11 5 7 8 6 9
3,7
9,5
P
X Y
46
65
A B
TA TB 1,5
1 Cap with integrated control electronics 24 54

2 Electrical zero point adjustment: 102
After removing the 2.5A/F plug, a correction, via potentiometer,
to the zero point is possible. 9
2 54
13,5
3 Plug-in connector 0,006/100mm 7,9 61,9

(separate order, see page 7)
R max 4
4 Space required to remove the plug-in connector, P
take connection cable into account! X A B Y
11,1
46
65
5 Exchangeable filter element Required surface finish TA TB

Material No.: R900306843 with FKM seal, 22A/F, MA = 30 Nm of the mating piece
6 Profile seal for filter screw 16 x 1.5 102
Material No.:R900012503 (FKM seal)
7 Name plate
8 Identical seal rings for ports A, B, P, TA and TB
Subplates to catalogue sheet RE 45 054 must be ordered separately.
9 Identical seal rings for ports X and Y
G 66/01 (G 3/8)
ports X and Y are also pressurised with the option
"internal"pilot oil. G 67/01 (G 1/2)
10 Machined valve contact area, position of ports to DIN 24 340 G 535/01 (G 3/4)
form A10, ISO 4401 and CETOP-RP121H G 535/02 (M 27 x 2)
11 Valve fixing screws G 536/01 (G 1) With ports X
4 off M6 x 70 DIN 912-10.9 NEL, MA = 16 Nm G 536/02 (M 33 x 2) and Y
RE 29 583/07.03 18/20 4WS.2E…

Pilot oil – conversion from internal/external
Pilot oil supply
2 External pilot oil supply
S.H.C.S. item 2 is fitted.
Internal pilot oil supply
1 S.H.C.S. item 2 is removed
1 Vavle housing
2 S.H.C.S. M3 x 5 DIN 912-10.9, MA = 1.4 Nm
P
Pilot oil drain External pilot oil drain
S.H.C.S. item 2 is fitted.
2
Internal pilot oil drain
1
S.H.C.S. item 2 is removed
3
1 Vavle housing
2 S.H.C.S. M3 x 5 DIN 912-10.9, MA = 1.4 Nm
3 Plug M8 x 1 with seal, Material No. 00017829
MA = 5 Nm
Y
Flushing plate to DIN 24 340 form A10 (dimensions in mm)
Symbol
With FKM seals,

TA P X A B Y TB Material No. R900912450, Weight: 2 kg
3
1 R-ring 13 x 1.6 x 2 (A, B, P, TA and TB)
2 R-ring 11,18 x 1.6 x 1.78 (X, Y)
46,5
3 4 off S.H.C.S. M6 x 50 DIN 912–10.9, MA = 16 Nm

40,5

4 Porting pattern to DIN 24340, form A10
In order to guarantee that the servo valves function correctly, it is
61,9
9,5
absolutely necessary to flush the system before commissioning. 1

Cleanliness class to ISO code, see page 6.
The following is a guide to the flushing time necessary for the in- 2 6,6
stallation: 2
t = Flushing time in hours
12
V P
t≥ q •5 V = Tank contents in litres
V A B
qV = Pump flow in X Y
70
litres per minute

If the tank neecs to be refilled with more than 10 % of its capacity TA TB
it will be necessary to reflush the system.
A directional control valve with a porting pattern to DIN 24 340 4
form A10 is more suitable than a flushing plate for the flushing 18
operation, as the actuator lines can also be flushed. Also see cata-
90 2
logue sheet RE 07 700.
4WS.2E… 19/20 RE 29 583/07.03

Notes
Bosch Rexroth AG Bosch Rexroth Limited The data specified above only serves to describe
Industrial Hydraulics the product. No statements concerning a certain
D-97813 Lohr am Main Cromwell Road, St Neots, condition or suitability for a certain application
Zum Eisengießer 1 • D-97816 Lohr am Main Cambs, PE19 2ES can be derived from our information.
Telefon 0 93 52 / 18-0 Tel: 0 14 80/22 32 56 The details stated do not release you from the
Telefax 0 93 52 / 18-23 58 • Telex 6 89 418-0 Fax: 0 14 80/21 90 52 responsibility for carrying out your own
eMail documentation@boschrexroth.de E-mail: info@boschrexroth.co.uk assessment and verification. It must be
Internet www.boschrexroth.de remembered that our products are subject to a
natural process of wear and ageing.
RE 29 583/03.99 20/20 4WS.2E…

BTL5-A/C/E/G1_-M/U_ _ _ _-K-SR 32/K_ _
english Technical Description

User's Guide
Balluff GmbH
Schurwaldstrasse 9
73765 Neuhausen a.d.F.
Germany
Phone +49 (0) 71 58/1 73-0
Fax +49 (0) 71 58/50 10
Servicehotline +49 (0) 71 58/1 73-3 70
E-Mail: balluff@balluff.de
http://www.balluff.de
BTL5-A/C/E/G1_-M/U_ _ _ _-K-SR 32/K_ _
Micropulse Linear Transducer - Rod Style
Contents 1 Safety Advisory
1 Safety Advisory ..................... 2 Read this manual before installing ducer system. In particular, steps
1.1 Proper application .................. 2 and operating the Micropulse trans- must be taken to ensure that should
1.2 Qualified personnel ................ 2 ducer. the transducer system become de-
1.3 Use and inspection ................ 2 fective no hazards to persons or
1.4 Scope ..................................... 2 1.1 Proper application property can result. This includes
the installation of additional safety
2 Function and The BTL5 Micropulse transducer is limit switches, emergency shutoff
Characteristics ..................... 3 intended to be installed in a ma- switches and maintaining the per-
2.1 Characteristics ....................... 3 chine or system. Together with a missible ambient conditions.
controller (PLC) or a processor (BTA)
2.2 Function ................................. 3
it comprises a position measuring
2.3 Available stroke lengths 1.4 Scope
system and may only be used for
and magnets .......................... 3 this purpose. This guide applies to the model
3 Installation ............................ 3 BTL5-A/C/E/G1...K... Micropulse
Unauthorized modifications and
3.1 Mounting ................................ 3 transducer.
non-permitted usage will result in
3.2 Transducer, Installation ........... 4 the loss of warranty and liability An overview of the various models
3.3 Magnets, Installation .............. 5 claims. can be found in section 7 Versions
(indicated on product label) on
4 Wiring .................................... 5 page 8.
1.2 Qualified personnel
5 Start-up ................................. 6 This guide is intended for special-
5.1 Check connections ................ 6 Note: For special versions, which
ized personnel who will perform the are indicated by an -SA_ _ _ des-
5.2 Set null and span ................... 6 installation and setup of the system.
5.3 Turning on the system ............ 7 ignation in the part number, other
technical data may apply (affect-
5.4 Check output values .............. 7 1.3 Use and inspection ing calibration, wiring, dimensions
5.5 Check functionality ................ 7 etc.).
5.6 Fault conditions ...................... 7 The relevant safety regulations must
be followed when using the trans-
6 Technical Data ...................... 8
6.1 Dimensions, weights,
ambient conditions ................. 8
6.2 Supply voltage (external) ........ 8
6.3 Outputs .................................. 8
6.4 Connection to processor ........ 8
6.5 Included in shipment .............. 8
6.6 Magnets
(order separately) .................... 8
6.7 Accessories (optional) ............ 8
7 Versions (indicated on
product label) ........................ 8
The CE Mark verifies Emission tests:

that our products meet RF Emission
the requirements of EN 55011 Group 1, Class A
EC Directive Noise immunity tests:
89/336/EEC (EMC Directive) Static electricity (ESD)
EN 61000-4-2 Severity level 3
and the EMC Law. Testing in our
Electromagnetic fields (RFI)
EMC Laboratory, which is accred-
EN 61000-4-3 Severity level 3
ited by DATech for Testing Electro-
magnetic Compatibility, has con- Fast transients (Burst)
firmed that Balluff products meet EN 61000-4-4 Severity level 3
The following patents have been the EMC requirements of the fol- Surge
granted in connection with this lowing Generic Standards: EN 61000-4-5 Severity level 2
product: Line-induced noise induced by
EN 50081-2 (emission) high-frequency fields
US Patent 5 923 164
Apparatus and Method for Auto- EN 61000-6-2 (noise immunity) EN 61000-4-6 Severity level 3
matically Tuning the Gain of an Magnetic fields
Amplifier EN 61000-4-8 Severity level 4
2 english
BTL5-A/C/E/G1_-M/U_ _ _ _-K-SR 32/K_ _
2 Function and Characteristics
2.1 Characteristics torsional wave in the waveguide Dimensions for installing the
which propagates at ultrasonic Micropulse transducer: ➥ Fig. 3-2
Micropulse transducers feature:
speed. Dimensions for installing the mag-
– Very high resolution, repeatability net: ➥ Fig. 3-4
and linearity The torsional wave arriving at the
end of the waveguide is absorbed in
– Wear- and maintenance-free 2.3 Available stroke lengths
the damping zone. The wave arriv-
– Immunity to shock, vibration, con- and magnets
ing at the beginning of the wave-
tamination and electrical noise guide creates an electrical signal in To provide for optimum fit in any
– An absolute output signal the coil surrounding the waveguide. application, a wide range of stan-
– Pressure rated to 600 bar The propagation time of the wave is dard stroke lengths and magnets in
used to derive the position. Depend- various form factors are available.
– Protection class per IEC 529: ing on the version the corresponding Magnets must therefore be ordered
IP 67 for connector version, value is output as a voltage or a cur- separately.
IP 68 (5 bar/48 h) for cable version rent either with rising or falling char-
acteristic. This process takes place The following nominal stroke
2.2 Function with measuring high precision and lengths are available:
repeatability within the stroke range Stroke lengths Increments
The Micropulse transducer contains
defined as nominal stroke length. [mm] [mm]
a tubular waveguide enclosed by an
outer stainless steel rod. A magnet At the rod end is a damping zone, 50 ... 500 25
attached to the moving member of within which no reliable signal is 500 ... 1000 50
the machine or to the cylinder pis- available, but which may be entered
ton is moved over the rod and its 1000 ... 2000 100
by the magnet.
position constantly updated. 2000 ... 4000 250
The electrical connection between
The magnet defines the measured the transducer, the processor/con- Other stroke lengths on request.
position on the waveguide. An inter- troller and the power supply is via a
nally generated INIT pulse interacts cable, which depending on the ver-
with the magnetic field of the mag- sion is either fixed or connected
net to generate a magnetostrictive using a female connector.
3 Installation
3.1 Mounting
When possible, use non-magnetiz-
able material for attaching the trans-
ducer and magnet ring. ➥ Fig. 3-1.
When attaching the transducer to

magnetizable materials, appro-
priate measures must be taken to
protect against magnetic disturb- non-magnetizable material
ances ➥ Fig. 3-1. Note the
recommended distance of the
transducer and cylinder from
strong, external magnetic fields.
➀ - ➂ for magnetizable materials a = Spacer made of non-mag-

➃ for non-magnetizable materials netizable materials
b = Magnet
Fig. 3-1: Mounting
english 3
BTL5-A/C/E/G1_-M/U_ _ _ _-K-SR 32/K_ _
3 Installation (cont.)
3.2 Transducer, Installation Connector BKS-S 33M

rotates in 90° steps
The smallest permissible distance BTL5...K-SR 32
Damping zone
between magnet ring and rod Nominal (unusable area)
mounting surface is shown in length
Fig. 3-2.
= stroke threaded hole
The sealing is carried cut with the M4 x 4/6 deep
O-ring supplied at the flange facing.
Important Installation Notes:

The contact surface of the trans-
Magnet ring
ducer must be completely con-
tacted by the mounting surface.
The O-ring supplied must make a Mounting surface
perfect pressure seal, i.e. the BTL5...K-K05
bevel for the O-ring must be con-
figured exactly as shown in 6 holes for
Fig. 3-3. mounting the
To achieve a secure mounting, transducer
attach the transducer with all
6 cylinder head screws ISO 4762,
M6 x 16 - A2-70 (➥ Fig. 3-2). All
screws must be tightened to Fig. 3-2: Transducer BTL5...K..., dimensions
3.5 Nm.
For horizontal mounting of trans-
ducer with stroke lengths greater
than 500 mm, the pressure tube
should be supported or attached
at its end.
When installing in a hydraulic
cylinder, do not allow the magnet
ring to rub against the pressure
tube. The bore diameter in the thru-hole
piston and cylinder rod should be
at least 13 mm.
Bevel for O-Ring 15.4 x 2.1
Fig. 3-3: Thru-hole design for mounting BTL with O-ring
4 english
BTL5-A/C/E/G1_-M/U_ _ _ _-K-SR 32/K_ _
3 Installation (cont.) 4 Wiring
3.3 Magnets, Installation Note the following when mak- The shield must be tied to the
ing electrical connections: connector housing in the BKS
A magnet is required for each trans-
connector (➥ Fig. 4-3); see in-
ducer. This must be ordered sepa- System and control cabi-
structions accompanying the con-
rately. ➥ Fig. 3-4. net must be at the same
nector.
ground potential.
For mounting the magnet we rec-
In the cable version the cable shield
ommend to use non-magnetizable To ensure the electromagnetic
is connected to the housing in the
material. ➥ Fig. 3-1. compatibility (EMC) which Balluff
PG fitting.
warrants with the CE Mark, the
following instructions must be The cable shield must be grounded
BTL-P-1013-4R strictly followed. on the control side, i.e., connected
to the protection ground.
BTL transducer and the proces-
sor/control must be connected Pin assignments can be found in
using shielded cable. ➥ Table 4-1. Connections on the
controller side may vary according
Shielding: Copper filament
to the controller and configuration
braided, 80% coverage.
used.
not used YE
0V GY
BTL-P-1013-4S
10...0 V PK
0...10 V GN
GND BU
+24 V BN
processor/
BTL5-A11-
controller with
...K_ _
analog input
Fig. 4-1: BTL5-A11...K_ _ with processor/controller, wiring example

BTL-P-1012-4R
When routing the cable between the BKS connector, view
transducer, controller and power towards solder side of
supply, avoid proximity to high volt- female BKS-S 32M-00
age lines to prevent noise coupling. or BKS-S 33M-00
Especially critical is inductive noise
caused by AC harmonics (e.g. from
phase-control devices), against Fig. 4-2: Pin assignments BKS,
which the cable shield provides only connector type BTL
Fig. 3-4: Magnet (optional) limited protection.
Cable length max. 20 m; Ø 6 to straignt right-angle
8 mm. Longer lengths may be used BKS-S 32M-00 BKS-S 33M-00
if construction, shielding and routing No. 99-5672-19-08 No. 99-5672-78-08
are such that external noise fields (Binder part no.) (Binder part no.)
will have no effect on signal integrity. Cable entry
(PG 9 fitting)
Fig 3-5: Spacer
Fig. 4-3: Connector (optional)
english 5
BTL5-A/C/E/G1_-M/U_ _ _ _-K-SR 32/K_ _
4 Wiring (cont.)
Output signals
Pin Cable BTL5-A11 -C10 -C17 -E10 -E17 -G11
1 YE yellow not used ➁ 0...20 mA 20...0 mA 4...20 mA 20...4 mA not used ➁ ➀
2 GY grey 0V
3 PK pink 10...0 V 10...0 V 10...0 V 10...0 V 10...0 V 10...–10 V ➀
4 not used
5 GN green 0...10 V 0...10 V 0...10 V 0...10 V 0...10 V –10...10 V ➀
Supply voltage (external)
Pin Cable BTL5-A/C/E/G1 ➀ Because of the separate output drivers and the current adjustment (Pin 1)
6 BU blue GND there are small voltage differences between Pin 3 and 5 (offset < 10 mV).
7 BN brown +24 V ➁ Unused leads can be tied to GND on the control side, but they must
never be connected to the shield.
8 WH white not used ➁
Table 4-1: Wiring
5 Start-up
5.1 Check connections The electrical output values of the

Although the connections are pro- null and endpoint are compensated
tected against polarity reversal, using the "0" and "E" potentiom-
components can be damaged by
3 screws eters ( ➥ Figs. 5-2 and 5-3 for loca-
M4 x 30 - A2 tion of these pots).
improper wiring and overvoltage.
tightening torque
Before you turn on the power,
max. 2.8 Nm Always adjust the "0" potentiom-
double check your connections.
eter first, then the "E" potentiom-
eter (regardless of whether the
5.2 Set null and span output is configured rising or
Should mounting conditions require falling).
it, the factory set null and/or end
point for the magnet can be shifted
by a total of max. 15% of the full
nominal stroke length.
Fig. 5-1: BTL housing screws
Caution when opening:

internal cable connections!
This recalibration is done
under power with ex- "0" pot
posed electronics! Do not
touch any other components with
the screwdriver, since a short blade size
"E" pot
circuit could destroy the unit. The max. 1.5 mm
warranty does not extend to
damage to the electronics result- Fig. 5-3: Location of the adjustment
ing from such carelessness. pots (cover opened)
Adjusting potentiom-
eter ( ➥ also Fig. 5-3)
3 M4 × 60 screws for securing the

cover during the recalibration proce-
dure
Fig. 5-2: BTL housing opened
6 english
BTL5-A/C/E/G1_-M/U_ _ _ _-K-SR 32/K_ _
5 Startup (cont.)
Example: Shift nullpoint out by 15%, no change to endpoint: 5.3 Turning on the system
Note that the system may execute
Step 1: Remove 3 M4 x 30 screws (see Fig. 5-1) and uncontrolled movements when first
replace with 3 M4 x 60 screws (not included). turned on or when the transducer is
Caution: internal cable connection! part of a closed-loop system whose
Remove cover carefully (see Fig. 5-2). parameters have not yet been set.
Therefore make sure that no haz-
Step 2: Bring magnet to new start point "0" . ards could result from these situa-
tions.
5.4 Check output values

After replacing or repairing a trans-
ducer, it is advisable to verify the
values for the start and end position
"0" "E" of the magnet in manual mode. If
values other* than those present
before the replacement or repair are
Step 3: Turn "0" pot until the desired start value is read found, a correction should be made.
on the output. * Transducers are subject to modifi-
cation or manufacturing tolerances.
5.5 Check functionality

Start
The functionality of the transducer
value:
system and all its associated com-
"0" pot
before ponents should be regularly
checked and recorded.
ing
ris fal
lin after 5.6 Fault conditions
g
When there is evidence that the
transducer system is not operating
properly, it should be taken out of
service and guarded against unau-
Step 4: Bring magnet to new endpoint "E". thorized use.
Step 5: Turn "E" pot until the desired end value is read
on the output.
before End value:

"E" pot
after
new nominal stroke 100 %
Step 6: Replace cover using the original (shorter) M4 x 30 screws, and

tighten using a max. tightening torque of 2.8 Nm.
Caution: Be sure the gasket is seated properly!
Avoid any damage to the O-ring.
Fig. 5-4: Recalibration
english 7
BTL5-A/C/E/G1_-M/U_ _ _ _-K-SR 32/K_ _
6 Technical Data
Typical values at DC 24 V and 25 °C. Ready for operation at once, full accuracy after warm-up. With magnet
BTL-P-1013-4R, BTL-P-1013-4S or BTL-P-1012-4R:
Resolution + hysteresis 6.1 Dimensions, weights, 6.3 Outputs

= repeatability ambient conditions
BTL5-A11...
Voltage 0.3 mV
Nominal length < 4000 mm Output voltage 0...10/10...0 V
Current 0.6 µA
Dimensions ➥ Fig. 3-2 Load current < 5 mA
Minimum 5 µm
Weight ca. 2 kg/m Ripple < 5 mV
Sampling rate: Housing Stainless steel BTL5-G11...
Nom. length fStandard Pressure tube Stainless steel 1.4571 Output voltage–10...10/10... –10 V
< 2000 mm 1 kHz diameter 10.2 mm Load current < 5 mA
wall thickness 2 mm Ripple < 5 mV
> 2000 mm 0.5 kHz
e-modulus ca. 200 kN/mm2 BTL5-C1_...
Non-linearity Mounting Output current 0...20/20...0 mA
Nom. length < 500 mm > 500 mm 6 socket head cap screws, Load resistance < 500 Ohm
in µm ±100 ±0,02 % FS ISO 4762 M6 x 16 - A2-70 BTL5-E1_...
Operating temp. –40 °C to +85 °C Output current 4...20/20...4 mA
Temperature coefficient Humidity < 90 %, non-dewing Load resistance < 500 Ohm
Voltage output: Protection rating per IEC 529
[150 µV/K + (5 ppm/K * P * V/NL)] * ∆T with connector attached: 6.4 Connection to processor
Current output: connector version IP 67
[0,6 µA/K + (10 ppm/K * P * I/NL)] * ∆T cable version IP 68 Analog interface
(type tested at 5 bar / 48 h) for shielded cable (max. length, see
V = output voltage range in [V]
Wiring), Ø 6 to 8 mm
I = output current range in [mA]
NL = nominal length in [mm] 6.2 Supply voltage (external)
No. 814 511 E • Edition 0108; specifications subject to changes • Replaces edition 9812.
6.5 Included in shipment
∆T = temperature coefficient in [K]
Regulated supply voltage
P = magnet position in [mm]
BTL5-_1... DC 20 to 28 V Transducer ➥ Fig. 3-2
Shock loading 100 g/6 ms Ripple < 0.5 Vpp
per IEC 68-2-27 1 Current draw < 150 mA 6.6 Magnets
Continuous shock 100 g/2 ms Inrush < 3 A/0.5 ms (order separately)
per IEC 68-2-29 1 Polarity reversal protection built-in Magnets BTL-P-1013-4R,
Vibration 12 g, 10 bis 2000 Hz Overvoltage protection BTL-P-1013-4S, BTL-P-1012-4R
per IEC 68-2-6 1 Transzorb diodes Dimensions ➥ Fig. 3-4
(take care to avoid inherent reso- Electric strength Weight approx. 10 g
nances of protective tube) GND to housing 500 V Housing anodized aluminum
Pressure up to 600 bar Operating temp. –40 °C to +85 °C
when installed in a Magnets BTL5-P-4500-1
hydraulic cylinder (Electromagnet)
1
Individual specifications as per Weight approx. 90 g
Balluff factory standard Housing plastic
Operating temp. –40 °C to +60 °C
6.7 Accessories (optional)

7 Versions (indicated on product label)
Connectors ➥ Fig. 4-3
Supply voltage: 1 = DC 24 V
Electr. connection, SR 32: with connector,
BTL5-A11-M0450-K-SR 32 K05: with 5 m cable
Rod style,
Micropulse
Linear Transducer
Mounting: 6 screws ISO 4762 M6 x 16 - A2-70

Nom. length (4 digits): M= metric in mm
U = inches in 1/10 Inch
Analog interface:
Voltage output A11 = 10 ... 0 V and 0 ... 10 V
G11 = 10 ... –10 V and –10 ... 10 V
Current output C10 = 0 ... 20 mA E10 = 4 ... 20 mA
C17 = 20 ... 0 mA E17 = 20 ... 4 mA
8 english
RE 07 300/12.02
Replaces: 02.01
Installation, commissioning and

maintenance of industrial valves
1. General 3. Installation
Before commissioning industrial valves, observe the notes in the 3.1 Rules for the installation
following data sheets: Before installing the valve on the system, compare the type desig-
– Related data sheet nation of the valve with the order data.
– German standard DIN 24 346 Make sure that the connection surfaces of the valve and the
– ISO standard ISO 4413 subplate are dry and free from oil.
2. System flushing – Cleanliness:
With external pilot oil supply, ensure that this connection is also • When installing the component, make sure that the industrial
flushed. valve and the surroundings are clean
The hydraulic fluid volume contained in the system should be flushed • The tank must be sealed against external contamination
through the filter at least 150 to 300 times. • Pipes and tank must be freed from contamination, scale, sand,
As a rule, the recommended flushing time can be calculated as chips, etc. prior to the installation.
follows: • Warm-bent or welded pipes must be pickled, flushed and oiled.
• For cleaning use only lint-free cloth or special paper.
t= V
qV x 2.5 to 5
– Sealing materials such as hemp, putty or sealing tape are not
permitted.
– For pipework use seamless precision steel pipes to DIN 2391/
Where:
parts 1 and 2.
t = flushing time in hours – The mounting face must feature a surface quality of
V = tank capacity in litres Rt max ≤ 4 µm and a flatness of ≤ 0.01 mm/100 mm length.
qV = pump flow in l/min – Fixing screws must comply with the dimensions and the strength
A decisive factor for the flushing time is the degree of contamina- class specified in the data sheet and must be tightened at the
tion of the hydraulic fluid according to section 4.3. To achieve the specified tightening torque.
required minimum cleanliness the hydraulic system must be flushed – As filler/breather filter we recommend a filter with the same
sufficiently long. This can be ensured only through continuous mesh width as the filter in the hydraulic system!
monitoring using a particle counter. 3.2 Valve installation
If the hydraulic fluid is changed over to special fluids that are not
When installing the valve, make sure that the mounting face and
compatible or miscible with the hydraulic fluids used before, con-
the subplates are dry and free from oil. If the presence of oil on the
siderably longer flushing times may be required.
connecting faces cannot be avoided, the fixing screws must be
During the flushing process, all filters must be checked at short tightened manually, not with the aid of power tools. In the case of
intervals and the filter elements replaced as required. more than 4 fixing screws, care should be taken that the central
screws are tightened first.
This measure ensures that the seal rings seal properly against the
valve connection face.
© 2003
by Bosch Rexroth AG, Industrial Hydraulics, D-97813 Lohr am Main
All rights reserved. No part of this document may be reproduced or stored, processed, duplicated or circulated using
electronic systems, in any form or by any means, without the prior written authorisation of Bosch Rexroth AG.
In the event of contravention of the above provisions, the contravening party is obliged to pay compensation.
This document was prepared with the greatest of care, and all statements have been examined for correctness.
This document is subject to alterations for reason of the continuing further developments of products.
No liability can be accepted for any incorrect or incomplete statements.
1/2 RE 07 300/12.02
3.3 Installation position 4.3 Filtration
Optional, preferably horizontal for directional valves! – Reliable filtration prolongs the service life of valves.
For valve versions such as, for example, Please also observe the recommendations with regard to the
– without spring centring of the spool max. permissible degree of contamination of the hydraulic fluid
– or with solenoids hanging downwards, according to NAS 1638 in our data sheet.
other installation positions can lead to malfunction or restrictions – The max. permissible differential pressure across the filter ele-
with regard to the specified technical data. ment must not be exceeded.
In the case of pressure switches with drain port the installation – We recommend the use of filters with clogging indicator.
position must be selected so that the max. permissible pressure of
2 bar is not exceeded. – Observe strict cleanliness when changing the filter.
Contamination on the outlet side of the filter is flushed into
3.4 Electrical connection
the system and causes malfunction.
For circuit examples and pin assignments, see the relevant data Contamination on the inlet side reduces the useful life of the
sheet.
filter element.
4. Commissioning 4.4 Bleeding
4.1 Hydraulic fluid – Bleeding of the valves is not necessary!
Observe the recommendations given in the data sheet! – However, to ensure proper operation of the valves, draining
Observe pressure and temperature ranges! of the tank line must be avoided (installation of a precharge
In general, the following fluids can be used: valve).
– Mineral oil (HL; HLP) to DIN 51 524 1) 5. Maintenance
Fast bio-degradable fluids to VDMA 24 568 5.1 The valves are basically maintenance-free; since seals are sub-
(see also RE 90 221) ject to natural wear and aging, they must be replaced as re-
– HETG (rape seed oil) 1) quired.
– HEPG (polyglycols) 2) 6. Storage
– HEES (synthetic esters) 2)
(other hydraulic fluids on enquiry) Storage requirements:
– Dry, dust-free room, free of corrosive substances and vapours
The maximum temperatures recommended by the fluid sup-
plier should not be exceeded. To ensure constant response char- When storing for periods of more than 6 months:
acteristics it is recommended that the hydraulic fluid tempera- – Fill the valve with preserving oils and seal it.
ture be kept constant (± 5 °C).
4.2 Is the sealing material used suitable?
For hydraulic fluids (e.g. HEPG and HEES) and in the case of
temperatures > 80 °C FKM seals must be used (identified with
“V” in the type code).
1) Suitable for NBR and FKM seals

2) Suitable for FKM seals only
Bosch Rexroth AG Bosch Rexroth Limited The data specified above only serve to describe
Industrial Hydraulics the product. No statements concerning a
D-97813 Lohr am Main Cromwell Road, St Neots, certain condition or suitability for a cetain
Zum Eisengießer 1 • D-97816 Lohr am Main Cambs, PE19 2ES application can be derived from our
Telefon 0 93 52 / 18-0 Tel: 0 14 80/22 32 56 information. It must be remembered that our
Telefax 0 93 52 / 18-23 58 • Telex 6 89 418-0 Fax: 0 14 80/21 90 52 products are subject to a natural process of
eMail documentation@boschrexroth.de E-mail: info@rexroth.co.uk wear and ageing.
Internet www.boschrexroth.de
RE 07 300/12.02 2/2
Installation, Commissioning and RE 07700/08.06
Replaces: 12.02
/4
Maintenance of Servo and

High-response Control Valves
1. General In order to obtain the required minimum cleanliness the hy-

Before commissioning servo valves, the guidelines stated draulic system must be flushed for a sufficiently long time.
within the following data sheets have to be taken into The oil volume in the system should be flushed through
account: the filter at least 150 to 300 times. As a rough guide, the
– Relevant catalogue sheet flushing time may be calculated as follows:
– The German standard DIN 24346 V
– ISO standard ISO 4413 t = x 2,5 to 5
qV
Note:
Each servo valve is subjected to functional tests prior to With:
delivery. This functional test is documented in test reports, t = flushing time in hours
which can be ordered when a valve is purchased. V = tank capacity in litres
Commissioning must be carried out by specialist personnel qV = pump flow in l/min
using the relevant calibration equipment.
Depending on the size and the requirements of an installa-
A decisive factor for the flushing time is the degree of conta-
tion, the customer‘s operating personnel may carry out the
mination of the hydraulic fluid according to paragraph 6.2.,
commissioning (provided that they have a sufficient expe-
which can only be determined by continuous monitoring by
rience with hydraulics or have completed a corresponding
means of a particle counter.
training course).
When changing over to special fluids, which are not compa-
tible or cannot be mixed with the hydraulic fluids used so far,
2. Flushing of the system the required flushing time may be considerably longer.
The system must be flushed without the servo valves being During the flushing procedure, check all the filters at short
fitted. Instead of the servo valves use either flushing plates intervals and, if required, replace the filter elements.
or, if the system allows, directional valves of the same size
(Spool symbol G or H), thus, allowing also the service lines
and the actuator to be flushed. With an external pilot oil sup-
ply make sure that this line is also flushed.
/4 Bosch Rexroth AG Hydraulics Installation, Commissioning and Maintenance RE 07700/08.06
3. Rules for correct installation 4. Installation position

3.1 Cleanliness A horizontal position is preferred, but the possible spool
– When installing or removing valves, take care that the position in relation to the type of feedback being used must
immediate area is clean. be taken into account.
– The tank must be fitted with a filler breather to prevent If the servo valve is mounted directly onto an actuator, a
external contamination from entering the tank and to position in which the valve spool is in parallel to the
permit the fluid level to vary according to system require- actuator‘s direction of acceleration should be avoided.
ments. For servo systems a pore size of 5 µm is recom-
mended. 5. Electrical connection
– Piping and reservoir must be cleaned of dirt, scale, swarf, For the electrical connection, please refer to the relevant
etc. before being installed into the system. data sheet. The servo valve can be operated in parallel or
– Hot-bent or welded pipes must then be pickled, flushed series circuits. For reasons of operational safety and to
and oiled. reduce the coil inductivity we recommend that a parallel
– Use only lint-free cloth or special paper for cleaning. circuit is used.
3.2 Valve assembly Special types of electrical insulation require special
measures to be taken to ensure the safe operation of the
When assembling the valve care is to be taken, to ensure
system.
that the valve and subplate mounting surfaces are dry and
free of oil. If it is not possible to carry out the assembly
without oil being present then the fixing screws must be 6. Commissioning
tightened manually, not with the aid of power tools. If there 6.1 Hydraulic fluid
are more than four fixing screws then care should be taken
The preferred fluid is mineral oil to DIN 51524. Other hy-
to ensure that the centre screws are tightened first.
draulic fluids on enquiry. In order to protect the hydraulic
By adhering to these procedures it is ensured that the seal fluid the manufacturer‘s recommendations concerning maxi-
rings correctly seal against the valve connection surface. mum temperatures should be observed. In order to obtain
3.3 Sealing materials such as hemp, putty or sealing tape are constant response characteristics from the system, it is
not permissible. recommended that the fluid temperature should be held
3.4 Hoses, especially for the connection to the actuator, should constant (± 5 °C).
be avoided wherever possible. 6.2 Filtration
3.5 The connecting lines to the actuator should be kept as – Install a filter with high pressure differential without by-
short as possible. We recommend that the servo valve is pass, if possible with a clogging indicator, immediately
mounted directly onto the actuator. The required finish of be fore the servo valve (possibly a sandwich plate filter).
the mounting face is as follows: – Permissible maximum degree of contamination of the
0,01/100mm hydraulic fluid for internally pilot operated valves:
class 18/16/13 - cleanliness class to ISO 4406 (c).
Rzmax 4 – For externally pilot operated valves, the permissible
maximum degree of contamination in the “X”-line is: class
18/16/13 - cleanliness class to ISO 4406 (c);
3.6 Pipes should be seamless precision pipes to DIN 2391/C in the “P”-line: class 20/18/15 - cleanliness class to
in order to ensure the required pressure resistance. ISO 4406 (c).
3.7 Before installing the valve, compare the nameplate of the – When changing the filter observe absolute cleanliness:
valve with the ordering data. • Contamination on the inlet side reduces the service life
3.8 Install the servo valves after completion of the flushing of the filter elements.
procedure and observe strictest cleanliness. • Contamination on the outlet side of the filter will be
Remove the protective cover from the servo valve only im- flushed into the system and eventually cause the
mediately prior to the installation of the valve and keep it system to completely break down.
safe for possible maintenance work (paragraph 7.3) in the 6.3 As part of the final inspection in the factory, the hydraulic
future. zero point of every valve is adjusted. However, in order to
3.9 Tighten the fixing screws to the torque specified in the obtain an optimum control quality for the specific applica-
data sheet. tion, it may be necessary to re-adjust the hydraulic zero
3.10 All hydraulic functions must first be tested at low pressures point either on the valve or in the closed loop control
under controlled conditions. electronics.
To facilitate commissioning and trouble-shooting, battery or
mains powered control units are available for the servo 7. Maintenance
valves. 7.1 f the tank volume is topped up by more than 10 % or if an
oil change is carried out, the system must again be flushed
according to paragraph 2.
7.2 Contamination in the flapper jet system is caused by
insufficient system filtration of the hydraulic fluid.
RE 07700/08.06 Installation, Commissioning and Maintenance Hydraulics Bosch Rexroth AG /4
Without special knowledge of servo valves, servicing is

limited to changing the protective filter inside the valve and
to re-adjusting the valve zero point.
7.3 Return of valves for repair
When returning a defective servo valve, it is necessary to
fix a clean protective plate (see paragraph 3.7) to the
base of the valve. Careful packaging is advisable in order
to prevent any damage during transportation.
7.4 Storage
When storing servo valves for periods longer than 6
months, they should be filled with a clean preservative oil.
Storage rooms must meet the following requirements: dry,
dust-free, low humidity, free of corrosive materials and
vapours, and no wide temperature fluctuations.
/4 Bosch Rexroth AG Hydraulics Installation, Commissioning and Maintenance RE 07700/08.06
Notes
Bosch Rexroth AG © This document, as well as the data, specifications and other information
Hydraulics set forth in it, are the exclusive property of Bosch Rexroth AG. It may not
Zum Eisengießer 1 be reproduced or given to third parties without its consent.
97816 Lohr am Main, Germany
The data specified above only serve to describe the product. No state-
Phone +49 (0) 93 52 / 18-0 ments concerning a certain condition or suitability for a certain application
Fax +49 (0) 93 52 / 18-23 58 can be derived from our information. The information given does not
www.boschrexroth.de must be remembered that our products are subject to a natural process of
wear and aging.
Installation, commissioning and RE 07900/10.06
Replaces: 08.06
/6
maintenance of hydraulic systems
1. General • For hydraulics fluids:

1.1 Long service life and functional reliability of hydraulic Take care of contamination and humidity; contamination
systems and their components depend on correct from the environment must not enter the tanks! Fill oil
handling. tanks only through filters, preferably system filters or
Ensure trouble-free operation by observing the following portable filter stations with fine filters.
points: Internal protective coatings, if any, must be resistant to
the hydraulic fluid used!
– The specific installation and operating instructions for the
relevant components • For parts taken from stock:
– Special instructions in individual cases The storage of parts that were not filled or treated with
anti-corrosion fluid can lead to the formation of resin.
– Technical data in the data sheet.
Solve the resin using a grease solvent and renew the
In addition, we would like to draw your attention to the fol- lubricating film.
lowing regulations:
– Check to see that all of the parts required for the installa-
– German standard “Hydraulic systems“ DIN 24346 tion are available!
– ISO standard ISO 4413 – Take note of any transport damage!
2. Installation 2.2 Carrying out the montage
2.1 Preparatory work for the installation – Use lifting lugs and transport facilities!
– Sauberkeit der Anlage gewährleisten! – Do not apply force to prevent transverse forces and tensi-
• For the surroundings: on on pipes and components. The valve mounting sur-
Keep power units, line connections and components faces must be perfectly even. The fixing screws must be
clean or clean them (e.g. pickling after, for example, pro- tightened evenly at the specified torque.
cesses have been carried out that involve heat, i.e. wel- Take care that pipes are adequately fixed!
ding, hot bending, etc.)! – When selecting pipes, hoses and fittings/flanges, obser-
ve the correct pressure stage (wall thickness, material).
Use only seamless precision steel pipes.
/6 Bosch Rexroth AG Hydraulics Installation, commissioning and maintenance of hydraulic systems RE 07900/10.06
– Do not use hemp or putty as sealing materials! This may As the hydraulic fluids often do not comply with the re-
cause contamination and thus malfunction. quired cleanliness, the fluids must be filled through a fil-
– To prevent external leakage, observe the installation ins- ter. The absolute filter rating of the filling filter should be at
tructions of the pipe fittings’ manufacturer. We recom- least that of the filters installed in the system.
mend the use of fittings with elastic seals. 3.2 Trial run
– Make sure that hoses are properly laid! Rubbing and – For safety reasons, only personnel of the machine ma-
abutting of the lines must be prevented. nufacturer and, if required, maintenance and operating
– Provide the correct hydraulic fluids personnel should be present.
• Mineral oils: – All pressure relief valves, pressure reducing valves,
HLP hydraulic oils according to DIN 51524 part 2 are pressure controllers of pumps must be unloaded. An
generally suitable for standard systems and compo- exemption to this are TÜV-set valves.
nents. – Open isolator valves completely!
• Fast bio-degradable hydraulic fluids: – Switch the system on briefly and check whether the di-
VDMA 24568. rection of rotation of the drive motor matches the pre-
For these fluids, the system and components must be scribed direction of rotation of the pump.
matched. – Check the position of the directional valves and, if ne-
• Hardly inflammable hydraulic fluids: cessary, move the spool to the required position.
VDMA 24317. For these fluids, the system and com- – Set the control spool to by-pass.
ponents must be matched. (Before filling in the spe- – Open suction valves of the pump. If required for design
cial media, check, whether the system is compatible reasons, fill pump housing with hydraulic fluids to pre-
with the intended fluid.) vent bearings and parts of the rotary group from run-
The following points must be observed in accordance ning dry.
with the relevant requirements: – If a pilot oil pump is provided, commission it1).
– Viscosity of the hydraulic fluid – Start up the pump, swivel it from its zero position and
– Operating temperature range listen for any noises.
– Type of seals used on the components fitted – Swivel the pump slightly out (ca. 5°)1).
– Bleed the system
3. Commissioning Carefully loosen fittings or bleed screws at high points
in the system. When the escaping fluid is free from bub-
When the installation has been carried out correctly, pro-
bles, then the filling process is completed. Re-tighten
ceed with commissioning and functional testing.
fittings.
3.1 Preparations for trial run
– Flush the system; if possible, short-circuit actuators.
– Tank cleaned? Flush the system until the filters remain clean; check
– Lines cleaned and properly installed? the filters!
– Fittings, flanges tightened? With servo-systems, the servo-valves must be remo-
ved and replaced by flushing plates or direction
– Lines and components correctly connected in line with
valves of the same size. Short-circuit the actuators.
installation drawings and circuit diagram?
During flushing, the hydraulic fluid in the complete hy-
Is the accumulator filled with nitrogen? Fill in nitrogen un- draulic system should reach temperatures that are at
til the pre-charge pressure p0 as specified in the cicuit least as high as later during operation. Change the fil-
di agram is reached. (On the fluid side the system must ter elements as required.
be pressureless!). It is recommended that the gas pre- Flushing continues until the required minimum cleanli-
charge pressure is marked on the accumulator itself (e.g. ness is reached. This can only be achieved by conti-
self-adhesive label) and in the hydraulic circuit so that a nuous monitoring using a particle counter.
comparative check is possible, if required.
– Check the system functions under no-load conditions, if
Caution! Use only nitrogen as pre-charge gas! possible, by hand; cold-test the electrohydraulic control.
Accumulators must comply with the safety regulations va- – When the operating temperature has been reached,
lid at the place of installation. test the system under load; slowly increase the pressu-
– Are the drive motor and pump properly installed and re.
aligned? – Monitor control and instrumentation equipment!
– Is the drive motor correctly connected? – Check the housing temperature of hydraulic pumps and
– Are filters with the prescribed filter rating used? hydraulic motors.
– Are filters fitted in the correct direction of flow? – Listen for noises!
– Has the specified hydraulic fluid filled up to the upper – Check the hydraulic fluid level; if required, top up!
marking?
1) As far as possible with the control elements fitted; otherwise,
start up at full displacement. In conjunction with combustion
engines, start up at idle speed.
RE 07900/10.06 Installation, commissioning and maintenance of hydraulic systems Hydraulics Bosch Rexroth AG /6
– Check the setting of pressure relief valves by loading or The most common faults are:
braking the system. – The fluid tank is not inspected.
– Inspect the system for leaks. – The hydraulic fluid is not filtered before being filled in.
– Switch off the drive. – The installation is not checked before commissioning
– Retighten all fittings, even if there is no evidence of lea- (subsequent conversion with loss of fluid!).
kage. – System components are not bled.
Caution! Only tighten fittings when the system is – Pressure relief valves are set only slightly higher than
depressurised! the operating pressure (closing pressure differential is
– Is the pipe fixing adequate, even under changing pres- not observed).
sure loads? – Pressure controllers of hydraulic pumps are set higher
– Are the fixing points at the correct positions? or to the same pressure as the pressure relief valve.
– Are the hoses laid so that they do not chamfer, even un- – The flushing time of servo systems is not adhered to.
der pressure load? – Abnormal pump noise is ignored (cavitation, leaking
– Check the fluid level. suction lines, too much air in the hydraulic fluid).
– Test the system for all functions. Compare measured – Transversal loads on cylinder piston rods are not obser-
values with the permissible or specified data (pressure, ved (installation error!).
velocity. Adjust further control components). – Hydraulic cylinders are not bled (damage to seals!)
– Jerky movements indicate, amongst other things, the – Limit switches are set too low.
presence of air in the system. By briefly swivelling the
– The switching hysteresis of pressure switches is not ta-
pump in one or both directions with the actuator being
ken into account when settings are made.
loaded or braked, it is possible to eliminate certain air
pockets. The system is completely bled when all func- – Hydraulic pump and hydraulic motor housings are not
tions are performed jerk-free and smoothly and the sur filled with hydraulic fluid prior to commissioning.
face of the hydraulic fluid level is free from foam. Expe- – Settings are not documented.
rience has shown that foaming should have ceased one – Adjustment spindles are not secured or sealed.
hour after start-up at the latest.
– Unnecessary personnel present during commissioning
– Check the temperature. of the system.
– Switch off the drive.
– Remove filter elements (off-line and full-flow filters) and 4. Maintenance
inspect them for residues. Clean filter elements or re-
According to DIN 31 051 the term “maintenance” in-
place them, if required. Paper or glass fibre elements
cludes the following fields of activity:
cannot be cleaned.
– Inspection
– If further contamination is found, additional flushing is
required to prevent premature failure of the system Measures to recognise and assess the actual situation,
components. i.e. recognise how and why the so-called wear reserve
continues to decrease.
– All the adjustments made are to be recorded in an ac-
ceptance report. – Maintenance
3.3 Commissioning of fast running systems Measures to preserve the nominal conditions, i.e. to
take precautions in order that the reduction in the wear
Such system can often not be commissioning using the
reserve during the useful life is kept as low as possible.
normal measuring instruments (such as pressure gauges,
thermometers, electrical multimeters, etc.) and standard – Repair
tools. Optimization is also not possible. Measures to restore the nominal condition, i.e. compen-
These systems include, for example, forging presses, sate for reduction in performance and restore the wear
plastics injection moulding machines, special machine reserve.
tools, rolling tools, crane controls, machines with electro- Maintenance measures must be planned and taken in ac-
hydraulic closed-loop control systems. cordance with the operating time, the consequences of a
Commissioning and optimization of these systems often failure and the required availability.
require more comprehensive measuring equipment to al-
4.1 Inspection
low several measurements to be taken at a time (e.g. se-
veral pressures, electrical signals, travel, velocities, flows, The individual points to be inspected should be summa-
etc.). rised for a specific system in so-called inspection lists in
order that the inspections can be carried out adequately
3.4 The most common faults occurring during commissioning
by employees with different qualification levels.
Apart from servicing, commissioning is very decisive for
Important points of inspection are:
the service life and functional reliability of a hydraulic sys-
tem. – Checking the hydraulic fluid level in the tank.
For this reason, faults during commissioning must be avo- – Checking the heat exchanger (air, water) for effec-
ided as far as possible. tiveness.
– Checking the system for external leakage (visual inspec- • daily during the first week and replace them as re-
tion). quired.
– Checking the hydraulic fluid temperature during operati- • After one week, the filters should be cleaned as re-
on. quired.
– Checking pressures • Maintenance of suction filters:
– Amount of leakage Suction filters require particularly thorough servicing.
– Checking the cleanliness of the hydraulic fluid After the running-in period, they must be inspected at
least once a week and cleaned, if necessary.
Caution!
– Service the system fluid
Visual inspections can only give an approximation (clou-
ding of the hydraulic fluid, darker appearance than at • Maintenance intervals depend on the following opera-
the time of filling, sediments in the fluid tank). ting factors:
If conventional particle counting is impossible, the fol- - Hydraulic fluid condition (e.g. water in oil, strongly
lowing three methods can be used for establishing the aged oil)
fluid cleanliness: - Operating temperature and oil fill
• Particle counts using electronic counting and sorting We recommend that the fluid be changed in depen-
equipment. dence upon an oil analysis. With systems whose oil
• Microscopic examination. is not analysed at regular intervals the fluid should be
replaced every 2000 to 4000 operating hours at the
• Gravimetric establishment of solids by means of finest
latest.
filtration of a certain fluid volume (e.g. 100 ml) and
weighing of the filter paper before and after the filtra- • Drain the system fluid at operating temperature and
tion process. This allows the establishment of the change it.
amount of solid particles in mg/l. • Severely aged or contaminated system fluid cannot
– Check the contamination of filters. A visual inspection be improved by adding new fluid!
of deep filters, which are widely used today, is no lon- • Only fill in oil via filters that have at least the same se-
ger possible. paration capacity as the filters installed in the system,
– Analyse the chemical properties of the hydraulic fluid. or use a system filter.
– Check the temperature at points where bearings are lo- • Take samples of the system fluid to have the type, size
cated. and amount of particles analysed in the lab. Record
the results.
– Check the generation of noise.
– Check the accumulator for its pre-charge pressure; for
– Test performance and velocity.
this, the accumulator must be depressurised on the flu-
– Inspect pipes and hoses. id side.
Caution! Caution!
Damaged pipes and hoses must be immediately re- Work on systems that include accumulators may
placed. only be carried out after the fluid pressure was un-
– Inspect accumulator stations. loaded.
4.2 Maintenance Welding or soldering work or any mechanical work on
In practice, inspection, maintenance and repair work is accumulators is not permitted.
not as strictly separated as the definitions may suggest. Improper repairs can lead to severe accidents. Repairs
Servicing is often done in conjunction with inspections. on hydraulic accumulator may therefore only be carried
For safety reason, pipe fittings, connections and compo- out by Rexroth Service service personnel.
nents must not be loosened or removed as long as the – The operating temperature must be measured. An in-
system is pressurised. crease in the operating temperature indicates increa-
Important service work is: sing friction and leakage.
– Create a maintenance book – Leakage in the pipework
We recommend that a maintenance book is created to Leakage, especially with underfloor piping, represents,
lay down the parts to be inspected. apart from loss of fluid, a risk for equipment and concre-
te floors.
– Check the hydraulic fluid level
For safety reasons, sealing work on the pipes may only
• continuously during commissioning
be carried out when the system is depressurised. Lea-
• shortly after commissioning kage at points that are sealed with soft seals (O-rings,
• later, at weekly intervals form seal rings, etc.) cannot be eliminated by tightening
– Inspect filters as these sealing elements are either destroyed or har-
dened. Sealing can only be achieved by replacing the
• during commissioning every two to three hours and, if
sealing elements.
necessary, replace them.
– Check main and pilot pressure Generally, defective components should not be repaired
• Check interval: One week on site, since for the proper repair, the required tooling
and the required cleanliness are usually not given on site.
• Document pressure corrections in the maintenance
On site, only complete components should be changed
book.
whenever possible, in order
• Frequent pressure adjustments indicate, among other
• to keep the time for which the opened system is expo-
things, wear of the pressure relief valve.
sed to ambient influences to a minimum,
4.3 Repair
• to keep the fluid loss as low as possible,
Locate and eliminate malfunction and damage.
• to ensure the shortest possible downtime through the
– Fault localisation use of overhauled and tested components.
A precondition for system repairs is successful, i.e. sys- After failed components are located, it is essential to
tematic fault search. check whether the entire system or parts of the system
This requires in any case detailed knowledge of the have been contaminated by broken parts or larger
structure and the operating principle of the individual amounts of abraded metal.
components as well as of the entire system. The req- 4.4 Repair and major overhaul of hydraulic components
uired documentation should be available and easily ac-
Generally, it can be said that only the component manu-
cessible.
facturer can carry out major overhauls in the most effici-
The most important measuring instruments (thermome- ently and reliably (same quality standard, trained person-
ter, electrical multimeter, industrial stethoscope, stop nel, test facilities, warranty, etc.).
watch, rpm counter, etc.) should also be available in the
vicinity of the system, especially in the case of large
systems.
– Fault correction
When carrying out any work, observe strictest cleanli-
ness. Before loosening fittings, clean the surrounding
area.
Hydraulics set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be
Zum Eisengießer 1 reproduced or given to third parties without its consent.
Telefon +49 (0) 93 52 / 18-0 ments concerning a certain condition or suitability for a certain application
Telefax +49 (0) 93 52 / 18-23 58 can be derived from our information. The information given does not release
documentation@boschrexroth.de the user from the obligation of own judgment and verification. It must be
www.boschrexroth.de remembered that our products are subject to a natural process of wear and
aging.
aging.
aging.
aging.
Pressure Filter for
Manifold Block Mounting DFP
up to 600 l/min, up to 315 bar
DFP DFP
DFP DFP DFP DFP DFP DFP DFP DFP 660 660 DFP DFP
60 110 140 160 240 280 330 500 1.X 2.X 990 1320
1. TECHNICAL 1.3 FILTER SPECIFICATIONS

SPECIFICATIONS Nominal pressure 315 bar
1.1 FILTER HOUSING Fatigue strength at nominal pressure 106 load cycles
Construction from 0 to nominal pressure
The filter housings are designed
Temperature range -30 °C to +100 °C
in accordance with international
regulations. They consist of a filter (-30 °C to -10 °C: pmax= 157.5 bar)
head with a screw-in filter bowl. Material of filter head EN-GJS 400-15
Standard equipment: Material of filter bowl Steel
zzconnection for a clogging indicator in Type of clogging indicator VD (differential pressure indication up
filter head
to 420 bar operating pressure)
zztwo-piece bowl for size DFP 990 and
above (optional for size DFP 660) Pressure setting of clogging indicator 5 bar (others on request)
zzdrain plug with pressure relief Cracking pressure of bypass (optional) 6 bar (others on request)
(size DFP 330 and above)
1.2 FILTER ELEMENTS Filter elements are available with the 1.10 IMPORTANT INFORMATION
Hydac filter elements are validated following pressure stability values: zzFilter housing must be earthed
and their quality is constantly Betamicron® (BN4HC): 20 bar
monitored according to the following zzWhen using visual clogging indicators
Betamicron® (BH4HC): 210 bar
standards: only the BM version should be used
Wire mesh (W): 20 bar
zzISO 2941 (visual with manual re-set).
Stainless steel fibre (V): 210 bar
zzISO 2942 zzWhen using electrical clogging
zzISO 2943 1.4 SEALS indicators, the electrical power supply
zzISO 3724 NBR (= Perbunan) to the system must be switched off
zzISO 3968 before removing the clogging indicator
1.5 MOUNTING connector
zzISO 11170
zzISO 16889 As pressure filter for manifold block
mounting
Contamination retention capacities in g Symbol for hydraulic systems
Betamicron® (BN4HC) 1.6 SPECIAL MODELS AND
DFP 3 µm 5 µm 10 µm 20 µm ACCESSORIES
60 6.5 7.3 7.8 8.0
110 13.8 15.5 16.4 16.9
zzBypass valve in head
140 18.1 20.3 21.5 22.2 zzSeals in FPM, EPDM
160 19.8 22.2 23.5 24.3
240 32.3 36.3 38.4 39.6 1.7 SPARE PARTS
280 70.6 79.3 83.9 86.6 See Original Spare Parts List
330 47.2 53.1 56.1 57.9 1.8 CERTIFICATES AND APPROVALS
500 76.9 86.5 91.5 94.4
660 102.2 114.9 121.5 125.4 On request
990 154.5 173.7 183.7 189.5 1.9 COMPATIBILITY WITH
1320 209.9 236.0 249.6 257.5 HYDRAULIC FLUIDS ISO 2943
Betamicron® (BH4HC) zzHydraulic oils H to HLPD DIN 51524
DFP 3 µm 5 µm 10 µm 20 µm
60 4.6 4.5 5.0 5.7
zzLubrication oils DIN 51517, API,
110 10.1 9.9 10.9 12.4 ACEA, DIN 51515, ISO 6743
140 13.3 13.0 14.3 16.3 zzCompressor oils DIN 51506
160 12.9 12.6 13.9 15.9 zzBiodegradable operating fluids VDMA
240 21.6 21.1 23.2 26.5
280 48.1 47.1 51.8 59.1 24568 HETG, HEES, HEPG
330 34.6 33.9 37.2 42.5 zzNon-flam operating fluids HFA, HFB,
500 57.5 56.3 61.8 70.5 HFC and HFD
660 76.8 75.2 82.6 94.3
E 7.551.9/02.08
zzOperating fluids with high water

990 111.8 109.4 120.2 137.2
1320 153.8 150.7 165.5 188.8 content (>50% water content) on
request
227
2. model code (also order example) DFP BN/HC 60 Q B 10 D 1 . X /-L24
2.1 complete FILTER
Filter type
DFP
Filter material of element
BN/HC Betamicron® (BN4HC)
BH/HC Betamicron® (BH4HC)
V Stainless steel fibre
W Wire mesh
Size of filter or element
DFP: 60, 110, 140, 160, 240, 280, 330, 500, 660, 990, 1320
Operating pressure
Q = 315 bar
Type and size of port
Type Port Filter size
60 110 140 160 240 280 330 500 660 990 1320
B G½   
C G¾   
D G1 ½     
Filtration rating in µm
BN4HC, BH4HC, V: 3, 5, 10, 20
W: 25, 50, 100, 200
Type of clogging indicator
Y plastic blanking plug in indicator port
A steel blanking plug in indicator port
BM visual for other clogging indicators
C electrical see brochure no. E 7.050../..
D visual and electrical
Type code
1 one-piece filter bowl
2 two-piece filter bowl (size DFP 660 to 1320)
Modification number
X the latest version is always supplied
Supplementary details
B. bypass cracking pressure (e.g. B6 = 6 bar); no details = without bypass valve
L... light with appropriate voltage (24V, 48V, 110V, 220V) only for clogging
LED 2 light emitting diodes up to 24 Volt indicators Type D
SO184 pressure release/oil drain screw (sizes DFP 660 to 1320)
V FPM seals
W suitable for HFA and HFC emulsions
2.2 REPLACEMENT ELEMENT 0060 D 010 BN4HC /-V

Size
0060, 0110, 0140, 0160, 0240, 0280, 0330, 0500, 0660, 0990, 1320
Type
D
Filtration rating in µm
BN4HC, BH4HC, V: 003, 005, 010, 020
W: 025, 050, 100, 200
Filter material
BN4HC, BH4HC, V, W
V, W (for descriptions, see point 2.1)
2.3 REPLACEMENT CLOGGING INDICATOR VD 5 D . X /-L24

Type
VD differential pressure indicator up to 420 bar operating pressure
Pressure setting
5 5 bar standard, others on request
Type of clogging indicator (see point 2.1 )
Modification number
X the latest version is always supplied
L..., LED, V, W (for descriptions, see point 2.1)
E 7.551.9/02.08
228
3. FILTER CALCULATION / 3.2 GRADIENT COEFFICIENTS (SK) FOR FILTER ELEMENTS
SIZING The gradient coefficients in mbar/(l/min) apply to mineral oils with a kinematic
viscosity of 30 mm2/s. The pressure drop changes proportionally to the change in
The total pressure drop of a filter at a
viscosity.
certain flow rate Q is the sum of the
housing ∆p and element ∆p and is DFP V W BH4HC
calculated as follows: 3 µm 5 µm 10 µm 20 µm – 3 µm 5 µm 10 µm 20 µm
60 16.0 11.0 6.5 3.3 1.683 58.6 32.6 18.1 12.2
∆ptotal = ∆phousing + ∆pelement
110 8.3 6.0 4.2 2.1 0.918 25.4 14.9 8,9 5.6
∆phousing = (see point 3.1) 140 5.9 3.8 3.0 1.7 0.721 19.9 11.3 8.1 4.3
∆pelement = Q • SK* • viscosity 160 4.5 3.2 2.3 1.4 0.631 16.8 10.4 5.9 4.4
1000 30 240 3.2 2.4 1.9 1.1 0.421 10.6 6.8 3.9 2.9
(*see point 3.2) 280 1.5 1.2 1.0 0.8 0.361 5.7 3.4 1.8 1.6
330 2.1 1.5 1.3 0.8 0.307 7.7 4.5 2.8 2.0
For ease of calculation, our Filter 500 1.4 1.0 0.8 0.5 0.202 4.2 2.6 1.5 1.2
Sizing Program is available on request 660 1.1 0.9 0.6 0.3 0.153 3.3 1.9 1.0 0.9
free of charge. 990 0.7 0.5 0.4 0.3 0.102 2.2 1.3 0.8 0.6
NEW: Sizing online at www.hydac.com 1320 0.6 0.5 0.3 0.2 0.077 1.6 1.0 0.6 0.4
BN4HC: DFP 60 BN4HC: DFP 280

3.1 ∆p-Q HOUSING GRAPHS BASED
ON ISO 3968
The housing graphs apply to mineral
∆p [bar]
∆p [bar]
oil with a density of 0.86 kg/dm3 and a

kinematic viscosity of 30 mm2/s. In
this case, the differential pressure
changes proportionally to the density.
DFP 60/110/140
Q [l/min] Q [l/min]
∆p [bar]
∆p [bar]
∆p [bar]
Q [l/min]
DFP 160/240/280
Q [l/min] Q [l/min]
∆p [bar]
∆p [bar]
∆p [bar]
Q [l/min]
DFP 330/500/660/990/1320 Q [l/min] Q [l/min]
∆p [bar]
∆p [bar]
∆p [bar]
Q [l/min]
Q [l/min] Q [l/min]
BN4HC: DFP 240 BN4HC: DFP 990/1320
∆p [bar]
∆p [bar]
E 7.551.9/02.08
Q [l/min] Q [l/min]
229
4. dimensions
DFP 60 - 280 DFP 330 - 1320
SW 27
SW 1
connection for SW 1
clogging indicator connection for
clogging indicator
SW 2
SW 2
SW 3
pressure release/
oil drain plug SW 1 oil drain
inlet
outlet
outlet
inlet
DFP 60 110 140 160 240 280 330 500 660 990 1320
b1 6 6 6 6 6 6 5 5 5 5 5
b2 104 104 104 115 115 115 70 70 70 70 70
b3 80 80 80 110 110 110 96.8 96,8 96.8 96.8 96.8
b4 89 89 89 90 90 90 84.1 84.1 84.1 84.1 84.1
b5 31.8 31.8 31.8 86 86 86 48.4 48.4 48.4 48.4 48.4
b6 - - - 61 61 61 16.7 16.7 16.7 16.7 16.7
b7 - - - 57 57 57 42.05 42.05 42.05 42.05 42.05
b8 31.6 31.6 31.6 38 38 38 21.4 21.4 21.4 21.4 21.4
b9 - - - 14 14 14 19 19 19 19 19
b10 7.5 7.5 7.5 12.5 12.5 12.5 50.7 50.7 50.7 50.7 50.7
b11 55.9 55.9 55.9 57.5 57.5 57.5 - - - - -
b12 - - - 9 9 9 - - - - -
b13 24.1 24.1 24.1 12 12 12 - - - - -
b14 - - - 26.5 26.5 26.5 - - - - -
b15 - - - 10.5 10.5 10.5 - - - - -
d1 68.2 68.2 68.2 95.2 95.2 95.2 158 158 158 158 158
d2 25.3 25.3 25.3 28.6 28.6 28.6 130 130 130 130 130
d3 17.5 17.5 17.5 21.4 21.4 21.4 41 41 41 41 41
d4 8.5 8.5 8.5 9 9 9 30 30 30 30 30
d5 - - - 7/18-14 UNC 7/18-14 UNC 7/18-14 UNC 11.5 11.5 11.5 11.5 11.5
d6 - - - - - - 6 6 6 6 6
d7 - - - - - - 20 20 20 20 20
d8 - - - - - - - - - 152 152
h1 158.5 227.5 269.5 199.5 259.5 441.5 339.5 432.5 510.0 660.0 826.0
h2 75 75 75 85 85 85 95 95 95 500 670
h3 76 76 76 83 83 83 174.5 174.5 174.5 174.5 174.5
h4 25 25 25 25 25 25 98 98 98 98 98
h5 - - - - - - 96 96 96 96 96
h6 - - - - - - 19 19 19 19 19
h7 - - - - - - - - - 112 112
t1 - - - 13 13 13 2.6 2.6 2.6 2.6 2.6
t2 - - - 18 18 18 - - - - -
t3 2 2 2 2 2 2 - - - - -
SW 27 27 27 32 32 32 - - - - -
SW1 - - - - - - 27 27 27 27 27
SW2 - - - - - - 36 36 36 36 36
SW 3 - - - - - - 10 10 10 10 10
Weight incl. element 5.1 6.0 6.6 9.1 10.4 14.7 21.0 25.5 29.0 39.2 47.1
[kg]
Volume of pressure
chamber [l] 0.20 0.33 0.40 0.60 0.80 1.60 1,50 2.30 3.00 4.20 5.60
NOTE Filtertechnik GmbH

The information in this brochure relates to the operating Industriegebiet
conditions and applications described. D-66280 Sulzbach/Saar
E 7.551.9/02.08
Tel.: 0 68 97 / 509-01
For applications or operating conditions not described,
Fax: 0 68 97 / 509-300
please contact the relevant technical department.
Internet: www.hydac.com
Subject to technical modifications. E-Mail: filter@hydac.com
230

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Bosch Rexroth AG

97816 Lohr am Main

BHEL Purchase Order No. B0V7060 ( 4500201006 / I18 )

Rexroth Sales Order No. 1005335855

3 Circuit diagram HS-A11-P295-2-B

9 Inspection certificate B for actuators D901272_1042

11 Poppet direct valve direct operated RE22058

12 Servo directional valve in 4- way design RE29583

13 Displacement transducer Sensor BTL5…

14 Assembly, commissioning and maintenance of industrial valves RE07300

15 Installation, commissioning and maintenance of electro-hydraulic RE07700

16 Assembly, commissioning and service of hydraulic systems RE07900

17 High pressure filters mfr Fa. Hydac

type DFP E 060 QB 25BM1.X/-V-W

Electro-hydraulic drives (EHA3)

Control and trip actuators

Steam Energy Cylinder

The safety regulations in Chapter 3 in particular must be read and

A copy of these instructions must always be kept at the energy

Publisher Bosch Rexroth AG

Systems & Engineering

D-97816 Lohr am Main

Tel.: +49 (0) 9352/18-1178

Doc No. CCE_ANTRIEBE-GE-CXE1-2X_BAL_V10_EN.doc

Issue date 07.06.

Copyright © Bosch Rexroth AG 2006

The contents of this publication—including extracts thereof—must

1 Identifying the product..............................................................................................6

1.1 Checking delivery................................................................................................6

1.2 Identifying the energy cylinder ............................................................................7

1.3 Proper use ..........................................................................................................7

1.4 Improper use.......................................................................................................8

2 Product documentation ............................................................................................9

2.1 About the Operating Instructions.........................................................................9

2.2 Technical drawing ............................................................................................. 11

2.3 Parts list/spare parts list.................................................................................... 11

3 General safety regulations ..................................................................................... 13

3.1 Basic principles ................................................................................................. 13

3.2 Key installation instructions............................................................................... 13

3.3 Safe operation................................................................................................... 14

3.4 Working on the energy cylinder.........................................................................14

3.5 Structural modifications..................................................................................... 17

3.6 Residual hazards posed by the energy cylinder................................................ 17

4 Technical description ............................................................................................. 19

4.1 Possible applications ........................................................................................ 19

4.2 Energy cylinder ................................................................................................. 19

5 Transportation and storage.................................................................................... 24

5.1 Storing/conserving the energy cylinder ............................................................. 24

5.2 Lifting and transporting the energy cylinder ...................................................... 25

6 Installation and commissioning............................................................................. 28

6.1 Preparing for mounting ..................................................................................... 28

6.2 Mounting the energy cylinder onto fitting .......................................................... 29

6.3 Connecting the energy cylinder to the pressure line ......................................... 30

6.4 Electrical connection for the energy cylinder..................................................... 31

6.5 Commissioning the energy cylinder .................................................................. 32

7.1 Normal operation .............................................................................................. 34

8 Inspection and maintenance activities.................................................................. 36

8.1 General ............................................................................................................. 36