4WRDE 25 V1-220L-5X Rexroth Proportional Valve 220 L/min 350 Bar

Model Number	4WRDE 25 V1-220L-5X/6L24K9/WG152MR

Product Description

Product Overview

The 4WRDE 25 V1-220L-5X/6L24K9/WG152MR series pilot-operated high-response proportional directional valve is manufactured to original Bosch Rexroth technical standards. Belonging to the 4WRDE series with size 25 (NG25 / ISO 4401-08), this valve is a 3-stage electro-hydraulic proportional directional control valve. Featuring a pilot-operated three-stage design conforming to ISO 4401 mounting standards, it is equipped with electrical position feedback and integrated on-board electronics (OBE). A 2-stage servo pilot control valve (4WS2EM 6-2X) drives the main stage spool for continuous, precise high-response control of both direction and flow magnitude.

This model employs spool symbol V1 with a nominal flow rate of 220 L/min (at Δp = 10 bar per control land) and maximum operating pressure of 350 bar (5075 psi). The main stage maximum flow capacity is 870 L/min. The command signal is ±10 V, supply voltage is 24 VDC, pilot oil supply/drain is external (X/Y configuration), and the electrical connector is a device plug per DIN EN 175301-803. The integrated electronics (OBE) compare the command value with the actual position value, driving the pilot stage to position the main spool proportionally to the command value.

This product is dimensionally and functionally identical to the original Rexroth 4WRDE 25 series valve, offering true drop-in interchangeability for direct replacement of same-specification OEM valves. Every unit undergoes 100% bench testing under simulated working conditions, including rated pressure holding, spool position accuracy, flow linearity, and dynamic response characterization.

Technical Specifications

General Specifications

Model: 4WRDE 25 V1-220L-5X/6L24K9/WG152MR
Product Series: 4WRDE (Size 25 / NG25 / ISO 4401-08)
Component Series: 5X
Spool Symbol: V1
Design: Pilot-operated, 3-stage high-response proportional directional valve with electrical position feedback and integrated on-board electronics (OBE)
Mounting Pattern: ISO 4401-08-08-0-05
Installation Position: Any

Hydraulic Parameters

Nominal Flow Rate: 220 L/min (at Δp = 10 bar per control land)
Maximum Main Stage Flow: 870 L/min
Maximum Operating Pressure (Ports P/A/B): 350 bar (5075 psi)
Hydraulic Fluid: Mineral-based hydraulic oil (HL, HLP, HLPD, HVLP, HVLPD) and HFC fluids
Fluid Temperature Range: -20°C to +80°C
Filtration: ISO 4406 18/16/13

Pilot Control Parameters

Pilot Valve Model: 4WS2EM 6-2X (2-stage servo pilot control valve)
Pilot Oil Supply: External
Pilot Oil Drain: External (X/Y configuration)
Main Stage Return: Spring centered

Electrical Parameters

Supply Voltage: 24 VDC (20 – 28 VDC)
Command Signal: ±10 V voltage input
Solenoid Type: Control motor (torque motor)
Integrated Electronics: OBE (On-Board Electronics), factory calibrated
Electrical Connector: Device plug per DIN EN 175301-803 (cable socket not included)
Seal Material: NBR

Materials & Construction

Valve Body: High-strength cast iron
Control Spool: Carburized steel, precision ground
Main Stage Control Edges: V-spool control spool and housing ground in to each other
Surface Treatment: Phosphating / anti-corrosion coating

Weight

Weight: approx. 15.62 kg

Key Technical Advantages

1. Three-Stage Pilot Control Structure with High-Response Dynamic Characteristics
The 4WRDE 25 V1-220L-5X employs a three-stage pilot control structure consisting of a control motor (torque motor), nozzle flapper plate hydraulic amplifier, and control spool socket unit forming a 2-stage servo pilot valve, which drives the third-stage main spool for high flow control. The integrated electronics (OBE) provide closed-loop control of the main spool position via an inductive position transducer that monitors the main spool position in real time, ensuring the spool position is independent of flow forces. This structure delivers high dynamic response characteristics, enabling rapid response to control signals, suitable for applications with high requirements on both dynamics and response sensitivity.

2. Integrated OBE Electronics with Closed-Loop Position Control
The valve integrates the proportional amplifier directly into the valve body (OBE), factory calibrated. The integrated electronics compare the command value with the actual position value of the main stage spool. In case of a control deviation, the pilot stage is controlled via the nozzle flapper plate system, creating a pressure differential that moves the main spool until the actual value corresponds to the command value. Valve dynamics are optimized via electric gain. Users can directly drive the spool via a ±10 V signal without an external amplifier, significantly simplifying system architecture.

3. V-Spool Precision Grinding for High-Accuracy Flow Control
With V control spools, the control edges of the control spool and housing are ground in to each other, with micron-level clearance control ensuring precise flow control even under high pressure and large flow conditions. The main spool stroke is proportional to the command value, with a corresponding control opening formed between the control spool position and housing control edges, to which the flow is proportional. This design achieves low hysteresis and high repeatability, meeting the demands of high-accuracy position, pressure, force, and velocity closed-loop control.

4. Pilot Valve Maintainability and System Flexibility
The pilot control valve (4WS2EM 6-2X) is designed to support maintenance. When the pilot control valve or control electronics are exchanged, they must be re-adjusted, with all adjustments implemented by instructed experts only. The pilot control valve may only be maintained by Bosch Rexroth employees, with the exception of filter and seal replacement according to the accessories list. During assembly, ensure the seal is properly seated and the plug screw is tightened to 30 Nm. The pilot oil circuit uses external supply and external drain, with the pilot stage supplied by an independent clean oil source isolated from main line transients, ensuring stability and reliability of pilot control.

5. 100% Simulated Working Condition Testing and Drop-in Interchangeability
Every 4WRDE 25 V1-220L-5X/6L24K9/WG152MR valve undergoes 100% bench testing prior to shipment, covering 350 bar rated pressure holding, spool position accuracy calibration, flow-signal linearity verification, internal leakage measurement, and dynamic response characterization. Mounting dimensions, port positions, electrical interfaces, and performance curves are strictly matched to the original Rexroth valve, enabling direct drop-in replacement without modifying piping or control programs.

Application Areas

Industrial Hydraulic Systems: Control of hydraulic cylinders, motors, and other actuators for high-accuracy closed-loop motion control applications
Injection Molding Machines: High-response proportional control of injection speed and holding pressure, precise control of mold closing and injection actions
Hydraulic Presses: Proportional speed and direction regulation for medium-to-high flow high-accuracy closed-loop control systems
Die Casting Machines: Shot speed and intensification pressure precise regulation
Metallurgical Equipment: Precision control for continuous casting machines and rolling mill auxiliary hydraulic systems, such as cooling fluid flow control
Machine Tools: Hydraulic clamping systems, feed control
Testing Equipment: Force-displacement closed-loop control for material testing
Marine & Offshore: Offshore platform hydraulic control systems

Expert Maintenance Tips

Installation Guidelines

The 4WRDE 25 V1-220L-5X series can be mounted in any position. Mounting surface flatness must be ≤ 0.05 mm. Tighten mounting bolts diagonally in stages to the specified torque value. The mounting surface conforms to ISO 4401-08 for direct installation on standard subplates or manifolds.
Thoroughly flush all piping circuits before installation. Ensure no welding slag, metal chips, or particulate contaminants remain. Prior to first operation, circulate the system through a 10 μm filter element for a minimum of 30 minutes. This valve has high fluid cleanliness requirements; recommended fluid cleanliness is ISO 4406 18/16/13 or better.
Pilot Oil Circuit Management: This valve uses external pilot supply and external pilot drain (X/Y configuration). The pilot supply line must provide an independent clean oil source, and the pilot drain line must return independently to the reservoir, not sharing a common return with other high-pressure circuits. Pilot valve tank line pressure rating refers to catalog curves.
Electrical connections must use a device plug conforming to DIN EN 175301-803 (cable socket not included) to maintain IP65 protection. Control signal cables should be shielded, with the shield grounded at one end to prevent electromagnetic interference causing spool oscillation.

Routine Maintenance Procedures

Fluid Cleanliness Management: Maintain system fluid cleanliness at ISO 4406 18/16/13 or better. Check fluid particulate contamination every 500 operating hours and replace filter elements and hydraulic fluid when contamination exceeds limits. This valve features a servo-quality pilot stage and precision-ground main spool, making it sensitive to fluid contamination.
Electrical Zero Point Verification: Periodically check the electrical zero point for drift with the power supply disconnected. If zero point deviation exceeds ± 2%, re-calibrate using dedicated tools via the OBE electronics.
Pilot Valve Filter Replacement: Replace the pilot valve filter according to the accessories list. When replacing the filter and seals, ensure the seal is properly seated and the plug screw is tightened to 30 Nm.
Pilot Valve and Control Electronics Adjustment: When the pilot control valve or control electronics are exchanged, they must be re-adjusted. All adjustments may be implemented by instructed experts only. The pilot control valve may only be maintained by Bosch Rexroth employees.
Internal Leakage Monitoring: Due to the design principle, pilot-operated proportional valves have inherent internal leakage which may increase over the life cycle. An annual internal leakage test is recommended. If leakage exceeds 150% of the factory standard, seal replacement should be scheduled.
Fail-Safe Position Verification: Periodically test that the spool reliably returns to the fail-safe position upon power loss. If abnormal return is observed, stop operation immediately and inspect springs and spool wear. System design must account for potential movement of the controlled component when the valve is in the fail-safe position.

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