4WRPE10EA80SJ-2X Rexroth Proportional Valve NG10 350 bar

Product Overview

The 4WRPE10EA80SJ-2X/G24K0/A1M-797 (Material No. 0811404752) is a direct-operated high-response proportional directional valve from Bosch Rexroth’s 4WRPE10 series, featuring electrical position feedback (LVDT) and integrated on-board electronics (OBE). Built on the 2X component series, it integrates the analog control amplifier directly onto the valve body, eliminating the external amplifier card required in conventional configurations and substantially simplifying control cabinet wiring and system integration.

The core technical characteristics of the 4WRPE10EA80SJ-2X/G24K0/A1M-797 are defined by three factors: the direct-operated architecture requires no external pilot oil, delivering faster response and greater contamination tolerance; the LVDT position sensor provides full closed-loop spool position control with extremely low hysteresis and high repeatability; and the 80 L/min rated flow combined with 350 bar maximum operating pressure covers applications ranging from precision injection molding to heavy-duty die casting. The integrated on-board electronics (OBE) compares the specified command value to the position actual value; in case of control deviations, the relevant solenoid is activated, and the changed magnetic force adjusts the control spool against the corresponding spring, with stroke proportional to the command value. With a command value presetting of 0 V, the electronics adjust the control spool to the center position.

The valve mounts via subplate according to ISO 4401-05-04 at nominal size NG10 (Cetop 5), with maximum operating pressure of 350 bar at ports P/A/B and 200 bar at port T. Model code breakdown: “EA” denotes E-type spool with overlap jump for reduced deadband and quick response; “80SJ” specifies 80 L/min rated flow at Δp = 5 bar per control edge with progressive flow characteristic (S); “G24K0” represents DC 24 V supply; “A1M” indicates ±10 V analog control signal; “-797” is the variant identifier.

As a drop-in replacement, the valve is fully compatible with the OEM Rexroth specification in mounting interface, electrical connection, and performance characteristics. Every unit undergoes 100% simulation-based testing prior to shipment, covering null stability, flow linearity, step response, and internal leakage.

Technical Specifications

All parameters below are based on Bosch Rexroth official datasheet RE 29122 (Edition 2019-07) and verified supplier technical pages:

• Complete Model: 4WRPE10EA80SJ-2X/G24K0/A1M-797

• Material Number (MNR): 0811404752

• Brand: Bosch Rexroth

• Product Series: 4WRPE10 series, component series 2X

• Product Type: Direct-operated high-response proportional directional valve with electrical position feedback and integrated electronics (OBE)

• Spool Function: 4/3-way proportional directional valve

• Spool Variant: E-type spool with overlap jump, reduced deadband

• Nominal Size: NG10 (ISO 4401-05-04-0-94 / Cetop 5)

• Mounting: Subplate mounting

• Max Operating Pressure (Ports P/A/B): 350 bar

• Max Operating Pressure (Port T): 200 bar

• Rated Flow: 80 L/min (at Δp = 5 bar per control edge)

• Flow Characteristic: S = progressive flow characteristic

• Drive Type: Direct-operated, dual proportional solenoids, no external pilot oil required

• Position Feedback: LVDT displacement sensor, full closed-loop control

• Integrated Electronics: OBE (on-board amplifier), analog signal

• Supply Voltage: DC 24 V (model code ‘G24’)

• Peak Power Consumption: 60 VA (maximum)

• Command Signal: ±10 V analog input (model code ‘A1’)

• Input Impedance: 100 kΩ

• Permitted Residual Ripple: 2.5 Vpp

• External Fuse: 2.5 A time-lag

• Electrical Connector: 6P+PE (DIN 43563-AM6)

• Protection Class: IP65

• Hydraulic Fluid: HLP/HM anti-wear hydraulic oil

• Viscosity Range: 10 – 800 mm²/s

• Seal Material: NBR nitrile rubber (model code ‘M’)

• Media Temperature Range: -20 °C to +70 °C (without performance degradation)

• Cleanliness Requirement: ISO 4406 18/16/13

• Mounting Screws: M6 × 40 (DIN 912-10.9 strength class)

• Vibration Resistance: 25 g

• Weight: 8.3 kg

Note: Specifications are based on Bosch Rexroth official datasheet RE 29122 (Edition 2019-07) and verified supplier technical pages. Model code breakdown: 4WRPE = 4/3 direct-operated proportional directional valve with integrated electronics (OBE); 10 = size NG10; EA = E-type spool with overlap jump; 80SJ = rated flow 80 L/min with S = progressive flow characteristic; 2X = component series; G24K0 = DC 24 V supply, K0 connector configuration; A1 = analog ±10 V; M = NBR seals; -797 = variant identifier. Material No. 0811404752 is the corresponding Rexroth designation for this model.

Key Technical Advantages

1. Direct-Operated Architecture with Integrated OBE for Plug-and-Play Operation

The 4WRPE10EA80SJ-2X employs a direct-operated design in which the spool is driven directly by dual proportional solenoids, eliminating the need for external pilot oil supply. Compared with pilot-operated proportional valves, this architecture removes the additional leakage and pressure losses associated with pilot oil circuits, delivers faster response, and significantly reduces sensitivity to fluid contamination. The valve features a reliable and robust design, no pilot oil demand, high flows with low pressure differential, suitability for position and velocity control, and high response sensitivity with minimal hysteresis. The integrated OBE electronics unit mounts the control amplifier directly on the valve body and is factory-calibrated, enabling operation with only a 24 V DC supply and command signal — no external amplifier card or associated wiring required. The integrated electronics compares the specified command value to the position actual value; in case of control deviations, the relevant solenoid is activated, and the changed magnetic force adjusts the control spool against the corresponding spring, with stroke proportional to the command value. With a command value presetting of 0 V, the electronics adjust the control spool to the center position.

2. LVDT Full Closed-Loop Control for High-Precision Flow Regulation

The valve’s core control architecture employs an LVDT displacement sensor to continuously measure actual spool position, feeding the signal back to the on-board OBE electronics for comparison against the command signal and dynamic correction of the solenoid drive current. This full closed-loop mechanism maintains spool positioning accuracy independent of fluid temperature variation, pressure fluctuation, and long-term wear, achieving hysteresis below 0.5% and repeatability at industrial servo-grade levels. In applications such as injection molding hold-pressure phases and precision press-fitting, where control precision directly determines product consistency, this characteristic is decisive.

3. Progressive Flow Characteristic with Overlap-Jump Spool Design

The valve features a progressive flow characteristic, enabling fine flow resolution at low command levels before opening wider for maximum delivery, improving positional stability in servo circuits. The EA-type spool with overlap jump (Overlap Jump) reduces the deadband during the transition from center to working position, enabling the valve to respond more quickly to command signal changes. The overlap jump activates at approximately 5% command value, which is particularly important for applications requiring fast response and precise stopping.

4. High Pressure Rating with Comprehensive Fail-Safe Protection

Maximum operating pressure at ports P/A/B is 350 bar with port T rated at 200 bar, allowing direct integration into high-pressure hydraulic circuits without additional pressure-reducing stages for heavy-duty industrial applications. The valve features comprehensive fail-safe protection: when supply voltage drops below 15 V (restart at ≥ 17.5 V), the electronics de-energize the control solenoids, and the spool is held in the mechanical center position by compression springs. The IP65 protection rating prevents dust ingress and water jet exposure from reaching internal electronics. An optional electronics protection membrane (-967) prevents condensate formation in the integrated electronics housing, recommended for use outside industry-standard conditions with high ambient air humidity and significant cyclic temperature changes. An optional damping plate (D) reduces acceleration amplitudes on the on-board electronics at frequencies above 300 Hz.

5. 100% Simulation-Based Testing and Drop-In Interchangeability

Every 4WRPE10EA80SJ-2X undergoes 100% simulation-based testing prior to shipment. Test protocols cover rated flow calibration, hysteresis and linearity measurement, step-response verification, and internal leakage detection. As a drop-in replacement, the valve is fully compatible with the OEM Rexroth specification in mounting dimensions (ISO 4401-05-04-0-94 interface), electrical interface (6P+PE connector per DIN 43563-AM6), and performance characteristics, enabling direct replacement of the original valve.

Application Areas

• Injection Molding Machines: Closed-loop control of injection velocity and hold pressure for consistent part quality

• Die Casting Equipment: High-speed dynamic pressure regulation and real-time switching control

• Hydraulic Presses: Precision position/velocity control, force/position hybrid control

• Material Testing Systems: Flow and pressure closed-loop control for electro-hydraulic servo loading systems, including high-frequency dynamic loading applications

• Vibration Tables & Test Rigs: Precision flow control under high-frequency dynamic response conditions

• Precision Press-Fitting Equipment: Servo-grade closed-loop force/position control

• Machine Tool Hydraulic Systems: Flow and direction control for precision hydraulic feed axes

• General Industrial Hydraulic Systems: Precision directional and flow control for automated production lines

Expert Maintenance Tips

Pre-Installation Checks:

• Verify the manifold mounting surface conforms to ISO 4401-05-04-0-94 standard; surface roughness Rzmax ≤ 4 μm, flatness deviation ≤ 0.01 mm/100 mm

• Flush all piping with clean hydraulic fluid prior to installation; ensure system cleanliness reaches ISO 4406 18/16/13 or better

• Inspect NBR O-rings for damage and confirm compatibility with the hydraulic fluid in use

• Tighten M6 × 40 mounting screws (DIN 912-10.9 strength class) in diagonal sequence to specified torque

Operational Maintenance:

• Use a 5–10 μm precision pressure filter, specified without bypass and equipped with a contamination indicator

• Recommended fluid: HLP/HM anti-wear hydraulic oil; maintain operating viscosity within 10 – 800 mm²/s

• Maintain media temperature within -20 °C to +70 °C; avoid overheating that degrades fluid quality

• Periodically inspect the integrated OBE electronics status indicators; confirm 24 V DC supply remains stable (above 15 V, restart requires ≥ 17.5 V)

• External fuse rating is 2.5 A time-lag; periodically check fuse continuity

• Verify supply residual ripple does not exceed 2.5 Vpp; add filter capacitor if necessary

• Monitor null output flow offset; significant increase indicates spool/sleeve wear or LVDT sensor anomaly

• In high-humidity or significant temperature cycling environments, the electronics protection membrane (-967) is recommended to prevent condensate formation

Troubleshooting Guide:

• Spool fails to actuate or responds abnormally: Check 24 V DC supply (electronics automatically de-energize below 15 V), verify ±10 V command signal reaches the A1 input correctly, confirm 6P+PE connector engagement is reliable

• Null-point drift: After ruling out fluid contamination, verify LVDT sensor feedback signal integrity; check whether the spool is stuck at a non-center position due to contamination

• Insufficient flow: Confirm system supply pressure is within the 350 bar allowable range; check spool metering edges for partial blockage by contaminant particles

• Electronics alarm: Verify supply voltage is within normal range; check external fuse (2.5 A) for continuity; confirm supply ripple is within specification

• Abnormal noise: Check that system return pressure does not exceed the 200 bar maximum; confirm no back-pressure blockage in the return line