1/12
Prefill valve – sandwich plate
Type ZSF and ZSFW
Sizes 32 to 160
Component series 1X; 2X
Maximum operating pressure 350 bar
RE 20478/06.06
Replaces: 02.03
Table of contents Features
– Hydraulic pilot operated check valve of sandwich plate design
• for flanged connection
• for in-pipe installation
– With or without pre-decompression
– Integrated high-pressure port
– Solenoid operated decompression through built-on directional
valve
– Further information:
Directional valve type 4WE 6 D … RE 23178
Information on available spare parts:
www.boschrexroth.com/spc
Contents Page
Features 1
Ordering code 2
Symbols 2
Function, section 3, 4
Orifices to be fitted 3
Technical data 5
Characteristic curves 6
Unit dimensions 7 to 9
Proposed dimension for mating flange 9
Valve fixing screws, mating flanges 10
Poppet geometry and determination
of minimum pilot pressure 10
Maximum flow
for various applications
11
Inhalt
Table of contents 1
Features 1
Ordering code 2
Symbols 2
Function, section: Type ZSF … 3
Orifices to be fitted 3
Function, section: Type ZSFW … 4
Technical data (for applications outside these parameters, please
consult us!) 5
Characteristic curves (measured with HLP46, ϑ
oil
= 40 °C ± 5
°C) 6
Unit dimensions: Type ZSF… (nominal dimensions in mm) 7
Unit dimensions: Type ZSFW… (nominal dimensions in mm) 8
Unit dimensions 9
Proposed dimension for mating flange (item 5) (nominal dimensi-
ons in mm) 9
Valve fixing screws, mating flanges 10
Poppet geometry and determination of minimum pilot pressure 10
Maximum flow q
V
in l/min (A to B) for various applications
11
Notes 12
2/12 Bosch Rexroth AG Hydraulics
ZSF; ZSFW RE 20478/06.06
Ordering code
Prefill valve – sandwich plate
For directional valve mounting
1)
= W
Size 32 = 32
Size 40 = 40
Size 50 = 50
Size 63 = 63
Size 80 = 80
Size 100 = 100
Size 125 = 125
Size 160 = 160
Type of connection
For flanged connection = F
With pre-decompression = 1
Without pre-decompession = 0
Further details in clear text
Connection version
01 = Mounting cavities with
pipe thread to ISO 228,
DIN EN 3852 part 2
M = NBR seals
(other seals on enquiry)
Caution!
Observe compatibility of seals with hydraulic
fluid used!
Sizes 32 to 100 and size 160:
1X = Component series 10 to 19
(10 to 19: unchanged installation and
connection dimensions)
Size 125
2)
:
2X = Component series 20 to 29
(20 to 29: unchanged installation and
connection dimensions)
Spring return of main poppet
1 = Cracking pressure ≈ 0.12 bar
ZSF F 1 M 01
*
1)
Ordering code “W“ required only in conjunction with version
for directional valve mounting.
Directional valve type 4WE 6 D…, separate order,
see data sheet RE 23178.
2)
Compatible with series 1X
Symbols
Prefill valve without directional valve type ZSF Prefill valve with built-on directional valve type ZSFW
X
B
P
A B
P T
A
X
B
P
A B
P T
X
A
a b
Provide for installation of orifices! Orifice included in the scope of supply
P
A
X
B
2 6 15
3
B
34
Hydraulics Bosch Rexroth AG
RE 20478/06.06 ZSF; ZSFW
3/12
Function, section: Type ZSF …
Valves of type ZSF are hydraulic pilot operated check valves
of sandwich plate design. They are used for the leak-free clo-
sure of pressurised working circuits (e.g. press cylinder). Due
to their design with favourable flow characteristics and the rela-
tively small closing force of compression spring (5) at the main
poppet they are ideal for anti-cavitation and filling functions,
e.g. for main cylinders on presses during fast closing move-
ments. The integrated pressure port P allows high pressure to
be built up in the pressing cylinder!
The valve basically consists of housing (1), pilot piston (2), main
poppet (3), pilot poppet (4) and compression springs (5) and
(6).
Version without pre-decompression feature
The valve allows free flow from A to B. In the opposite direc-
tion, main poppet (3) is held on its seat by compression spring
(5) and the pressure acting on port B. Due to the pressure in
pilot port X, pilot piston (2) is shifted downwards by compres-
sion spring (6) and pushes main poppet (3) off its seat. The
fluid can now also flow through the valve in the opposite direc-
tion.
Version with pre-decompression feature
The operating principle of this version basically corresponds to
that of the version without pre-decompression feature.
When pressure is applied to pilot port X, pilot piston (2) initially
only opens pilot poppet (4). This ensures a shock-free decom-
pression of the compressed hydraulic fluid.
Type ZSF…F1… (with pre-decompression feature)
Type ZSF…F0…
(without pre-decompression, vertical installation orientation)
Size 32 40 50 63 80 100 125 160
Orifice Ø in mm
0.8 0.8 0.8 0.8 1.0 1.0 1.2 1.5
Generally, the following is valid:
An orifice in channel P of the directional valve is imperative
(separate order). The orifice Ø must be selected according to
the size of the prefill valve (see table below).
Orifices to be fitted
B
T
A
P
X
A
P
B
2 6 15
34
78
4/12 Bosch Rexroth AG Hydraulics
ZSF; ZSFW RE 20478/06.06
Function, section: Type ZSFW …
The operating principle of valve type ZSFW basically corre-
sponds to that of type ZSF.
Pilot piston (2) is unloaded by the operation of the directly
built-on directional valve (optional).
Generally, the following is valid:
The required orifice (8) is installed in channel P. Unloading of
pilot piston (2) is achieved by operation of the built-on direc-
tional valve (see “Orifices to be fitted” on page 3).
Type ZSFW…F1…
(with pre-decompression feature and built-on directional valve,
vertical installation orientation)
Directional valve type 4WE 6 D
(separate order)
drawn rotated through 90°!
Hydraulics Bosch Rexroth AG
RE 20478/06.06 ZSF; ZSFW
5/12
Technical data (for applications outside these parameters, please consult us!)
General
Size 32 40 50 63 80 100 125 160
Weight kg 3.5 4.2 5.5 7 10 15 26 47
Installation orientation Optional
Vertical
Ambient temperature range – Type ZSF °C –30 to +80
– Type ZSFW °C –30 to +50
Hydraulic
Maximum operating
pressure
– Ports B, P bar 350
– Port X bar 150
– Port A bar 16
Cracking pressure
1)
bar ≈ 0.12
Maximum flow l/min See Applications on page 11
Hydraulic fluid Mineral oil (HL, HLP) to DIN 51524; fast bio-degradable
hydraulic fluids to VDMA 24568 (see also RE 90221); HETG
(rape seed oil); other hydraulic fluids on enquiry
Hydraulic fluid temperature range °C –30 to +80
Viscosity range mm
2
/s 10 to 800
Max. permissible degree of contamination of the hy-
draulic fluid - cleanliness class to ISO 4406 (c)
Class 20/18/15
2)
Technical data of the directional valve See data sheet RE 23178
1)
Pressure differential across the main poppet for overcomingPressure differential across the main poppet for overcoming
the spring force.
2)
The cleanliness classes specified for components must be
adhered to in hydraulic systems. Effective filtration prevents
malfunction and, at the same time, prolongs the service life
of components.
For the selection of filters, see data sheets RE 50070,
RE 50076, RE 50081, RE 50086 and RE 50088.
100
300
0
600200
0,3
0,1
0,2
0,4
1
2
3
500 700
400
400 8000 1200 1600 2000
0,3
0,1
0,2
0,4
6
4
5
200 600 1000 1400 1800
400 8000 1200 1600 2000 2400 2800
0,3
0,1
0,2
0,4
3200 3600 4000
7
8
6/12 Bosch Rexroth AG Hydraulics
ZSF; ZSFW RE 20478/06.06
Characteristic curves (measured with HLP46, ϑ
oil
= 40 °C ± 5 °C)
Pressure differential ∆p between ports A and B in dependence upon flow q
V
with flow in suction direction A to B.
Sizes 32, 40 and 50
Pressure differential in bar →
Flow in l/min →
Sizes 63, 80 and 100
Pressure differential in bar →
Flow in l/min →
Sizes 125 and 160
Pressure differential in bar →
Flow in l/min →
1
Size 32
2
Size 40
3
Size 50
4
Size 63
5
Size 80
6
Size 100
7
Size 125
8
Size 160
B3
B5
B4
H2
H1
H4
P
X
H5
H3
B1
D4
B2
ØD
3
ØD2
4 x 90
8 x 45
45
22,5
30
B3
B4
ØD3
ØD2
15
T1
1
4
5
2
3
2
6
ØD7
ØD5
ØD6
ØD1
B
12 x 30
A
7
T2 min
B6 B6
10
0,01/100mm
Rzmax 4
Hydraulics Bosch Rexroth AG
RE 20478/06.06 ZSF; ZSFW
7/12
NG B1 B2 B3 B4 B5 B6
max
ØD1 ØD2 ØD3
±0.2
D4 ØD5 ØD6 ØD7 H1 H2 H3 H4 H5 P T1 T2
min
X
32
65 110 40 55 7.5 1.5 46 93 110 M16 88 42 49.5 77 3.5 50 26.5 26.5 G1/2 8 30 G1/4
40
70 115 40 55 7.5 1.5 58 108 125 M16 102 52 61.5 80 3.5 50 26.5 26.5 G1/2 10 35 G1/4
50
110 140 40 55 7.5 1.5 71 128 145 M16 122 70 75.7 97 4 50 26.5 26.5 G1/2 12 30 G1/4
63
115 145 45 55 7.5 1.5 90 143 160 M16 138 83 97.7 110 4.5 55 27.5 27.5 G3/4 14 35 G1/4
80
125 160 45 55 7.5 1.5 107 169 190 M20 162 100 112 123 5 60 30 30 G3/4 16 30 G1/4
100
140 190 55 55 7.5 1.5 132 212 240 M27 188 124 138.5 145 6 65 32.5 40 G1 25 55 G3/8
125
180 210 65 60 0 1.5 170 248 280 M30 218 148 176 215 9 75 37.5 50 G1 33 50 G3/8
160
220 255 70 60 0 1.5 220 310 345 M33 285 200 233 279 12 95 48.5 68 G1 1/4 55 50 G1/2
Size 160
With sizes 32 and 40
Unit dimensions: Type ZSF… (nominal dimensions in mm)
Sizes 32 to 125
With sizes 50 to 125
Required surface quality of the
valve contact face
For the explanation of items, see page 9
B3
ca.
115
H2
H1
H4
P
H5
B1
D4
B2
ØD
3
ØD2
4 x 90
8 x 45
45
22,5
X
B5
83 15
X
160
H3
30
ØD6
ØD5
ØD7
B4
B3
B4
ØD3
ØD2
15
A
T1
1
4
5
9
2
3 8
6
2
ØD1
B
12 x 30
7
T2 mi
n
B6
B6
0,01/100mm
Rzmax 4
P
10
8/12 Bosch Rexroth AG Hydraulics
ZSF; ZSFW RE 20478/06.06
Unit dimensions: Type ZSFW… (nominal dimensions in mm)
With sizes
50 to 125
Sizes 32 to 125
Size 160
With sizes
32 and 40
NG B1 B2 B3 B4 B5 B6
max
ØD1 ØD2 ØD3
±0.2
D4 ØD5 ØD6 ØD7 H1 H2 H3 H4 H5 P T1 T2
min
X
32
65 107 40 55 85 1.5 46 93 110 M16 88 42 49.5 77 3.5 50 26.5 34 G1/2 8 30 G1/4
40
70 112 40 55 90 1.5 58 108 125 M16 102 52 61.5 80 3.5 50 26.5 34 G1/2 10 35 G1/4
50
110 137 40 55 115 1.5 71 128 145 M16 122 70 75.7 97 4 50 26.5 34 G1/2 12 30 G1/4
63
115 142 45 55 120 1.5 90 143 160 M16 138 83 97.7 110 4.5 55 27.5 34.5 G3/4 14 35 G1/4
80
125 157 45 55 135 1.5 107 169 190 M20 162 100 112 123 5 60 30 37.5 G3/4 16 30 G1/4
100
140 186 55 55 165 1.5 132 212 240 M27 188 124 138.5 145 6 65 32.5 40 G1 25 55 G3/8
125
180 206 65 60 184 1.5 170 248 280 M30 218 148 176 215 9 75 37.5 50 G1 33 50 G3/8
160
220 251 70 60 225 1.5 220 310 345 M33 285 200 233 279 12 95 48.5 68 G1 1/4 55 50 G1/2
Required surface quality of the valve contact face
For the explanation of items, see page 9
ØD
Ød4
Ød3
Ød1
s
Ød2
Øk
h2
h1
b
f
r
0,01
min. ØD6
1)
Rzmax 4
Rz 160
Hydraulics Bosch Rexroth AG
RE 20478/06.06 ZSF; ZSFW
9/12
Unit dimensions
1
Pilot poppet (pre-decompression)
2
Centring diameter
3
Nameplate
4
Seal rings
5
Mating flange (separate order; proposed dimension,
see below
6
Stroke of main poppet (see page 10)
7
Caution!
Provide valve contact face (e.g. press cylinder, carrier
structures, etc.) with a sufficient bending resistance!
The prefill valve must not be subjected to bending
stress!
8
Directional valve type 4WE 6 D… to RE 23178 (sepa-
rate order)
9
Space required to remove plug-in connector
10
Valve fixing screws (separate order, see page 10)
Calculation according to ISO 2505/preliminary standard
p
max
= 350 bar
Material: C 22
Proposed dimension for mating flange (item 5) (nominal dimensions in mm)
Shape of welding groove:
Standard version
s ≤ 16 welding groove 22 DIN 2559
s > 16 welding groove 3 DIN 2559
Special version,
see DIN 2559
1)
See drawing and dimensional table on pages 7 and 8
2)
For seamless steel tubes, wall thickness 16 to DIN EN 10220
Size Flange Neck Raised face
Ød1
2)
Ød2 ØD b Øk h1 Ød3 s
2)
r h2 Ød4 f
32
48.3 18 150 22 110 49 64 3.2 6 7 88 3
40
60.3 18 165 29 125 57 75 3.6 6 8 102 3
50
76.1 18 185 34 145 64 90 3.6 6 10 122 3
63
88.9 18 200 43 160 77 105 3.6 8 12 138 3
80
114.3 22 235 51 190 95 134 3.6 8 12 162 3
100
139.7 30 295 62 240 116 168 4.0 8 12 188 3
125
168.3 33 345 79 280 138 202 4.5 10 12 218 3
160
219.1 36 415 118 345 186 256 5.9 10 16 285 3
For valve fixing screws and ordering code for mating flange,
see page 10.
B
A
A2
A1
A3
X
F2
F1
s1
s2
p
ö
0,12 bar
10/12 Bosch Rexroth AG Hydraulics
ZSF; ZSFW RE 20478/06.06
Valve fixing screws, mating flanges
Valve fixing screws Mating flange
Size Qty Dimension Tightening torque M
T
in Nm (±4 %) Material no.
Socket head cap screws
ISO 4762 - 10.9
Socket head cap screws
DIN 912 - 10.9
32
4 M16 x 100 280 – R900842693
40
4 M16 x 110 280 – R900825610
50
8 M16 x 110 280 – R900826441
63
8 M16 x 130 280 – R900849622
80
8 M20 x 140 560 – R900862915
100
8 M27 x 180 – 1400 R900834583
125
8 M30 x 200 1900 – R900861508
160
12 M33 x 260 – 2600 R900846478
Valve fixing screws (separate order)
The following valve fixing screws are recommended:
Poppet geometry and determination of minimum pilot pressure
Without pre-decompression
With pre-decompression
Size
A1
in cm
2
A2
1)
in cm
2
A3
in cm
2
s1
in mm
s2
in mm
F1
in N
F2
in N
V
st
in cm
3
Unchecking ratio
2)
in bar
3)
in bar
32
8.04 0.50 2.01 8.5 6.5 9 to 22 58 to 109 1.3 4.0 0.3
40
13.52 0.79 3.14 10.0 7.0 14 to 29 93 to 162 2.2 4.3 0.3
50
21.24 1.13 4.71 12.5 9.0 23 to 49 149 to 261 4.2 4.5 0.3
63
32.67 1.77 7.07 14.5 11.0 35 to 63 206 to 348 7.8 4.6 0.3
80
49.02 2.54 10.18 17.0 13.0 57 to 127 310 to 579 13.2 4.8 0.3
100
73.13 3.80 15.90 22.0 16.0 81 to 193 476 to 952 25.5 4.6 0.2
125
120.76 5.72 28.27 30.0 22.5 135 to 319 878 to 1667 59.4 4.3 0.2
160
196.07 9.08 45.36 40.0 27.0 241 to 516 1335 to 2395 122.0 4.3 0.2
1)
Not provided for version “withou pre-decompression" (ZSF...0...)
2)
Without pre-decompression
3)
With pre-decompression
A1 =
Effective area of main poppet
A2 =
Effective area of pilot poppet
A3 =
Effective area of pilot piston
s1 =
Main poppet stroke
s2 =
Pilot poppet stroke
F1 =
Spring force of valve spring
F2 =
Spring force of pilot piston compression spring
V
st
=
Pilot oil volume for opening the valve
p
Ö
=
Cracking pressure (pressure differential across main
poppet for overcoming spring force F1)
p
p
=
Pilot pressure in port X
p
B
=
System pressure in port B
Socket head cap screws ISO 4762 - 10.9 or DIN 912 - 10.9
Friction coefficient µ
total
= 0.12 to 0.17
Unchecking ratio =
Pilot pressure p
p
System pressure p
B
Example: Type ZSF32…F0; p
B
= 30 bar
p
p
= 4.0 x 30 bar = 120 bar
Hydraulics Bosch Rexroth AG
RE 20478/06.06 ZSF; ZSFW
11/12
Maximum flow q
V
in l/min (A to B) for various applications
Size 32 40 50 63 80 100 125 160
Application 1
200 300 500 800 1200 1900 3000 4200
Application 2
170 250 400 650 1000 1600 2600 3900
Application 3
140 220 360 560 900 1400 2200 3400
Application 4
100 150 240 380 620 950 1500 2300
Application 5
70 110 170 280 450 700 1100 1690
Applications
Caution!
Too small a prefill valve or an insufficient-
ly dimensioned pipe results in gas es-
caping from the hydraulic fluid with the
associated consequences and frequently
to long-term damage to cylinder seals.
Application 1 Application 2 Application 3
a
4
3
2
1
A
B
a
b
2
1
A
B
c
a
b
2
1
B
A
Size of the prefill tank
min. 1.5 x cylinder volume
Application 4 Application 5 Note on applications 2 to 5
a
b
2
1
A
B
a
b
2
1
A
B
h
A
B
For applications close to the limiting pa-
rameters, please consult us. It is, howev-
er, often sufficient to select the pipe one
size larger.
1
Cylinder
2
Prefill valve
3
The metal sheet is not included in the scope of supply.
In the case of small tank dimensions and minimum pres-
sure level (a) it prevents the formation of funnels.
4
Observe supply cross-section!
a
Min. 300 mm with extended cylinder
b
Up to 1000 mm with the specified maximum flows
c
h ≤ 500 mm
h
300 mm ≤ h < 500 mm
Bosch Rexroth AG
Hydraulics
Zum Eisengießer 1
97816 Lohr am Main, Germany
Phone +49 (0) 93 52 / 18-0
Fax +49 (0) 93 52 / 18-23 58
documentation@boschrexroth.de
www.boschrexroth.de
© This document, as well as the data, specifications and other information
set forth in it, are the exclusive property of Bosch Rexroth AG. Without
their consent it may not be reproduced or given to third parties.
The data specified above only serve to describe the product. No state-
ments concerning a certain condition or suitability for a certain application
can be derived from our information. The information given does not release
the user from the obligation of own judgment and verification. It must be
remembered that our products are subject to a natural process of wear and
aging.
12/12 Bosch Rexroth AG Hydraulics
ZSF; ZSFW RE 20478/06.06
Notes
