MCV116 - Insane Hydraulics

1 1 MCV116 Pressure Control Pilot (PCP) ValveBLN-95-9033-5 Issued: October 2003 DESCRIPTIONThe MCV116 Pressure Control Pilot (PCP) Valve is an inex-pensive control valve for use in electrohydraulic systems whichcontrol machines used in construction, farming, material han-dling, marine, mining and industrial applications. The device isdesigned to control pilot-operated flow control valves (propor-tional main spool valves in the 5 50 gpm range), pilot-operated variable displacement pumps and motors and anyother device which is pilot differential pressure PCP is a torque-motor actuated, double-nozzle flappervalve that produces a differential output pressure proportionalto the applied electrical input signal. It is a single-stage, stand-alone, closed loop pressure control valve which uses internalhydraulic pressure reactions to achieve its closed loop controlcharacteristics.

2 Copyright 2003, Sauer-Danfoss (US) rights reserved. Contents subject to PCP accepts a dc current and produces a proportionalhydraulic differential pressure output. See the InternalWorkings Schematic. Input current controls the torquemotor stage, a bridge network consisting of an armaturemounted on a torsion pivot and suspended in the air gap ofa magnetic field. Two permanent magnets polarized inparallel and a connecting plate form a frame for the magneticbridge. At null the armature is centered in the air gapbetween the magnets opposing poles by the equivalence oftheir magnetic forces and the null-adjust centering input current rises, the end of the armature becomesbiased either north or south, depending on the direction ofthe current. The resulting armature movement is deter-mined by the amperage of control current, the spring con-stant and the differential pressure feedback forces (whichseek a torque balance, as explained below).

3 Linearity of theinput/output relationship is less than 10% through 80% ofrated magnetic bridge output, the flapper torque, in turncontrols the hydraulic bridge ratio. At null, the flapper iscentered between two nozzles. Upstream from each nozzleis an orifice which provides a nominal pressure drop whenthe system is at null. Between the nozzle and the orifice oneach side is a control port. As the torque shifts the flapperaway from one nozzle towards the other, a differentialcontrol pressure results, the high side being the one nearerthe PCP is a closed-loop pressure control valve usinginternal hydraulic pressure reactions to effect an intrinsicfeedback. With a step input from the current source, theflapper initially moves towards full stroke to close the (com-manded) high-side nozzle. Fluid pressure rises on this sideand moves the flapper back towards null.

4 When the torqueoutput from the motor equals the torque output from thepressure feedback, the system is in equilibrium. Deferentialpressure is then proportional to command OF OPERATIONINTERNAL WORKINGS SCHEMATICCENTERINGSPRINGSPOLEPIECEARMATU REPOLEPIECEPIVOTFLAPPERORIFICEORIFICENOZ ZLENOZZLEC1 PRC2 PSMAGNETMAGNETP ressure Control Pilot (at null).1025278,7( )56,1( )17,5 DIA (2)( )PACKARD CONNECTOR ASSY(see page 10 for additional connectoroptions)2 CONNECTOROPTIONSSHOWNMS CONNECTORMANUAL OPERATORNULLADJUSTACCESSSCREWOUTPUT PORT - C1 4,8 ( ) DIA12,8 ( ) X 1,78 ( ) O-RINGPRESSURE PORT THRU FILTER 5,6 ( ) DIA12,8 ( ) X 1,78 ( ) O-RINGRETURN PORT 4,8 ( ) DIA12,8 ( ) X 1,78 ( ) O-RINGOUTPUT PORT - C2 4,8 ( ) DIA12,8 ( ) X 1,78 ( ) O-RING38,1( )70,1 ( )76,2 ( )95,2 ( )2,5 ( ) (2)3,0 ( )9,5 ( )6,3( )50,8( )MAX38,1( )34,9( )19,0( )5,5 ( ) DIA (4)12,7( )1 INTRINSICALLYSAFE DEVICEENCLOSUREGROUNDINGTERMINAL12 Null Adjust-Remove screw, make null adjustment with 3/32 inch hex key,replace screw.

5 Adjust only for special offset considerations, orwhen adjusting neutral for the Flow Control Servovalve (KVF). 2 Phasing-Positive voltage to either red lead (Pins B or D on either the Packard or MS Connector; or pins 2 or 4 of the Duetsch Connector) produces a pressure rise at Output DIMENSIONSD imensions of the MCV116 Pressure Control Pilot (PCP) Valve in Millimeters (Inches).BLN 95-9033-5 Standard manual override Withstands mobile equipment vibration and shock con-ditions Controls both pilot-operated pumps/motors and mainspool valves Optional environmental electrical connector (see PCPM ating Connectors, page 10) Self-contained pressure feedback Constant scale factor with varying pilot pressure Can be used in either closed loop or open loop systemsFEATURES1234567890123456789012345 6789012123456789012345678901234567890123 4567890123456789012123456789012345678901 2345678901234567890123456789012123456789 0123456789012345678901234567890123456789 0121234567890123456789012345678901234567 89012345678901212345678901234567890If the pilot is used as the first stage of electrical displacementcontrol (EDC)

6 , pump or motor, do not adjust the pilot the second stage valve 95-9033-5 FREQUENCY RESPONSED efined at -90 phase lag using a sine wave equal to 30% input amplitude of the test current loaded into bar differential pressure transducer (load capaci-tance cubic centimeters/bar) and 8 cubiccentimeters of oil on each side between the valve andthe transducer. Response bandwidth will decrease withincreasing flow demanded by the driven load. SeeFrequency SYMMETRYD efined as the difference of the differential outputpressure obtained over the test current high and lowend divided by the larger number, expressed as OUTPUT RANGER ated at saturation by measuring the deviation of the center of atest hysteresis loop from the best straight line betweenthe positive and negative extremes of the test currentrange, expressed as a percentage of the as the input signal to produce a detectablepressure at Hz cycled through the test NULL AS SHIPPEDD efined as the output offset at the center of the hyster-esis loop at zero input FLOWD efined across a bar (100 psi) load pressure drop atsaturation current.

7 See Load Pressure Droop Slope,page PRESSURE DROOP SLOPED efined at bar (250 psi) supply and 50 mA Load Pressure Droop Slope, page NULL SHIFTD efined as a percentage of supply pressure changewhen supply pressure is varied from bar to NULL SHIFTD efined as the maximum temperature null shift C (100 F) from -29 to 121 C (-20 to 250 F).SATURATION CURRENTD efined as the magnetic saturation of the torque FACTORSee Scale Factor in the table MCV116 Specifications,page RESPONSET hese curves demonstrate the amplitude and phase responseof the valve tested over a given frequency range with a supplypressure of bar. Frequency response curves are on thebottom of the graph, phase lag on top. The amplitude at lowfrequency was 30 mA and the load was a bar response varies with the applied load. Curves areshown with a current (DECIBLES)10501002001801501209060300 PHASING LAG (DEGREES)FREQUENCY (HERTZ)1 TYPE 10-6 AMPLITUDE (DECIBLES)10501002001801501209060300 PHASING LAG (DEGREES)FREQUENCY (HERTZ)1 TYPE 20-6 AMPLITUDE (DECIBLES)10501002001801501209060300 PHASING LAG (DEGREES)FREQUENCY (HERTZ)1 TYPE 3 & 4-12-12-121076A4 BLN 95-9033-5 SCALE FACTORLOAD PRESSURE DROOP SLOPET hese curves demonstrate the typical relationship betweeninput current and output differential pressure.

8 Curve slopes areinsensitive to input pressure, temperature and load. Supplypressure is curves demonstrate the output impedance characteris-tics of the valve. Output flow versus output differential pres-sure are shown at various positive and negative constant inputcurrents. The slopes of these curves indicate the outputconductance (load pressure droop slope) or impedance of thevalve. Supply pressure is bar. Dual coil and low currentcoil devices have similar load pressure droop slope curves atproportionally different steady current DATASHOCK50 G for 11 ms. Three shocks in both directions of thethree mutually perpendicular axes for a total of a vibration test designed for mobile equip-ment controls consisting of two from 5 to 2000 Hz in each of the three dwell for one million cycles for eachresonance point in each of the three from 1 to 46 G. Acceleration level varies being placed in a controlled atmosphere of 95%humidity at 49 C (120 F)

9 For 10 days, the pilot willperform within specification ccm500 ccm250 ccm250 ccm500 ccm750 ccm15 bar10 bar5 bar5 bar10 bar15 bar100 mA75 mA50 mA25 mA25 mA50 mA75 mA100 mA1250 ccm1000 ccm750 ccm500 ccm250 ccm250 ccm500 ccm750 ccm1000 ccm1250 ccm15 bar10 bar5 bar5 bar10 bar15 bar125 mA100 mA75 mA50 mA25 mA125 mA100 mA75 mA50 mA25 mA1000 ccm750 ccm500 ccm250 ccm250 ccm500 ccm750 ccm1000 ccm15 bar10 bar5 bar5 bar10 bar15 bar150 mA125 mA100 mA75 mA50 mA25 mA175 mA200 mA225 mA250 mA25 mA50 mA75 mA100 mA125 mA150 mA250 mA225 mA200 mA175 mATYPE 1 TYPE 2 TYPE 3 & 45 bar10 bar15 bar5 bar10 bar15 bar100 mA50mA50mA100mA1L11 DTYPE 15 bar10 bar15 bar5 bar10 bar15 bar200 mA100mA100mA200mA22 DTYPE 25 bar10 bar15 bar5 bar10 bar15 bar200 mA100mA100mA200mA3 & 43D & 4 DTYPE 3 & 45 MCV116 SPECIFICATIONSBLN 95-9033-5 Type 1 Type 2U/MA11 XXA12 XXA13 XXA14 XXA15 XXA21 XXA22 XXScale FactorDelta bar/mA .165.

10 028 .378 .034 .866 .082 .107 ..007 Delta ..1 Typical Pressurepsi500500500500500250250 Coil Resistanceohms23 (32)19 (25/22)69 (92)106 (145)643 (900)23 (32)19 (25/22)Coil CurrentmA 85 125 42 40 13 85 125 Saturation CurrentmA250350*/175**15011050250350*/17 5**Minimum PressureDelta bar Output RangeDelta psi 300 300 300 300 300 160 160 Typical Null asDelta bar0 ShippedDelta psi0 50 50 50 50 50 50 5 Pressure Null Shift% 2 2 2 2 2 NullDelta bar ShiftDelta psi 4 4 4 4 4 3 3C1/C2 Null Pressure ..34 Typical Supply Pressurepsi160 10160 10160 10160 10160 10115 5115 5 Internal LeakageLPM< < < < < < < < < < < < < < FlowLPM> > > > > > > > > > > > > > PressureLPM/bar> > > > > > > Droop Slopecis/psi> > > > > > > < 9 < 9 < 9< 9< 9< 7< 7 Symmetry%< 10< 10< 10< 10< 10< 10< 10 Linearity%< 5 < 5 < 5< 5< 5< 5< 5 ThresholdmA< 1< 1< 5< < < 1< 1 Resonant FrequencyHz> 300> 300> 300> 300> 300> 350> 350 Frequency ResponseHz (min.)