PVG 120 Proportional Valve Service Manual - Danfoss

1 MAKING MODERN LIVING POSSIBLES ervice ManualProportional Valve GroupPVG historyTable of revisionsDateChangedRevMay 2014 Converted to Danfoss layout DITA CMS, major revisionJAJan 2012 Pos. 3 changeIDFeb 2011 Table on page 35 changed, layout changes - all pagesICFeb 2010 Handles on drawingsIAJan 2010 Japan locationHCService ManualPVG 120 Proportional Valve Group2520L0247 Rev JA May 2014 pvg 120 Service parts exploded viewPVG 120 sectional viewSafety in applicationControl system 8 Examples of wiring block 10 IdentificationIdentification ..12 InstallationInstallation and plug , PVP, Pump Side 13 Oil flow 14 Tightening 14 PVM, Lever 16 Setting of max. 16 Pressure , LS Relief Valve Pressure , LS Relief Valve Pressure , Oil Flow Direction and Setting of max of relief 20 PVPH and LS 21 PVPE technical 21 Connection , Pump Side 23 PVPD, PVPH, PVPE, Accessories for 25 PVLP / PVLAPVLP / PVLA, Shock and Suction Valve Port 27 PVBP, PVBR, PVBC, PVBUPVBP, PVBR, PVBC, PVBU Accessories for 29 PVMPVM, Mechanical Activating 31 PVMD and PVHPVMD, Cover for PVM and PVH, Hydraulic 33 PVGIPVGI, Interface for pvg 120 and PVG 34 PVEH and PVEOPVEH and PVEO, Electrical Activating Module, , Tank Side Module Upper , Tank Side Module Lower and PVGIPVGI, Assembly 41 PVAS, Assembly 41 Asssembly 41 Set of sealsSet of Seals.

2 43 pvg 120 Modules Selection ChartPVG 120 module selection 44 Order specificationService ManualPVG 120 Proportional Valve GroupContents520L0247 Rev JA May 20143 Ordering of modules for oil flow exceeding 180 l/min [ US gal/min]..48 Order ManualPVG 120 Proportional Valve GroupContents4520L0247 Rev JA May 2014 pvg 120 Service parts exploded ManualPVG 120 Proportional Valve GroupPVG 120 Service parts exploded view520L0247 Rev JA May 20145 pvg 120 sectional :1 Main spool2 Pressure adjustment spool in PVP3 Shuttle valve4 Pressure relief Valve in PVP5 Pressure compensator in PVB6 LS pressure relief Valve in PVB7 Shock and suction Valve PVLP8 Suction Valve PVLA9 Orifice, closed center PVP.

3 Plug, open center PVP10 LS connection11 Orifice, open center PVP12 Plug, closed center PVPS ervice ManualPVG 120 Proportional Valve GroupPVG 120 sectional view6520L0247 Rev JA May 2014 All makes and all types of control valves (incl. Proportional valves ) can fail, thus the necessary protectionagainst the serious consequences of function failure should always be built into the system. For eachapplication an assessment should be made for the consequences of pressure failure and uncontrolled orblocked determine the degree of protection that is required to be built into the application, system tools suchan FMEA (Failure Mode and Effect Analysis) and Hazard and Risk Analysis can be IEC EN 61508 FMEA (Failure Mode and Effect Analysis) is a tool used for analyzing potential risks.

4 This analyticaltechnique is utilized to define, identify, and prioritize the elimination or reduction of known and/orpotential failures from a given system before it is released for production. Please refer to IEC FMEAS tandard and risk analysis ISO 12100-1 / 14121 This analysis is a tool used in new applications as it will indicate whether there are special safetyconsiderations to be met according to the machine directives EN 13849. Dependent on the determinedlevels conformity this analysis will detirmine if any extra requirements for the product design,development process, production process or maintenance, the complete product life makes/brands and types of directional control valves inclusive Proportional valves can fail andcause serious damage.

5 It is therefore important to analyze all aspects of the application. Because the Proportional valves are used in many different operation conditions and applications,the manufacturer of the application is alone responsible for making the final selection of the products and assuring that all performance, safety and warning requirements of the application are met. The process of choosing the control system and safety levels is governed by the machine directivesEN 13849 (Safety related requirements for control systems). Service ManualPVG 120 Proportional Valve GroupSafety in application520L0247 Rev JA May 20147 Control system exampleExample of a control system for manlift using PVE Fault monitoring input signals and signals from externalsensors to ensure the PLUS+1 main controllers correct function of the.

6 1 Main power supply2 Emergency stop/man present switch3 HMI/Joystick control4 Movement detection sensors5 Main controller6 PVG control valve7 Hydraulic deactivationService ManualPVG 120 Proportional Valve GroupSafety in application8520L0247 Rev JA May 2014 Electrical block diagram for the above illustrationWWarningIt is the responsibility of the equipment manufacturer that the control system incorporated in themachine is declared as being in conformity with the relevant machine 32 mainly used in system with fixed displacement pumps: PVSK, commonly used in crane application - full flow dump PVPX, LS dump to tankPVG 100 alternative LS dump or pilot supply disconnect: PVPP, pilot oil supply shut off External cartridge Valve connecting LS pressure or main pressure to tankPVG 120 pump disconnect / block for variable pumps.

7 PVPE, full flow dump for the pvg 120 External cartridge Valve connecting LS pressure to tankService ManualPVG 120 Proportional Valve GroupSafety in application520L0247 Rev JA May 20149 Examples of wiring block diagramExample of a typical wiring block diagram using PVEH with neutral power off switch and fault monitoringoutput for hydraulic detection outputhigh=onlow=offAlarmlogic2)Memory3) E1E2 OutputANDORUDC2 ErrorUSNeutral detection / Supply controlsignal neutralOFFD elay 1)UDC2 ErrorUSPVEH with AMP connectorPVEH with AMP connectorHydraulicdeactivationNeutral detection / Supply controlsignal neutralOFFD elay 1)PVE 1 PVE 2 Emergency stopMan present switchCCDBBAP301 318A Emergency stop / man present switchB PVE Fault monitoring signalsC Neutral signal Hydraulic deactivationSystem Control Logic PLUS+1 for signal monitoring and triggering signal for deactivation of thehydraulic is the responsibility of the equipment manufacturer that the control system incorporated in themachine is declared as being in conformity with the relevant machine ManualPVG 120 Proportional Valve GroupSafety in application10520L0247 Rev JA May 2014 Example of fault monitoring for deactivation of the hydraulic system with extra fault inputs using the PVE swith DI (Direction Indication) detection / Supply controlsignal neutralOFFD elay 1)

8 Fault detection outputPVEH-DIAMP supply connector PVEH-DIAMP supply connector PVEH-DIAMP connector PVEH-DIAMP connector ANDhigh=onlow=offNeutral detection / Supply controlsignal neutralOFFD elay 1)PVE 1 PVE 2 Fault detectionDelayDILogicMemoryUSDI-ADI-B2)4 )3)OutputFault detectionDelayDILogicMemoryUSDI-ADI-B2)4 )3)OutputOREmergency StopMan present switchP301 319 UDC2 ErrorUSDI-BErrorDI-AUDC2 ErrorUSErrorDI-AHydraulicdeactivationSys tem Control Logic PLUS+1 for signal monitoring and triggering signal for deactivation of thehydraulic is the responsibility of the equipment manufacturer that the control system incorporated in themachine is declared as being in conformity with the relevant machine ManualPVG 120 Proportional Valve GroupSafety in application520L0247 Rev JA May 201411 IdentificationPVG 120 : PVG number, week and year of installationD: PVP pressure settingE: PVP number, week, year and day manufacturing, issue and series : PVB A-Port, number, week, year and day manufacturing, issue and series.

9 PVT week and year of manufacturingService ManualPVG 120 Proportional Valve GroupIdentification12520L0247 Rev JA May 2014 Installation and plug orientationInstallation Dimensions60 Nm[530 lbf in]60 Nm[530 lbf in]190 [ ]*100 [ ]*190 [ ]*100 [ ]*105 [ ]L4xM12x18[4x7 ] * Room for dismantlingModule of PVB12345678L mm168235302369436503570637L , PVP, Pump Side ModuleService ManualPVG 120 Proportional Valve GroupInstallation520L0247 Rev JA May 201413 Oil flow directionMechanical / electrical actuationMechanical / hydraulic TorquesMax. tightening torques Connection Threads Type G (ISO 228/1)Max. tightening torquesPortsPA, PBMALS, LX, PPSealing threadG 1/4G 1/4G 3/8 With steel washer35 N m [310 lbf in]40 N m [350 lbf in]60 N m [530 lbf in]With cooper washer30 N m [270 lbf in]20 N m [180 lbf in]35 N m [310 lbf in]With aluminium washer30 N m [270 ]30 N m [270 ]40 N m [350 lbf in]With cutting edge35 N m [310 ]40 N m [350 ]60 N m [530 lbf in] Service ManualPVG 120 Proportional Valve GroupInstallation14520L0247 Rev JA May 2014 Max.

10 Tightening torques Mounting Threads in SAE J 518c FlangesPortSizeThreadsTightening torqueP1 inM12, 18 deep68 N m7/16 - 14 UNC deep[600 lbf in]A/B3/4 inM10, 17 deep45 N m3/8 - 16 UNC deep[400 lbf in]T1 inM10, 17 deep45 N m3/8 - 16 UNC deep[400 lbf in]Max. tightening torques UN and UNF Connection Threads O-ring Boss PortMax. tightening torquesPortsPA/BTPA/PBMALS, LX, PPSealing/Thread1 5/16 in-12 UN1 1/16 in-12 UN1 5/16 in-12 UN in-20 UNF in-20 UNF in-20 UNFO-ring160 N m120 N m160 N m30 N m30 N m60 N m[1410 in lbs][1060 in lbs][1410 in lbs][270 in lbs][270 in lbs][530 in lbs]Ports identificationService ManualPVG 120 Proportional Valve GroupInstallation520L0247 Rev JA May 201415 PVM, Lever PositionsBase with an angle of Base with an angle of of max.