PVG and After Sales and Service Blue Graphics

PVG and After Sales and Service © Blue Graphics Concept Sauer-Danfoss

PVG and After Sales and Service Agenda Index After Sales and Service • Technical information • General guidelines in systems • Trouble shooting • Disassembly / assembly of valves 2

PVG and After Sales and Service PVG 32 Valve Proportional Group PVG 32 1988 280 bar*65 l/min = 32 KW 600 2011 400 bar*130 l/min = 86 KW 600 3 Output in KW

Introduction to PVG Valves All families of valves PVG 20 PVG 16 PVG 100 PVG 120 PVG 32 PVG/HIC Hybrid solution PVX 4

BA PVG Product Roadmap Product Portfolio Valve portfolio 0 -240 Lpm, low to high performance, analog and digital. PVG 16 5

PVG 32/100/120 Specifying a PVG • Customer can specify their own PVG Valve • Flexible modular design • Each specification sheet is unique • More than 100. 000 customer valve variants • 1– 12 sections PVG 32 • Combination between PVG 32 and PVG 120 is possible (4 section PVG 120 & 8 section PVG 32) • Combination between PVG 32, PVG 16 and PVG 100 6

PVG 32 PVG modular build concept – all parts interchangeable PVMD/F/H/R covers PVS endplates App. 30 variants PVBS spools App. 680 variants PVE actuator PVM handles App. 110 variants PVP inlets App. 135 variants Know-How in Motion™ App. 22 variants PVB work sections App. 75 variants 7 7

PVG 32/100/120 Specifying a PVG 32 Specification Subsidiary/Dealer PAE Hydraulics Ltd. Customer Application 110 xxxxx PVG No. BA sales PVG Customer Part No. Revision No. Training Vehicle A-Port B-Port Section Extra Features v Function 4 5 6 7 8 9 10 11 12 13 14 15 16 17 157 B a 157 B 3171 Bow truster b 157 B Up/down 157 B 5110 157 B p = 0380 bar 157 B 6200 157 B LSA bar a 157 B 3175 157 B 6233 Bow truster prop. b 157 B 2150 LSA 0120 bar a 157 B 157 B b 157 B LSA bar a 157 B 157 B b 157 B LSA bar a 157 B b 157 B LSA bar 157 B a 157 B b 157 B LSA bar 157 B 2014 157 B End section PVAS section "Reserved for Painting" Comments: Filled in by: S. Larsen 157 B 8600 LSB bar 7124 LSB 0320 bar LSB bar LSB bar LSB bar b 157 B c 157 B b 157 B c 157 B b 157 B c 157 B b 157 B c 157 B 2350 157 B c 157 B 4735 157 B b 157 B c 157 B 4745 157 B 7005 157 B 157 B LSB bar 157 B b 157 B c 157 B b 157 B LSB bar 8002 8 v Inlet 3 v 1 2 Date: 10 -05 -2011

PVG Identification PVG 32 Module Information ( internal production. no) PVE Module Information Assembly Information 9

PVG Identification PVG 32 Assembly Identification Assigned Assembly /Group Number (today: 11 xxxxxx no. ) Build Center Code Bar code + Date Code / Build and Test Date 47 10 Relief Pressure Setting (bar)

PVG Identification PVG 32 Module Identification 157 B 5110 4901 B 032550 157 B 6200 All PVB and PVP modules identified with Part Number and Date Code engraved on module “A” port side. 4901 B 022550 Internal production. no engraved on “B port” side 11

PVG Identification PVG 32 Module Identification PVE Module 11095110 4901 B 022550 Voltage Rating 12 VDC Part Number 157 B 4911 4901 E 03664 Date Code 12

PVG Identification 157 B 5111 PVP P Pressure reduction valve Pp Pressure gauge (M) Pressure relief valve T T Pp LS connection P LS 13 13

PVG Identification 157 B 6233 PVB LS pressure limiting valve Shock & suct valve T Tank (PVE) Pilot PVE Pp LS Expander Pp LS A/B Shuttlevalve P For Cleaning 14 14

PVG Identification PVG 100 Assembly Identification ( label) 15

PVG Identification PVG 100 module Identification PVT PVB PVP All PVB, PVP and PVT modules produced in Easly identified with Part Number and Date Code engraved and labeled. Parts produced in Nordborg has no marking. ( project started) 16

PVG Identification PVG 120 Assembly Identification PVG 120 Identification label is locatated on the PVP (inlet) module with; -code no. -Pressure. setting -date stamp 17

PVG Identification PVG 120 PVB Date code 10 26 26 4 PVB code no. 18 Last four digits G 601 4 G 601 10 Identification

PVG Identification PVG 120 PVP and PVT Date code 1707 19

PVG Identification PVG 120 155 G 6302 20 PVB casting code; cannot be used for identification

PVG Identification PVBS Identification PVG 120 spool PVG 100 spool PVG 32 spool 21

PVG Identification PVBS Identification Flow from 65 -240 l/min Flow from 40 -240 l/min PVG 120 spool PVG 100 spool Flow from 5 -130 l/min PVG 32 spool 22

PVG Identification PVBS Identification PVG 32 (157 B)7004 Markings pre 1998 (157 B)7004 Today’s spool (155 L)7354 110 xxxxxx Relief grooves 23

PVG Identification Notch identification Open in neutral; i. e. for hydraulic motors Open in Neutral Closed in neutral; i. e. for cylinders Closed in neutral LS a/b Check valve 24

Work Section Options PVB 32 <-- Without LSA/B- Shuttle With--> Check valve LSA/B- Shuttle valve LS Relief valve 25

• Hauptschieber 26 26

PVG Identification PVBS Identification PVG 100 spool 27

PVG Identification PVBS Identification PVG 100 LS Bleed Down Holes Closed Ported Cut Open Ported, Restrictive Cut Date Code Balancing / Timing Grooves for P. O. Logic 28 Part Number

PVG 120 Training 29

PVG Identification 6466 PVBS Identification PVG 120 Last four digits of the code no. Eg 155 G 6466, datecode on opposite side PVG 120 spool 30

PVG Identification PVLP for PVG 32 and 100 Suction Spring Work port pressure Shock Spring Tank pressure 31 Pressure range Tolerances 25 -> 80 bar 85 -> 230 bar 235 -> 350 bar +23 bar +10%

PVG Identification PVLP Identification PVG 32 and PVG 100 Date stamp 1 230 Pressure setting in Bar 32

PVG Identification PVLP Identification PVG 120 Work port pressure 25 0 Tank pressure Pressure setting eg. 250 BAR 33 Suction Spring

PVE Identification ASIC Electronic modules 2*Normally Open (NO) Cover Base plate Coil packages 34 2*Normally Closed (NC) Aluminum block Solenoid valves LVDT

PVE Identification • PVE Electrical / hydraulic data ON / OFF 12/24 V/DC Proportional 11 -32 V/DC, Medium, High, Super CAN – Bus Float Ramps Hirschmann- , AMP-, Deutsch-Connector Passive- , Aktive-Fault monitoring -30° to +60°C Ambient-temp. -30° to +90°C Oil-temp. 35

PVE Identification PVEO, on/off PVES, -H & -A Ratio-metric analogue w. spool feed back PVEP PWM controlled w. spool feed back PVED CAN controlled w. spool feed back 36

PVE Identification Electrical connections 37

PVE Identification Elektronic 2/2 way valves Mainspool in PVG 2008 38

PVE Identification Solenoid valve principle, type 1 …used in: • PVEA / PVEA-DI 39

PVE Identification Solenoid valve principle, type 2 …used in: • PVEO / PVEO-R • PVEM • PVEH / PVEH-DI • PVES 40

PVE Identification The Function 2013 41

PVE Identification 2013 42

PVE Identification Fault monitoring description Input signal monitoring The input voltage is continuous monitored. The acceptable signal range is between 15% and 85% of the supply voltage. If Signal voltage goes outside of this range, the system will switch into an error state. Transducer supervision If one of the wires to the LVDT sensor, or inside the sensor, is broken or shorted, the system will switch ínto an error state. Supervision of the closed loop The spool position must always correspond to the position requested by the input signal. If the spool is 15% farther from neutral (providing more flow) than requested, the system detects an error and will switch into an error state. 2013 43

PVE Identification Fault monitoring description Supply voltage: Nominal 11 -32 volts = 100 % Acceptable signal range: Working Signal range: Spool position error 100 % 85 % 75 % Working range 50 % Spool position Input signal 50 % Working range + _ Deadband 7% Input signal Spool position 0 % 2013 25 % 15 % 0 % 0 % 44 > 15% ==> ERROR

PVE Identification PVE Series 4 PVEH, PVEA, PVEP and PVES Faultmonitoring versions Active or Passive. Active version Passive version LED Input signal Transducer Fault mon. logic LED Input signal Error signal out - 750 ms delay (PVEA) Transducer Fault mon. Error signal out logic - 750 ms delay (PVEA) 500 ms delay (PVEH) 250 ms delay (PVEH) - Memory - No memory Closed loop Solenoid Disable valves Error output state signal is available in the connector 2013 45 Solenoid valves continuously active with power on

PVE Identification PVE series 4 Visible Fault Indication in PVEA, PVEH and PVES Constant Green = OK Blinking Red = External failure (input signal) Constant Red = Internal failure 2008 46

PVE Identification PVE 4 performance 2008 47

PVED-CC – PLUS+1 Service Tool Introduction Introducing the PVED-CC PLUS+1 Service Tool! • Replaces current Web. GPI PVED interface tool. • PVED - PC interface using CG 150. • Displays all PVED on bus togeter with PVED setting • Easy change of communication target • Easy data upload/download between file and PVED • OEM data and Spool data stored as XML files 48

PVG 16/32/100/120 PVE / PVED Suggested Information http: //www. sauer-danfoss. com 49

Valve Installation Considerations 50

Valve Installation Considerations ¨BE AWARE¨ s. em t s y Dirt s Dirt Contamination Dirt e rc u o s t Contamination es t a Is r fo ra d y Contamination h in re lu i a f ic l u Contamination Dirt re g e th Contamination Dirt 51

Valve Installation Considerations Contamination • Containments from maintenance repair and installation (tools, metal burr‘s, peeling paint, welding debri etc. ) • Dirt inside system components (Tank, Cylinder, Plumbing, etc. • Contaminated Hydraulic Oil from supplier • Containments entering the cylinder due to cavitation, Oil refill in the tank, hydraulic tank ventilation etc. • Normal wear and tear of the components. • Condensation and moisture 52

Valve Installation Considerations Assembly and Maintenance things to consider • • • Cleaniness in and the around the work area Keep fittings and hose plugs on as long as possible. Clean pipes before mounting. Plugged ports until assembly. Torque according to specification. Keep tools clean. Filter Oil upon filling system. Pressure filter between pump and PVG ( recommended). Follow maintenance instruction (Filter / Changes) Oil check and analyses 53

Valve Installation Considerations Hydraulic tubes and hoses Selection criteria • Steel pipe or hoses. • Oil velocity • Diameter, length, quality depends on l /min. // Pressure • Bending radius. Impact on the system at the wrong choice. • Pressure drop • Pulsations / pressure spikes • Oil velocity • Reaction, response time ( Ls lines especially) 54

Valve Installation Considerations Filter and Oil cleanness 55

Valve Installation Considerations Filter and Oil cleanness Filter recommendations 56

Valve Installation Considerations Ingress Protection (IP) - IP 65 Testing 57

Valve Installation Considerations Ingress Protection (IP) DIN Connector Amp Connector 58 Deutsch Connector

Valve Installation Considerations Ingress Protection (IP) - NEMA to IP 59

Valve Installation Considerations Ideal Situation • Flat Mounting Surface – 0. 35 mm * (Number of Spool Sections + Inlet Section) • Close to Pump – 3 meters or less • Below Reservoir (Tank) – Flooded System • Electronic Protection 60

Troubleshooting Valve Systems Troubleshooting Hydraulic Systems 61

Troubleshooting Valve Systems How to Think! Problem? Think Simple Which is the simplest correct way start? Mechanical How and what to eliminate first? No Can we narrow in on the problem? Hydraulic No No Electrical Electronic No Software 62 Think Complex

Troubleshooting Valve Systems • Isolate Mechanical vs. Electrical vs. Hydraulic • Actuate spools manually • Watch lever movement with remote actuation • Actuate each section by itself vs. in combination with others 63

PVG Troubleshooting PVG 32/100/120 General Service and troubleshooting 64

Troubleshooting Valve Systems PVG Troubleshooting • Verify if fault is mechanical, hydraulic, or electrical – Check movement of lever manually – monitor movement of manual lever when hydraulic or electrical controller is operated 65

Troubleshooting Valve Systems PVG Troubleshooting Mechanical Fault; • • • Verify main spool limit stops are not misadjusted Main spool seized or jammed Main spool centering spring broken or damaged Pressure Compensator in valve section not functioning Faulty shock or anti-cavitation valves Spool Control Yoke ( PVM) 66

Troubleshooting Valve Systems PVG Troubleshooting Electrical Fault; • Verify electrical circuit • Faulty neutral position switch in remote control • Incorrect signal voltage – Proportional Operation • Verify Pin : Supply Voltage (100%) • Verify Pin : Variable Signal Voltage (25 -50 -75%) • Verify Pin : Ground connection (0) – On-Off Operation • Verify Pin for port A : Supply Voltage if Selected • Verify Pin for port B : Supply Voltage if Selected • Verify Pin : Ground connection (0) 67

Troubleshooting Valve Systems PVG Troubleshooting Hydraulic (Remote) Pilot Supply Fault; • Insufficient Pilot control Pressure (PVG 32/100/120: 5 -15 bar) • Insufficient pilot oil flow – (Flow should be 1. 5 L/min. per function) • • Air in pilot line Pilot lines incorrectly sized Faulty Remote pilot operator Sticking pressure control valve in remote hydraulic controller 68

Troubleshooting Valve Systems PVG Troubleshooting Fault- Erratic output response; • Electric or hydraulic actuator faulty • Main spool centering spring faulty • Main spool position feedback transducer signal incorrect • Contamination in hydraulic fluid • Air in hydraulic lines • Verify Hydraulic Oil Supply 69

Troubleshooting Valve Systems PVG Troubleshooting Fault- Erratic output response; • Open Center PVP – Low Stand By Pressure in PVP • PVG 32: 8 bar minimum • PVG 100: 12 or 20 bar minimum for OC • PVG 120: 12 bar minimum – Check condition of compensator spool spring 70

Troubleshooting Valve Systems PVG Troubleshooting Fault- Erratic output response; • Open / Closed Center systems – Low Standby pressure in pump control • Standby pressure should be greater than 15 bar – – – PVP Pressure relief valve faulty PVP orifices blocked Internal filters blocked ( PVE) Insufficient Internal hydraulic pilot pressure Supply lines blocked Insufficient load pressure at compensation spring chamber (Test load pressure at LS port in PVP module) – Load pressure too high for pressure settings of system – Blocked LS galleries – Faulty shuttle valves 71

Troubleshooting Valve Systems PVG Troubleshooting Problem • Hydraulic motor does not turn. 72

PVG 32/100/120 Suggested Information • PVG 32 Technical Information – #520 L 0344 • PVG 32 Service Parts Manual – #520 L 0211 • PVG 32 Service Manual - # 11039167 • PVG 100 Technical Information - #520 L 0720 • PVG 100 Service Parts Manual - #520 L 0888 • PVG 120 Technical Information - #520 L 0356 • PVG 120 Service Parts Manual - #520 L 0247 • and more…. . • www. sauer-danfoss. com - Literature 73