Cartridge Valves Technical Information Introduction
Contents
IN ••••••••••••••••••••••••••••••••••••• Introduction
CV ••••••••••••••••••••••••••••••••••• Check Valves
SH •••••••••••••••••••••••••••••••••••Shuttle Valves
RV •••••••••••••••••••••••••••••••••••• Relief Valves
PR ••••••••••••••••••••••••• Pressure Reducing Valves
SQ ••••••••••••••••••• Sequence and Unloading Valves
FC •••••••••••••••••••••••••••••• Flow Control Valves
PO ••••••••••••••••••••••• Pilot Operated Check Valves
CB ••••••••••••••••••••••••••• Counterbalance Valves
DV •••••••••••••••••••••••••Directional Control Valves
LE •••••••••••••••••••••••••••••••••••Logic Elements
SV ••••••••••••••••••••••••••••••••• Solenoid Valves
PV •••••••••••••••••••••••••••••• Proportional Valves
FD •••••••••••••••••••••••••••••••••• Fan Drive HICs
MM ••••••••••••••••••••••••••••••Motor Mount HICs
TR •••••••••••••••••••••••••••••Traction Control HICs
SP ••••••••••••••••••••••••••••••Spreader Valve HICs
MX ••••••••••••••••••••••••• Mix-N-Match Dual Bodies
D3 ••••••••••••••••••••••••••• DCV03 Solenoid Valves
D5 ••••••••••••••••••••••••••• DCV05 Solenoid Valves
AC ••••••••••••••••••••••••••••••••••••• Accessories
CA ••••••••••••••••••••••••••••••••••••••••Cavities
HS •••••••••••••••••••••••••••••••••••••• Housings
CL •••••••••••••••••••••••••••••••••••••••••• Coils
CR ••••••••••••••••••••••••••••••••• Cross Reference
ID •••••••••••••••••••••••••••••••••••••••••••Index
BC332373683099en-000101 • February 2020
IN - 1
Cartridge Valves Technical Information Introduction
Cartridge Valves
CARTRIDGE VALVE
INTRODUCTION
Cartridge valves are compact and economical components that can be used for
directional, pressure, or ow control in systems from 0.4 L/min [0.1 US gal/min] up to
400 l/min [100 gpm], and for pressures up to 350 bar [5000 psi]. By combining standard
cartridge valves almost any hydraulic circuit can be easily created. Using cartridge
valves in a custom manifold, a designer can create a hydraulic integrated circuit (HIC)
that provides a compact package for hydraulic control with reduced plumbing, easier
installation, easier service, and fewer leak points than traditional hydraulic systems.
Each valve has several key ratings, specications, and settings:
· Each Danfoss ICS cartridge valve ts a Danfoss ICS standard cavity. These cavities
are designed around SAE or metric standard o-ring straight thread ports. In many
cases these cavities are interchangeable with cavities used by other manufacturers.
See catalog sheets for details.
· The pressure rating is based on NFPA T.2.6.1 fatigue test standards and a burst test
with a minimum safety factor of 3:1
· The ow rating is based on the ow at a pressure drop of 7 bar [100 psi] for
directional valves or a pressure rise or drop of 7 bar [100 psi] for pressure relief and
reducing valves, with 32 mm2/s (cSt) [151 SUS] uid. Note that for many valves this
ow can be exceeded if the resulting higher pressure drop and the associated heat
generation are acceptable. The exceptions to this are solenoid-operated spooltype directional valves and proportional ow control valves where the ow ratings
indicate a performance limit.
· The solenoid voltage is a nominal value. All solenoid valves are designed to
operate at 85% of nominal voltage with full rated ow and pressure and at an
ambient temperature of 40 °C [104 °F].
· Pressure settings for check, relief, reducing, sequence, and motion control valves,
commonly referred to as the crack pressure, are set at a ow rate of 0.95 L/min
[0.25 gpm] through the valve.
· Leakage is generally measured at rated pressure limits or in the case of relief and
motion control valves at 70-80% of crack pressure setting, with 32 mm2/s (cSt) [151
SUS] uid. See individual catalog sheets for details.
· Temperature ratings vary by model and options. Seal materials provide ranges
of -40 °C to 100 °C [-40°F to 212 °F] (buna-n or polyurethane) or -26 °C to 204 °C
[-15 °F to 400 °F] (viton). The recommended minimum uid viscosity is
12 mm2/s (cSt) [66 SUS] which will override the maximum seal temperature limit
for most uids. Solenoid valves are rated for 60 °C [140 °F] maximum ambient
temperature for continuous duty. Consult factory for extreme applications.
BC332373683099en-000101 • February 2020
IN - 2
Cartridge Valves Technical Information Introduction
Fluid and ltration recommendations
FLUIDS
FILTRATION
Ratings and performance data for cartridge valves are based on operating with premium
hydraulic uids containing oxidation, rust, and foam inhibitors.
These premium uids include premium turbine oils, API CD engine oils per SAE J183,
M2C33F or G automatic transmission uids (ATF), Dexron II (ATF) meeting Allison C-3 or
Caterpillar TO-2 requirements, and certain specialty agriculture tractor uids. For further
information see Danfoss publication 520L0463, Hydraulic Fluids and Lubricants Technical
Information.
CAUTION
Never mix hydraulic uids.
Product performance will generally be within catalog limits with uids meeting the
recommended viscosity limits shown below.
Product can be operated at viscosities outside the recommended limits, however
performance may be greatly degraded. Extreme conditions must be evaluated by the
user to determine acceptibility of product performance.
Contact your Danfoss ICS representative for more information regarding uids.
It is imperative that only clean oil be used with cartridge valves to maintain valve
operation and prevent premature wear. System ltration capable of controlling the uid
cleanliness to the limits shown below is required.
The selection of lters depends on a number of factors including the contamination
ingression rate and the desired maintenance interval. Filters are selected to meet the
below requirements using rating parameters of eciency and capacity.
Filter eciency may be measured using a Beta (β) ratio.* A lter with a β-ratio within the
range of β10=10 is typically required.
Since each system is unique, the ltration requirement for that system will be unique and
must be determined by test in each case. It is essential that monitoring of prototypes
and evaluation of components and performance throughout the test program be the
nal criteria for judging the adequacy of the ltration system. For further information
see Danfoss publication 520L0467, Design Guidelines for Hydraulic Fluid Cleanliness
Technical Information.
Fluid specications
Product
Cartridge and
Electrohydraulic valves
* Filter βx ratio is a measure of lter eciency dened by ISO 4572. It is dened as the ratio of the number
of particles greater than a given size (x) upstream of the lter to the number of particles greater than the same
size downstream of the lter. The βx ratio applies to a specic particle size, measured in microns.
Cleanliness
(per ISO 4406, 1999)
18/16/13 or better 12-54 [66-250] 12-400 [66-1854]
Recommended Viscosity limits
mm2/sec (cSt) [SUS]
Absolute Viscosity limits
mm2/sec (cSt) [SUS]
BC332373683099en-000101 • February 2020
IN - 3
Cartridge Valves Technical Information Introduction
Standard pressure settings and adjustment options
STANDARD PRESSURE
SETTINGS
The tables below detail coding for standard pressure settings. Use these tables for
reference when lling in valve ordering options for valves with selectable pressure
settings. Use the table on this page for valves that specify pressure in psi—typically
those beginning with the letters CP. Use the table on the next page for valves that
specify pressure in bar—typically those that do not begin with the letters CP.
Standard settings for valves set in psi
Crack Pressure
(Code x 10 = psi)
001 10 psi [0.69 bar]
002 20 psi [1.38 bar]
003 30 psi [2.07 bar]
004 40 psi [2.76 bar]
005 50 psi [3.45 bar]
006 60 psi [4.14 bar]
007 70 psi [4.83 bar]
008 80 psi [5.52 bar]
009 90 psi [6.21 bar]
010 100 psi [6.9 bar]
012 120 psi [8.28 bar]
014 140 psi [9.66 bar]
015 150 psi [10.34 bar]
016 160 psi [11.0 bar]
018 180 psi [12.4 bar]
020 200 psi [13.8 bar]
022 220 psi [15.2 bar]
024 240 psi [16.6 bar]
025 250 psi [17.2 bar]
026 260 psi [17.9 bar]
028 280 psi [19.3 bar]
030 300 psi [20.7 bar]
035 350 psi [24.1 bar]
040 400 psi [27.6 bar]
045 450 psi [31.0 bar]
050 500 psi [34.5 bar]
060 600 psi [41.4 bar]
070 700 psi [48.3 bar]
080 800 psi [55.2 bar]
090 900 psi [62.1 bar]
100 1000 psi [69.0 bar]
110 1100 psi [75.9 bar]
120 1200 psi [82.8 bar]
130 1300 psi [89.7 bar]
140 1400 psi [96.6 bar]
Crack Pressure, psi [bar]
Crack Pressure
(Code x 10 = psi)
150 1500 psi [103 bar]
160 1600 psi [110 bar]
170 1700 psi [117 bar]
180 1800 psi [124 bar]
190 1900 psi [131 bar]
200 2000 psi [138 bar]
210 2100 psi [145 bar]
220 2200 psi [152 bar]
230 2300 psi [159 bar]
240 2400 psi [166 bar]
250 2500 psi [172 bar]
260 2600 psi [179 bar]
270 2700 psi [186 bar]
280 2800 psi [193 bar]
290 2900 psi [200 bar]
300 3000 psi [207 bar]
320 3200 psi [221 bar]
340 3400 psi [234 bar]
350 3500 psi [241 bar]
360 3600 psi [248 bar]
380 3800 psi [262 bar]
400 4000 psi [276 bar]
420 4200 psi [290 bar]
440 4400 psi [303 bar]
460 4600 psi [317 bar]
480 4800 psi [331 bar]
500 5000 psi [345 bar]
520 5200 psi [359 bar]
540 5400 psi [372 bar]
560 5600 psi [386 bar]
580 5800 psi [400 bar]
600 6000 psi [414 bar]
XXX Standard pressure setting;
Crack Pressure, psi [bar]
refer to cartridge individual
catalog page for standard
setting value
BC332373683099en-000101 • February 2020
IN - 4
SETTINGS (continued)
A
E - internalEN-externalM-handwheel
Cartridge Valves Technical Information Introduction
Standard pressure settings and adjustment options
Standard settings for valves set in barSTANDARD PRESSURE
Crack Pressure
Code (bar)
10 10 bar [145 psi]
15 15 bar [218 psi]
20 20 bar [290 psi]
25 25 bar [363 psi]
30 30 bar [435 psi]
35 35 bar [508 psi]
40 40 bar [580 psi]
45 45 bar [653 psi]
50 50 bar [725 psi]
55 55 bar [798 psi]
60 60 bar [870 psi]
65 65 bar [943 psi]
70 70 bar [1015 psi]
75 75 bar [1088 psi]
80 80 bar [1160 psi]
85 85 bar [1233 psi]
90 90 bar [1305 psi]
95 95 bar [1378 psi]
100 100 bar [1450 psi]
105 105 bar [1523 psi]
110 110 bar [1595 psi]
120 120 bar [1740 psi]
130 130 bar [1885 psi]
Crack Pressure, bar [psi]
Crack Pressure
Code (bar)
140 140 bar [2030 psi]
150 150 bar [2175 psi]
160 160 bar [2320 psi]
170 170 bar [2465 psi]
180 180 bar [2610 psi]
190 190 bar [2755 psi]
200 200 bar [2900 psi]
210 210 bar [3045 psi]
220 220 bar [3190 psi]
230 230 bar [3335 psi]
240 240 bar [3480 psi]
250 250 bar [3625 psi]
260 260 bar [3770 psi]
270 270 bar [3915 psi]
280 280 bar [4060 psi]
290 290 bar [4205 psi]
300 300 bar [4350 psi]
310 310 bar [4495 psi]
320 320 bar [4640 psi]
330 330 bar [4785 psi]
340 340 bar [4930 psi]
350 350 bar [5075 psi]
XXX Pressure code stamped on
Crack Pressure, bar [psi]
valve; Pressure not set
MECHANICAL VALVE
Adjustment options - CP valves
ADJUSTMENT OPTIONS
- internal adjustment
- tamper resistant
F
- external adjustment
E
- knob adjustment
K
Adjustment options - other valves
BC332373683099en-000101 • February 2020
IN - 5
Cartridge Valves Technical Information Introduction
2
2
4
3
1
3
Cartridge valve installation procedure
INSPECT THE VALVE
BLOCK
PREPARE CARTRIDGE
FOR INSERTION INTO
THE BLOCK
ASSEMBLY
TEST
CAVITY PORT
IDENTIFICATION
Refer to specic pages within this catalog to ensure proper port identication for
cartridge functions. Inspect the valve cavity to be sure it is free of burrs, chips or other
contamination.
Check the cartridge to ensure it is free of external contamination, and the O-rings
and back-up rings are intact. Dip the cartridge in clean oil to the top of the threads to
lubricate the O-rings.
Insert and screw the cartridge into its cavity by hand. It should turn easily up to the top
O-ring. If it does not turn easily, the cavity has been machined improperly and the body
should not be used.
Torque all cartridges per specication shown on catalog sheet. Torque all coil nuts to 5-8
N•m [4-6 lbf•ft] unless otherwise specied.
Test the entire system to ensure that the cartridges are performing correctly and to
check for leaks.
Cavity 2 way Cavity 3 way
2
1
3
Cavity 4 way
3
1
4
2
Cavity 5 way
1
BC332373683099en-000101 • February 2020
IN - 6
Cartridge Valves Technical Information Introduction
Hydraulic integrated circuits
DESCRIPTION
DESIGN CAPABILITIES
Cartridge valves can be installed in custom designed manifolds to create a Hydraulic
Integrated Circuit (HIC). HICs provide many advantages over traditional hydraulic
control systems:
· HICs are compact packages that
simplify machine plumbing, reducing
costs for ttings, tubes, hoses, and
installation.
· Leak points are eliminated.
· Service time and costs are dramatically
reduced. Components can be
replaced without disturbing machine
plumbing.
· HICs can be centralized on a machine
or strategically located near a function.
Using a custom HIC provides the designer unlimited exibility to optimize
machines for assembly, plumbing, wiring, service, and weight distribution.
A custom HIC can be specied and designed
to meet your circuit requirements using
Danfoss’s EasyManifold tool.
· EasyManifold allows you to eortlessly
create your hydraulic circuit schematic
from Danfoss’s digital library of cartridge
valves using a drag and drop interface.
· With the new Automatic Design feature,
small to medium sized HIC designs can
now be completed through the tool. At
the click of a button, your project can be submitted and EasyManifold will generate
a 2D drawing and 3D model. In less than an hour, you can take your project from a
concept to a design ready for manufacturing.
· For larger HICs, manifolds are designed using our state of the art CAD software by
our regional HIC engineering design teams.
HICs can be designed with custom interfaces to mount directly to other Danfoss
products, including stackable spool valves and motors. This provides a compact and
ecient hybrid solution to meet your machine requirements.
Industry-leading rapid prototyping is available globally to support your program
requirements.
BC332373683099en-000101 • February 2020
IN - 7
Cartridge Valves Technical Information Introduction
Hydraulic integrated circuits
PRODUCTION
CAPABILITIES
· Manifolds are machined from
6061-T6 or 2011 aluminum (for
pressures to 210 bar [3,000 psi]) or
ductile iron (pressures to 480 bar
[7,000 psi]).
· State-of-the art exible CNC
machining centers are used to
maintain the highest quality
standards.
· All manifolds go through extensive
deburring and cleaning operations.
· Aluminum manifolds can be nished with clear or color anodizing on request for
added cleanliness, enhanced corrosion resistance, and improved appearance.
· Ductile iron manifolds are zinc plated.
Clear plastic training aid
HIC Assembly
· HICs are 100% tested on computerized
test stands. Performance requirements
are unique for each custom HIC and
are agreed to by Danfoss ICS and the
customer prior to production.
· HICs can be supplied with hydraulic
ttings installed upon request.
· All HICs are identied with a Danfoss
part number and manufacturing date
code. HICs can also be manufactured
with customer specied part numbers,
logos, etc., upon request.
BC332373683099en-000101 • February 2020
IN - 8
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