Danfoss MCV111B Installation guide

DESCRIPTION

The MCV111B Electrical Displacement Control (EDC) is a
two-stage electrohydraulic pump stroke control which uses
mechanical feedback to establish closed loop control of the
swashplate angle of Danfoss Series 90 Pumps.

The first stage, the MCV110 Pressure Control Pilot (PCP) is
a torque-motor actuated, double-nozzle flapper valve that
produces a differential output pressure proportional to the
applied electrical signal. The second stage uses the
differential pressure to drive its unique spool arrangement
and port oil to the pump servo cylinders. The second-stage
spool configuration allows a null deadband (for machine
safety) in the pump’s output while maintaining optimum
dynamic response to control commands.

FEATURES

MCV111B

Electrical Displacement Control-PV
Series 90

BLN-95-8995-4 Issued: September 1996

•Servo control deadband independent of signal null
deadband: offers safety combined with accurate and
responsive control

• Resistance to the environment: standard silicone oil
filled torque motor, environmentally sealed first/second
stage interface, full environmental testing

ORDERING INFORMATION

The MCV111B Electrical Displacement Control is ordered by
specifying the pump size and pilot type as shown in Table A.
Consult Danfoss, Minneapolis, MN, with further
questions.

TABLE A. INFORMATION NECESSARY TO SPECIFY
THE EDC.

MCV111B

BASE
DEVICE

PUMP
SIZE

PILOT STYLE

1. PUMP SIZE

MODEL CODE PUMP SIZE

03 30 cc

05 42 or 55 cc

07 75 cc

10 100 cc

13 130 cc Pump S/N < 92 - 19

XX XX

•Minimum long term null shift

• Dual coil torque motor can be used to sum two command
sources

2. PILOT

MODEL CODE PILOT STYLE

02 MS Connector

04 Packard Connector

EDCs ordered separate from the pump must have mounting
kits ordered separately:

30/55 cc PUMP KIT (KIT NUMBER KK11655)

Comprised of one K07652 gasket and six 9007314­0611 bolts

75/100/130 cc PUMP KIT (KIT NUMBER KK11675)

Comprised of one K07653 gasket and six 9007314­0611 bolts

42 cc PUMP KIT (KIT NUMBER KK11642)

Comprised of one K07652 gasket, six 9007314-0611
bolts and one K09123 washer

180/250 cc PUMP KIT (KIT NUMBER KK11618)

Comprised of one K07653 gasket, six 9007314-0611
bolts and one K09123 washer

14 130 cc Pump S/N ≥ 92 -19

18/25 180 or 250 cc

© Danfoss, 2013-09 BLN-95-8995-4 1

.

.

TECHNICAL DATA

ELECTRICAL

FULL STROKE CURRENT

85 ± 11.3 mA (single coil)
42 ± 5.6 mA (series coils)
85 ± 11.3 mA (parallel coils)
See Current vs. Swashplate Angle curve

NOMINAL INPUT IMPEDANCE

24.7 ohms, .093 henries, each coil

DEADBAND

32 ± 7 psi divided by the scale factor

HYDRAULIC

FILTRATION

The system hydraulics must have 10 micron or better
filtration. The pump will contain screen filters near the
interface to the EDC at the charge port and control port
locations. The pilot will have screen filters at its input and
output control ports.

CURRENT VS. SWASHPLATE ANGLE

FLUID

Automatic transmission fluid or hydraulic oil, such as
Mobil DTE 24 or equivalent

OIL VISCOSITY

40-6000 SSU

OIL TEMPERATURE

-40° C (-40° F) minimum; 104° C (220° F) maximum

OPERATING SUPPLY PRESSURE

Typically 300-400 psi above case pressure

RATINGS

SCALE FACTOR

1.15 psi/mA (single coil)

2.3 psi/mA (coils in series)

1.15 psi/mA (coils in parallel)

TEMPERATURE

The valve will meet all specifications over the range of
21° to 82° C (70° to 180° F)

15°

10°

5°

100mA80 60 40 20

20 40 60 80 100

5°

10°

15°

Current Vs. Swashplate Angle of the Single Coil MCV111B.

ELECTRICAL CHARACTERISTICS

INPUT SHAFT ROTATION VS. TERMINAL CONNECTION VS. OUTPUT FLOW

(+) Voltage to Terminal

One of Dual Coils Dual Coils in Parallel Dual Coils in Series

BC D

Input Produces

ABCD

Shaft Flow Out

Rotation Of Port

++

A

+

BC D

A

+

mA

1390

Clockwise A or C B or D A or C B or D A D A B

Counterclockwise A or C B or D A or C B or D A D B A

Start Current 14 mA with 0.43 Vdc 14 mA with 0.22 Vdc 7 mA with 0.43 Vdc

Full Stroke Current 85 mA with 2.3 Vdc 85 mA with 1.15 Vdc 42 mA with 2.3 Vdc

BLN-95-8995-4

2

DIMENSIONS, 75, 100, 130, 180, AND 250 cc PUMP EDC

8,6 REF.

(0.34)

CONTROL

LINKAGE

10,4

(0.41)

22,4

(0.88)

MS CONNECTOR
OPTION

PACKARD
WEATHER-PACK
CONNECTOR
OPTION

27,94
(1.10)

52,83
(2.08)

SAE

SERVO PORT

FITTING X1

203,2
(8.00)

141,22

(5.56)

186,06

(7.33)

MANUAL OPERATOR

49,78
(1.96)

108,46

(4.27)

169,67

(6.68)

7,11

(0.28)

NEUTRAL ADJUST

LOCK NUT

7,14 DIA 6 PLACES
(0.28 DIA)

31,62
(1.25)

SERVO PORT

FITTING X2

9,4

(0.37)

Dimensions of the MCV111B EDC for 75, 100, 130, 180, and 250 cc Pumps in Millimeters (Inches).

36,07
(1.42)

SAE

55,37
(2.18)

89,41
(3.52)

12,2

(0.48)

122,99

(4.84)

1788

DIMENSIONS, 42 cc AND 55 cc PUMP EDC

27,94
(1.10)

52,83
(2.08)

MS CONNECTOR

OPTION

PACKARD
WEATHER-PACK
CONNECTOR

CONTROL

LINKAGE

10,4

(0.41)

22,4

(0.88)

OPTION

SAE

SERVO PORT

FITTING X1

203,2
(8.00)

141,22

(5.56)

186,06

(7.33)

108,46

(4.27)

169,67

(6.68)

MANUAL OPERATOR

7,14 DIA 6 PLACES
(0.281 DIA)

31,62
(1.25)

49,78
(1.96)

(0.37)

8,6 REF.

(0.34)

7,11

(0.28)

NEUTRAL ADJUST

LOCK NUT

55,37
(2.18)

36,07
(1.42)

SAE

SERVO PORT

FITTING X2

9,4

122,99

(4.84)

89,41
(3.52)

12,2

(0.48)

1789

Dimensions of the MCV111B EDC for 42 cc and 55 cc Pumps in Millimeters (Inches).

3

BLN-95-8995-4

DIMENSIONS, 30 cc PUMP EDC

CONTROL

LINKAGE

LOCK

NUT

PACKARD
WEATHER-PACK
CONNECTOR
OPTION

9,9

(0.39)

19,3

(0.76)

MS CONNECTOR
OPTION

SERVO PORT

SAE

FITTING X1

181,03

(7.13)

131,06

(5.16)

166,12

(6.54)

153,42

99,06
(3.90)

(6.04)

8,6 REF
(0.34)

44,7

(1.76)

Dimensions of the MCV111B EDC for 30 cc Pumps in Millimeters (Inches).

NEUTRAL

ADJUST

7,1

(0.28)

103,25

(4.07)

MANUAL OPERATOR

7,14 DIA 6 PLACES
(0.28) DIA

32,26

30,99

(1.27)

(1.22)

SAE

SERVO PORT

FITTING X2

5,6

(0.22)

41,66
(1.64)

81,28
(3.20)

8,26

(0.33)

99,57
(3.92)

1790

THEORY OF OPERATION

A command source such as a joystick, control handle or
electronic controller applies current signals to the pilot stage
of the MCV111B Electrical Displacement Control, which
results in flow out of the pump. The input current commands
the pilot’s torque motor stage, a bridge network consisting of
an armature mounted on a torsion pivot and suspended in the
air gap of a magnetic field. Two permanent magnets
polarized together with two pole pieces form a frame for the
magnetic bridge. At null the armature is centered in the air
gaps between the magnets’ opposing poles by the
equivalence of their magnetic forces and the null adjust
centering springs. As the input differential current rises to the
dual coils, the end of the armature becomes biased either
north or south, depending on the magnitude of the current
differential. The resulting armature movement is determined
by the amperage of control current, the spring constant and
the differential pressure feedback forces, explained below.
See Internal Workings Schematic.

The magnetic bridge output, flapper torque, in turn controls
the hydraulic bridge ratio. At null, the flapper is centered
between two nozzles. Upstream from each nozzle is an
orifice which provides a nominal pressure drop when the
system is at null. Between the nozzle and the orifice on each
side is a control port. As the torque motor shifts the flapper
away from one nozzle toward the other, a differential control
pressure results, the high side being the one nearer the
flapper. Fluid pressure rises on this side and moves the
flapper back towards null. When the torque output from the
motor equals the torque output from the pressure feedback,

BLN-95-8995-4

the pilot system is in equilibrium. It is this pressure feedback
that makes the pilot a stand-alone closed loop pressure
control valve. The pilot stage is silicone oil filled for protection
against the environment and for proper valve operation.

The second stage of the EDC uses a unique spool-barrel
feedback arrangement that serves to separate the null
deadband from the feedback, giving both safety against null
drift and quick dynamic response to command changes.

The second stage’s null adjust is set with a feedback spring
compressed to a 16 psi threshold (measured at the center of
the hysteresis loop), which is the amount of differential
pressure required to begin to move the actuator spool one
direction or the other. The threshold is a factory setting. By
tightening or loosening the main null adjust screw, the fixed
deadband is adjusted so that the pump starts to stroke with
equal output current on either side of null.

As differential control pressure input from the pilot rises
beyond the 16 psi deadband, the spool moves in one
direction or the other, opening one of the control ports to
supply charge pressure to the pump’s servo-cylinders,
moving the swashplate. As the swashplate moves, the
linkage follows, moving the barrel in the opposite direction of
the spool’s original motion. The barrel’s feedback movement
tends to drive the spool back toward neutral through its
internal feedback spring. Oil returns from the servo cylinders
through the spool to the case.

4

INTERNAL WORKINGS SCHEMATIC

PILOT

P

s

P

1

BOOST STAGE

PUMP

P

t

P

s

AB

P

s

P

2

P

t

PERFORMANCE

HYSTERESIS

Less than 7 psi divided by the scale factor. Measured at
a frequency of .01 Hz at 30% of rated current when run
from plus to minus 98 psi divided by the scale factor

SYMMETRY

The differences in the currents to drive to either side of
rated output will not exceed 15%

LINEARITY

No point plotted on the current/swashplate angle curve
shall fall outside the area defined by a ±10% slope
deviation from the scale factor, exclusive of the
deadband

FAIL SAFETY

The spool will return to neutral if the electrical signal is
disconnected or if the pilot output pressure goes to case
pressure. Mechanical feedback must be present.

FREQUENCY RESPONSE
(EXCEPT FOR 130 cc PUMPS)

2 Hz minimum with .052 pressure limiter orifices

SWASHPLATE

LINKAGE

1393B

3 Hz minimum without pressure limiter orifices (with
pressure limiters inoperative)
Under 500-1000 psi load at 90° phase lag with 10 mA
signal at 45 mA offset

TIME RESPONSE (EXCEPT FOR 130 CC PUMPS)

1.0 seconds (0 to full stroke with .052 pressure limiter
orifices)

2.0 seconds (full to full stroke with .052 pressure limiter
orifices)
.30 seconds (0 to full stroke without pressure limiter
orifices)
.40 seconds (full to full stroke without pressure limiter
orifices)
under 500-1000 load conditions

SENSITIVITY

The valve will respond to a 2% change in input current
throughout the rated current range except for the
deadband region

DIMENSIONS

See the Dimension drawings

BLN-95-8995-4

5

ENVIRONMENTAL

SHOCK

50 g’s for 11 milliseconds. Three shocks in both
directions of the three mutually perpendicular axes for a
total of 18 shocks

VIBRATION

Withstands a vibration test designed for mobile
equipment control consisting of two parts:

1. Cycling from 5 to 2000 Hz in each of the three axes

2. Resonance dwell for one million cycles for each
resonance point in each of the three axes

Subject to acceleration levels of 1 g to 46 g’s
Acceleration level varies with frequency

WIRING

Two wiring styles are available: MS and Packard Weather­Pack. The MS Connector (MS3102C14S-2P) has four pins.
See the MS Connector Diagram for pin locations. (Note: The
device MS connector is not field replaceable.) See the
Electrical Characteristics section for pump phasing.

Mating connectors must be ordered separately. For the MS
connector order part number K08106. The mating Packard

HUMIDITY

After being placed in a controlled atmosphere of 95%
humidity at 49° C (120° F) for 10 days, the EDC will
perform within specification limits.
Meets MIL-STD-810B

connector is a bag assembly part number K03384,
comprised of :

1. 4, 14-16 gauge sleeves

2. 4, 18-20 gauge sleeves

3. 1 plastic housing

4. 4 green cable seals (accept 2, 2-2, 8 mm wire diameter)

5. 4 gray cable seals (accept 2, 81-3, 49 mm wire diameter)

6. 4 blue cable seals (accept 3, 50-4, 21 mm wire diameter)

See Ordering Information.

MS CONNECTOR

PACKARD CONNECTOR

A

D

C

A

B

B

C

D

1276 1622

Pin Orientation of the Optional MS Connector. This Part
is not Field Replaceable.

Pin orientation of the optional Packard Weather-Pack
connector. Part number K03384.

PACKARD CONNECTOR CRIMP PACKARD CONNECTOR PARTS

Crimp Location and Distance from Tang to Third Rib of
Packard Weather-Pack Connector.

BLN-95-8995-4

1077 1792

Packard Weather-Pack Interlocked Connector Halves
with Parts Identified.

6

DIMENSION A

DIMENSION A

1123

Dimension A for Selecting Correct Terminal.

WIRING

(continued)

TO ASSEMBLE THE FEMALE TOWER CONNECTOR

1. Isolate the wires that extend from the command source
to the EDC.

2. Strip back the insulation 5,5 millimeters on both wires.

3. Push a ribbed cable seal over each of the wires with the
smaller diameter shoulder of the seals toward the wire
tip. Select the pair of seals that fits tightly over the wires.
The distance from the tip of the wires of the first (nearest)
rib should be 9.5 millimeters. Thus the insulation should
just protrude beyond the seal.

4. Select the larger of the two sets of pins, as measured at
Dimension A (see the Dimension A drawing), if using
14-16 gauge wire. Choose the smaller if using 18-20
gauge. Place the wire into the socket so that the seal
edge is pushed through and extends slightly beyond the
circular tabs that hold it in place. Crimp in the locations
shown in the Packard Connector Crimp drawing with a
Packard 12014254 crimp tool. The distance from the

MOUNTING

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1

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Exercise care when placing the valve on a surface before
mounting on a transmission. Dropping or otherwise force­fully setting the valve down may damage the pin.

WARNING

back of the tangs to the furthest rib may not exceed
19,5 mm.

5. Manually insert the assembled wires into the back end
(large hole) of the plastic housing. Push until the wire
detents with an audible click, then pull back slightly to
ensure proper seating (Observe the proper phasing of
the wires when installing: Black wire to “A” hole, Red
wire to “B”, Black to “C” and Red to “D”). Terminals may
be removed from the connector bodies with a Packard
12014012 removal tool.

6. Swing the holder down into the detented position to trap
the wires in the housing. The third rib should be sealed
into the housing.

7. Plug the shroud connector from the valve into the tower
connector just constructed. They are sealed with a
quadruple plug seal over the quadruple barrel of the
tower assembly. The two connector halves should
detent into each other. See the Packard Connector
Parts drawing.

required because of the different lengths. To help avoid a
mounting problem it may be necessary to order an EDC
mounting kit. See Ordering Information.

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WARNING

Before mounting the MCV111B, remove the manual control
or the blanking plate that comes with the pump. First thor­oughly clean all external surfaces of the pump with steam or
solvent. Then remove the six hex head cap screws from the
housing using a 5 mm internal hex wrench. Lift the manual
control or plate from the pump.

Before the new control is installed it is recommended that a
new mounting gasket be installed. If going from a manual
control to an EDC the same mounting bolts can be used. If
going from a blanking plate to an EDC new mounting bolts are

The MCV111B EDC cannot be hydraulically connected
with another device through the servo ports (X1 and X2).
Do not disconnect the SAE servo port fittings for this
purpose. Doing so may cause the EDC to go on stroke.
The fittings are to be used only for troubleshooting
purposes. When hydraulic connections are required,
such as for a staging function, the MCV111
used. Also an orifice (Danfoss orifice fitting
part number 9002875-0039) must be located in each of
the hydraulic connections. See Ames Bulletin No. 9104
for details.

7

C must be

BLN-95-8995-4

MOUNTING

4

4

4

4

4

4

4

(continued)

TO INSTALL THE NEW CONTROL

1. Place a new gasket on the pump housing. Ensure that
the control orifice and spring are in the proper position in
the control.

2. Engage the pin on the control linkage in the mating hole
in the link attached to the swashplate. To ensure that
linkage is engaged before adding mounting bolts simply
place a finger under the electrical input connection and
lightly lift. If the control moves more than 3/8-inch the pin
is not engaged. Try again. See the Control Linkage
Assembly photograph.

3. Ensure that the pin is engaged in the link by tilting the
control upwards from the pilot valve end. If the pin

CONTROL LINKAGE ASSEMBLY

catches in the link and allows only a slight upward tilt,
there is positive engagement. If the control swings up
freely, the pin is not properly aligned.

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WARNING

Ensure positive pin engagement. Failure to do so may
result in pump output, and the vehicle may move.

4. Position the control into place against the pump housing.
Align the gasket. Install the cap screws (On 42 cc and
180/250 cc pumps use the included seal washer per
the Seal Washer Location drawing) and torque to 10-12
ft-lbs.

SEAL WASHER LOCATION

1394 1396

Assembly of Control Linkage.

PUMP NEUTRAL ADJUSTMENT

Use the following procedure to bring the pump to neutral
once the electrical displacement control has been mounted.

1. Install a 600 psi gauge into the charge pressure gauge
port on the pump. See the Pump Port Location
photograph.

2. Using a 10 mm wrench, loosen the hex lock nut on the
null adjustment screw. See the Dimension drawings.

SEAL WASHER
(USED ON 42, 180, AND
250 cc MODELS ONLY)

Location of Seal Washer on 42, 180, and 250 cc
Pump EDCs.

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WARNING

To adjust neutral requires operating the pump. Take the
necessary safety precautions, such as having
unnecessary personnel stand away from the machine.
Maximum system pressure may occur upon start-up,
and the machine may move. Ensure that the operator is
not in a position to be injured should the machine move.

3. Disconnect the electrical source at the connector.

4. Start the prime mover and run at low idle.

BLN-95-8995-4

5. Warm the system up for several minutes to bleed air.

6. Slowly increase the prime mover speed to rated rpm.

8

PUMP NEUTRAL ADJUSTMENT

(continued)

7. If the transmission operates as indicated by motor shaft
rotation, reduce speed to idle. Using a 3 mm internal hex
wrench, slowly turn the null adjustment screw clockwise
or counterclockwise until the transmission does not
operate. Repeat step 6. Note that charge pressure
should drop with forward or reverse stroking of the pump
swashplate due to the shifting of the shuttle valve in the
motor manifold. Slowly turn the null adjustment screw
clockwise until charge pressure decreases.

8. With a 3 or 4 mm (4 mm units built after April 95) internal
hex wrench, slowly turn the null adjustment screw
counterclockwise, observing the wrench angle rotation,
until charge pressure decreases again (charge pressure
will rise in neutral and drop when going into stroke).

9. Turn the adjustment screw clockwise half the amount of

PUMP PORT LOCATION

the turn observed in step 8. This should be the center of
neutral.

10. Hold the adjustment screw and securely tighten the hex
lock nut on the adjustment screw to 14-18 foot-pounds.
Note that if a motor is used that does not have a manifold,
neutral should be adjusted (steps 8 - 10) by observing
the motor shaft rotation without a load.

11. Stop the prime mover.

12. Reconnect the electrical signal source.

13.Run the system briefly to ensure that it operates
proportionally on both sides of null. Swashplate
movement can be verified by watching motor shaft
rotation without a load.

CASE DRAIN

Location of Pump Ports.

CUSTOMER SERVICE

NORTH AMERICA

ORDER FROM

Danfoss (US) Company
Customer Service Department
3500 Annapolis Lane North
Minneapolis, Minnesota 55447
Phone: [phone]
Fax: [phone]

DEVICE REPAIR

For devices in need of repair or evaluation, include a
description of the problem and what work you believe
needs to be done, along with your name, address and
telephone number.

CHARGE PRESSURE
GAUGE PORT

2000

EUROPE

ORDER FROM

Danfoss (Neumünster) GMBH & Co.
Order Entry Department
Krokamp 35
Postfach 2460
D-24531 Neumünster
Germany
Phone: [phone]
Fax: [phone]

RETURN TO

Danfoss (US) Company
Return Goods Department
3500 Annapolis Lane North
Minneapolis, Minnesota 55447

9

BLN-95-8995-4