Danfoss PVE-EX Ex User guide
Technical Information
Electrohydraulic Actuators for PVG32,
PVG100 and PVG120
PVE-EX Ex db version
powersolutions.danfoss.com
Technical Information
Electrohydraulic Actuators PVE-EX
Revision history Table of revisions
Date Changed Rev
October 2017 Major revision 0102
January 2017 First edition 0101
2 | © Danfoss | October 2017 BC00000393en-US0102
Technical Information
Electrohydraulic Actuators PVE-EX
Contents
General information
PVE-EX Introduction........................................................................................................................................................................ 5
Literature Reference........................................................................................................................................................................5
Product Certification....................................................................................................................................................................... 5
Protection............................................................................................................................................................................................5
Warnings..............................................................................................................................................................................................5
Nameplate Description (PVE-EX db version)..........................................................................................................................7
Description of the EX Code (PVE-EX db).................................................................................................................................. 8
EPL / Equipment Category............................................................................................................................................................ 8
Functionality
PVE-EX functionality........................................................................................................................................................................9
PVE hydraulic subsystems........................................................................................................................................................9
PVE-EX control
PVE-EX: PVE control by voltage.................................................................................................................................................10
PVE-EX ON/OFF activation..........................................................................................................................................................10
PVE-EX: PVE hysteresis..................................................................................................................................................................11
Specifications
7-pin Layout.....................................................................................................................................................................................12
4-Pin layout...................................................................................................................................................................................... 12
Radiometric Control Signal........................................................................................................................................................ 12
Radiometric Fixed Control Signal (0-10 V)............................................................................................................................ 12
Radiometric Control Signal – On/Off Activation.................................................................................................................13
Adjustment/calibration............................................................................................................................................................... 13
Technical data
Fluid specification..........................................................................................................................................................................14
PVE-EX electrical data...................................................................................................................................................................14
Reaction times.................................................................................................................................................................................15
Adjustment/calibration............................................................................................................................................................... 15
Installation
PVE-EX Dimensions ...................................................................................................................................................................... 16
Mounting of PVE-EX......................................................................................................................................................................16
Cable...................................................................................................................................................................................................17
Mounting of Cable................................................................................................................................................................... 17
Cable Gland......................................................................................................................................................................................18
Supplied Built-in Cable Gland..............................................................................................................................................18
PVE-EX Pre-certified Cable Gland........................................................................................................................................18
Mounting of PVG............................................................................................................................................................................19
Mounting options and guidelines......................................................................................................................................19
Direction of cable exit.............................................................................................................................................................20
Safety and monitoring
Safety in application..................................................................................................................................................................... 21
Safety guidelines............................................................................................................................................................................21
PVE-EX fault monitoring and reaction....................................................................................................................................22
Control signal monitoring.....................................................................................................................................................22
Transducer supervision.......................................................................................................................................................... 22
Supervision of spool position...............................................................................................................................................22
PVE-EX fault monitoring.........................................................................................................................................................23
Direction indication feedback (-DI)......................................................................................................................................... 23
Internal and external earth-connection
Earthing terminals......................................................................................................................................................................... 25
Internal earth-connection...........................................................................................................................................................25
External earth-connection..........................................................................................................................................................26
Maintenance, service, troubleshooting
PVE-EX installation, start-up, and operation ....................................................................................................................... 27
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Technical Information
Electrohydraulic Actuators PVE-EX
Contents
Warnings
PVE-EX warnings.............................................................................................................................................................................28
Code numbers
PVE-EX Ex part numbers..............................................................................................................................................................29
Declaration of confromity
EC-Declaration of Conformity....................................................................................................................................................30
Certificates
EU-Type Examination Certificate..............................................................................................................................................32
IECEx Certificate of Conformity.................................................................................................................................................35
Safety certificate J2014084.........................................................................................................................................................39
Safety certificate J2014085.........................................................................................................................................................40
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Technical Information
Electrohydraulic Actuators PVE-EX
General information
PVE-EX Introduction
The Danfoss PVE-EX is a PVE series 7 actuator for PVG32, PVG100 and PVG120.
The PVE-EX is an explosion proved PVE designed to be used in harsh environments like mining and oil
and gas industries.
The PVE-EX has been certified by NEMKO, IECEx and MA.
Literature Reference
Literature reference for PVG and PVE products
Title Type Order number
PVG 32 Proportional Valve Groups Service Manual 11039167
PVG 100 Proportional Valve Groups Service Manual 11048807
PVG 32 Proportional Valve Groups Technical Information 520L0344
PVG 100 Proportional Valve Groups Technical Information 520L0720
PVG 120 Proportional Valve Groups Technical Information 520L0356
PVG 32 Metric ports Technical Information 11051935
Product Certification
The PVE-EX db version is developed according to and in compliance:
•
EN ISO 4413:2010 Hydraulic fluid power - General rules and safety requirements for systems and their
components
•
EN 60079-0:2012/A11:2013, IEC 60079-0:2011 Explosive atmospheres - Part 0: Equipment - General
requirements
•
EN/IEC 60079-1:2014 Electrical apparatus for explosive gas atmospheres-part 1: Flameproof
enclosures “d”
Installation and Maintenance standards:
•
EN/IEC 60079-14 Explosive atmospheres - Part 14: Electrical installations design, selection and
erection
•
EN/IEC 60079-17 Explosive atmospheres - Part 17: Electrical installations inspection and maintenance
The PVE-EX is in conformity with listed EU Directive(s):
•
EMC Directive 2004/108/EC
•
EN/IEC 61000-6-2:2005 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity
for industrial environments
•
EN 61000-6-4:2007/A1:2011, IEC 61000-6-4:2006 Electromagnetic compatibility (EMC) - Part 6-4:
Generic standards - Emission standard for industrial environments
Protection
All PVE-EX modules comply with protection class IP66 and IP69k according to EN60529. However, in
particularly exposed applications, protection in the form of shielding is recommended.
Warnings
Before implementing actuators in any application, read all warnings.
Warnings are listed next to the most relevant section and repeated in Warnings chapter.
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Technical Information
Electrohydraulic Actuators PVE-EX
General information
Do not regard the warnings as a full list of potential dangers. Depending on the application and use,
other potential dangers can occur.
Warning
All brands and all types of directional control or proportional valves, which are used in many different
operation conditions and applications, can fail and cause serious damage.
Analyze all aspects of the application. The machine builder/system integrator alone is 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 directives EN
13849 (Safety related requirements for control systems).
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V310 459
Danfoss
6430 Nordborg, Denmark
Type PVEx-yy-EX
111xxxxx wwyyd47xxxx
Ta -40° to + 60°C xx-yyVDC
Ex db I Mb
0470
Ԑx
I M 2
Presafe 14ATEX5153X Thread:
IECEx PRE14.0008X "M20"
MA: J201408x
10
8
7
4
3
1
9
6
2
5
Danfoss
6430 Nordborg, Denmark
Type PVEx-yy-ZZ
111xxxxx wwyyd47xxxx
Ta -40° to + 60°C xx-yyVDC
Ex db IIB T5 Gb
0470 Ԑx
II 2G
Presafe 14ATEX5153X Thread:
IECEx PRE14.0008X "M20"
MA: J201408x
10
8
7
4
3
1
9
6
2
5
Technical Information
Electrohydraulic Actuators PVE-EX
General information
Nameplate Description (PVE-EX db version)
PVE-EX Ex db version, Group I (left) and Group II (right)
Nameplate legend
Number Description
1 PVE-EX type, see the table below.
2 Part Number Example: 111xxxxx
3
4 Supply voltage
5 Ambient temperature range
6 Notified body Example: NEMKO/Presafe
7
8
9 Ex Certificate Number
Production date and serial number
IECEx Equipment Group and protection category X-marking
ATEX Equipment Group and protection category X-marking
10 Thread Threaded entry: M20 x 1.5
PVE-EX Ex db types with part numbers, Group I and Group II
Type Part No. Type Part No.
PVEO-EX-12V 11156462 PVEO-EX-24V 11156467
PVEO-EX-24V 11123165 PVEH-EX 11156463
Group I Group II
Example: 42 12 C xxxxxx
Week: 42 Year: 2012 Day: C=Wednesday (A=Monday) serial Number
Specific conditions for safe use (“X”-mark)
Originally supplied “SD cable glands” may not provide sufficient
clamping. User shall provide additional clamping of the cable to
ensure that pulling and twisting is not transmitted to the
terminations.
Determined temperature at entry point is +76º C, use appropriate
cables and cable gland
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Technical Information
Electrohydraulic Actuators PVE-EX
General information
PVE-EX Ex db types with part numbers, Group I and Group II (continued)
Type Part No. Type Part No.
PVEO-DI-EX-24V 11156461 PVES-EX 11156464
PVEH-DI-EX 11127696 PVEH-U-EX 11156465
PVEH120-DI-EX 11166357 PVES-U-EX 11156466
PVEO120-DI-EX-12V 11170401 PVES120-U-EX 11156568
Description of the EX Code (PVE-EX db)
IEC marking of the EX code db version
Description IEC Marking
Explosion protection marking Ex
Protection type db
Equipment Group I IIB
T-class N/A T5
Equipment Protection Level (EPL) Mb Gb
Group I Group II
PVEO120-EX-24V 11156468
PVES120-EX 11156567
PVEH120-EX 11161000
EPL / Equipment Category
EU marking of the EX code db version
Description EU Marking
CE conformity marking CE
Identification number of notified body involved in production control stage 0470
Explosion protection marking
Equipment Group I II
Equipment Category M2 2G
EPL/Equipment Category
Definition
Mines
Gas atmospheres
Level of
protection
very high N/A Ma
high Mb M2
very high 0 Ga
enhanced 2 Gc 3G
Typical zone of
application
EPL Group Category Group
IEC EU
I
II
M1
1G
I
IIhigh 1 Gb 2G
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Pp
NC3
NC1
Spool
NO4
NO2
Tank
LVDT
Set point
V310073.A
1.0 [0.039]
Electronics
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Technical Information
Electrohydraulic Actuators PVE-EX
Functionality
PVE-EX functionality
The PVE-EX is an electro mechanical device, meaning that functionality is depending on mechanical,
hydraulic, electrical and control conditions given by PVE, PVG, application and vehicle. The result of this is
that implementing operation and safety conditions also must include vehicle specific considerations.
PVE hydraulic subsystems
The hydraulic subsystem is used for moving the spool and thereby open the valve for work flow.
Pilot oil diagram
The hydraulic subsystem moves the spool and thereby opens the valve for work flow. The heart in the
hydraulic subsystem is the solenoid valve bridge which controls the Pilot Pressure (Pp) on spool ends. It
consist of four poppet valves, the two upper are normally closed (NC) and the two lower are normally
open (NO).
The Pp will work against the PVBS neutral spring when the spool is moved out of blocked (neutral) and
together with the spring when going in blocked. This combined with a larger opening in the NO than in
the NC will give a faster movement towards blocked than out of blocked.
When the PVE is powered the solenoids are all put in closed state. To move the PVBS to the right NC1 and
NO4 are opened and NC3 and NO4 are kept closed.
The activation of the solenoid valves represents oil consumption and thereby also a pressure drop in the
pilot oil gallery. By simultaneous use of multiple PVE the Pp can fall and result in performance problems.
The two check valves next to the NO are anti-cavitation valves. The orifice to tank reduces tank pressure
spikes and can also be used for ramp function.
Warning
Obstacles for the Pilot oil pressure (Pp) can have direct influence on spool control. Reduced Pp will limit
spool control. Too high Pp can harm the PVE.
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PVEU
fixed
7.5V
5V2.5V
kwa1463778286972
Technical Information
Electrohydraulic Actuators PVE-EX
PVE-EX control
PVE-EX: PVE control by voltage
PVE characteristic – control by voltage
PVE-EX ON/OFF activation
The PVEO has two independent powered sets of solenoids. By powering a set of pins the actuator is
activated. By standard mounted PVE the A set gives full flow on A port and B gives on B port. Both
directions activated at same time will keep the spool in neutral.
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kwa1464034339820
Technical Information
Electrohydraulic Actuators PVE-EX
PVE-EX control
PVEO schematic and characteristic
Warning
The PVEO is designed to have UDC=12 V or UDC=24 V.
The solenoids might be activated by voltage down to 6 V.
PVE-EX: PVE hysteresis
The controllability of the PVE depends on the solenoid valve bridge and the electronic capacity of the
module. Hysteresis is a measurement on spool position precision and repeatability. Hysteresis is not a
description of position maintaining.
PVES (left) and PVEH (right) position diagrams
The PVES has an ASIC closed loop circuit and NC-S solenoids.
The PVEH has an ASIC closed loop circuit and NC solenoids.
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1 2 3 4 5 6 7
1 2 3 4
Technical Information
Electrohydraulic Actuators PVE-EX
Specifications
7-pin Layout
7-pin connector
4-Pin layout
4-Pin connector, Group II
Radiometric Control Signal
Versions Pin 1 Pin 2 Pin 3 Pin 4
PVEO-EX-24V, PVEO120-EX-24V UDC-A UDC-B GND —
PVEH/-EX/-U-EX, PVES/-EX/-U-EX, PVES120/-EX/-U-EX, PVEH120-EX U
V
s
bat
GND Error
Radiometric control signal for PVEH/PVES
PIN Function of the pin Versions
1 U
2 V
S
bat2
3 GND Ground
4 Error Error pin (See PVE-EX fault monitoring on page 23)
5 GND DI-A Signal low when spool is stroked to A side (Only for DI versions)
6 GND DI-B Signal low when spool is stroked to B side (Only for DI versions)
7 V
*
Pin 2 and 7 shall be connected together for PVE modules without the DI function.
bat
*
Demand signal
Supply voltage to solenoid valves (can be switched off separately)
Supply voltage to DI versions
PVES-EX
PVEH-EX
PVES120-EX
PVEH120-EX
PVEH-DI-EX
PVEH120-DI-EX
Signal voltage (US) Control
Neutral Q: P → A Q: P → B
US = 0.5 • U
DC
US = (0.5 → 0.25) • U
DC
US = (0.5 → 0.75) • U
DC
Radiometric Fixed Control Signal (0-10 V)
Radiometric control signal for PVEH/PVES
PIN Function of the pin Versions
1 U
2 V
S
bat
3 GND Ground
Demand signal
Supply Voltage
PVEH-U
PVES-U-EX
PVES120-U-EX
4 Error Error pin (See PVE-EX fault monitoring on page 23)
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Technical Information
Electrohydraulic Actuators PVE-EX
Specifications
Signal voltage (US) Control
Neutral Q: P → A Q: P → B
US = 5 V US = 5 V → 2.5 V US = 5 V → 7.5 V
Radiometric Control Signal – On/Off Activation
Radiometric control signal for PVEO versions
PIN Function of the pin Versions
1 UDC(A) Input signal direction A
2 UDC(B) Input signal direction B
3 GND Ground
4 GND Ground
5 DI-A Signal low when spool is stroked to A side (Only for DI
6 DI-B Signal low when spool is stroked to B side (Only for DI
7 V
bat
versions)
versions)
Supply voltage to DI versions
PVEO-EX-12V
PVEO-EX-24V
PVEO-DI-EX-24V
PVEO120-EX-24V
PVEO120-DI-EX-12V
Adjustment/calibration
Signal voltage Control
Signal voltage Neutral Q: P → A Q: P → B
A 0 UDC (A) 0
B 0 0 UDC (B)
The PVE-EX is pre-calibrated from the factory to be inside the dead band of the proportional valve. The
position sensor built into the PVE-EX cannot be adjusted by user. Any biasing of the position has to be
incorporated in the demand signal.
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Technical Information
Electrohydraulic Actuators PVE-EX
Technical data
Fluid specification
The following data is from typical test results. Mineral based hydraulic oil with a viscosity of 21 mm2/s
[102 SUS] and a temperature of 50 °C [122 °F] was used for the hydraulic system testing.
Warning
The PVE is designed for use with pilot oil supply. Use without oil supply can harm the system.
Intermission is no longer than 5 seconds and not more than once per minute.
Oil consumption
Supply voltage Pilot oil flow per
Without Neutral 0 0 0
With Locked 0.1 0.1 0.1
Oil viscosity, Oil temperature and Pilot pressure
Parameter Minimum Maximum Range
Oil viscosity
Oil temperature
Pilot pressure (relative to T pressure)
Intermittent pressure peaks up to
PVE-EX Function
Actuating 0.7 0.7 0.8
PVEO Versions PVEH Versions PVES Versions
l/min l/min l/min
4 mm2/s
[39 SUS]
-30 ˚C
[-22 ˚F]
10 bar
[145 psi]
– 50 bar [725 psi] –
460 mm2/s
[2128 SUS]
90 ˚C
[194 ˚F]
15 bar
[217 psi]
12 - 75 mm2/s
[65 - 347 SUS]
30 to 60 ˚C
[86 to140 ˚F]
Nominal 13.5 bar
[196 psi]
PVE-EX electrical data
Filtering in the hydraulic system
Required operating cleanliness level (ISO 4406, 1999 version)
Specification PVEO Versions PVEH and PVES Versions
Grade of enclosure EN 60529 IP 66 and IP 69k
Ambient temperature Minimum -40 °C [-40 °F]
Maximum 60 °C [140 °F]
Maximum (submitting) surface temperature, T5 100 °C [212 °F]
Supply voltage Rated 12 / 24 V
Range PVEx-EX-12V 11-16 V
Range PVEx-EX-24V 22-30 V
Maximum ripple 5% 5%
Current consumption at
rated voltage (12/24 VDC)
Power consumption at rated voltage 9 W 7 W
Current via DI 0.1 A 0.1 A
Input impedance in relation 0.5 x U
Fault monitoring Maximum load N/A 60 mA
Typical 0.74 A / 0.37 A 0.57 A / 0.33 A
Minimum 0.55 A / 0.29 A N/A
Maximum 0.82 A / 0.42 A N/A
DC
Reaction time at fault N/A 500 ms
DC
DC
DC
N/A 12 kΩ
18/16/13
11-30 V
N/A
N/A
DC
For more information about PVEO, PVES and PVEH versions please refer to Nameplate description.
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