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

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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.

W 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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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)

	Danfoss
	6430 Nordborg, Denmark
2	Type PVEx-yy-EX			1	2
	111xxxxx	wwyyd47xxxx		3
5	Ta -40° to + 60°C		xx-yyVDC	4	5
6	0470	Ex db I Mb		7	6
			Ԑx I M 2	8
9	Presafe 14ATEX5153X		Thread:	10	9
	IECEx PRE14.0008X		"M20"
	MA: J201408x

	Danfoss
	6430 Nordborg, Denmark
	Type PVEx-yy-ZZ			1
	111xxxxx	wwyyd47xxxx		3
	Ta -40° to + 60°C		xx-yyVDC	4
	Ex db IIB T5 Gb			7
	0470		Ԑx II 2G	8
	Presafe 14ATEX5153X		Thread:	10
	IECEx PRE14.0008X		"M20"
	MA: J201408x

V310 459

Nameplate legend

Number	Description
1	PVE-EX type, see the table below.
2	Part Number	Example: 111xxxxx
3	Production date and serial number	Example: 42 12 C xxxxxx
		Week: 42 Year: 2012 Day: C=Wednesday (A=Monday) serial Number
4	Supply voltage
5	Ambient temperature range
6	Notified body	Example: NEMKO/Presafe
7	IECEx Equipment Group and protection category X-marking
8	ATEX Equipment Group and protection category X-marking
9	Ex Certificate 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.
10	Thread	Threaded entry: M20 x 1.5
		Determined temperature at entry point is +76º C, use appropriate
		cables and cable gland

PVE-EX Ex db types with part numbers, Group I and Group II

		Group I			Group II
	Type		Part No.	Type		Part No.
	PVEO-EX-12V		11156462	PVEO-EX-24V		11156467
	PVEO-EX-24V		11123165	PVEH-EX		11156463

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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)

	Group I			Group II
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
			PVEO120-EX-24V		11156468
			PVES120-EX		11156567
			PVEH120-EX		11161000

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

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

EPL/Equipment Category

Definition	Level of	Typical zone of		IEC			EU
	protection	application	EPL		Group	Category		Group
Mines	very high	N/A	Ma		I	M1		I
	high		Mb			M2
	very high	0	Ga			1G
Gas atmospheres	high	1	Gb		II	2G		II
	enhanced	2	Gc			3G

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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

Set point

Electronics

Pp

NC1

NC3

Spool

LVDT

NO4

NO2

1.0 [0.039]

Tank

V310073.A

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.

W 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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Technical Information

Electrohydraulic Actuators PVE-EX

PVE-EX control

PVE-EX: PVE control by voltage

PVE characteristic – control by voltage

					PVEU
2.5V		5V		7.5V fixed

kwa1463778286972

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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Technical Information

Electrohydraulic Actuators PVE-EX

PVE-EX control

PVEO schematic and characteristic

kwa1464035903701

W 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

kwa1464034339820

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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Technical Information

Electrohydraulic Actuators PVE-EX

Specifications

7-pin Layout

7-pin connector

1 2

3 4

5 6 7

4-Pin layout

4-Pin connector, Group II

										1			2		3				4

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	Us	Vbat	GND	Error

Radiometric Control Signal

Radiometric control signal for PVEH/PVES

	PIN		Function of the pin	Versions
	1	US	Demand signal
	2	Vbat2	Supply voltage to solenoid valves (can be switched off separately)	PVES-EX
				PVEH-EX
	3	GND	Ground
				PVES120-EX
	4	Error	Error pin (See PVE-EX fault monitoring on page 23)
				PVEH120-EX
	5	GND DI-A	Signal low when spool is stroked to A side (Only for DI versions)
				PVEH-DI-EX
	6	GND DI-B	Signal low when spool is stroked to B side (Only for DI versions)	PVEH120-DI-EX
	7	Vbat*	Supply voltage to DI versions

* Pin 2 and 7 shall be connected together for PVE modules without the DI function.

Signal voltage (US) Control

Neutral	Q: P → A	Q: P → B
US = 0.5 • UDC	US = (0.5 → 0.25) • UDC	US = (0.5 → 0.75) • UDC

Radiometric Fixed Control Signal (0-10 V)

Radiometric control signal for PVEH/PVES

	PIN		Function of the pin	Versions
	1	US	Demand signal	PVEH-U
	2	Vbat	Supply Voltage
				PVES-U-EX
	3	GND	Ground
				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	PVEO-EX-12V
	4	GND	Ground	PVEO-EX-24V
				PVEO-DI-EX-24V
	5	DI-A	Signal low when spool is stroked to A side (Only for DI
				PVEO120-EX-24V
			versions)
				PVEO120-DI-EX-12V
	6	DI-B	Signal low when spool is stroked to B side (Only for DI
			versions)
	7	Vbat	Supply voltage to DI versions

Signal voltage Control

Signal voltage	Neutral	Q: P → A	Q: P → B
A	0	UDC (A)	0
B	0	0	UDC (B)

Adjustment/calibration

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.

W 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	PVEO Versions	PVEH Versions	PVES Versions
	PVE-EX Function
		l/min	l/min	l/min
Without	Neutral	0	0	0
With	Locked	0.1	0.1	0.1
	Actuating	0.7	0.7	0.8

Oil viscosity, Oil temperature and Pilot pressure

Parameter	Minimum	Maximum	Range
Oil viscosity	4 mm2/s	460 mm2/s	12 - 75 mm2/s
	[39 SUS]	[2128 SUS]	[65 - 347 SUS]
Oil temperature	-30 ˚C	90 ˚C	30 to 60 ˚C
	[-22 ˚F]	[194 ˚F]	[86 to140 ˚F]
Pilot pressure (relative to T pressure)	10 bar	15 bar	Nominal 13.5 bar
	[145 psi]	[217 psi]	[196 psi]
Intermittent pressure peaks up to	–	50 bar [725 psi]	–

Filtering in the hydraulic system

Required operating cleanliness level (ISO 4406, 1999 version)					18/16/13
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 VDC		11-30 VDC
		Range PVEx-EX-12V	11-16 VDC		N/A
		Range PVEx-EX-24V	22-30 VDC		N/A
		Maximum ripple	5%		5%
Current consumption at		Typical	0.74 A / 0.37 A		0.57 A / 0.33 A
rated voltage (12/24 VDC)
		Minimum	0.55 A / 0.29 A		N/A
		Maximum	0.82 A / 0.42 A		N/A
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 UDC			N/A		12 kΩ
Fault monitoring		Maximum load	N/A		60 mA
		Reaction time at fault	N/A		500 ms

PVE-EX electrical data	For more information about PVEO, PVES and PVEH versions please refer to Nameplate description.
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