Danfoss PVE Series 4, PVHC User guide
Technical Information
PVE Series 4 and PVHC
Electrohydraulic Actuators
www.danfoss.com
Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
Revision history Table of revisions
Date Changed Rev
April 2020 Added note to PVE Control section, updated version number to match online
catalogue
Changed document number from 'BC00000050' to 'BC152886484010' XX
December 2018 PVEA tech data update. 0808
June 2018 edits to PVE Hysteresis and Ripple topic 0807
April 2018 Safety - minor edits 0806
March 2018 add to Code numbers - PVE accessories 0805
February 2018 Removal of line of text from page 23 0804
2006 - 2017 Various changes. 0102-0803
May 2005 First edition. 0101
0910
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
Contents
General Information
List of abbreviations for PVG/PVE...............................................................................................................................................5
Literature reference for PVG products......................................................................................................................................6
Standards for PVE............................................................................................................................................................................. 7
PVE with connector variants.........................................................................................................................................................7
Warnings..............................................................................................................................................................................................8
PVE series 4 introduction...............................................................................................................................................................8
PVE stands for PVE actuator .........................................................................................................................................................8
PVG with PVE structural layout....................................................................................................................................................9
Functionality
PVG functionality............................................................................................................................................................................11
PVE functionality............................................................................................................................................................................ 11
PVE hydraulic subsystems..................................................................................................................................................... 11
Variant of hydraulic subsystem: PVEA......................................................................................................................... 12
Variant of hydraulic subsystem: PVE with ramp.......................................................................................................13
Variant of hydraulic subsystem: PVHC.........................................................................................................................13
Mechanical subsystem............................................................................................................................................................14
Electronic subsystem...............................................................................................................................................................14
Safety
Safety and monitoring................................................................................................................................................................. 16
PVG fault monitoring and reaction.................................................................................................................................... 16
Active fault reaction is activated after 500 ms of error (PVEA: 750 ms). .........................................................16
Passive fault reaction is activated after 250 ms of error (PVEA: 750 ms).........................................................16
The solenoid valves are disabled when:..................................................................................................................... 17
Spool position feedback (-SP).............................................................................................................................................. 17
Direction indication feedback (-DI)....................................................................................................................................18
Solenoid disabling function (-NP).......................................................................................................................................18
Safety in Application.....................................................................................................................................................................19
Example of a control system for manlift...........................................................................................................................20
Examples of wiring block diagram................................................................................................................................21
PVE Control
PVE control by voltage.................................................................................................................................................................23
PLUS+1® Compliant..................................................................................................................................................................24
ATEX PVE......................................................................................................................................................................................24
PVEU–PVE with fixed control signal range......................................................................................................................24
PVE controlled with PWM signal.........................................................................................................................................24
PVEP control.....................................................................................................................................................................................25
PVEO................................................................................................................................................................................................... 26
PVE ON/OFF activation........................................................................................................................................................... 26
PVE for float spool..........................................................................................................................................................................26
There are two variants of float spool PVBS......................................................................................................................27
PVHC control....................................................................................................................................................................................28
PVE Hysteresis and Ripple...........................................................................................................................................................29
Example of PVE use....................................................................................................................................................................... 29
Technical Data
PVE operating parameters .........................................................................................................................................................32
PVHC control specification.........................................................................................................................................................33
PVEO and PVEM control specification....................................................................................................................................33
PVEA, PVEH, PVES and PVEU control specification ........................................................................................................... 34
PVEP Technical Data......................................................................................................................................................................35
PVE dimensions for PVG 32 and PVG 100..............................................................................................................................35
PVE dimensions for PVG 120......................................................................................................................................................37
PVEO pinout.....................................................................................................................................................................................39
PVEO connection............................................................................................................................................................................40
PVE standard connection data / pinout ................................................................................................................................40
PVE standard connections.....................................................................................................................................................41
Standard PVE with DI...............................................................................................................................................................42
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
Contents
Standard PVE with SP..............................................................................................................................................................42
Standard PVE with NP............................................................................................................................................................. 43
PVHC connection........................................................................................................................................................................... 43
PVE with separate float pin.........................................................................................................................................................44
PVEP with controled PWM..........................................................................................................................................................44
Warnings
PVE warnings...................................................................................................................................................................................46
Code Numbers
PVE code numbers for PVG 32 and PVG 100 use................................................................................................................47
PVE code numbers for use on PVG 120..................................................................................................................................48
PVE accessories...............................................................................................................................................................................49
Connector code numbers at other suppliers ......................................................................................................................50
PVED-CC code numbers for use on PVG 32 and PVG 100............................................................................................... 50
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
General Information
List of abbreviations for PVG/PVE
Abbreviation Description
ASIC Application Specific Integrated Circuit - the part of the PVE where spool position is controled to
ATEX Certificated for use in explosive environment
AVC Auxillery Valve Comand - ISOBUS/J1939 standard signal for valve control
AVCTO Auxillery Valve Comand Time Out - Fault monitoring setting
AVEF Auxillery Valve Estimated Flow - ISOBUS/J1939 standard signal for valve feedback
CAN Controller Area Network - Communication method used by PVED
CLC Closed Loop Circuit
CRC Cyclic Redundancy Check - Method for ensuring validity of data.
-DI PVE with Direction Indication
DM1 Diagnostic Message 1 - J1939 message informing about present fault
DM2 Diagnostic Message 2 - J1939 message informing about fault history
DM3 Diagnostic Message 3 - J1939 message clearing fault history
DSM Device State Machine. Deterministic description of system process
ECU Electronic Control Unit
EH Electrohydraulic
-F PVE for Float spool. Two variants: 4 pin with float at 75%. 6 pin with separate float.
FMEA Failure Mode Effect Analysis
ISOBUS Communication standard for CAN
J1939 Communication standard for CAN
LED Light Emitting Diode
LS Load Sensing
LVDT Linear Variable Differential Transducer - Position sensor
NC Normally Closed solenoid valve in PVE
NC-H Normally Closed standard solenoid valve in PVEH
NC-S Normally Closed solenoid valve Super in PVES
NO Normally Open solenoid valve in PVE
PLC Programmable Logical Circuit
®
PLUS+1
POST Power On Self Test. Boot up evaluation for PVED
Pp Pilot Pressure. The oil gallery for PVE actuation
PVB Proportional Valve Basic module - valve slice
PVBS Proportional Valve Basic module Spool
PVBZ Proportional Valve Basic module Zero leakage
PVE Proportional Valve Electric actuator
PVEA PVE variant with 2-6 % hysteresis
PVED PVE variant Digital controlled via CAN communication
PVEH PVE variant with 4-9% Hysteresis
PVEM PVE variant with 25-35% hysteresis
PVEO PVE variant with ON/OFF actuation
PVEP PVE variant PWM controled
PVES PVE variant with 0-2% hysteresis
PVEU PVE variant with US 0-10V
PVG Proportional multi-section Valve Group
PVHC PV variant with High Current controlled valve actuator
follow setpoint
Trademark for Danfoss controllers and programming tool
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
General Information
Abbreviation Description
PVM Proportional Valve Manual control with handle
PVP Proportional Valve Pump side module.Inlet
PVS Proportional Valve end plate
PVSK Proportional Valve end plate crane. Inlet module with Spool Control
PWM Pulse Width Modulation
S4 DJ Series 4 Digital J1939 service tool software for PVED-CC
SAE Society Automotive Engineering
-R PVE with Ramp function
-NP PVE with solenoid disable in Neutral Position
-SP PVE with Spool Position feedback
uC Microcontroller
uCSM Microcontroller State Machine
U
DC
U
S
Literature reference for PVG products
Power supply Direct Current; also called V
Steering voltage for the PVE control; also called V
for battery voltage
bat
S
Literature reference
Literature title Type Order
PVG 32 Proportional Valve Group Technical Information BC152886483
PVG 100 Proportional Valve Group Technical Information BC152886483
PVG 120 Proportional Valve Group Technical Information BC152886483
PVG 32 Metric ports Technical Information BC152886484
PVE Series 7 Technical Information BC173386484
PVE Series 4 Technical Information BC152886484
PVED-CC Electro-hydraulic actuator Technical Information 520L0665
PVED-CX Electro-hydraulic actuator Technical Information BC152886483
PVE-CI Technical Information BC163786485
Basic module for PVBZ Technical Information BC152886484
PVSK module with integrated diverter valve and P-disconnect function Technical Information BC152886484
PVPV / PVPM pump side module Technical Information BC152886484
Combination module PVGI Technical Information BC152886483
PVSP/M Priority module Technical Information BC152886484
Hitch Control System Description AB152886482
User Manual 11033753
number
664
475
344
163
192
010
682
206
167
133
316
392
066
484
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
General Information
Literature reference (continued)
Literature title Type Order
PVBZ Data Sheet AI1528864823
PVBZ-HS Data Sheet AI1528864822
PVBZ-HD Data Sheet AI1528864821
MC024-010 and MC024-012 Controllers Data Sheet AI1528864807
Standards for PVE
International Organization for Standardization ISO 13766 Earth moving machinery - Electromagnetic
•
compatibility.
EN 50014:1997 +A1, A2: 1999
•
EN 50028: 1987. For ATEX approved PVE
•
IEC EN 61508
‒
ISO 12100-1 / 14121
‒
EN 13849 (Safety related requirements for control systems)
‒
Machinery Directive 2006/42/EC” (1st Edition December 2009)
‒
number
57
19
40
85
PVE with connector variants
Hirschmann/DIN variant DEUTSCH variant AMP variant
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
General Information
Warnings
Before implementing actuators in any application, read all warnings. Warnings are listed next to the most
relevant section and repeated in the chapter PVE-EX warnings.
Do not regard the warnings as a full list of potential risks. Depending on the application and use, other
potential risks 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.
You must perform a risk assessment. 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 for choosing the control system and safety levels is governed by the Machinery Directive
2006/42/EC and EU harmonized standard EN 13849 (Safety related requirements for control systems).
PVE series 4 introduction
PVE Series 4 is the common name for the Danfoss PVG electrical actuator. This technical information
covers our voltage controlled PVE and our current controlled PVHC actuator. For the PVHC please see in
the PVHC sectionl. The digital actuators PVED-CC and PVED-CX are covered in their special technical
information.
PVE controlled PVG with PVSK
PVE stands for PVE actuator
The Danfoss PVE is built on more than thirty years experience of electrical valve control and is the perfect
fit for our high performance proportional valves PVG 32, PVG 100 and PVG 120, as it is for our EH steering.
All our products are developed in close cooperation with system manufacturers from the mobile
hydraulic market. That is the reason for our high performance in all market segments
The PVE can be controlled from a switch, a joystick, a PLC, a computer or a Danfoss PLUS+1
microcontroller. The PVE is available in multiple variants. A short list here just gives the main variations.
Available PVE variants
Actuation On/Off
Proportional - Closed loop controlled
Proportional - Direct control
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
General Information
Available PVE variants (continued)
Control signal Voltage
Precision Standard precision
Feedback Spool position
Connectors DEUTSCH
Fault detection and reaction Active
Power supply 11 V – 32 V multi-voltage
PWM
Current (PVHC)
High precision
Super high precision
Direction indicator
Error
None
AMP
DIN/Hirschmann
Passive
None
12 V
24 V
PVG with PVE structural layout
The PVG is a sectional spool valve stack with up to 12 individually controlled proportional valves. The PVG
with the PVE can be operated as single valves or several valves in cooperation. The oil flow out of the
work section (A- or B-port) can be controlled by a combination of the following:
PVE controlling the spool position using pilot oil pressure.
•
A handle (PVM) in mechanical interface with the spool.
•
PVG 32 structural lay-out with naming
Legend:
A – A-port
B – B-port
C – PVS end plate
D – PVB basic module
E – Connector Pin
T – Tank port
P – Work flow
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V310072.A
PVE
Electronics
NC Solenoid valve
Pilot oil supply
B port
Oil
A port
PVB
PVM
Neutral spring
PVBS
NO solenoid valve
LVDT
<- Retract towards PVE
Extend away from PVE ->
P -> A
Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
General Information
Valve section - standard mounted - seen from PVP with naming
Oil out of A-port → PVM pushed towards PVB → retract → LVDT moves into PVE
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V310072.A
PVE
Electronics
NC Solenoid valve
Pilot oil supply
B port
Oil
A port
PVB
PVM
Neutral spring
PVBS
NO solenoid valve
LVDT
<- Retract towards PVE
Extend away from PVE ->
P -> A
Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
Functionality
PVG functionality
This chapter will give an overview of the PVG and its functionality.
Valve section with naming - standard mounted - seen from PVP
PVE functionality
The PVG valve distributes oil from pump flow to a particular work function in the application via a specific
valve section. This is done by moving the spool (PVBS).
Depending on the choice of components the oil work flow enters the PVG through the PVP (proportional
valve pump side module) or the PVSK (proportional valve end plate for crane) and enters the PVB
(proportional valve basic module) via the P gallery and leaves through the T gallery.
In the figure above you see a valve section seen from PVP towards PVSK with the PVM and PVE standard
mounted. PVM and PVE can in general be interchanged, that is called option mounted.
With the spool in neutral, where it is kept by the neutral spring, the connection to the application via
ports is blocked.
Moving the spool towards the PVE, as in figure 4, opens a connection between P and A and also between
B and T. This is done by either pushing the PVM or sending a retract command to PVED. The PVED move
the spool by letting Pilot Oil Pressure (Pp) push on the right end of the PVBS and releasing pressure from
the left end. For details on PVG please see relevant technical information.
Any PVG with PVM can be operated by PVM alone, independent of a power supply. Any PVG with can
monitor PVBS if power and communication conditions are present.
This section has focus on how the PVE works and interacts. The description here is general and variant
specific descriptions will all refer to this.
The PVE 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.
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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
PVE Series 4 for PVG 32/100/120 and PVHC
Functionality
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.
Variant of hydraulic subsystem: PVEA
Hydraulic variant: PVEA
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
Functionality
NO2 and NO4 are replaced with orifices.
Warning
PVEA is not for use on PVG 100.
Variant of hydraulic subsystem: PVE with ramp
Hydraulic subsystem variant: PVE with ramp
Tank orifice has smaller diameter.
With electrical proportional actuation, the main spool
position is adjusted so that its position corresponds to an
electrical control signal.
The control signal is converted into a hydraulic pressure
signal that moves the main spool in the PVG. This is done
by means of two proportional pressure-reducing valves.
The electrical actuator can be controlled either by a
current amplifier card, or directly from a programmable
microcontroller.
For more information see these technical informations:
•
PVG 32 Proportional Valve Groups BC152886483664,
•
PVG 100 Proportional Valve Groups BC152886483475 and
•
PVG 120 Proportional Valve Groups BC152886483344.
Variant of hydraulic subsystem: PVHC
The PVHC does not work as a PVE and does not have transducer, anti cavitation nor protection against
tank pressure spikes. It is necessary to use the PVHC in combination with 25 bar [362.6 psi] pilot pressure,
and standard FC spools fitted for hydraulic actuation. Because of the 25 bar pilot pressure, it is not
possible to combine PVHC with PVE on a PVG.
Hydraulic subsystem variant: PVHC
With electrical proportional actuation, the main spool position is adjusted so that its position corresponds
to an electrical control signal. The control signal is converted into a hydraulic pressure signal that moves
the main spool in the PVG. This is done by means of two proportional pressure-reducing valves. The
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V310 390B
Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
Functionality
electrical actuator can be controlled either by a current amplifier card, or directly from a programmable
microcontroller.
For more information see these technical informations:
•
PVG 32 Proportional Valve Groups BC152886483664,
•
PVG 100 Proportional Valve Groups BC152886483475 and
•
PVG 120 Proportional Valve Groups BC152886483344.
Mechanical subsystem
The mechanical subsystem gives interface to valve and control system and provides protection to
hydraulic and electrical/electronic subsystem. The LVDT, not used on all variants, gives feed back to
electronics on spool position. The LVDT is calibrated in production and recalibration should only be done
in special cases. The standard PVE has an aluminum block for distributing pilot oil. PVE with anodized
block are available.
The connector gives the electrical interface to power and control system. Danfoss have a variety of
connectors. We know that tradition and the aspects of serviceability are important when our customers
choose. We have chosen the Deutsch connector as our main solution. The quality of wiring has direct
influence on water integrity and signal quality therefore disturbance or changes in cabling can influence
safety and performance.
PVE connectors: Hirschmann/DIN, AMP and Deutsch
Electronic subsystem
The PVE (A/H/M/S/U) control signal is a low current voltage, a PWM can also be used. The PVEP has buildin a PWM evaluation and cannot be controlled by proportional voltage. The control signal is referred to as
US.
Function blocks for electronics
The PVE features Closed Loop Control (CLC). This is made possible by on board electronics and an
integrated feedback transducer that measures spool movement. The integrated electronics compensate
for flow forces on the spool, internal leakage, changes in oil viscosity, pilot pressure, etc. This results in
lower hysteresis and better resolution.
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
Functionality
In principle the set-point determines the level of pilot pressure which moves the main spool. The position
of the main spool is sensed in the LVDT which generates an electric feed-back signal registered by the
electronics. The variation between the set-point signal and feed-back signal actuates the solenoid valves.
The solenoid valves are actuated so that hydraulic pilot pressure drives the main spool into the correct
position.
The LVDT (Linear Variable Differential Transducer) is an inductive transducer with very high
resolution. When the LVDT is moved by the main spool a voltage is induced proportional to the spool
position. The use of LVDT gives contact-free connection between mechanics and electronics. This means
an extra long lifetime and no limitation as regards the type of hydraulic fluid used.
The PVEO and PVHC do not have embedded control electronics and do not support closed loop control.
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Technical Information
PVE Series 4 for PVG 32/100/120 and PVHC
Safety
Safety and monitoring
The choice of PVE also decides the level of feedback and safety. PVE are available with fault monitoring,
spool direction indication, spool position feedback and separate float control.
The fault monitoring is available in PVEA/H/S/P/U and is a utilization of the ASIC.
Direction Indication is available in PVEO/A/H and they are dual powered PVE where separate pins give an
active feedback for spool movement.
Spool position is available in PVES and is a precise feedback on a separate pin for actual spool position.
The separate float control is a protection against unintended float activation.
The PVEM, PVEO and PVHC do not have fault monitoring.
PVG fault monitoring and reaction
The fault monitoring system is available in two versions:
Active fault monitoring provides a warning signal and deactivates the solenoid valves. A reboot of the
•
PVE is required to reactivate.
Passive fault monitoring provides a warning signal only. A reboot is not required.
•
Both active and passive fault monitoring systems are triggered by the same four main events:
1.
Control signal monitoring
The Control signal voltage (US) is continuously monitored. The permissible range is between 15% and
85% of the supply voltage. Outside this range the section will switch into an error state. A
disconnected US pin (floating) is recognized as neutral set point.
2.
Transducer supervision
The internal LVDT wires are monitored. If the signals are interrupted or short-circuited, the PVE will
switch into an error state.
3.
Supervision of spool position
The actual position must always correspond to the demanded position (US). If the actual spool
position is further out from neutral than the demanded spool position or in opposite direction, the
PVE will switch into an error state. Spool position closer to neutral and in same direction will not
cause an error state. The situation is considered “in control”.
4.
Float monitoring
Float must be entered or left within a time limit. On the six pin float PVE too high delay will cause an
error state. The float Time Outs has own thresholds. Only relevant for the six pin PVEH-F.
Active fault reaction is activated after 500 ms of error (PVEA: 750 ms).
The solenoid valve bridge is disabled and the PVBS is released to spring control
•
The error pin is powered*
•
The LED change color
•
The state is memorized and continues until PVE reboot
•
Passive fault reaction is activated after 250 ms of error (PVEA: 750 ms)
The solenoid valve bridge is NOT disabled and the PVBS is NOT released
•
The error pin is powered ( for PVE with direction indication both DI pins goes low by fault.)
•
The LED change color
•
The state is active for minimum 100 ms and is reset when error disappears
•
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