Danfoss PVG 120 User guide

Technical Information

Proportional Valve Group

PVG 120

powersolutions.danfoss.com

Technical Information

PVG 120 Proportional Valve Group

Revision history	Table of revisions
	Date	Changed	Rev
	March 2017	minor updates	1002
	Mar 2014	Chapters re-order, Modules selection chart	JA
	Dec 2013	Converted to Danfoss layout – DITA CMS	ID
	2006 - 2012	Various updates	AB - IC
	Apr 2006	New edition	AA

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Technical Information

PVG 120 Proportional Valve Group

Contents

Literature reference for PVG products

General Information

	Valve System......................................................................................................................................................................................	6
	General Characteristics...................................................................................................................................................................	6
	Pump Side Module – PVP..............................................................................................................................................................	6
	Basic Module – PVB..........................................................................................................................................................................	7
	Actuation Modules...........................................................................................................................................................................	7
	Electronic Accessories.....................................................................................................................................................................	7
	Remote Controls Units....................................................................................................................................................................	8
Function
	PVG 120 with PVP Open Center..................................................................................................................................................	9
	PVG 120 with PVP Closed Center................................................................................................................................................	9
PVG 120 sectional view
Safety in application
	Control system example..............................................................................................................................................................	12
	Examples of wiring block diagram.....................................................................................................................................	14
Technical Data
	PVG 120 technical data................................................................................................................................................................	16
	PVM, mechanical actuation........................................................................................................................................................	16
	PVH, hydraulic actuation.............................................................................................................................................................	17
	PVE, electrical actuation .............................................................................................................................................................	17
	PVPE, electrical relief valve, normally open..........................................................................................................................	17
Electrical Actuation
	PVEO, ON-OFF.................................................................................................................................................................................	19
	PVEH, proportional high..............................................................................................................................................................	19
	PVEH, Inductive Transducer (LVDT – Linear Variable Differential Transformer)................................................	20
	PVEH, Pulse Width Modulation (Integrated)...................................................................................................................	21
	PVEH fault monitoring..................................................................................................................................................................	21
	PVEH, connection to fault monitoring output...............................................................................................................	22
Technical Characteristics
	General...............................................................................................................................................................................................	23
	PVP, pump side module..............................................................................................................................................................	23
	PVB, Basic Module..........................................................................................................................................................................	24
	PVLP, Shock Valve Characteristic (with Pressure Relief Valve).......................................................................................	26
	PVLP/PVLA, Suction Function....................................................................................................................................................	27
Hydraulic system examples
	Example of PVG 120 with variable displacement pump..................................................................................................	28
	Example of PVG 120 with fixed displacement pump........................................................................................................	29
Other operating conditions
	Hydraulic fluids for PVG...............................................................................................................................................................	30
	Particle Content, Degree of Contamination.........................................................................................................................	30
	Filtering..............................................................................................................................................................................................	30
	Conversion Factors........................................................................................................................................................................	31
Dimensions
	PVG 120 dimensions.....................................................................................................................................................................	32
	PVM, Lever Positions.....................................................................................................................................................................	34
Modules and Code Numbers
	PVP and PVPV, Pump Side Modules .......................................................................................................................................	35
	PVP, Accessories for Open Center Pump Side Modules...................................................................................................	35
	PVB, Basic Modules........................................................................................................................................................................	36
	PVB, Accessories for Basic Modules ........................................................................................................................................	36
	PVLA, Suction Valve.......................................................................................................................................................................	37
	PVLP, Shock and Suction Valves for A/B Port Connections............................................................................................	37
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Technical Information
PVG 120 Proportional Valve Group
Contents
PVBS, Main Spools..........................................................................................................................................................................	38
PVM, Mechanical Actuation.......................................................................................................................................................	38
PVMD, Cover for Mechanical Actuation.................................................................................................................................	38
PVH, Hydraulic Actuation............................................................................................................................................................	38
PVHC, High Current Actuator.....................................................................................................................................................	39
PVE, Electrical Actuation..............................................................................................................................................................	39
PVT, tank side module..................................................................................................................................................................	39
PVAS, Assembly Kit........................................................................................................................................................................	40
PVG 120 Modules Selection Chart
PVG 120 module selection chart..............................................................................................................................................	41
Order specification
Ordering of modules for oil flow exceeding 180 l/min [47.6 US gal/min].................................................................	45
Order Form.......................................................................................................................................................................................	45
Reordering...................................................................................................................................................................................	46

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Technical Information

PVG 120 Proportional Valve Group

Literature reference for PVG products

Literature reference

Literature title	Type	Order
		number
PVG 32 Proportional Valve Group	Technical Information	520L0344
PVG 100 Proportional Valve Group	Technical Information	520L0720
PVG 120 Proportional Valve Group	Technical Information	520L0356
PVG 32 Metric ports	Technical Information	11051935
PVE Series 4	Technical Information	520L0553
PVED-CC Electro-hydraulic actuator	Technical Information	520L0665
PVED-CX Electro-hydraulic actuator	Technical Information	11070179
PVE-CI	Technical Information	L1505234
Basic module for PVBZ	Technical Information	520L0721
PVSK module with integrated diverter valve and P-disconnect function	Technical Information	520L0556
PVPV / PVPM pump side module	Technical Information	520L0222
Combination module PVGI	Technical Information	520L0405
PVSP/M Priority module	Technical Information	520L0291
Hitch Control	System Description	11036124
	User Manual	11033753
PVBZ	Data Sheet	520L0681
PVBZ-HS	Data Sheet	520L0956
PVBZ-HD	Data Sheet	11035599
MC024-010 and MC024-012 Controllers	Data Sheet	520L0712

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Technical Information

PVG 120 Proportional Valve Group

General Information

Valve System

Load sensing proportional valve type PVG 120 is a combined directional and flow control valve which is supplied as a valve group consisting of modules specified to match particular customer needs. The flexible nature of this valve will allow an existing valve bank to be easily adapted to suit changes in requirements.

General Characteristics

•Load-independent flow control:

‒Oil flow to an individual function is independent of the load of this function

‒Oil flow to one function is independent of the load pressure of other functions

•Good regulation characteristics

•Central pilot supply built in when the valves are actuated electrohydraulically

•Energy-saving

•Up to eight basic modules per valve group

Pump Side Module – PVP

•Built-in pressure relief valve

•System pressure up to 400 bar [5800 psi]

•Pressure gauge connection

•Versions:

‒Open centre version for systems with fixed displacement pumps

‒Open centre version prepared for an extra relief module

‒Closed centre version for systems with variable displacement pumps

‒Closed centre version without system pressure relief valve for variable displace ment pumps with built-in pressure relief valve.

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Technical Information

PVG 120 Proportional Valve Group

General Information

Basic Module – PVB

•Integrated pressure compensator in channel P

•Interchangeable spools

•Depending on requirements the basic module can be supplied with:

‒Shock/suction valves

‒Adjustable LS pressure limiting valve for ports A and B

‒LS connection

‒Module for oil flows exceeding 180 l/min [47.6 US gal/min]

‒Different spool variants

Actuation Modules

The basic module is always fitted with mechanical actuation PVM, which can be combined with the following as required:

•Electrical actuation:

‒PVEH - proportional, high performance (11 - 32 V )

‒PVEO - On/off (12 V == or 24 V ==)

•Cover for hydraulic remote control, PVH

•Cover for mechanically actuated valve group, PVMD

Electronic Accessories

•EHF, low adjustment unit

•EHR, ramp generator

•EHS, speed control

•EHSC, closed loop speed control

•EHA, alarm logic

•EHC, closed loop position control

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Technical Information

PVG 120 Proportional Valve Group

General Information

Remote Controls Units

PVRE, electrical control unit, 162F…

PVRH, hydraulic control unit, 155N…

155N0003 155N0001 155N0004 155N0005 155N0002

PVREL, electrical control unit, 155U… PVRES, electrical control unit, 155B…

Prof 1, 162F…

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Technical Information

PVG 120 Proportional Valve Group

Function

PVG 120 with PVP Open Center

When the pump is started and the main spools (1) in the individual basic modules are in neutral position, oil flows from the pump, through connection P, across the pressure adjustment spool (2) to tank.

The oil flow led across the pressure adjustment spool determines the pump pressure (stand-by pressure). If a reduced stand-by pressure is required, an extra relief valve PVPH or PVPE can be used in PVP.

When the main spools are actuated the highest load pressure is distributed across the shuttle valve circuit (3) to the spring chamber behind the pressure adjustment spool (2) and completely or partly closes the connection to tank.

The pump pressure is applied to the right-hand side of the pressure adjustment spool (2). The pressure relief valve (4) opens when the load pressure exceeds the set value, allowing pump flow to be diverted back to tank.

In the basic module the compensator (5) maintains a constant pressure drop across the main spool – both when the load changes and when a module with a higher load pressure is activated.

Shock and suction valves with a fixed setting (7) and the suction valves (8) on ports A and B are used to protect individual working functions against overload.

In the basic module it is possible to build in an adjustable LS pressure relief valve (6) to limit the pressure from each working function.

The LS pressure limiting valve saves energy:

•Without LS pressure limiting valve all the oil flow to the working function will be led across the combined shock and suction valves to tank if the pressure exceeds the fixed setting of the valves.

•With LS pressure limiting valve an oil flow of only about 2 l/min [0.5 US gal/min] will be led across the LS pressure limiting valve to tank if the pressure exceeds the valve setting.

PVG 120 with PVP Closed Center

In the closed center version an orifice (9) has been fitted instead of the plug. This means that the pressure adjustment spool (2) will only open to tank when the pressure in channel P exceeds the pressure relief valve setting (4).

In load sensing systems the load pressure is led to the pump regulator via the LS connection (10), so the orifices (11) have been removed, and a plug (12) has been fitted instead of one of the orifices.

In neutral position the pump regulator will set the displacement so that leakage in the system is just compensated for.

When a main spool is activated, the pump regulator will adjust the displacement so that the set differential pressure between P and LS is maintained.

The pressure relief valve (4) in PVP is set for a pressure of about 30 bar [435 psi] above maximum system pressure (set at the pump or an external pressure relief valve).

If the system or the pump regulation has a pressure relief valve, it is possible to use a PVPV pump side module, without integrated pressure adjustment spool and pressure relief valve.

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Technical Information

PVG 120 Proportional Valve Group

PVG 120 sectional view

PVG 120 sectional view

X-X

10

11

12

11

4

pma

T	P	T
X X

P

A

1

9 2 A

B

13
T	P	T
3

LS

A 7 5

1 B 8

P	B
	13
	T	P	T
	3

	6																									5
																																				V310100.A
Legend:
1	– Main spool																	7							– Shock and suction valve PVLP
2	– Pressure adjustment spool in PVP																	8							– Suction valve PVLA
3	– Shuttle valve																	9							– Orifice, closed center PVP; Plug, open center PVP
4	– Pressure relief valve in PVP																	10								– LS connection
5	– Pressure compensator in PVB																	11								– Orifice, open center PVP
6	– LS pressure relief valve in PVB																	12								– Plug, closed center PVP

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Technical Information

PVG 120 Proportional Valve Group

Safety in application

All types of control valves (incl. proportional valves) can fail, thus the necessary protection against the serious consequences of function failure should always be built into the system. For each application an assessment should be made for the consequences of pressure failure and uncontrolled or blocked movements. To determine the degree of protection that is required to be built into the application, system tools such an FMEA (Failure Mode and Effect Analysis) and Hazard and Risk Analysis can be used.

FMEA – IEC EN 61508

FMEA (Failure Mode and Effect Analysis) is a tool used for analyzing potential risks. This analytical technique is utilized to define, identify, and prioritize the elimination or reduction of known and/or potential failures from a given system before it is released for production. Please refer to the standard IEC FMEA 61508.

Hazard and risk analysis ISO 12100-1/14121

This analysis is a tool used in new applications as it will indicate whether there are special safety considerations to be met according to the machine directives EN 13849. Dependent on the determined levels conformity this analysis will detirmine if any extra requirements for the product design, development process, production process or maintenance, example the complete product life cycle.

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

PVG 120 Proportional Valve Group

Safety in application

Control system example

Example of a control system for manlift using PVE Fault monitoring input signals and signals from external sensors to ensure the PLUS+1® main controllers correct function of the manlift.

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Technical Information

PVG 120 Proportional Valve Group

Safety in application

Electrical block diagram for the above illustration

W Warning

It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.

PVG 32 – mainly used in system with fixed displacement pumps:

•PVSK, commonly used in crane application - full flow dump

•PVPX, LS dump to tank

PVG 100 – alternative LS dump or pilot supply disconnect:

•PVPP, pilot oil supply shut off

•External cartridge valve connecting LS pressure or main pressure to tank

PVG 120 – pump disconnect / block for variable pumps:

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Technical Information

PVG 120 Proportional Valve Group

Safety in application

•PVPE, full flow dump for the PVG 120

•External cartridge valve connecting LS pressure to tank

Examples of wiring block diagram

Example of a typical wiring block diagram using PVEH with neutral power off switch and fault monitoring output for hydraulic deactivation.

Emergency		Man present
A	stop	switch
PVE 1	Neutral detection / Supply control						PVEH
C		1)					with AMP
	signal	OFF					connector
	≠						US
		Delay
	neutral						UDC2
						B	Error
PVE 2	Neutral detection / Supply control						PVEH
C		1)					with AMP
	signal	OFF					connector
	≠						US
		Delay
	neutral						UDC2
						B	Error
			E1		E2
			2)	Alarm
				logic
					Output
		<![if ! IE]> <![endif]>OR	3) Memory
				<![if ! IE]> <![endif]>AND	high=on
					low=off
		Fault detection output				D	Hydraulic
							deactivation
							P301 318

A– Emergency stop / man present switch B– PVE Fault monitoring signals

C– Neutral signal detection. D– Hydraulic deactivation

System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the hydraulic system.

W Warning

It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.

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Technical Information

PVG 120 Proportional Valve Group

Safety in application

Example of fault monitoring for deactivation of the hydraulic system with extra fault inputs using the PVE’s with DI (Direction Indication) function.

Emergency			Man present
	Stop		switch
PVE 1	Neutral detection / Supply control						PVEH-DI
			1)				AMP supply
	signal		OFF				connector
	≠						US
			Delay
	neutral						UDC2
							Error
							PVEH-DI
							AMP connector
	DI-B	2)	Fault detection				DI-A
			3)	4)			DI-B
	DI-A	DI	Output Delay	Memory			Error
	US	Logic
PVE 2	Neutral detection / Supply control						PVEH-DI
			1)				AMP supply
	signal		OFF				connector
	≠						US
			Delay
	neutral						UDC2
							Error
							PVEH-DI
							AMP connector
		2)	Fault detection				DI-A
	DI-B
			3)	4)
	DI-A	DI	Output Delay	Memory			Error
	US	Logic
					<![if ! IE]> <![endif]>OR
					<![if ! IE]> <![endif]>AND	high=on
						low=off
					Fault detection output		Hydraulic
							deactivation
							P301 319

System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the hydraulic system.

W Warning

It is the responsibility of the equipment manufacturer that the control system incorporated in the machine is declared as being in conformity with the relevant machine directives.

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