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
2 | © Danfoss | March 2017 520L0356 | BC00000040en_US1002
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
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
PVBZ Data Sheet 520L0681
PVBZ-HS Data Sheet 520L0956
PVBZ-HD Data Sheet 11035599
MC024-010 and MC024-012 Controllers Data Sheet 520L0712
number
User Manual 11033753
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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
Pump Side Module – PVP
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
•
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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PVRE, electrical control unit, 162F…
Prof 1, 162F…
PVREL, electrical control unit, 155U…
PVRES, electrical control unit, 155B…
PVRH, hydraulic control unit, 155N…
155N0003 155N0001 155N0004 155N0005 155N0002
Technical Information
PVG 120 Proportional Valve Group
General Information
Remote Controls Units
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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:
•
•
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.
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.
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4
10
12
11
11
X-X
X
X
P A
V310100.A
9
2 1
T
P
T
p
ma
A B
A B
3
7 5 1 8
T
P
T
13
6
5
LS
T
P
T
3
13
P B
Technical Information
PVG 120 Proportional Valve Group
PVG 120 sectional view
PVG 120 sectional view
Legend:
1 – Main spool
2 – Pressure adjustment spool in PVP
3 – Shuttle valve
4 – Pressure relief valve in PVP
5 – Pressure compensator in PVB
6 – LS pressure relief valve in PVB
7 – Shock and suction valve PVLP
8 – Suction valve PVLA
9 – Orifice, closed center PVP; Plug, open center PVP
10 – LS connection
11 – Orifice, open center PVP
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.
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
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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Fault detection output
high=on
low=off
Alarm
logic
2)
Memory3)
E1
E2
Output
AND
OR
U
DC2
Error
U
S
Neutral detection / Supply control
signal
≠
neutral
OFF
Delay
1)
U
DC2
Error
U
S
PVEH
with AMP
connector
PVEH
with AMP
connector
Hydraulic
deactivation
Neutral detection / Supply control
signal
≠
neutral
OFF
Delay
1)
PVE 1
PVE 2
Emergency
stop
Man present
switch
C
C
D
B
B
A
P301 318
W
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.
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.
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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Neutral detection / Supply control
signal
≠
neutral
OFF
Delay
1)
Fault detection output
PVEH-DI
AMP supply
connector
PVEH-DI
AMP supply
connector
PVEH-DI
AMP connector
PVEH-DI
AMP connector
AND
high=on
low=off
Neutral detection / Supply control
signal
≠
neutral
OFF
Delay
1)
PVE 1
PVE 2
Fault detection
Delay
DI
Logic
Memory
U
S
DI-A
DI-B
2)
4)
3)
Output
Fault detection
Delay
DI
Logic
Memory
U
S
DI-A
DI-B
2)
4)
3)
Output
OR
Emergency
Stop
Man present
switch
P301 319
U
DC2
Error
U
S
DI-B
Error
DI-A
U
DC2
Error
U
S
Error
DI-A
Hydraulic
deactivation
W
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.
System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the
hydraulic system.
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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