Danfoss PVG 120 User manual

MAKING MODERN LIVING POSSIBLE
Service Manual
Proportional Valve Group
PVG 120
powersolutions.danfoss.com

Revision history Table of revisions
Date Changed Rev
May 2014 Converted to Danfoss layout – DITA CMS, major revision JA
Jan 2012 Pos. 3 change ID
Feb 2011 Table on page 35 changed, layout changes - all pages IC
Feb 2010 Handles on drawings IA
Jan 2010 Japan location HC
Service Manual PVG 120 Proportional Valve Group
2520L0247 • Rev JA • May 2014

PVG 120 service parts exploded view
PVG 120 sectional view
Safety in application Control system example................................................................................................................................................................8
Examples of wiring block diagram.....................................................................................................................................10
Identification Identification ...................................................................................................................................................................................12
Installation Installation and plug orientation..............................................................................................................................................13
Connection, PVP, Pump Side Module.....................................................................................................................................13
Oil flow direction............................................................................................................................................................................14
Tightening Torques.......................................................................................................................................................................14
PVM, Lever Positions.....................................................................................................................................................................16
Setting of max. flow...................................................................................................................................................................... 16
Pressure Setting..............................................................................................................................................................................17
PVP, LS Relief Valve Pressure Setting.................................................................................................................................17
PVB, LS Relief Valve Pressure Setting.................................................................................................................................17
Option, Oil Flow Direction and Setting of max Flow.........................................................................................................18
Installation of PVE.......................................................................................................................................................................... 18
Bleeding.............................................................................................................................................................................................20
PVPE/PVH relief valves................................................................................................................................................................. 20
PVPH and LS connections...........................................................................................................................................................21
PVPE technical data.......................................................................................................................................................................21
Connection PVPE............................................................................................................................................................................22
PVP PVP, Pump Side Module.............................................................................................................................................................. 23
PVPD, PVPH, PVPE, Accessories for PVP................................................................................................................................. 25
PVLP / PVLA PVLP / PVLA, Shock and Suction Valve Port A/B.................................................................................................................27
PVBP, PVBR, PVBC, PVBU PVBP, PVBR, PVBC, PVBU Accessories for PVB......................................................................................................................29
PVM PVM, Mechanical Activating Module......................................................................................................................................31
PVMD and PVH PVMD, Cover for PVM and PVH, Hydraulic Activation...................................................................................................... 33
PVGI PVGI, Interface for PVG 120 and PVG 32................................................................................................................................ 34
PVEH and PVEO PVEH and PVEO, Electrical Activating Module, ON-OFF...................................................................................................35
PVT PVT, Tank Side Module – Upper Part.......................................................................................................................................37
PVT, Tank Side Module – Lower Part.......................................................................................................................................39
PVAS and PVGI PVGI, Assembly Kit.........................................................................................................................................................................41
PVAS, Assembly Kit........................................................................................................................................................................41
Asssembly sequence............................................................................................................................................................... 41
Set of seals Set of Seals .......................................................................................................................................................................................43
PVG 120 Modules Selection Chart
PVG 120 module selection chart.............................................................................................................................................. 44
Order specification
Service Manual PVG 120 Proportional Valve Group
Contents
520L0247 • Rev JA • May 2014 3

Ordering of modules for oil flow exceeding 180 l/min [47.6 US gal/min].................................................................48
Order Form.......................................................................................................................................................................................48
Reordering...................................................................................................................................................................................49
Service Manual PVG 120 Proportional Valve Group
Contents
4520L0247 • Rev JA • May 2014

PVG 120 service parts exploded view
13
8
7
2
3
3
3
3
11
14
12
4
5
4
14
1
9
10
5
5
5
6
V310144.A
6
6
6
Service Manual PVG 120 Proportional Valve Group
PVG 120 service parts exploded view
520L0247 • Rev JA • May 2014 5

PVG 120 sectional view
4
10
12
11
11
X-X
X
X
P A
V310100.A
92 1
TPT
pma
A B
A B
3
7 5 1 8
TPT
13
65
LS
TPT
3
13
P B
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
Service Manual PVG 120 Proportional Valve Group
PVG 120 sectional view
6520L0247 • Rev JA • May 2014

All makes and 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 IEC FMEA
Standard 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, i.e. the complete product life cycle.
W
Warning
All makes/brands and types of directional control valves – inclusive proportional valves – can fail and
cause serious damage. It is therefore important to analyze all aspects of the application.
Because the proportional valves are used in many different operation conditions and applications,
the manufacturer of the application is alone 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).
Service Manual PVG 120 Proportional Valve Group
Safety in application
520L0247 • Rev JA • May 2014 7

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.
Legend:
1 – Main power supply
2 – Emergency stop/man present switch
3 – HMI/Joystick control
4 – Movement detection sensors
5 – Main controller
6 – PVG control valve
7 – Hydraulic deactivation
Service Manual PVG 120 Proportional Valve Group
Safety in application
8520L0247 • Rev JA • May 2014

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:
•PVPE, full flow dump for the PVG 120
•External cartridge valve connecting LS pressure to tank
Service Manual PVG 120 Proportional Valve Group
Safety in application
520L0247 • Rev JA • May 2014 9

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.
Fault detection output
high=on
low=off
Alarm
logic
2)
Memory3)
E1 E2
Output
AND
OR
UDC2
Error
US
Neutral detection / Supply control
signal
≠
neutral
OFF
Delay
1)
UDC2
Error
US
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
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.
Service Manual PVG 120 Proportional Valve Group
Safety in application
10 520L0247 • Rev JA • May 2014

Example of fault monitoring for deactivation of the hydraulic system with extra fault inputs using the PVE’s
with DI (Direction Indication) function.
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
US
DI-A
DI-B 2)
4)
3)
Output
Fault detection
Delay
DI
Logic Memory
US
DI-A
DI-B 2)
4)
3)
Output
OR
Emergency
Stop Man present
switch
P301 319
UDC2
Error
US
DI-B
Error
DI-A
UDC2
Error
US
Error
DI-A
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.
Service Manual PVG 120 Proportional Valve Group
Safety in application
520L0247 • Rev JA • May 2014 11

Identification
PVG 120 Identification
PVMD
PVH
F
D
C
PVP
PVM
PVB
PVT
E
G
PVEO
PVEH
S
MA P
PVM
V310156.A
C: PVG – number, week and year of installation
D: PVP – pressure setting
E: PVP – number, week, year and day manufacturing, issue and series No.
F: PVB – A-Port, number, week, year and day manufacturing, issue and series No.
G: PVT – week and year of manufacturing
Service Manual PVG 120 Proportional Valve Group
Identification
12 520L0247 • Rev JA • May 2014

Installation and plug orientation
Installation Dimensions
60 Nm
[530 lbf•in] 60 Nm [530 lbf•in]
190 [7.48]*
100 [3.94]*
190 [7.48]*
100 [3.94]*
105 [4.13]
L
4xM12x18
[4x7/16-14UNCx0.7]
V310179.A
* Room for dismantling
Module of PVB 1 2 3 4 5 6 7 8
L mm 168 235 302 369 436 503 570 637
L in 6.61 9.25 11.88 14.53 17.17 19.80 22.44 25.08
Connection, PVP, Pump Side Module
Service Manual PVG 120 Proportional Valve Group
Installation
520L0247 • Rev JA • May 2014 13

Oil flow direction
Mechanical / electrical actuation Mechanical / hydraulic actuation
A
B
P B
V310169.A
AP A
PA PB
P
B
V310163.A
A
B
P B
V310162.A
AP A
PA PB
P
B
V310170.A
Tightening Torques
Max. tightening torques – Connection Threads Type G (ISO 228/1)
Max. tightening torques
Ports PA, PB MA LS, LX, PP
Sealing thread G 1/4 G 1/4 G 3/8
With steel washer 35 N•m [310 lbf·in] 40 N•m [350 lbf·in] 60 N•m [530 lbf·in]
With cooper washer 30 N•m [270 lbf·in] 20 N•m [180 lbf·in] 35 N•m [310 lbf·in]
With aluminium washer 30 N•m [270 lbf.in] 30 N•m [270 lbf.in] 40 N•m [350 lbf·in]
With cutting edge 35 N•m [310 lbf.in] 40 N•m [350 lbf.in] 60 N•m [530 lbf·in]
Service Manual PVG 120 Proportional Valve Group
Installation
14 520L0247 • Rev JA • May 2014

Max. tightening torques – Mounting Threads in SAE J 518c Flanges
Port Size Threads Tightening torque
P 1 in M12, 18 deep 68 N•m
7/16 - 14 UNC 0.7” deep [600 lbf·in]
A/B 3/4 in M10, 17 deep 45 N•m
3/8 - 16 UNC 0.7” deep [400 lbf·in]
T 1 in M10, 17 deep 45 N•m
3/8 - 16 UNC 0.7” deep [400 lbf·in]
Max. tightening torques – UN and UNF Connection Threads – O-ring Boss Port
Max. tightening torques
Ports P A/B T PA/PB MA LS, LX, PP
Sealing
/Thread
1 5/16 in-12 UN 1 1/16 in-12 UN 1 5/16 in-12 UN ½ in-20 UNF ½ in-20 UNF ¾ in-20 UNF
O-ring 160 N•m 120 N•m 160 N•m 30 N•m 30 N•m 60 N•m
[1410 in•lbs] [1060 in•lbs] [1410 in•lbs] [270 in•lbs] [270 in•lbs] [530 in•lbs]
Ports identification
Service Manual PVG 120 Proportional Valve Group
Installation
520L0247 • Rev JA • May 2014 15

PVM, Lever Positions
Base with an angle of 37.5° Base with an angle of 22.5°
37.5˚
67.5˚
97.5˚
127.5˚
157.5˚
187.5˚
19.5˚
19.5˚
V310018.A
22.5˚
52.5˚
82.5˚
112.5˚
142.5˚
172.5˚
19.5˚
19.5˚
V310014.A
Setting of max. flow
Setting of Max. Flow
10[0.39]
8 Nm
-
+
+
-
B
A
max.B
[70 lbf in]
LX
T
PP
3[0.12]
Q
Qmax.A
max.
Qmax. Q
max.B
Q
max.A
Q
V310101.A
Service Manual PVG 120 Proportional Valve Group
Installation
16 520L0247 • Rev JA • May 2014

Pressure Setting
PVP, LS Relief Valve Pressure Setting
PVP, LS Relief Valve Setting
8[0.31]
3[0.12]
360° ~ 130 bar
[360° ~ 1900 psi] 35 Nm
[310 lbf•in]
3 Nm
[27 lbf•in]
P
MA
LS
6[0.24]
6[0.24]
3[0.12]
3[0.12]
V310102.A
PVB, LS Relief Valve Pressure Setting
PVB, LS Relief Valve Setting
360° ~ 130 bar
[360° ~ 1900 psi] 3 Nm
[27 lbf•in]
LX
T
PP
3[0.12]
6[.24]
8[0.31]
3[0.12]
6[.24]
3[0.12]
[510 lbf•in]
35 Nm
V310094.A
Service Manual PVG 120 Proportional Valve Group
Installation
520L0247 • Rev JA • May 2014 17

Option, Oil Flow Direction and Setting of max Flow
Oil flow direction
PVEO
PVEH
B
A
B
A
P A
P B
MA P
S
V310158.A
Installation of PVE
For security reasons, any replacement of O-rings between valve block 1 and intermediate plate 2 may
only be effected at service shops authorized by Danfoss.
C
Caution
Mixing up PVE series 2 for PVG 120 may lead to self-actuation.
Service Manual PVG 120 Proportional Valve Group
Installation
18 520L0247 • Rev JA • May 2014

PVEH, PVEO
Service Manual PVG 120 Proportional Valve Group
Installation
520L0247 • Rev JA • May 2014 19

Bleeding
PVG 120 installed vertically
*
190[7.48]
*
100[3.94]
T
LX
PP
V310105.A
If the group is installed vertically, it is recommended to bleed it at the adjusting screws.
PVPE/PVH relief valves
Max. tightening torque for PVPE/PVH
Position Across flats Max. tightening torque
1 22 mm [0.87 in] 5 N•m [45 lbf•in]
2 36 mm [1.42 in] 85 N•m [750 lbf•in]
3 36 mm [1.42 in] 85 N•m [750 lbf•in]
Tightening PVPE/PVH
S
MA P
2.5[0.098]
2 Nm
[17.5 lbf•in)
L
PVP
PVPH
2
LS
LS
V310157.A
1
PVPE
Service Manual PVG 120 Proportional Valve Group
Installation
20 520L0247 • Rev JA • May 2014