Danfoss PVE 7 Series User manual

Service Manual
Electrohydraulic Actuators
PVE Series 7
powersolutions.danfoss.com

Revision history Table of revisions
Date Changed Rev
August 2017 First edition 0101
Service Manual
PVE Series 7
2 | ©Danfoss | August 2017 AX00000348en-US | 0101

Abbreviations Chart List of abbreviations for PVG/PVE...............................................................................................................................................4
Danfoss Literature Reference.......................................................................................................................................................5
Warnings PVE warnings......................................................................................................................................................................................6
General Information Introduction........................................................................................................................................................................................7
General instructions........................................................................................................................................................................ 8
Safety precautions............................................................................................................................................................................8
PVG with the PVE overview...........................................................................................................................................................9
Troubleshooting............................................................................................................................................................................... 9
Connector Overview.....................................................................................................................................................................10
Hydraulic Principle Variants....................................................................................................................................................... 12
Exchanging PVE Before replacing or dismounting a PVE.................................................................................................................................14
Dismounting of PVE......................................................................................................................................................................14
Mounting of Replacement..........................................................................................................................................................15
Test and use of PVG and Actuator........................................................................................................................................... 15
Returning Replaced Actuator for Customer Claims.......................................................................................................... 15
Service Manual
PVE Series 7
Contents
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List of abbreviations for PVG/PVE
Abbreviation Description
ASIC Application Specific Integrated Circuit - the part of the PVE where spool position is controled to
follow setpoint
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®Trademark for Danfoss controllers and programming tool
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
Service Manual
PVE Series 7
Abbreviations Chart
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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
UDC Power supply Direct Current; also called Vbat for battery voltage
USSteering voltage for the PVE control; also called VS
Danfoss Literature Reference
Danfoss literature reference for PVG and PVE products
Title Type Order number
PVG 32 Proportional Valve Groups Service Manual 11039167
PVG 100 Proportional Valve Groups Service Manual 11048807
PVG 32 Proportional Valve Groups Technical Information 520L0344
PVG 100 Proportional Valve Groups Technical Information 520L0720
PVG 120 Proportional Valve Groups Technical Information 520L0356
PVE Series 7 Technical information BC00000XXXen-US0101
PVG 32 Metric ports Technical Information 11051935
Service Manual
PVE Series 7
Abbreviations Chart
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PVE warnings
W
Warning
Not applying to the Operational Conditions can compromise safety.
All brands and all types of directional control valves – including 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 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.
A PVG with PVE can only perform according to description if conditions in this Technical Information are
met.
In particularly exposed applications, protection in the form of a shield is recommended.
When the PVE is in fault mode the quality of performance and validity of feedback is limited depending
on the fault type.
Error pins from more PVEs may not be connected. Inactive error pins are connected to ground and will
disable any active signal. Error pins are signal pins and can only supply very limited power consumption.
Deviation from recommended torque when mounting parts can harm performance and module.
Adjustment of the position transducer (LVDT) will influence calibration, and thereby also safety and
performance.
When replacing the PVE, the electrical and the hydraulic systems must be turned off and the oil pressure
released.
PVEA is not for use on PVG 100.
Hydraulic oil can cause both environmental damage and personal injury.
Module replacement can introduce contamination and errors to the system. It is important to keep the
work area clean and components should be handled with care.
After replacement of modules or cables wiring quality must be verified by a performance test.
By actuation at voltage below nominal PVG will have reduced performance.
The PVE is not designed for use with voltage outside nominal.
Obstacles for the Pilot oil can have direct influence on spool control.
Reduced pilot oil pressure will limit spool control.
Too high pilot oil pressure can harm the PVE.
Service Manual
PVE Series 7
Warnings
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Introduction
This manual includes information for trouble shooting and servicing the PVE actuators. The actuators are
used on PVG 32, PVG 100, PVG120 and some EH steerings. This manual does not cover the PVG in general
nor any steering.
PVE actuators
The PVE for PVG 32 and PVG 100 are the same, for PVG 120 includes a special interface plate, has another
LVDT-pin and allows larger spool travel. Service on the actuators is identical independent of valve size.
In general service on PVE is limited to exchange of O-rings and connectors or whole actuator.
Performing service, trouble shooting and repair may require removal of valve and valve parts from the
application. This can easily introduce misplaced parts and contamination and thereby thread
performance and safety. Following cleanliness requirements is a prerequisite for service.
For general description, specifications and operating parameters on PVG valves and actuators please see
the relevant Technical Information listed in reference list. Danfoss technical literature is available on
www.danfoss.com.
A worldwide network of Danfoss Global Service Partners is available for major repairs. Danfoss trains and
certifies Global Service Partners on a regular basis. You can locate your nearest Global Service Partner
using the distributor locator at www.danfoss.com.
W
Warning
Do not attempt to service PVG valves without build sheet specifications for reference.
Service Manual
PVE Series 7
General Information
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General instructions
Follow these general procedures when servicing PVG 32 valves:
Avoid injuries or material damage
Plan the process thoroughly. Block wheels and other moving parts to prevent undesired movement.
Secure against leakage of hydraulic fluid. Hydraulic fluid can cause contamination, cause burns due to
temperature and other injuries due to high pressure. Follow all instructions from machine builder.
Keep it clean
Cleanliness is the primary mean of assuring long lifetime for the application. Clean the outside of the
valve thoroughly before any disassembly. Cap ports and hoses when opening. Avoid contamination by
both dirt and chemical agents. Clean parts using a clean solvent wash and air dry.
Replace all O-rings and gaskets
Danfoss recommends inspection of O-rings and gaskets and replacement if wear or contamination
could be relevant. Dried out O-rings and gaskets must be replaced.
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others
from injury. Follow instructions from machine manufacture carefully. Read and include the warnings from
the relevant PVG literature in your work planing.
W
Warning
Ensure stable conditions
Manipulation on a mechanical, hydraulic and electrical system can potentially create dangerous
situations. Please ensure that all necessary precautions are taken to prevent dangerous situations.
W
Warning
Release hydraulic pressure in system
Shut down pump and release pressure in all work functions, in tank and pilot pressure if not released by
previous operations
W
Warning
Disengage electrical system
Disengage power supply and system control. If relevant for application, disengage system output e.g.
error pin, direction indicator.
Service Manual
PVE Series 7
General Information
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PVG with the PVE overview
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.
The analog PVE Series 7 is an electro-hydraulic actuator used to control a single work section of a PVG
proportional valve group. The PVE Series 7 actuator program includes variants with different
performance levels and features for PVG 32/100/120/128/256.
The actuator positions the main spool in a PVG work section in order to control either the flow or the
pressure of the oil distributed to/from the work function. The control signal to the actuator is an analog
voltage signal, enabling the user to operate the work function remotely by means of a joystick, a
controller or the like.
The electro-hydraulic solenoid valve bridge of the actuator is available in different designs, utilizing
different regulation principles, depending on performance variant. The actuator positions the main spool
by distributing pilot oil pressure to either side of it, pressurizing one side by pilot pressure while relieving
the opposite side to tank and vice versa. All proportional actuators feature a closed-loop spool control
and continuous fault monitoring.
The analog PVE Series 7 actuator program features five different main hydraulic principle variants
(PVEO/M/A/H/S). The different hydraulic principles combined with the different solenoid valve regulation
principles determine whether the actuator controls the spool proportionally according to a demand
signal or ON/OFF according to a voltage signal.
Valve section - standard mounted - seen from PVP with naming
Troubleshooting
The Service Manuals for PVG 32 and PVG 100 have a thorough description of system troubleshooting and
parts troubleshooting. Please look for descriptions there before starting with the actuator. The actuator is
an electrohydraulic subsystem used for moving the spool and thereby opens the valve for work flow.
Service Manual
PVE Series 7
General Information
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Connector Overview
PVEO/PVEO-R/PVEO-HP
Connector Pin 1 Pin 2 Pin 3 Pin 4
1x4 AMP Udc_A Udc_B GND GND
1x4 DEU Udc_A GND GND Udc_B
1x4 DIN Udc_A Udc_B GND
PVEO-DI
Connector Pin 1 Pin 2 Pin 3 Pin 4
2x4 AMP (A) Udc_A Udc_B GND GND
2x4 AMP (B) DI-B DI-A GND Udc2
PVEM
Connector Pin 1 Pin 2 Pin 3 Pin 4
1x4 DIN Udc Us Error GND
PVEA/PVEH/PVES
Connector Pin 1 Pin 2 Pin 3 Pin 4
1x4 AMP Us Udc GND Error
1x4 DEU Us Error GND Udc
1x4 DIN Udc Us Error GND
PVEA-DI/PVEH-DI
Connector Pin 1 Pin 2 Pin 3 Pin 4
2x4 AMP (A) Us Udc GND Error
2x4 AMP (B) DI-A DI-B GND Udc2
2x4 DEU (A) Us Error GND Udc
2x4 DEU (B) Udc2GND DI-A DI-B
PVEH-FLA
Connector Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6
1x6 AMP Us Udc GND Error Float
1x6 DEU Us Error Float GND Udc
PVEH-SP/PVES-SP
Connector Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6
1x6 DEU Us Error SP GND Udc
Service Manual
PVE Series 7
General Information
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