Danfoss Series 90 User manual

S
eries 90 Intrinsically Safe Contr
ol
Installation, Maintenance
© Danfoss A/S, 202 • • 1
This line of Intrinsically Safe Pressure Control Pilots receives a low current input signal from a variety of machine controllers and
converts the current signal into a proportional dierential pressure signal suitable to control larger hydraulic equipment in hazardous
locations. The Intrinsically Safe Controls can be added to a Series 90 pump as a standard option or purchased separately.
Danfoss oers five dierent models of Intrinsically Safe Pressure Control Pilots to accommodate a variety of standard industrial
process controllers. Various combinations of hydraulic nozzle sizes and coil resistances yields a relationship between electrical current
(input) and hydraulic dierential pressure (output).
Refer to the Unit Specifications tables on pages three and four for proper selection.
Ensure that the four supplied O-rings are in place on the bottom of the unit. These pressure control pilots are fastened to the second
stage of the control with four M5 x 0.8 x 16 mm socket head screws. Torque to 5 Nm (44 in-lb).
A Mil-Spec Connector (MS3102C-14S-2P) provides the means for electronic signal input to the device. Proper selection of the mating
connector to ensure safe operation in a hazardous environment is required (Recommended MS3108E-14S-S, Danfoss Kit number
K08106). A suppression circuit is incorporated in the PCP torque motor cover but by itself does not insure intrinsic safety. An additional
safety barrier used to connect intrinsically safe circuits with non-intrinsically safe circuits must be connected in series between the
PCP and controller. The safety barrier and electrical controller must be isolated from the hazardous area either through use of a purge
enclosure or mounted in a safe area. The intrinsically safe device enclosure grounding terminal must be connected to a robust chassis
ground. The connection must be in accordance with applicable standards where required.

Refer to the following wiring diagrams for proper connections.
Wiring diagram for 11101116 Wiring diagram for 11101126, 11101118, 11101115, 11101106
No adjustment is possible.
Do not attempt to disassemble or adjust the control.
For instructions on putting a pump with the Intrinsically Safe Control in service, refer to Initial Startup Procedure in the Series 90 Pumps
Service Manual, .
Prior to installation, inspect packaging and unit for any damage. Do not continue installation if unit has visible signs of damage.
Danfoss is not responsible for the design of the control input circuit outside of the installed Mil-Spec connector. Proper design
on the entire system as noted in the applicable standards is required for safe usage in hazardous environments.
The EDC is designed to be controlled from a DC current source or voltage source. Pulse width modulation (PWM) is not required. But, if
a PMW signal is used, use a carrier frequency between 200 Hz and 4000 Hz. Do not use a pulse current of more than 120% of that
required for full output(refer to unit specifications below).
2 © Danfoss A/S, 202
• •
Hazardous location Non-hazardou location
V = 8.6 V
I = 250mA
P = 537.5mW
C = 0.4 µF
L = 0 mH
V = 8.6 V
I = 250mA
P = 537.5mW
C = 0.4 µF
L = 0 mH
PCP
C
D
A
B
Single coil
Dual coil
Hazardous location Non-hazardous location
PCP
A
B
Exi Cl I, Div 1, Gp CD T4
Ex ia / AEx ia IIB T4 Ga
FM12ATEX0031X II 1 G Ex ia IIB T4 Ga
IECEx FMG 15.0008X Ex ia IIB T4 Ga
= 16.0 V
I= 110mA
P= 440mW
C= 0.4 µF
L= 0 mH

Coil resistance
Dual coil
A
B
C
D
Single coil
A B
P108 686E
© Danfoss A/S, 202 3
fi
(PWM) The PCP is designed to be controlled from a dc current source or voltage source. If a PWM signal is used, do not use a pulse
current of more than 120% of that required.
Single Coil
Coil Resistance
A-B 23 Ω at 70° F,
A-B 29 Ω at 200° F
A-B 23 Ω at 70° F,
A-B 29 Ω at 200° F
A-B 106 Ω at 70° F,
A-B 130 Ω at 200° F
Dual Coil
Coil Resistance
A-B 20 Ω at 70° F,
A-B 25 Ω at 200° F
C-D 16 Ω at 70° F,
C-D 20 Ω at 200° F
A-B 20 Ω at 70° F,
A-B 25 Ω at 200° F
C-D 16 Ω at 70° F,
C-D 20 Ω at 200° F
Phasing
Positive voltage to pin
A produces a pressure
rise at output port C1
Positive voltage to pin
B produces a pressure
rise at output port C2
Positive voltage to pin
A produces a pressure
rise at output port C1
Positive voltage to pin
B produces a pressure
rise at output port C2
Positive voltage to pin
A produces a pressure
rise at output port C1
Positive voltage to pin
B produces a pressure
rise at output port C2
Positive voltage to
pin A or C produces a
pressure rise at output
port C1 Positive
voltage to pin B or D
produces a pressure
rise at output port C2
Positive voltage to
pin A or C produces a
pressure rise at output
port C1 Positive
voltage to pin B or D
produces a pressure
rise at output port C2
Current/Voltage Range up to 145 mA at 3.90
Vdc (linear range)
up to 190 mA at 4.75
Vdc (linear range)
4 mA at 0.50 Vdc
to 20 mA at 2.2 Vdc
(linear range)
up to 205 mA at 4.50
Vdc (linear range)
up to 170 mA at 4.50
Vdc (linear range)
Scale Factor 0.165 ± 0.013 Bar/mA
2.4 ± 0.2 psid/mA
0.079 ± 0.007 Bar/mA
1.15 ± 0.1 psid / mA
0.379 ± 0.034 Bar/mA
5.5 ± 0.5 psid / mA
0.101 ± 0.010 Bar/mA
1.47 ± 0.15 psid / mA
0.054 ± 0.006 Bar/mA
0.78 ± 0.08 psid / mA
• •

4 © Danfoss A/S, 202
fi
Oil Viscosity must be in the 40 – 6000 SSU [cSt] range.
Oil Cleanliness of ISO 4406 class 22/18/13 (SAE J1165) or better, under normal operating conditions.
For detailed information on lubricants and cleanliness refer to Hydraulic Fluids and Lubricants, and Design
Guidelines for Hydraulic Fluid Cleanliness
Maximum supply pressure: 69 bar
1000 psid
69 bar
1000 psid
69 bar
1000 psid
69 bar
1000 psid
69 bar
1000 psid
Recommended range: 27.6 - 41.4 bar
400 - 600 psid
20.7 - 34.5 bar
300 - 500 psid
20.7 - 34.5 bar
300 - 500 psid
34.5 - 41.4 bar
500 - 600 psid
20.7 - 34.5 bar
300 - 500 psid
Maximum return pressure: 13.8 bar
200 psid
13.8 bar
200 psid
13.8 bar
200 psid
13.8 bar
200 psid
13.8 bar
200 psid
Maximum internal leakage:
at 500 psid supply
3.41 lpm
0.90 gpm
2.46 lpm
0.65 gpm
2.46 lpm
0.65 gpm
2.46 lpm
0.65 gpm
2.46 lpm
0.65 gpm
Maximum linear psid output
pressure:
24.1 bar at
34.5 bar supply
350 psid at
500 psid supply
15.2 bar at
20.7 bar supply
220 psid at
300 psid supply
15.2 bar at
20.7 bar supply
220 psid at
300 psid supply
21.4 bar at
34.5 bar supply
350 psid at
500 psid supply
13.8 bar at
20.7 bar supply
220 psid at
300 psid supply
Load flow: the output
di rential flow across a 100
psid load pressure drop at
maximum current:
>0.738 l/m
> 45 cim
>0.0492 l/m
> 30 cim
>0.0492 l/m
> 30 cim
>0.738 l/m
> 45 cim
>0.0492 l/m
> 30 cim
• •

11101116
© Danfoss A/S, 202 5
Part of the enclosure is constructed from plastic. To prevent the risk of electrostatic sparking the plastic surfaces should
only be cleaned with a damp cloth.
No other maintenance is required.
For overhaul or repair return to: Danfoss
Power Solutions
2800 East 13th Street
Ames IA, 50010
Labels
11101126, 11101118, 11101115, 11101106
2809
Intrinsically Safe / Sécurité intrinséque
Exi, Cl I, Div 1, Gp CD T4
Ex ia / AEx ia IIB T4 Ga
FM12ATEX0031X II 1 G Ex ia IIB T4 Ga
IECEx FMG 15.0008X Ex ia IIB T4 Ga
Install per control drawing:
Input: 8.6 VDC; 250mA
MODEL NO.
XXXXXXXXXXX
DANFOSS POWER SOLUTIONS (US) COMPANY, 2800 E. 13th St. Ames, IA 50010
S/N: A123456789
Made in USA
IP66
• •
MODEL NO.
XXXXXXXXXXX
DANFOSS POWER SOLUTIONS (US) COMPANY, 2800 E. 13th St. Ames, IA 50010
Intrinsically Safe / Sécurité intr inséque
FM12ATEX0031X
Install per control drawing: DWG00019589
Input: 16 VDC; 110mA
2809
IP66
11101126, 11101118, 11101115, 11101106
11101116
Part of the enclosure is constructed from plastic. To prevent the risk of electrostatic sparking the plastic surfaces should
only be cleaned with a damp cloth.

6 © Danfoss A/S, 202
• •