Moog D661K Series User manual

Operating
Instructions
CA49305-001; Version 3.0, 10/07
Servo and proportional valves
with integrated electronics for
areas with potentially explosive atmospheres
D661K, D662K, D663K and D664K Series
ISO 4401, sizes 05 to 08

2 Operating Instructions D661K, D662K, D663K and D664K (CA49305-001; Version 3.0, 10/07) © 2007 Moog GmbH

© 2007 Moog GmbH Operating Instructions D661K, D662K, D663K and D664K (CA49305-001; Version 3.0, 10/07) 3
Table of Contents
1 Safety Instructions page 3
2 Description page 4
3 Technical Data page 7
4 Installation page 10
5 Setting up page 14
6 Maintenance page 14
7 Malfunctions – Causes and Troubleshooting page 15
8 Declaration of Manufacturer page 15
9 Tools page 15
10 Spare Parts and Accessories page 16
11 Ordering Information page 18
1 Safety Instructions
D661K, D662K, D663K and D664K Series
1.4 Selection and qualification of personnel
Service work carried out by the user on explosion protection
valves is prohibited, as intervention by third parties renders
the explosion protection permit null and void.
1.5 Safety instructions for specific operational phases
1.5.1 Take the necessary precautions to ensure that the valve is
used only when in a safe and reliable state.
1.5.2 Check the valve at least once per working shift for obvious
damage and defects (e.g., leakage or damaged cables).
Report any changes to the responsible group/person
immediately. If necessary, stop the machine immediately
and secure it.
1.5.3 In the event of malfunction, stop the machine/plant
immediately and secure it. Have any defects rectified
immediately.
1.5.4 If the machine/plant is completely shut down for
maintenance and repair work at the valve, it must be
secured against inadvertent start up by:
ULocking the principal control elements and
removing the key.
Uattaching a warning sign to the main switch.
1.6 Safety instructions for the operation of hydraulic
plants
1.6.1 Work on electrohydraulic equipment must be carried out
only by personnel having special knowledge and experience
in electrohydraulic controls.
1.6.2 Check all lines, hoses and fittings of the plant regularly for
leaks and obvious damage. Repair damage immediately.
Splashed oil may cause injury and fire.
1.6.3 Before removing the valve depressurize all system sections
to be opened, pressure lines and accumulators of the
hydraulic system in accordance with the specific instructions
for the plant.
1.6.4 When handling oil, grease and other chemical substances,
observe safety regulations valid for each product.
1.1 Warnings and symbols
Refers to special instructions and prohibitions to
prevent damage
Refers to special instructions and prohibitions to
prevent injury or property damage
1.2 Correct application
1.2.1 The permissible gas groups, which are part of the below
identification, have been modified according to IEC 60079.
Operation with other gases is not allowed!
Prior to starting-up the valve, it must be checked if the gas
used is among the permissible gases.
1.2.2 The valves series D661K, D662K, D663K and D664K are
electrical equipment for hazardous areas, type of protection
"d" ("d" Flameproof enclosure to IEC 60079-1).
Identification D661K/D662K/D663K/D664K Series:
II 2G Ex d IIB+H2 T5 Ta: 80°C
Nemko 07ATEX1060, 0123.
1.2.3 The valves are servo and proportional valves intended for
position, velocity, pressure and force control in hydraulic
control systems that operate with mineral oil based fluids.
Using the valves for purposes other than those mentioned
above is considered contrary to the intended use. The user
bears entirely the risk of such misuse.
Correct application involves also observing the operating
instruction and complying with the inspection and
maintenance directives.
1.3 Organizational measures
1.3.1 We recommend to include this operating instruction into
the maintenance plan of the machine/plant.
1.3.2 In addition to the operating instruction, observe also all
other generally applicable legal and other mandatory
regulations relevant to accident prevention and environ-
mental protection. Instruct the operator accordingly.
1.3.3 All safety and danger prevention instructions of the
machine/plant must meet the requirements of EN 982 and
IEC 60079-0.

4 Operating Instructions D661K, D662K, D663K and D664K (CA49305-001; Version 3.0, 10/07) © 2007 Moog GmbH
D661K, D662K, D663K and D664K Series
2 Description
Valves of the D66XK Series are servo and proportional valves
with a Jetpipe pilot valve insensitive to dirt and electrical
return of the spool position.
In servo valves, the control spool runs in a bushing, which
is fitted into the body of the valve.
In proportional valves, the control spool runs directly in the
valve body.
Proportional valve D661K Series
2.1 Design and funktion
2.1.1 Servo and proportional valves
The D66XK Series valves are throttle valves for 2-, 3- and
4-way applications. 5-way applications are also possible
with the D661K proportional valve.
These valves are suitable for electrohydraulic position,
velocity, pressure or force control systems with high dynamic
response requirements.

© 2007 Moog GmbH Operating Instructions D661K, D662K, D663K and D664K (CA49305-001; Version 3.0, 10/07) 5
D661K, D662K, D663K and D664K Series
Proportional valve D662K Series
2.1.1.1 General
All explosion protected servo and proportional valves are
equipped with a D061K Jetpipe pilot valve.
The Jetpipe pilot valve essentially comprises a torque motor
with a coil and armature, a Jetpipe and a receiver.
A current through the coil results in the anchor with the
Jetpipe being extended. The extended fluid jet, which is
bundled via the specific nozzle shape, impinges more on
one of the two receiver bores than on the other one.
In this way, a pressure difference is generated in the control
areas of the main stage. The resultant useful volume flow
displaces the control spool of the main stage. The return
to the tank is implemented via the ring area under the jet.
2.1.1.2 Operating principle of the two-stage valve
An electrical input signal (flow rate command) is applied
to the integrated control amplifier, which drives a current
through the coil of the pilot stage torquemotor. The thus
deflected Jetpipe produces a pressure difference across the
drive areas of the spool and effects its movement.
The position transducer which is excited via an oscillator
measures the position of the spool (actual value, position
voltage). This signal is then demodulated and fed back to
the controller where it is compared with the command
signal. The controller drives the torquemotor until the error
between command signal and feedback signal is zero. Thus
the position of the spool is proportional to the electric
command signal.

6 Operating Instructions D661K, D662K, D663K and D664K (CA49305-001; Version 3.0, 10/07) © 2007 Moog GmbH
D661K, D662K, D663K and D664K Series
2.1.3 D66XK proportional valves in a fail safe version
For applications with proportional control valves where
certain safety regulations are applicable, a defined mete-
ring spool position is needed in order to avoid potential
damage.
Therefore fail safe versions are offered as an option
for the proportional valves.
After external triggering this fail-safe function causes a
defined metering spool position.
2.1.3.1 Mechanical fail safe version
The safe position of the spool will be obtained after cut-
off of pilot pressure X (external pilot connection) or
operating pressure supply (internal pilot connection).
See page 19 of the ordering information values for
fail safe functions.
2.1.3.2 Hydraulically operated fail safe version
In proportional valves, the two drive areas of the spool are
short-circuited in order to move into the safe position via a
2/2-way solenoid poppet valve.
The spool in fail safe version Kgoes into the middle position
after switching off pressure Zof the solenoid poppet valve.
When the supply voltage of the valve electronics drops,
but if the solenoid poppet valve is further supplied and the
control pressure is available, the spool moves to a defined
end position in version H.
Proportional valve D661K Series
with hydraulic fail safe valve

© 2007 Moog GmbH Operating Instructions D661K, D662K, D663K and D664K (CA49305-001; Version 3.0, 10/07) 7
D661K Series
Model ... Type D661K...3...
Mounting pattern ISO, with additional 2nd T-port ISO 4401-05-05-0-05
Valve version 4-way
2-stage with bushing spool assembly
Pilot stage Jetpipe Standard
Pilot connection Optional, internal or external X and Y
Mass [kg] 5,7
Rated flow QN(±10 %) at ∆pN= 35 bar per land [l/min] 20 / 90 120 / 160 / 200
Maximum operating pressure pmax.
Main stage ports P with X external, A, B [bar] 350
ports T, T2with Y internal [bar] 20 % of pilot pressure, max. 100 bar
ports T, T2with Y external [bar] 350
Pilot stage regular version [bar] 210
with dropping orifice (on request) [bar] 350
Response time1) for 0 to 100 % stroke [ms] 14 18
Threshold1) [%] < 0,1
Hysteresis1) [%] < 0,5
Null shift with ∆T = 55 K [%] < 1,5 < 1,0
Null leakage flow1) total max. (~ critical lap) [l/min] 3 / 4,5 4,5 / 4,5 / 4,5
Pilot leakage flow1) Pilot stage only [l/min] 1,7 1,7
Pilot flow1) max, for 100 % step input [l/min] 1,7 1,7
Temperature range Ambient [°C] –20 to 60
Fluid [°C] –20 to 80
Operating fluid2) mineral oil based hydraulic fluid
(DIN 51524, part 1 to 3),
other fluids on request
Viscosity recommended [mm²/s] 15 to 45
allowable [mm²/s] 5 to 400
Cleanliness class
ISO 4406:1999 for normal operation 19 / 16 / 13
for longer life3) 17 / 14 / 11
3 Technical Data
3.1 Technical data of servo valve D661K Series
1) At 210 bar pilot or operating pressure, fluid viscosity 32 mm²/s
and fluid temperature of 40°C
2) The cleanliness of the hydraulic fluid greatly influences the
functional safety and the wear and tear of the valve. In order to
avoid malfunctions and increased wear and tear, we recommend
filtrating the hydraulic fluid accordingly.
3) For long life wear protection of metering lands
For additional technical information , such
as dimensions, ordering information etc.
see the catalogue.

8 Operating Instructions D661K, D662K, D663K and D664K (CA49305-001; Version 3.0, 10/07) © 2007 Moog GmbH
D661K Series
Model ... Type D661K...3... D661K...8...
Mounting pattern according to ISO ISO 4401-05-05-0-05 ISO 4401-05-05-0-05
(D661K Series with additional 2nd T-port)
Valve version 4-way, 2x2-way, 5-way 4-way, 2x2-way, 5-way
2-stage, standard spool 2-stage, standard spool
Pilot stage D061K Jetpipe Standard High Flow
Pilot connection Optional, internal or external X and Y X and Y
Mass [kg] 5,6 5,6
Rated Flow QN(±10 %) at ∆pN= 5 bar per land [l/min] 30 / 60 / 80 / 2 x 80 30 / 60 / 80 / 2 x 80
Maximum operating pressure pmax.
Main stage ports P, A, B [bar] 350 350
port T with Y internal [bar] 20 % of pilot pressure, max. 100 bar
port T with Y external [bar] 350 350
Pilot stage regular version [bar] 210 210
with dropping orifice (on request) [bar] 350 350
Response time1) for 0 to 100 % stroke [ms] 28 18
Threshold1) [%] < 0,1 < 0,1
Hysteresis1) [%] < 0,5 < 0,5
Null shift with ∆T = 55 K [%] < 1,0 < 1,0
Null leakage flow1) total max. (~ critical lap) [l/min] 3,5 4,4
Pilot leakage flow1) Pilot stage only [l/min] 1,7 2,6
Pilot flow1) max, for 100 % step input [l/min] 1,7 2,6
Temperature range Ambient [°C] –20 to 60
Fluid [°C] –20 to 80
Operating fluid2) mineral oil based hydraulic fluid
(DIN 51524, part 1 to 3),
other fluids on request
Viscosity recommended [mm²/s] 15 to 45
allowed [mm²/s] 5 to 400
Cleanliness class
ISO 4406:1999 for normal operation 19 / 16 / 13
for longer life 3) 17 / 14 / 11
3.2 Technical Data Proportional valve D661K Series
1) At 210 bar pilot or operating pressure, fluid viscosity 32 mm²/s
and fluid temperature of 40°C
2) The cleanliness of the hydraulic fluid greatly influences the
functional safety and the wear and tear of the valve. In order to
avoid malfunctions and increased wear and tear, we
recommend filtrating the hydraulic fluid accordingly.
3) For long life wear protection of metering lands
For additional technical information, such
as dimensions, ordering information etc.
see the catalogue.

© 2007 Moog GmbH Operating Instructions D661K, D662K, D663K and D664K (CA49305-001; Version 3.0, 10/07) 9
D662K, D663K and D664K Series
D662K..D..3... D662K..D..8... D663K..L..8... D664K..L..8...
ISO 4401-07-07-0-05 ISO 4401-07-07-0-05 ISO 4401-08-08-0-05 ISO 4401-08-08-0-05
4-way, 2x2-way 4-way, 2x2-way 4-way, 2x2-way 4-way, 2x2-way
2-stage, stub shaft spool 2-stage, stub shaft spool 2-stage, stub shaft spool 2-stage, stub shaft spool
Standard High Flow High Flow High Flow
X and Y X and Y X and Y X and Y
11 11 19 19
150 / 250 150 / 250 350 550
350 350 350 350
20 % of pilot pressure, max. 100 bar
350 350 350 350
210 210 210 210
350 350 350 350
44 28 37 48
< 0,1 < 0,1 < 0,1 < 0,1
< 0,5 < 0,5 < 0,5 < 0,5
< 1,0 < 1,0 < 1,0 < 1,0
4,2 5,1 5,6 5,6
1,7 2,6 2,6 2,6
1,7 2,6 2,2 2,6
–20 to 60
–20 to 80
mineral oil based hydraulic fluid
(DIN 51524, part 1 to 3),
other fluids on request
15 to 45
5 to 400
19 / 16 / 13
17 / 14 / 11
Technical Data D662K, D663K and D664K Series

10 Operating Instructions D661K, D662K, D663K and D664K (CA49305-001; Version 3.0, 10/07) © 2007 Moog GmbH
4 Installation
4.1 General Information
4.1.1 Compare model number and valve type with information
from the hydraulic schematic or bill of material.
4.1.2 The valve can be mounted in any direction, fixed or
movable.
4.1.3 Check mounting surface for flatness (0,02 mm for 100 mm)
and surface roughness (Ra <1 µm)
4.1.4 Pay attention to cleanliness of mounting surfaces and
surroundings when installing the valve.
4.1.5 Use lint-free tissue to clean!
4.1.6 Before installation, remove protection plate from the valve
and replace it when the valve removed.
4.1.7 Pay attention to correct position of ports and location of
o-rings during installation.
D661K... 05-05-0-05 M6 x 60 4 13
D662K... 07-07-0-05 M10 x 60 4 65
M6 x 55 2 13
D663K... 08-08-0-05 M12 x 75 6 110
D664K... 08-08-0-05 M12 x 75 6 110
Series Socket head
screws Qty. Torque [Nm]
Mounting
pattern
ISO 4401
D661K, D662K, D663K and D664K Series
4.1.8 Use socket head screws according to DIN EN ISO 4762
(hitherto DIN 912) for mounting, strength class 10.9, and
tighten them diagonally according to following table.
Torque tolerance ±10 %.
4.2 Dimensions
4.2.1 Proportional or Servo valves D661K Series
shown without optional hydraulic fail safe valve