PVG and After Sales and Service

© Blue Graphics Concept Sauer-Danfoss© Blue Graphics Concept Sauer-Danfoss

PVG and After Sales and Service

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Agenda Index

After Sales and Service • Technical information• General guidelines in systems• Trouble shooting• Disassembly / assembly of valves


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PVG 32Output in KW

Proportional ValveGroup

PVG32

280 bar*65 l/min600

400 bar*130 l/min600

1988

2011

= 32 KW

= 86 KW


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PVG 32

PVG/HIC Hybrid solution

PVG 100

PVG 120

PVX

PVG 20

Introduction to PVG ValvesAll families of valves

PVG 16

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BA PVG Product Roadmap

Valve portfolio 0-240Lpm, low to high performance, analog and digital.

Product Portfolio

PVG 16

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• Customer can specify their own PVG Valve

• Flexible modular design• Each specification sheet is unique• More than 100.000 customer valve

variants• 1–12 sections PVG32

• Combination between PVG32 and PVG 120 is possible (4 section PVG 120 & 8

section PVG 32)• Combination between PVG32, PVG16

and PVG100

Specifying a PVGPVG32/100/120

7Know-How in Motion™ 7

PVMD/F/H/R covers PVS endplates

App. 30 variants

PVBS spoolsApp. 680 variants

PVM handlesApp. 22 variants

PVB work sectionsApp. 75 variants

PVP inletsApp. 135 variants

PVE actuatorApp. 110 variants

PVG modular build concept – all parts interchangeablePVG 32

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PVG 32Specification 110xxxxxSubsidiary/Dealer PAE Hydraulics Ltd. PVG No.

Customer BA sales PVG Customer Part No.

Application Training Vehicle Revision No.

SectionA-Port B-Port

v Function vExtra Features

v

1

Inlet

157B 5110 157B

157B p = 0380 bar 157B

2 Bow truster

a 157B 3171 157B 6200 157B 7005 157B 4745 c

b 157B LSA bar LSB bar 157B b

Up/down

3 Bow truster prop.

a 157B 3175 157B 6233 157B 7124 157B 4735 c

b 157B 2150 LSA 0120 bar LSB 0320 bar 157B 2350 b

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a 157B 157B 157B 157B c


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a 157B 157B 157B 157B c


6

a 157B 157B 157B 157B c


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a 157B 157B 157B 157B c


8

a 157B 157B 157B 157B c


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a 157B 157B 157B 157B c


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a 157B 157B 157B 157B c


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a 157B 157B 157B 157B c


12

a 157B 157B 157B 157B c


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a 157B 157B 157B 157B c


157B 157B

14

a 157B 157B 157B 157B c


15 End section 157B 2014 16 PVAS section 157B 8002

17"Reserved for Painting" 157B8600

Comments:

Filled in by: S.Larsen Date: 10-05-2011

PVG32/100/120Specifying a PVG

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PVG Identification

Assembly Information

Module Information

PVE Module Information

PVG32Module Information ( internal

production.no)

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PVG 32 Assembly Identification

Build Center Code

Assigned Assembly /Group Number (today: 11xxxxxx no.)

Bar code + Date Code / Build and Test Date

Relief Pressure Setting (bar)

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PVG Identification

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PVG 32 Module Identification

All PVB and PVP modules identified with Part Number and Date Code engraved on

module “A” port side. Internal production.no

engraved on “B port” side

157B51104901B032550

157B62004901B022550

PVG Identification

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PVE Module

Voltage Rating

Part Number

Date Code

12VDC

157B49114901E03664

PVG IdentificationPVG 32 Module Identification

110951104901B022550

13 13

157B5111 PVP

Pressure gauge (M)

P

Pressure relief valve

T

LS connection

T

Pressure reduction valve PpP

LS

Pp

PVG Identification

14 14

157B6233 PVB

LS pressure limiting valve

Tank (PVE)

Pilot PVE

Expander

Pp

LS A/B Shuttlevalve

Shock & suction valve

T

PpLS

P

For Cleaning

PVG Identification

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PVG100 Assembly Identification ( label)PVG Identification

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All PVB, PVP and PVT modules produced in Easly identified with Part Number and Date Code engraved and labeled.Parts produced in Nordborg has no marking. ( project started)

PVBPVP

PVT

PVG100 module IdentificationPVG Identification

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PVG IdentificationPVG 120 Assembly Identification

PVG 120 Identification label is locatated on the PVP (inlet) module with; -code no.

-Pressure. setting -date stamp

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PVG IdentificationPVG 120

G6014 2610

26102610

PVB code no. Last four digits PVB Date code

PVBIdentification

G6014

G6014

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1707 1707

PVP and PVTDate code

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PVB casting code; cannot be used for identification155G6302

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PVBS Identification

PVG 120 spool

PVG 100 spool

PVG 32 spool

PVG Identification

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PVBS Identification

PVG 120 spool

PVG 100 spool

PVG 32 spool

Flow from 5-130 l/min



PVG Identification

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PVBS Identification PVG 32

Relief grooves

(157B)7004 Markings pre 1998 (157B)7004 (157B)7004 Today’s spool (155L)7354

110xxxxxx

PVG Identification

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Notch identification

Open in NeutralOpen in neutral; i.e. for hydraulic motors

Closed in neutralClosed in neutral; i.e. for cylinders

PVG Identification

LS a/b Check valve LS a/b Check valve

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<-- Without LSA/B- Shuttle With-->

LSA/B- Shuttle valve

Check valve

LS Relief valve

Work Section OptionsPVB32

26 26

• Hauptschieber

27


PVG 100 spool

PVG Identification

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Closed Ported Cut

Open Ported, Restrictive Cut

Balancing / Timing Grooves for P.O. Logic

LS Bleed Down Holes

Date Code Part Number


PVG Identification

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PVG 120X - X

pma

A B

A B

LS

LS

P B

P A

T P T

TP

T

TP

T

XX

PVG 120 Training

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PVG 120 spool

PVG Identification

Last four digits of the code no. Eg 155G6466, datecode on opposite side

6466

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PVG Identification PVLP for PVG 32 and 100

Pressure range Tolerances25 -> 80 bar +20 bar85 -> 230 bar +23 bar235 -> 350 bar +10%

Suction Spring

Shock Spring

Work port pressure

Tank pressure

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PVLP Identification PVG 32 and PVG 100

PVG Identification

2311

230

Date stamp

Pressure setting in Bar

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PVLP Identification PVG 120

PVG Identification

250

Pressure setting eg. 250 BAR

Suction Spring

Work port pressure

Tank pressure

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Solenoid valves

Electronic modules

Coil packages

Cover Base plate Aluminum block

LVDT

ASIC

2*Normally Open (NO) 2*Normally

Closed (NC)

PVE Identification

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• PVE Electrical / hydraulic dataON / OFF 12/24 V/DCProportional 11-32 V/DC, Medium, High, SuperCAN – BusFloatRampsHirschmann- , AMP-, Deutsch-ConnectorPassive- , Aktive-Fault monitoring-30° to +60°C Ambient-temp.-30° to +90°C Oil-temp.

PVE Identification

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PVEO, on/off

PVES, -H & -A Ratio-metric analoguew. spool feed back

PVEP PWM controlledw. spool feed back

PVED CAN controlledw. spool feed back

PVE Identification

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PVE IdentificationElectrical connections

382008

Mainspool in PVG

Elektronic

2/2 way valves

PVE Identification

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Solenoid valve principle, type 1

…used in: • PVEA / PVEA-DI

V INP.

TRD PWM

s

0.6[0.024] 0.6[0.024]

PVE Identification

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1.0[0.039]

TRD

INP.sV

PWM

Solenoid valve principle, type 2

…used in: • PVEO / PVEO-R

• PVEM• PVEH / PVEH-DI

• PVES

PVE Identification

412013

~60mm/s

Demand signal

Spool position

The FunctionPVE Identification

422013

PVE Identification

432013

Input signal monitoring

The input voltage is continuous monitored. The acceptable signal range is between 15% and 85% of the supply voltage. If Signal voltage goes outside of this range, the system will

switch into an error state.

Transducer supervision

If one of the wires to the LVDT sensor, or inside the sensor, is broken or shorted, the system will switch ínto an error state.

Supervision of the closed loop

The spool position must always correspond to the position requested by the input signal. If the spool is 15% farther from

neutral (providing more flow) than requested, the system detects an error and will switch into an error state.

Fault monitoring descriptionPVE Identification

442013

0 %

11-32 volts = 100 %

Supply voltage:

50 %

Acceptablesignal range:

0 %

100 %

50 %

15 %

85 %

Working Signal range:

0 %

100 %

50 %

15 %

85 %

25 %

75 %

Spool position error

0 %

100 %

50 %

15 %

85 %

25 %

75 %Spool positionInput signal

Spool positionInput signal

> 15% ==> ERROR

> 15% ==> ERROR

Workingrange

Workingrange

Nominal

+_Deadband 7%

Fault monitoring descriptionPVE Identification

452013

Input signal

Transducer

Closed loop

Fault mon.logic

Solenoidvalves

Error signal out

LED

Disable

Input signal

Transducer

Closed loop

Fault mon.logic

Error signal out

LED

Active version Passive version

- 750 ms delay (PVEA)

- Memory500 ms delay (PVEH)

- 750 ms delay (PVEA)

- No memory250 ms delay (PVEH)

PVE Series 4

Error output state signal is available in the connector

PVEH, PVEA, PVEP and PVES Faultmonitoring versionsActive or Passive.

Solenoid valves continuously active with power on

PVE Identification

462008

Visible Fault Indication in PVEA, PVEH and PVES

Constant Green = OK

Blinking Red = External failure (input signal)

Constant Red = Internal failure

PVE series 4PVE Identification

472008

PVE4 performance

Hysteresis% Neutal to

full strokeFull stroke to neutral

PVEO - 120 ms 90 msPVEM 20 450 ms 450 msPVEA < 2 450 ms 450 msPVEH < 4 120 ms 90 msPVES < 1 120 ms 90 ms

Reaction timeHydraulic performance

2%20%

PVEM PVEA

+8

+6

+4

+2

0

-2

-4

-6

-8

4%

PVEH

157-347.11

PVE Identification

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PVED-CC – PLUS+1 Service ToolIntroduction

• Replaces current WebGPI PVED interface tool.

• PVED - PC interface using CG 150.

• Displays all PVED on bus togeter with PVED setting

• Easy change of communication target

• Easy data upload/download between file and PVED

• OEM data and Spool data stored as XML files

Introducing the PVED-CC PLUS+1 Service Tool!

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http://www.sauer-danfoss.com

Suggested InformationPVG 16/32/100/120 PVE / PVED

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Valve Installation Considerations


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ContaminationDirt

Is the greatest s

ource fo

r failure in hydraulic

systems.

¨BE AWARE¨

Contamination

Contamination Contamination

Contamination

DirtDirt

Dirt

Dirt

Dirt

Dirt

Contamination


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• Containments from maintenance repair and installation (tools, metal burr‘s, peeling paint, welding debri etc.)

• Dirt inside system components (Tank, Cylinder, Plumbing, etc.• Contaminated Hydraulic Oil from supplier• Containments entering the cylinder due to cavitation, Oil refill

in the tank, hydraulic tank ventilation etc.• Normal wear and tear of the components.• Condensation and moisture

ContaminationValve Installation Considerations

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• Cleaniness in and the around the work area• Keep fittings and hose plugs on as long as possible.• Clean pipes before mounting.• Plugged ports until assembly.• Torque according to specification.• Keep tools clean.• Filter Oil upon filling system.• Pressure filter between pump and PVG ( recommended).• Follow maintenance instruction (Filter / Changes)• Oil check and analyses

Assembly and Maintenance things to consider


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Selection criteria• Steel pipe or hoses.• Oil velocity• Diameter, length, quality depends on l /min. // Pressure• Bending radius.

Impact on the system at the wrong choice.• Pressure drop• Pulsations / pressure spikes• Oil velocity• Reaction, response time ( Ls lines especially)

Valve Installation ConsiderationsHydraulic tubes and hoses

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Valve Installation ConsiderationsFilter and Oil cleanness

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Filter and Oil cleanness Filter recommendations


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Ingress Protection (IP) - IP65 TestingValve Installation Considerations

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Ingress Protection (IP)

DIN Connector Amp Connector

Deutsch Connector


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Ingress Protection (IP) - NEMA to IP


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Valve Installation ConsiderationsIdeal Situation

• Flat Mounting Surface– 0.35 mm * (Number of Spool Sections + Inlet Section)

• Close to Pump – 3 meters or less

• Below Reservoir (Tank)– Flooded System

• Electronic Protection

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Troubleshooting Hydraulic Systems

Troubleshooting Valve Systems

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Problem?

MechanicalNo

HydraulicNo

ElectricalNo

ElectronicNo

Software

Troubleshooting Valve SystemsHow to Think!

Think Simple

Think Complex

Which is the simplest correct way start?How and what to eliminate first?

Can we narrow in on the problem?

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• Isolate Mechanical vs. Electrical vs. Hydraulic

• Actuate spools manually

• Watch lever movement with remote actuation

• Actuate each section by itself vs. in combination with others

Troubleshooting Valve Systems

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PVG 32/100/120 General Service and troubleshooting

PVG Troubleshooting

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• Verify if fault is mechanical, hydraulic, or electrical

– Check movement of lever manually– monitor movement of manual lever when hydraulic or electrical

controller is operated

Troubleshooting Valve SystemsPVG Troubleshooting

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Mechanical Fault;• Verify main spool limit stops are not misadjusted• Main spool seized or jammed• Main spool centering spring broken or damaged• Pressure Compensator in valve section not functioning• Faulty shock or anti-cavitation valves• Spool Control Yoke ( PVM)


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Electrical Fault;• Verify electrical circuit• Faulty neutral position switch in remote control• Incorrect signal voltage

– Proportional Operation• Verify Pin : Supply Voltage (100%)• Verify Pin : Variable Signal Voltage (25-50-75%)• Verify Pin : Ground connection (0)

– On-Off Operation• Verify Pin for port A : Supply Voltage if Selected • Verify Pin for port B : Supply Voltage if Selected• Verify Pin : Ground connection (0)


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Hydraulic (Remote) Pilot Supply Fault;• Insufficient Pilot control Pressure (PVG 32/100/120: 5-

15 bar)• Insufficient pilot oil flow

– (Flow should be 1.5 L/min. per function)• Air in pilot line• Pilot lines incorrectly sized• Faulty Remote pilot operator• Sticking pressure control valve in remote hydraulic

controller


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Fault- Erratic output response;• Electric or hydraulic actuator faulty• Main spool centering spring faulty• Main spool position feedback transducer signal

incorrect• Contamination in hydraulic fluid• Air in hydraulic lines• Verify Hydraulic Oil Supply


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Fault- Erratic output response;• Open Center PVP

– Low Stand By Pressure in PVP• PVG 32: 8 bar minimum• PVG 100: 12 or 20 bar minimum for OC• PVG 120: 12 bar minimum

– Check condition of compensator spool spring


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Fault- Erratic output response;• Open / Closed Center systems

– Low Standby pressure in pump control• Standby pressure should be greater than 15 bar

– PVP Pressure relief valve faulty– PVP orifices blocked– Internal filters blocked ( PVE)– Insufficient Internal hydraulic pilot pressure – Supply lines blocked– Insufficient load pressure at compensation spring chamber (Test

load pressure at LS port in PVP module) – Load pressure too high for pressure settings of system– Blocked LS galleries– Faulty shuttle valves


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Problem• Hydraulic motor does not turn.


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• PVG32 Technical Information – #520L0344

• PVG32 Service Parts Manual – #520L0211

• PVG 32 Service Manual - # 11039167

• PVG100 Technical Information - #520L0720

• PVG100 Service Parts Manual - #520L0888

• PVG120 Technical Information - #520L0356

• PVG120 Service Parts Manual - #520L0247

• and more…..• www.sauer-danfoss.com - Literature

Suggested InformationPVG32/100/120

http://www.sauer-danfoss.com/

PVG and After Sales and Service

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