PVG and After Sales and Service

© Blue Graphics Concept Sauer-Danfoss

© Blue Graphics Concept Sauer-Danfoss
PVG and After Sales and Service

Agenda Index

After Sales and Service

• Technical information
• General guidelines in systems
• Trouble shooting
• Disassembly / assembly of valves

2
PVG and After Sales and Service
PVG32

Proportional Valve
Group

PVG 32
1988 280 bar*65 l/min = 32 KW
600

2011 400 bar*130 l/min Output in KW

= 86 KW
600

3
 Introduction to PVG Valves
All families of valves
PVG 20
PVG 100

PVG 120
PVG 32
PVG 16

PVG/HIC Hybrid solution

PVX
4
 BA PVG Product Roadmap
Product Portfolio
Valve portfolio 0-240Lpm, low to high performance, analog and digital.

PVG
16

5
PVG32/100/120
Specifying a PVG

• 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

6
 PVG 32
PVG modular build concept – all parts interchangeable
PVMD/F/H/R covers
PVS endplates
App. 30 variants

PVBS spools
App. 680 variants
PVE actuator PVM handles
App. 110 variants App. 22 variants

PVP inlets PVB work sections

App. 135 variants App. 75 variants

Know-How in Motion™ 7 7
PVG32/100/120
Specifying a PVG
PVG 32Specification
110xxxxx
Subsidiary/Dealer PAE Hydraulics Ltd. PVG No.

Customer BA sales PVG Customer Part No.

Application Training Vehicle Revision No.

A-Port B-Port
Section
Extra Features
v Function v v

157B 5110 157B

1

Inlet 157B p= 0380 bar 157B

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

2
Bow truster b 157B LSA bar LSB bar 157B b

Up/down

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

3
Bow truster prop. b 157B 2150 LSA 0120 bar LSB 0320 bar 157B 2350 b

a 157B 157B 157B 157B c

4
b 157B LSA bar LSB bar 157B b

a 157B 157B 157B 157B c

5
b 157B LSA bar LSB bar 157B b

a 157B 157B 157B 157B c

6
b 157B LSA bar LSB bar 157B b

a 157B 157B 157B 157B c

7
b 157B LSA bar LSB bar 157B b

a 157B 157B 157B 157B c

8
b 157B LSA bar LSB bar 157B b

a 157B 157B 157B 157B c

9
b 157B LSA bar LSB bar 157B b

a 157B 157B 157B 157B c

10
b 157B LSA bar LSB bar 157B b

a 157B 157B 157B 157B c

11
b 157B LSA bar LSB bar 157B b

a 157B 157B 157B 157B c

12
b 157B LSA bar LSB bar 157B b

a 157B 157B 157B 157B c

13
b 157B LSA bar LSB bar 157B b

157B 157B

a 157B 157B 157B 157B c

14
b 157B LSA bar LSB bar 157B b

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

17
"Reserved for Painting" 157B8600
Comments:

8
Filled in by: S.Larsen Date: 10-05-2011
PVG Identification
PVG32
Module Information ( internal
production.no)

PVE Module
Information

Module
Information

Assembly
Information

9
PVG Identification
PVG 32 Assembly Identification
Assigned Assembly /Group Number
(today: 11xxxxxx no.)
Relief Pressure
Setting (bar)
Bar code + Date Code / Build Center Code
Build and Test Date

47

10
PVG Identification
PVG 32 Module Identification

157B6200
157B5110
4901B032550
4901B022550 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

11
PVG Identification
PVG 32 Module Identification

PVE Module

11095110
4901B022550
Voltage Rating

12VDC

157B4911 Part Number

4901E03664

Date Code

12
 PVG Identification
157B5111 PVP
P
Pressure reduction valve Pp
Pressure gauge (M)
Pressure relief valve

Pp
LS connection
P

LS
13
13
PVG Identification
157B6233 PVB

LS pressure limiting valve Shock & suct

valve

Tank (PVE)

Pilot PVE Pp
LS
Expander

Pp

LS A/B
Shuttlevalve P

For Cleaning
14
14
PVG Identification
PVG100 Assembly Identification ( label)

15
PVG Identification
PVG100 module Identification

PVT

PVB
PVP

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)

16
 PVG Identification
PVG 120 Assembly Identification

PVG 120 Identification

label is locatated on the
PVP (inlet) module with;
-code no.
-Pressure. setting
-date stamp

17
 PVG Identification
PVG 120
PVB
Identification

PVB code no. 18

Last four digits PVB Date code
PVG Identification
PVG 120

PVP and PVT

Date code

1707 1707

19
PVG Identification
PVG 120

PVB casting code;

cannot be used
155G6302 for identification

20
PVG Identification
PVBS Identification

PVG 120 spool

PVG 100 spool

PVG 32 spool

21
PVG Identification
PVBS Identification

Flow from 65-240 l/min

Flow from 40-240 l/min PVG 120 spool

PVG 100 spool

Flow from 5-130 l/min

PVG 32 spool

22
PVG Identification
PVBS Identification PVG 32

(157B)7004 Markings pre 1998 (157B)7004

(157B)7004 Today’s spool (155L)7354
110xxxxxx

Relief grooves

23
 PVG Identification
Notch identification

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

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

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

24
Work Section Options
PVB32
<-- Without LSA/B- Shuttle With-->

Check valve

LSA/B- Shuttle valve

LS Relief valve

25
• Hauptschieber

26
26
PVG Identification
PVBS Identification PVG 100

PVG 100 spool

27
 PVG Identification
PVBS Identification PVG 100

LS Bleed Down Holes Closed Ported Cut

Open Ported, Restrictive Cut

Balancing / Timing Grooves for P.O. Logic

Date Code Part Number

28
 PVG 120 Training

X-X PVG 120

pm a

T T
P

X
X
LS

P A
A B

T T
P

LS

A B

P B

T T
P

29
 PVG Identification
PVBS Identification PVG 120
6466

PVG 120 spool

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

30
 PVG Identification
PVLP for PVG 32 and 100

Suction Spring

Pressure range Tolerances

25 -> 80 bar +20 bar
85 -> 230 bar +23 bar
Work port 235 -> 350 bar +10%
pressure

Shock Spring Tank pressure

31
PVG Identification
PVLP Identification PVG 32 and PVG 100
Date stamp

Pressure setting in Bar

32
PVG Identification
PVLP Identification PVG 120

Work port
pressure

Tank pressure
Suction Spring

Pressure setting
eg. 250 BAR

33
PVE Identification

ASIC
Electronic
modules

2*Normally
Open (NO)
2*Normally
Closed (NC)
Cover Base plate Aluminum block

Coil packages Solenoid valves LVDT

34
PVE Identification

• PVE Electrical / hydraulic data

ON / OFF 12/24 V/DC
Proportional 11-32 V/DC, Medium, High, Super
CAN – Bus
Float
Ramps
Hirschmann- , AMP-, Deutsch-Connector
Passive- , Aktive-Fault monitoring
-30° to +60°C Ambient-temp.
-30° to +90°C Oil-temp.

35
PVE Identification

PVEO, on/off

PVES, -H & -A Ratio-metric analogue

w. spool feed back

PVEP PWM controlled

w. spool feed back

PVED CAN controlled

w. spool feed back

36
PVE Identification
Electrical connections

37
PVE Identification

Elektronic

2/2 way valves

Mainspool in
PVG

38
2008
 PVE Identification
Solenoid valve principle, type 1

Vs INP.

TRD PWM …used in:

• PVEA / PVEA-DI

0.6[0.024] 0.6[0.024]

39
PVE Identification
Solenoid valve principle, type 2

Vs INP.

TRD PWM
…used in:
• PVEO / PVEO-R
• PVEM
• PVEH / PVEH-DI
• PVES
1.0[0.039]

40
PVE Identification
The Function

~60mm/s

Demand signal

Spool position

41
2013
PVE Identification

42
2013
PVE Identification
Fault monitoring description

The input voltage is continuous monitored. The acceptable

Input signal signal range is between 15% and 85% of the supply voltage.
monitoring If Signal voltage goes outside of this range, the system will
switch into an error state.

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

The spool position must always correspond to the position

Supervision of requested by the input signal. If the spool is 15% farther
the closed loop from neutral (providing more flow) than requested, the
system detects an error and will switch into an error state.

43
2013
PVE Identification
Fault monitoring description

Acceptable Working Spool position error

Supply voltage:
signal range: Signal range:
Nominal
11-32 volts = 100 % 100 % 100 % 100 %

85 % 85 % 85 %

75 % 75 %
Spool position
Working > 15% ==> ERROR
Input signal
range

50 % 50 % 50 % 50 % Deadband +
_ 7%

Working
range
Input signal
> 15% ==> ERROR
Spool position
25 % 25 %

15 % 15 % 15 %

0% 0% 0% 0%

44
2013
PVE Identification
PVE Series 4

PVEH, PVEA, PVEP and PVES Faultmonitoring versions

Active or Passive.

Active version Passive version

Input signal LED Input signal LED

Faultmon. Error signal out Fault mon. Error signal out

Transducer Transducer
logic - 750 ms delay (PVEA) logic - 750 ms delay (PVEA)
500 ms delay (PVEH) 250 ms delay (PVEH)
- Memory - No memory

Closed loop Closed loop

Solenoid valves
continuously
Solenoid
active with
Disable valves power on

Error output state signal is available in the connector

45
2013
PVE Identification
PVE series 4

Visible Fault Indication in PVEA, PVEH and PVES

Constant Green = OK

Blinking Red = External failure (input signal)

Constant Red = Internal failure

46
2008
PVE Identification
PVE4 performance

Hydraulic performance
Hysteresis Reaction time
Neutal to Full stroke
%
full stroke to neutral
PVEO - 120 ms 90 ms
PVEM 20 450 ms 450 ms
PVEA < 2 450 ms 450 ms
PVEH < 4 120 ms 90 ms
PVES < 1 120 ms 90 ms
+8

+6

PVEM PVEA PVEH

+4

+2

0
20% 2% 4%

-2

-4

-6

-8
157-347.11

47
2008
PVED-CC – PLUS+1 Service Tool
Introduction
Introducing the PVED-CC PLUS+1 Service Tool!
• 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

48
PVG 16/32/100/120 PVE / PVED
Suggested Information
http://www.sauer-danfoss.com

49
Valve Installation Considerations

Valve Installation
Considerations

50
Valve Installation Considerations

¨BE AWARE¨

Dirt
Contamination Dirt
Contamination

Dirt Contamination
Dirt

Dirt
Contamination
Contamination

Dirt

Contamination
Dirt
51
 Valve Installation Considerations
Contamination

• 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

52
 Valve Installation Considerations

Assembly and Maintenance things to consider

• 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

53
 Valve Installation Considerations
Hydraulic tubes and hoses

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)

54
Valve Installation Considerations
Filter and Oil cleanness

55
 Valve Installation Considerations
Filter and Oil cleanness

Filter recommendations

56
Valve Installation Considerations
Ingress Protection (IP) - IP65 Testing

57
Valve Installation Considerations
Ingress Protection (IP)

DIN Connector
Amp Connector

Deutsch Connector
58
Valve Installation Considerations
Ingress Protection (IP) - NEMA to IP

59
Valve Installation Considerations
Ideal 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
60
Troubleshooting Valve Systems

Troubleshooting Hydraulic
Systems

61
Troubleshooting Valve Systems
How to Think!
Problem? Think Simple
Which is the simplest correct way start?

No How and what to eliminate first?

Mechanical Can we narrow in on the problem?

No
Hydraulic

No
Electrical

No
Electronic Think Complex

Software

62
Troubleshooting Valve Systems

• 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

63
PVG Troubleshooting

PVG 32/100/120 General Service

and troubleshooting

64
Troubleshooting Valve Systems
PVG Troubleshooting

• 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

65
Troubleshooting Valve Systems
PVG Troubleshooting

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)

66
Troubleshooting Valve Systems
PVG Troubleshooting
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)

67
Troubleshooting Valve Systems
PVG Troubleshooting

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

68
Troubleshooting Valve Systems
PVG Troubleshooting

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

69
Troubleshooting Valve Systems
PVG Troubleshooting

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

70
Troubleshooting Valve Systems
PVG Troubleshooting

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

71
Troubleshooting Valve Systems
PVG Troubleshooting

Problem
• Hydraulic motor does not turn.

72
PVG32/100/120
Suggested Information
•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
73