Danfoss PVG 32 Electro Hydraulic Actuator Installation Guide

Danfoss PVG 32 Electro Hydraulic Actuator Installation Guide

General information

Literature reference

Literature reference for PVG and PVE products

PVE-EX introduction

The Danfoss PVE-EX is an actuator for PVG 32 and PVG 128/256.
The PVE-EX is an explosion proof PVE designed to be used in potentially explosive atmospheres like mining and oil and gas industries.
The PVE-EX has been certified by UL

Product Certification

The PVE-EX Apex db. version is developed according to and in compliance with:

• EN ISO 4413:2010 Hydraulic fluid power – General rules and safety requirements for systems and their components

• EN 60079-0:2018 IEC 60079-0:2017 Explosive atmospheres – Part 0: Equipment – General requirements

• EN/IEC 60079-1:2014 Electrical apparatus for explosive gas atmospheres – Part 1: Flameproof enclosures “d”

• UL 60079-0 – Explosive Atmospheres – Part 0: Equipment – General Requirements – Edition 7 – RevisionDate 04/15/2020

• UL 60079-1 – Explosive Atmospheres – Part 1: Equipment Protection by Flameproof Enclosures ‘d’ – Edition 7 – Revision Date 23/01/2020

• UL 61010-1 – Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use – Part 1: General Requirements – Edition 3 – Revision Date 04/2016

• CSA C22.2 No. 60079-0, Electrical Apparatus for Explosive Gas Atmospheres – Part 0: General Requirements, Edition 4, Issue Date 02/2019

• CSA C22.2 No. 60079-1, Explosive Atmospheres – Part 1: Equipment protection by flameproof enclosures “d” – Edition 3 – Issue Date 05/2016

• CAN/CSA C22.2 No.61010-1-12 safety requirements for Electrical Equipment for
  Measurement,control, and Laboratory use – part 1 : General Requirements – Edition 3 – Revision Date04/2016

• National Electrical Code: (ANSI/NFPA 70 NEC)

General information

Installation and Maintenance standards:

• EN/IEC 60079-14 Explosive atmospheres – Part 14: Electrical installations design, selection and erection
• EN/IEC 60079-17 Explosive atmospheres – Part 17: Electrical installations inspection and maintenance

The PVE-EX is in conformity with listed EU Directive (s) and EU harmonized standards:

• EMC Directive 2004/108/EC
• EN/IEC 61000-6-2:2005 Electromagnetic compatibility (EMC) – Part 6-2: Generic standards – Immunity for industrial environments
• EN 61000-6-4:2007/A1:2011, IEC 61000-6-4:2006 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards – Emission standard for industrial environments

Environmental conditions

• Altitude up to 2000 m
• Maximum relative humidity 95% non condensing
• Rated pollution degree (evaluated for pollution degree 2 rating)

Protection

All PVE-EX actuators comply with protection class IP67 and IP69k according to EN60529. However, in particularly exposed applications, protection in the form of shielding is recommended.

Specific conditions for safe use

• The flameproof joints are not intended to be repaired.
• Only separately listed cable glands that comply with the NEC, the CEC, or other local codes as applicable are permitted.
• Fasteners used for enclosure shall be made from stainless steel grade A4 or stronger (yield stress 210 MPa)

Warnings

Before implementing actuators in any application, read all warnings. Warnings are listed next to the most relevant section and repeated in the chapter PVE- EX warnings on page 18.

Do not regard the warnings as a full list of potential risks. Depending on the application and use, other potential risks can occur.

Warning
All brands and all types of directional control or proportional valves, which are used in many different operation conditions and applications, can fail and cause serious damage.
You must perform a risk assessment. 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.
The process for choosing the control system and safety levels is governed by the Machinery Directive 2006/42/EC and EU harmonized standard EN 13849 (Safety related requirements for control systems).

General information

Oil flow direction for standard assembled groups

Oil Flow Direction for Standard Assembled Groups

PVE-EX Apex db. version Nameplate

Nameplate Legend:

1. PVE-EX type, see the PVE-EX Apex db. types with part numbers in the table below.
2. PVE-EX part number (111xxxxx)
3. PVE-EX serial number (incl production date) Example: 20 18 c yy xxxx (Week: 20 Year:2018 Day: Wednesday (A= Monday) yy=prod.line number xxxx=serial number)
4. Ambient temperature range
5. Supply voltage
6. Apex class and zone protection category
7. Apex class and division protection category
8. IEC-EX group and protection category
9. UL file number
10. Certifying body logo
11.  Cable entry thread and temp specification
12. Product Identity” Process control equipment for use in Hazardous Locations

Part numbers for PVE-EX Apex db. version

Installation

PVE-EX dimensions

PVE-EX dimensions, mm [in]

Mounting of PVE-EX

1. Protect the LVDT pin.
2. Ensure all O-rings are mounted and properly aligned in the grooves before mounting the PVE-EX to the PVG valve.
3. Only use the four screws (M6 x 40 mm) A2, Tensile strength min. 600 N/mm2 , 0,2% Proof stress min. 450 N/mm2

Warning
The installation must be performed as intended in order to have a safe system and a proper functional application. In a case of damage to enclosure, plug or cable, the PVE-EX actuator must be replaced. Please refer to the information in this manual for assistance, or consult with a professional.

Warning
The flameproof enclosure is provided with metric threaded entry M20x1,5 6H according to ISO 965-1 and 3 complying with Article 500.8 of NEC ANSI/NFPA 70.
To maintain the flame proof abilities installer must use the wiring method complying with the
requirements contained in NEC Article 505 ANSI/NFPA 70.

Mounting of cable

The PVE-EX is equipped with a top part that holds the cable gland for cable installation.

1. Remove the insulation of an appropriate length to expose the wires.
   If wire shall be connected to the earth terminal, make sure to have insulation enough to crimp into
   the cable shoe and attach properly to the chassis.
   Cable material must be according to the specification.

2. Strip the wires so that a suitable length of cooper is exposed.

3. Insert wires and cable through the gland and grommet.

4. Insert wires into screw terminals and tighten the screws.

5. Pull the cable back to the position where the cable insulation is still going through the grommet.

6. Immerse the terminal compartment and mate the male and female connector.

7. Ensure that the O-ring is properly seated in its groove and that excess wires are not trapped between the two elements.

8. lighten the screws (M6 x 12 mm) to the specified torque 6 ± 1 NM.

9. Tighten the gland to the specified torque in which the cable is locked correctly.

Cable gland

The PVE-EX is required to be installed with a cable specified to the surrounding conditions and to the given diameter of the cable gland.

PVE-EX Pre-certified Cable Gland

Appropriate certified entry devices with flame barrier shall be used. Only separate listed cable glands that comply with the NEC, the CEC, or other applicable local codes are permitted.

For cable diameter specification, refer to the relevant instruction from the supplier of the pre-certified cable gland. In order to comply with the product certification the pre-certified cable gland must be marked with the following markings:

Warning
Pre-certified cable gland must have thread: M20 x 1.5 mm 6g/6H and must be sealed with O-ring Ø20   1.5 mm at the spot face of the threaded entry. Allowed surface roughness of the spot face is max. Ra 6.3.

Installation

Mounting of PVG

For mounting information regarding PVG products, see Literature reference.

Mounting options and guidelines
The PVE-EX can be installed as either standard or optional assembly. Standard assembly

Direction of cable exit
The design of the PVE-EX enables the customer to choose if the cable will exit towards or away from the PVG group.
Cable exits towards PVG (left); Cable exits away from PVG (right)

Specifications

pin layout

7-pin connector

Minimum wire size 0.75 mm2 /AWG18
Maximum wire size 2.5 mm2 /AWG14

Radiometric fixed control signal (0-10 V)

Pin 2 and 7 shall be connected together for PVE modules without the DI function

Control signal (US

Control signal – on/off activation

Control signal for PVEO versions

Control Signal

Signal voltage| Neutral| Q: P → A| Q: P → B
---|---|---|---
A| 0| UDC (A)| 0
B| 0| 0| UDC (B)

Adjustment/calibration

The PVE-EX is pre-calibrated from the factory to be inside the dead band of the proportional valve. The position sensor built into the PVE-EX cannot be adjusted by user. Any biasing of the position has to be incorporated in the demand signal

Earth connection

Connector terminal

1. Internal earth terminals
2. External earth terminals
   

Internal earth connection

Internal earth terminal enables an earth wire to be connected to chassis.

1. Remove the insulation from the earth wire at a length that allows mounting the cable shoe to the threaded hole next to the connector.
2. Crimp or solder the earth wire to the cable shoe.
3. Attach the cable shoe to the chassis via the M4 screw, washer and spring washer.
4. Tighten the screws to the specified torque 2.5 ± 0.5 NM. (M4 x 8 mm, Property class 70)

External earth connection

External earth terminal enables an earth wire to be connected to the PVE-EX. The external earth
connection is supplementary, where local codes or authorities require such connection.

1. Crimp or solder the earth wire to the cable shoe.
2. Attach the cable shoe to the chassis via the M4 screw, washer and spring washer.
3. Tighten the screws to the specified torque 2.5 ± 0.5 NM. (M4 x 8 mm, Property class 70)

Fault monitoring

PVE-EX fault monitoring

Fault monitoring overview

Caution
The installation must be performed as intended in order to have a safe system.
Please refer to the information in this manual for an assistance, or consult with a professional.

Technical data

Fluid specification

The following data is from typical test results. Mineral based hydraulic oil with a viscosity of 21 mm2 /s [102 SUS] and a temperature of 50 °C [122 °F] was used for the hydraulic system testing.

Warning
The PVE is designed for use with pilot oil supply. Use without oil supply can damage the system.
Intermission is no longer than 5 seconds and not more than once per minute.

Oil consumption

Oil viscosity, Oil temperature and Pilot pressure

SUS]
Oil temperature| -30 ˚C[-22 ˚F]| 90 ˚C[194 ˚F]| 30 to 60 ˚C[86 to140 ˚F]
Pilot pressure (relative to T pressure)| 10 bar[145 psi]| 15 bar[217 psi]| Nominal 13.5 bar[196 psi]
Intermittent pressure peaks up to| –| 50 bar [725 psi]| –

Filtering in the hydraulic system

PVE-EX electrical data

/ 0.33 A
Minimum| 0.55 / 0.29 A| N/A
Maximum| 0.82 / 0.42 A| N/A
Power consumption at rated voltage| 9 W| 7 W
Input impedance in relation 0.5 x UDC| N/A| 12 kΩ
Fault monitoring| Maximum load| N/A| 60 mA
Reaction time at fault| N/A| 250 ms

Technical data

Reaction times

Reaction time for PVEH versions

200 mms
From max. spool travel to neutral position| 65 mms| 90 mms| 100 mms

Reaction time for PVEO versions

mms
Power off| From max. spool travel to neutral position

Maintenance, service and troubleshooting

PVE-EX installation, start-up and operation

The inspection intervals and definitions are to be seen in the standard EN/IEC 60079-17 and the
corresponding Inspection schedules-table. Operators must under no circumstance try to repair or open a PVE-EX. A failing or damaged PVE-EX is to be replaced.

Warning
The installation must be performed as intended in order to have a safe system and a proper functional application. In a case of damage to enclosure, plug or cable, the PVE-EX actuator must be replaced. Please refer to the information in this manual for assistance, or consult with a professional.

Warning
All national safety regulations must be fulfilled in connection with installation, start-up and operation of Danfoss PVE-EX electrical actuation’s. Furthermore, the requirements of the Declaration of Conformity and national regulations for installations in potentially explosive atmospheres applies as well.Disregarding such regulations involves a risk of serious personal injury or extensive material damage.

Warning
Work in connection with the electrical actuations must be performed only by professionals and qualified persons.

Safety guidelines

• If failure, damage or defect occurs, the PVE-EX has to be replaced.
• A failing PVE-EX must under no circumstance be repaired.
• No modifications, which could damage the explosion-safety and protection, are allowed to the PVEEX, the cable gland, or on the cable.
• Demounting a PVE-EX must be done in an atmosphere with no potential for explosions.
• The manufacturer has the application responsibility and is solely responsible for the safety of the system.
• Deviations from recommended torque when mounting parts can harm performance and the PVE-EX.
• Do not adjust, bend or damage the position transducer (LVDT) as this will influence the safety and performance.
• If replacing the PVE-EX, the electrical and the hydraulic systems must be turned off and the oil pressure released.
• Hydraulic oil can cause both environmental damage and personal injuries.
• Actuator 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.

Warnings

PVE-EX warnings

Warning
All brands and all types of directional control or proportional valves, which are used in many different operation conditions and applications, can fail and cause serious damage.
You must perform a risk assessment. 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.
The process for choosing the control system and safety levels is governed by the Machinery Directive 2006/42/EC and EU harmonized standard EN 13849 (Safety related requirements for control systems).

Warning
The installation must be performed as intended in order to have a safe system and a proper functional application. In a case of damage to enclosure, plug or cable, the PVE-EX actuator must be replaced. Please refer to the information in this manual for assistance, or consult with a professional.

Warning

• Not applying to the Operational Conditions can compromise safety.
• A PVG with PVE-EX can only perform according to specification if conditions in this Installation Guide are met.
• In particularly exposed applications, protection in the form of a shield is recommended.
• If the PVE-EX is in fault mode the quality of performance and validity of feedback is limited depending on the fault type.
• Error signals from more PVE-EX’s must not be connected together. 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.
• After replacement of actuators or cables wiring quality must be verified by a performance test.
• By actuation outside specified supply voltage range PVG will have reduced performance.
• The PVE-EX is not designed for use with supply voltage outside nominal.
• Obstacles for the Pilot oil can have direct influence on spool control.
• Reduced pilot oil pressure will limit spool control.
• Pilot oil pressure outside specification can damage the PVE-EX.
• The PVE-EX must be installed so that the flanged joints are not within 0.5 mm of a solid object that is not part of the PVG

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Danfoss Power Solution s is a global manufacturer and supplier of high- quality hydraulic and electric components. We specialize in providing state- of-the-art technology and solutions that excel in the harsh operating conditions of the mobile off-highway market as well as the  marine sector. Building on our extensive applications expertise, we work closely with you to ensure exceptional performance for a broad range of applications. We help you and other customers around the world speed up system development, reduce costs and bring vehicles and vessels to market faster.

Danfoss Power Solutions – your strongest partner in mobile hydraulics and mobile electrification.

Go to www.danfoss.com for further product information.

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References

• Daikin Sauer Danfoss - Home
• Engineering Tomorrow | Danfoss
• Hydro-Gear Drivetrain Solutions | Home

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