Installation and start-up guidelines
Installation and start-up guidelines for Eaton™ proportional valves with integral amplifiers

KBD/TG4V-3 and KBDG5V-*-11 Series

This product has been designed and tested to meet specific standards outlined in the
European Electromagnetic Compatibility
Directive (EMC) 2014/30/EU which repealed
Directive 2004/108/EC. For Restriction of Hazardous Substances, complies to (RoHS) Directive 2011/65/EU. For instructions on installation requirements to achieve effective protection levels, see the Installation Wiring Practices for Eaton’s Electronic Products. Wiring practices relevant to this Directive are indicated by Electromagnetic Compatibility (EMC).

introduction

1.1 The Eaton™ “KB-D/T” range of proportional valves allows direction and rate of hydraulic fluid flow in a system to be controlled by a voltage command signal applied directly to the integral amplifier.

It is not necessary to make any adjustments to the valve/ amplifier assembly prior to putting it into service either on a new installation or when replacing a valve on an existing installation.
1. 2

WARNING: This valve with its integral electronic amplifier was factory tested prior to dispatch for conformance to the cataloged specification and performance data but Eaton Hydraulics warranty may be nullified by such actions as:

• Dismantling or adjusting any part of the assembly other than may be indicated in this leaflet.
• Incorrect installation.
• Application of the valve outside its cataloged performance limits.
• Incorrect electrical connections.
• Incorrect electrical control signals.

1.3 Before installing the valve check that the model designation on the nameplate shows it to be the correct valve for the application.
1.4 For further information

• Proportional Valves with Integral Amplifiers see catalogs V-VLPO-MC001-E1, V-VLDI-MC014-E1.

Valve for new application

2.1 Installation
2.1.1 The valve can be mounted in any attitude but the piping must be arranged to ensure that the valve is kept full of fluid at all times.
2.1.2 Do not remove the protection pad on the bottom face of the valve until immediately before installation. Take care not to lose the seals from the
valve ports. ensure that the surface on which the valve is to be mounted is clean and free from burrs and damage. This applies also to any intermediate “stacking/sandwich” valves which may be used.
2.1.3 Size 03 valves have a locating pin between ports P & B in their bottom face. This ensures that the valve is correctly oriented on the mounting face,
which should contain a mating hole.
2.1.4 Install the valve and any intermediate “stacking/ sandwich” valves on the mounting surface and secure them with bolts to class 12.9 (ISO 898)
or better. Torque bolts according to the following recommendations. For details of available Eaton TM bolt kits see catalog 2314A “Fixing bolt kits”.

• Minimum actual bolt lengths are the sum of relevant clamping heights plus the minimum engagement lengths in ferrous materials – see table below:

Metric
Bolt size| Min. Engagement
---|---
M5| 10 mm
M6| 10 mm
M10| 13 mm
M20| 35 mm
Inch
Bolt size| Min. Engagement
---|---

10-24| 0.39”

1/4”| 0.39”
3/8”| 0.52”
3/4”| 1.38”

2.1.5 Electrical Connections
Before starting to connect cables ensure that all power is switched off. Electrical connections must be made via the 7-pin plug mounted on the amplifier.
The recommended cable should have at least 6 cores with pairs of conductors individually screened and an overall braided screen.
A suitable product is offered by RS components (stock No 368-390) and consists of 3 pairs of 7/0.254 mm 2 (22AWG) and one pair of 7/0.32 mm 2
(20 AUG) plain copper conductors with polyethylene insulation. each pair is wrapped in aluminized tape. The pairs are placed around a central drain wire with a tinned copper overall braid and gray PVC sheath (10 mm overall dia).

For additional wiring Information, see installation & wiring guidelines GB- 2468A.

Command signals and outputs

WARNING
To conform to the requirements of the European Community directive on Electromagnetic Compatibility (EMC) the valves with integral amplifiers must be fitted with a metal plug. Suitable plugs are:

1. EatonTM part no. 934939 which also gives environmental protection to IP67 when tightened with a torque of 2-2,5 Nm (1.5-2.0 lbf ft).
2. ITT -Cannon part no. CA 06 COM-E 14S A7 S (not available from Eaton hydraulics).

The plastic plug part no. 694534 is only suitable for use in a sealed electromagnetic environment or outside of the European Community.

Plug assembly instructions

The metal 7-pin plug part no. 934939 must be used with this valve to achieve the full EMC specification. The assembly of the plug ls as shown in the diagram.

Assembly instructions for plastic plug part number 694534

Wiring assembly procedure

1. Lead the cable through items a, b, c, d, and e.

2. Make soldered connections to plug terminals:
   Pin A Power supply
   Pin B Power supply 0V and current command return
   Pin C Enable input (PH7 & PR7 options)
   Pin D Command signal (+V or current in)
   Pin E Command signal (-V or current GND)
   Pin F Output monitor
   Pin G Protective ground

3. Push cable clamp (e) into contact assembly housing (f) and tighten damp screws.

4. Screw body (d) Into (f) and tighten.

5. Push rubber grommet (c) and washer (b) into the body (d)

6. Thread clamp nut (a) into the body and tighten to firmly clamp the cable.

7. The plug assembly can now be connected to the amplifier.

Installation and start-up guidelines for Vickers proportional valves with integral amplifiers E-VLVI-II001-E May 2021 www.eaton.com

Figure 1. Wiring connections for valves with integral amplifier

Pin C may be connected to the ground or left unconnected.

Figure 2. Wiring connections for valves with “Enable” feature

• Output monitor voltage (pin F) will be referenced to the KB power 0 volts (pin B).
Note:
In applications where the valve must conform to European RFI/EMC regulations, the outer screen (shield) must be connected to the outer shell of the 7- pin connector and the valve body must be fastened to the earth ground. Proper earth grounding practices must be observed in this case, as any differences in command source and valve ground potential will result in a screen (shield) ground loop.
2.1.6 Power and signal levels
Power supply ……….24V DC (22 to 36V including 10% peak-to-peak ripple)
Command signal …..+/-10V or 4-20 mA (model code option)
Monitor signal ………H option coil = 1.7V per amp solenoid current output impedance 10 kΩ

2.2 Start-up
2.2.1 Single-stage valves

1. Switch power on.
2. The valve response to a command signal can be monitored via the connection from plug pin F (for pin F voltages, see 2.1.6). If the monitor signal does not follow the command signal, check to command signal connections to the amplifier.
   2.2.2 It is advisable to bleed air from the solenoids of these valves. slacken bleed screws (counterclockwise) until fluid starts to escape.
   Allow fluid to continue to escape until it is seen to be free of air bubbles. The higher the pressures at the tank port, the faster this process.

† Bleed screw locations.
Re-tighten the screws to the following torque values:
6,5 – 7,5 Nm (57-66 lbf ft).
2.2.3 Two-stage valves
The procedure for bleeding the air for the single-stage valves (section 2.2.2 above) can be applied to the two-stage valves provided that the valve is supplied with hydraulic pilot pressure.
EX models (external Pilot supply):
pressure at X port = 50 bar (725 psi) minimum
X models (internal pilot supply):
pressure at P port = 50 bar (725 psi) minimum

Replacing an existing valve

3.1 Installation
3.1.1 The following are advisory and may not be applicable to specific systems or applications. The user may need to establish procedures to suit the application.
WARNING· Before removing an existing valve:

• Tum off all electrical power.
• Relieve hydraulic pressure. Accumulators must either be isolated from the system by suitable valves or the hydraulic fluid discharged to the reservoir.
• Any overhead or positive head reservoirs must be isolated from the system by suitable valves.
• Lower all vertical cylinders
• Block any cylinders whose movement could generate pressure.

3.1.2 Disconnect electrical plug from the valve.
3.1.3 Before removing the valve, make provisions to prevent any hazard arising from the fluid that will drain from exposed mounting surfaces.
3.1.4 Unscrew the valve mounting bolts, removing these and the valve. Keep the valve mounting surface clear of any contamination whilst draining all fluid from it. If returning the valve to Eaton Hydraulics for repair, fit the protection plate from the new valve after ensuring that all fluid has been drained.
3.1.5
As 2.1.1.
3.1.6
As 2.1.2.
3.1.7 Install the new valve using the existing bolts and electrical plugs if in good condition. If not, refer to sections 2.1.4 and 2.1.5 respectively.

3.2 Re-start-up
3.2.1 Restore the application to its state immediately prior to section 3.1.1.
3.2.2 After initial start-up of the repaired system, bleed the new valve as in section 2.2.2.
3.2.3 Proceed as for new valve (sections 2.2.1).
4. Ramp adjustment
4.1 The ramp adjustment feature is accessed by removing the amplifier lid. Note: N Before adjusting the ramp setting ensure that precautions are taken to prevent static discharge harming the amplifier.

Ensure that the amplifier lid seal is not damaged or lost during adjustment.

4.2 In normal operation the amplifier status LED will flash. To activate the RAMP adjustment mode:

1. Select button
2. Ramp increase button
3. Ramp decrease button
4. Status LED – green
5. Store LED – red
6. Ramp increase/solenoid operation LED – green
7. Ramp decrease/solenoid operation LED – green

Adjustment

|

Notes

---|---
Press Select button (1)| The amplifier is now able to accept adjustments to the ramp rate. The Status LED will stop flashing during this adjustment mode.
Adjust the ramp rate by using either the Ramp Increase (2) or Ramp Decrease (3) buttons| The Ramp LEDs will illuminate as the Ramp Increase or Ramp Decrease buttons are activated
When the ramp adjustment is complete press the Select button (1) to store the ramp adjustment| This enters the adjusted Ramp Values into the amplifier memory.
The Status LED will begin flashing to indicate that normal operating mode has been resumed.

Note:
If you wish to exit the ramp adjustment mode without storing the ramp settings then switch off power to the amplifier. the amplifier will return to
previously stored settings.

4.3 When refitting the amplifier lid ensure that the seal is fitted correctly and is not damaged. The amplifier lid screws should be tightened to 0,7-0,9 Nm

Eaton
EMEA Headquarters
Route de la Longeraie 7
1110 Morges, Switzerland
Eaton.eu
© 2021 Eaton
All Rights Reserved
Printed in US
Document No. E-VLVI-II001-E
May 2021

Changes to the products, to the information contained in this document, and to prices are reserved; so are errors and omissions. Only order confirmations and technical documentation by Eaton are binding. Photos and pictures also do not warrant a specific layout or functionality. Their use in whatever form is subject to prior approval by Eaton. The same applies to Trademarks (especially Eaton, Moeller, and Cutler-Hammer). The Terms and Conditions of Eaton apply, as referenced on Eaton Internet pages and Eaton order confirmations.

Eaton is a registered trademark.
All trademarks are property of their respective owners.

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>