Eaton Vickers KBD/TG4V-3 Serie Mode D'emploi

999424
GB
Installation and Start-up Guidelines for Vickers
Proportional Valves with Integral Amplifiers
KBD/TG4V-3 and KBDG5V-*-10 Series
This product has been designed and tested to meet specific standards
outlined in the European Electromagnetic Compatibility Directive (EMC)
89/336/EEC, amended by 91/263/EEC, 92/31/EEC and 93/68/EEC,
article 5. For instructions on installation requirements to achieve effective protection
levels, see this leaflet and the Installation Wiring Practices for Vickers
Products leaflet 2468. Wiring practices relevant to this Directive are indicated by
Electromagnetic Compatibility (EMC).
1. Introduction
1.1 The Vickers TM "KB-D/T" range of proportional valves allow 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 catalogued specification and
performance data but Eaton Hydraulics warranty may be nullified by such actions as:
• Dismantling or adjusting of any part of the assembly other than may be
indicated in this leaflet.
• Incorrect installation.
• Application of the valve outside its catalogued 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.
2. 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
TM
available Vickers bolt kits see catalog 2314A "Fixing Bolt Kits".
V l a e v C a l m i p g n e h g i t h o B s t l s / u t s d
m m ( ) n i S I O 4 4 1 0
( r o t u q ) e
K D B T / 3 - 1 2 0 ( 8 . ) 2 4 x M - 5 g 6
7 ( 9 - N ) m
K D B 5 G 5 V 0 3 1 ( 1 . ) 8 4 x M - 6 g 6
K D B 5 G 7 V 3 3 1 ( ) 3 . 4 x M 0 1
K D B 5 G 8 V 2 4 5 , 1 ( 6 . ) 7 6 x M 2 1
K D B G V 5 0 1 5 3 1 ( 3 . ) 8 6 x M 0 2
Minimum actual bolt lengths are the sum of relevant clamping heights plus
the minimum engagement lengths in ferrous materials - see table below:
M t e c i r n I h c
B t l o i s e z M . n i n E a g e g m e t n B t l o i s e z
M 5 0 1 m m # 1 - 0 4 2
/ 1 " 4
M 6 0 1 m m
M 0 1 3 1 m m / 3 " 8
M 0 2 5 3 m m / 3 " 4
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 (22 AWG) and one pair of 7/0.32 mm
(20 AWG) plain copper conductors with polyethylene insulation. Each pair is
wrapped in an 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).
24V
18V
16V
10V
0m 12m
Cable length
For additional wiring information, see Installation & Wiring Guidelines GB-2468A.
o C m m a d n i S
7 p - n i l p g u
TM
C m o a m d n =
l o V ( s t 1 ± ) V 0
TM Electronic
C m o a m d n =
C r r u t n e
- 4 ( 0 2 m ) A
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) Vickers TM
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 is as shown in the diagram.
Screen to be folded back over rubber
grommet and trimmed to length
Cable stripping detail
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
r o f m u o i t n g n u s a f r e c Pin B
Pin C
A N S B / I 3 9 7 . M
Pin D
( r o t u q ) e
Pin E
4 x 1 # - 0 4 2 N U - C 1 3
Pin F
( 6 9 - 2 6 7 f b l ) n i
Pin G
4 x 1 4 / - " 0 2 N U - C A 3
3. Push cable clamp (e) into contact assembly housing (f) and tighten clamp
4 x 3 8 / - " 6 1 U C N
screws.
6 x 1 2 / - " 3 1 U C N 4. Screw body (d) into (f) and tighten.
5. Push rubber grommet (c) and washer (b) into body (d).
6 x 3 4 / - " 0 1 N U - C B 2
6. Thread clamp nut (a) into body and tighten to firmly clamp the cable.
7. The plug assembly can now be connected to the amplifier.
Figure 1
Wiring Connections for Valves with Integral Amplifier
M . n i n E a g e g m e t n
User Panel
0 3 . " 9
Power
0 3 . " 9
supply
0 5 . " 2
1 3 . " 8
Demand
signal
Solenoid
current
monitor
Enclosure
0V must be
2
connected to ground
Pin C may be connected to ground or left unconnected.
Figure 2
Wiring Connections for Valves with "Enable" Feature
User Panel
Power
supply
Enable
signal
Demand
signal
Solenoid
current
monitor
24m
0V must be
connected to ground
Output monitor voltage (pin F) will be referenced to the KB power 0 volts (pin B).
n g s l a a d n O t u u p s t
l F w o r i d t c e n o i
P n i D P n i E
o P t i s e v i V 0 P o t A
V 0 e N t a g e v i
V V - = o P t i s e v i
D E
e N t a g e v i V 0 P o t B
V 0 o P t i s e v i
V V - = e N t a g e v i
D E
P n i D P n i E P n i B
m e r o h t n a 2 1 m A C r u n e r G t D N C r r u t n e t e r n r u
e l s s h t n a 2 1 m A C r u n e r G t D N C r r u t n e t e r n r u
part no. 934939 which also gives environmental protection to
Clamp nut torque Coupling ring torque
3,75 Nm (2.77 lbf ft) 1,8 Nm.(1.33 lbf ft)
Tighten backshell
until it bottoms
28 (1.1 in)
3,5 (0.14 in)
(a) Clamp nut
(c) Rubber
(e) Cable clamp
G
A
grommet
F B
E C
D (b) Washer
(d) Body
(f) Contact housing assembly
Power supply
Power supply 0V and current command return
Enable input (PH7 & PR7 options)
Command signal (+V or current in)
Command signal (-V or current GND)
Output monitor
Protective ground
KB...PC7/PE7 valve
Outer Screen
+24V
A
0V B
C
Inner Screen
D or E
0V
+/-10V
Drain Wire
G
0V
Input
F
KB...PR7/PH7 valve
Outer Screen
A
+24V
B
0V
0V
+8.5V C
to 36V
Inner Screen
D or E
E or D
0V
Drain Wire
G
F
Connector
shell
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
Command signal ............................. +/-10V or 4-20 mA (model code option)
Monitor signal ............... H option coil = 0.4V per amp solenoid current output
2.2 Start-up
2.2.1 Single-Stage Valves
1. Switch power on.
l F w o r i d t c e n o i
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 monitor signal does
P o t A
not follow command signal, check command signal connections to amplifier.
P o t B
2.2.2 It is advisable to bleed air from the solenoids of these valves. Slacken
bleed screws (counter-clockwise) 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
3. 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:
• Turn 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 valve, make provision to prevent any hazard arising from
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.
Notes:
Valve must be
- Before adjusting the ramp setting ensure that precautions are taken to
connected to
ground via
prevent static discharge harming the amplifier.
subplate
- 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:
Connector shell
(see note in Fig. 2)
1. Select button
2. Ramp Increase button
3. Ramp Decrease button
Valve must be
4. Status LED - green
connected to
5. Store LED - red
ground via
subplate 6. Ramp Increase /solenoid operation LED - green
7. Ramp Decrease/solenoid operation LED - green
including 10% peak-to-peak ripple)
impedance 10 kΩ
†
3 2 1 4
7 6 5