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KVEB

Electrical Displacement Control


For Series 90 - PV
BLN-95-9060-4 Issued: November 2003

DESCRIPTION

The KVEB Electrical Displacement Control (EDC) is a two-stage


electrohydraulic pump stroke control which uses mechanical feedback to
establish closed loop control of the swashplate angle of Sauer-Danfoss Series
90 Pumps.

The first stage, the MCV116 Pressure Control Pilot (PCP) is a torque-motor
actuated, double-nozzle flapper valve that produces a differential output
pressure proportional to the applied electrical signal. The second stage uses
the differential pressure to drive its unique spool arrangement and port oil to
the pump servo cylinders. The second-stage spool configuration allows a
null deadband (for machine safety) in the pumps output
while maintaining optimum dynamic response to
control commands.

KVEB Electrical Displacement Control (EDC)


Mounted On A Series 90 - PV.

FEATURES
Servo control deadband independent of signal null Minimum long term null shift
deadband: offers safety combined with accurate and
Dual coil torque motor can be used to sum two command
responsive control
sources
Resistance to the environment: standard silicone oil
Optional current (mA) ranges
filled torque motor, environmentally sealed first/second
stage interface, full environmental testing
Intrinsically Safe option for use in hazardous areas (4 to
20 mA). See Control Option, page 6

ORDERING INFORMATION

The KVEB Electrical Displacement Control is ordered by 2. PUMP SIZE


specifying the pump size and pilot type as shown in Table A.
MODEL CODE PUMP SIZE
Note, KVEBXXXXX replaces KVEAXXXXX.
03 30 or 42 cc

TABLE A. INFORMATION NECESSARY TO SPECIFY 05 55 cc


THE EDC. 07 75 cc
KVEB X XX XX
10 100 cc
BASE DEVICE 13 130 cc Pump S/N < 92 - 19
CONFIGURATION 14 130 cc Pump S/N * 92 -19
PUMP SIZE 18 180 or 250 cc
PILOT STYLE
1. CONFIGURATION 3. PILOT (NOT ALL SHOWN)
MODEL CODE CURRENT RANGE (mA) MODEL CODE PILOT STYLE
A 4-20 (single coil) 02 MS Connector (14-85 mA)
B 14-85 (dual coil) 04 Packard Connector (14-85 mA)
E* 14-85 (dual coil) 07 MS Connector (4-20 mA)
S** 4-20 (single coil) 09 Deutsch Connector (14-85 mA)
99 MS Connector (4-20 mA Intrinsically Safe)
* High response, no pressure limiter (PL) orifices, annular housing
** Intrinsically Safe
Copyright 2003, Sauer-Danfoss (US) Company.
1 All rights reserved. Contents subject to change.
ORDERING INFORMATION (continued)
EDCs ordered separate from the pump must have mounting 42 cc PUMP KIT (KIT NUMBER KK11642)
kits ordered separately: Comprised of one K07652 gasket, six 9007314-0611
bolts and one K09123 washer
30/55 cc PUMP KIT (KIT NUMBER KK11655)
Comprised of one K07652 gasket and six 9007314- 180/250 cc PUMP KIT (KIT NUMBER KK11618)
0611 bolts Comprised of one K07653 gasket, six 9007314-0611
bolts and one K09123 washer
75/100/130 cc PUMP KIT (KIT NUMBER KK11675)
Comprised of one K07653 gasket and six 9007314-
0611 bolts

TECHNICAL DATA
ELECTRICAL
OIL TEMPERATURE
FULL STROKE CURRENT -40 C (-40 F) minimum; 104 C (220 F) maximum
A (Configuration) 18 1.5 mA (single coil)
S (Configuration) 18 2.0 mA (single coil) OPERATING SUPPLY PRESSURE
B & E (Configuration) 85 11.3 mA (dual coil) Typically 300-400 psi above case pressure
42 5.6 mA (series coils)
RATINGS
85 11.3 mA (parallel coils)
See Electrical Characteristics for complete range of cur-
rents SCALE FACTOR
A (Configuration) 6.2 psid/mA (single coil)
THRESHOLD CURRENT B & E (Configuration) 1.15 psi/mA (single coil)
A (Configuration) 5 1.0 mA 2.3 psi/mA (coils in series)
S (Configuration) 6 1.5 mA 1.15 psi/mA (coils in parallel)
B & E (Configuration) 14 3.0 mA S (Configuration) 5.5 psid/mA (single coil)

NOMINAL INPUT IMPEDANCE TEMPERATURE


A (Configuration) 650 ohms for A/B coil The valve will meet all specifications over the range of
B & E (Configuration) 20.0 ohms for A/B coil 21 to 82 C (70 to 180 F)
16.0 ohms for C/D coil
S (Configuration) 110 ohms for A/B coil

NOTE: The EDC is designed to be controlled from a dc current


source or voltage source. Pulse width modulation (PWM) is not
required. But, if a PMW signal is used use a carrie frequency
200 Hz. Do not use a pulse current of more than 120% of that
required for full output.

HYDRAULIC

FILTRATION
The system hydraulics must have 10 micron or better
filtration. The pump will contain screen filters near the
interface to the EDC at the charge port and control port
locations. The pilot will have a screen filter at its input port
and internal output control ports screen.

FLUID
Automatic transmission fluid or hydraulic oil, such as Mobil
DTE 24 or equivalent. Fluid cleanliness is ISO 4406 code
18/15 or better.

OIL VISCOSITY
40-6000 SSU

BLN-95-9060-4
2
ELECTRICAL CHARACTERISTICS (B & E Configuration)
One of Dual Coils Dual Coils in Parallel Dual Coils in Series

A B C D A B C D A B C D Produces
Flow Out of
+ phasing to terminals + phasing to terminals
+ phasing to terminals Pump Port
Clockwise A or C A and C A A
PUMP SHAFT
ROTATION

Clockwise B or D B and D D B
Counterclockwise A or C A and C A B
Counterclockwise B or D B and D D A
A/B 14 mA with 0.3 Vdc
REQUIREMENTS

Start Current 3 mA 14 mA with 0.13 Vdc 7 mA with 0.25 Vdc


ELECTRICAL

Full Stroke Current A/B 85 mA with 1.7 Vdc 85 mA with 0.75 Vdc 43 mA with 1.55 Vdc
11 mA
Start Current C/D 14 mA with 0.23 Vdc
(These Vdc levels are at 75F (24C). At this temperature the coil
3 mA
Full Stroke Current C/D 85 mA with 1.36 Vdc resistance is approximately 16 for C/D and 20 for A/B.)
11 mA
MAXIMUM CONTINUOUS VOLTAGE @ 93.9C (200F): 6 Vdc, if one coil or parallel, 12 Vdc, if coils in series.

ELECTRICAL CHARACTERISTICS (A CONFIGURATION)


INPUT SHAFT ROTATION VS. TERMINAL CONNECTION VS. OUTPUT FLOW

Input Produces
Shaft
A B
Flow Out
Rotation Of Port

Clockwise A B A B
Counter
A B B A
Clockwise
Start Full Stroke Start Full Stroke Coil Coil
Current (mA) Current (mA) Voltage (Vdc) Voltage (Vdc) 75 F 220 F
4.5 - 5.5 16.5 - 19.5 2.9 - 3.6 11 - 12.6 650
4.5 - 5.5 16.5 - 19.5 3.8 - 4.7 14.0 - 16.5 650

MAXIMUM CONTINUOUS VOLTAGE @ 93.9C (200F): 24 Vdc.

DIMENSIONS, 75, 100, 130, 180, AND 250 cc PUMP EDC


11,70 mm REF
0.46 in REF
29,20 mm
1.15 in 9,70 mm
54,90 mm 0.38 in
2.16 in Neutral Adjust

201,0 mm
MS Connector 7.9 in
Option

Packard
Control Connector
Linkage Option 138,18 mm
5.44 in
89,41 mm
Spacer 3.52 in
(130, 180 cc) 55,37 mm
103,45 mm
2.18 in
4.073 in 38,07 mm
31,62 mm 1.42 in
1.245 in

49,78 mm
12,20 mm
108,46 mm 1.96 in 0.48 in
144,22 mm 4.27 in
5.56 in 169,67 mm 8,60 mm
185,70 mm 6.68 in 0.34 in
7.31 in
2016
Dimensions of the KVEA EDC for 75, 100, 130, 180, and 250 cc Pumps in Millimeters (Inches).
BLN-95-9060-4
3
DIMENSIONS, 55 cc PUMP EDC

13,00 mm REF
0.51 in REF

29,20 mm
1.15 in 9,70 mm
0.38 in
54,90 mm
2.16 in Neutral Adjust

181,60 mm
MS Connector 7.15 in
Option

Packard
Control Connector
Linkage 6 x 7,14 mm DIA 138,18 mm
Option 6 x .281 in DIA 5.44 in
89,41 mm
3.52 in
96,70 mm 55,37 mm
3.81 in 30,99 mm 38,07 mm 2.18 in
1.22 in 1.42 in

44,70 mm
1.76 in
99,06 mm
3.90 in 12,20 mm
131,06 mm 0.48 in
5.16 in
153,42 mm
5,6 mm
6.04 in
166,12 mm 0.22 in
6.54 in

2017

Dimensions of the KVEA EDC for 55 cc Pumps in Millimeters (Inches).

DIMENSIONS, 30 cc AND 42 cc PUMP EDC

.51 REF
(13)

.38
(9,7)

NEUTRAL ADJUST

PACKARD
CONNECTOR
OPTION

MS CONNECTOR
OPTION

7.03
(178,6)
CONTROL
LINKAGE
6 x .281 DIA
(6 x 7,14 DIA) 3.94
(100,1)
3.200
(81,28)
2.61 1.640
(66,3) 1.220 1.270 (41,66)
(30,99) (32,26)

2.795 1.760
(70,99) (44,7) .325
3.900 (8,26)
3.68 (99,06)
(93,5) 5.160
(131,06) 6.040 .22
(153,42) (5,6)
6.540
(166,12)
2018

Dimensions of the KVEA EDC for 30 cc and 42 cc Pumps in Millimeters (Inches).


BLN-95-9060-4
4
THEORY OF OPERATION
A command source such as a joystick, control handle or the pilot system is in equilibrium. It is this pressure feedback
electronic controller applies current signals to the pilot stage that makes the pilot a stand-alone closed loop pressure
of the KVEB Electrical Displacement Control, which results in control valve. The pilot stage is silicone oil filled for protection
flow out of the pump. The input current commands the pilots against the environment and for proper valve operation.
torque motor stage, a bridge network consisting of an
armature mounted on a torsion pivot and suspended in the air The second stage of the EDC uses a unique spool-barrel
gap of a magnetic field. Two permanent magnets polarized feedback arrangement that serves to separate the null
together with two pole pieces form a frame for the magnetic deadband from the feedback, giving both safety against null
bridge. At null the armature is centered in the air gaps drift and quick dynamic response to command changes.
between the magnets opposing poles by the equivalence of
The second stages null adjust is set with a feedback spring
their magnetic forces and the null adjust centering springs.
compressed to a 16 psi threshold (measured at the center of
As the input differential current rises to the dual coils, the end
the hysteresis loop), which is the amount of differential
of the armature becomes biased either north or south,
pressure required to begin to move the actuator spool one
depending on the magnitude of the current differential. The
direction or the other. The threshold is a factory setting. By
resulting armature movement is determined by the
tightening or loosening the main null adjust screw, the fixed
amperage of control current, the spring constant and the
deadband is adjusted so that the pump starts to stroke with
differential pressure feedback forces, explained below. See
equal output current on either side of null.
Internal Workings Schematic.
As differential control pressure input from the pilot rises
The magnetic bridge output, flapper torque, in turn controls
beyond the 16 psi deadband (KVEBB and KVEBE models),
the hydraulic bridge ratio. At null, the flapper is centered
the spool moves in one direction or the other, opening one of
between two nozzles. Upstream from each nozzle is an
the control ports to supply charge pressure to the pumps
orifice which provides a nominal pressure drop when the
servo-cylinders, moving the swashplate. As the swashplate
system is at null. Between the nozzle and the orifice on each
moves, the linkage follows, moving the barrel in the opposite
side is a control port. As the torque motor shifts the flapper
direction of the spools original motion. The barrels feedback
away from one nozzle toward the other, a differential control
movement tends to drive the spool back toward neutral
pressure results, the high side being the one nearer the
through its internal feedback spring. Oil returns from the
flapper. Fluid pressure rises on this side and moves the
servo cylinders through the spool to the case.
flapper back towards null. When the torque output from the
motor equals the torque output from the pressure feedback,

INTERNAL WORKINGS SCHEMATIC


CENTERING
SPRINGS

ARMATURE
POLE POLE
PIECE PIECE
C/D
COIL

A/B
COIL

PILOT
Ps Ps

P1 P2

Pt Ps Pt

BOOST STAGE
PUMP A B

SWASHPLATE

LINKAGE

2044

BLN-95-9060-4
5
APPLICATION
Advantages of the KVE are; These changes will not affect form or fit. In nearly all cases,
Reduction in deceleration rollout characteristics function is not affected. There is one exception: When one
Optional input currents (part number specific) side of the pilot valve is tapped to utilize the absolute pressure
Uses no loctite, which eases repair and internal parts to pilot external devices such as a one line motor control (see
replacement details below).

The KVE is intended as a direct replacement for the MCV111. 1. Abnormal case drain pressures.
But when 2 or more EDC are used in a vehicle propel 2. Oil cleanliness.
application they should all be of one type or the other, don't
mix them for reasons as described in this application section. This change went into effect January 1, 1999. Various pump
frame sizes may incorporate this change at different times
The KVE and MCV use a torque-motor based electrical dependent upon the manufacturing location and initial con-
actuator scheme that is designed to work with a current (dc trol availability.
mA) signal, i.e., 75 mA will produce the same pump flow
every time. However, the KVE and MCV have different One line motor controls: It is always best to use a two line
electrical coil arrangements, resulting in the following pre- motor control when phasing a variable motor hydraulically
cautions: with a Series 90 pumps (via the X1 and X2 ports). Applica-
Both are dual coil, but have different coil values (KVE 16 tions using only a one line hydraulic control rely on controlling
and 20 /MCV 25 and 25 ). This may cause the variable motor with pressure from only one of the EDC
problems in applications where there is a mix of KVE and ports, either X1 or X2, but not both. The pump phasing in
MCV, they are controlled simultaneous and electrically these applications will be adversely affected by this EDC
tied together in a parallel arrangement. In those parallel change. Although the delta pressure (X1 - X2) versus coil
circuits the KVE pump will be stroked ahead of the MCV current is not affected by this change, the individual gage
by approximately 25%. Therefore to ensure that KVE and pressures at X1 and X2 are significantly reduced. Depending
MCV pumps stroke at the same rate use a series electri- on fluid temperature and viscosity, and the pump charge
cal connection, which will ensure that all EDCs receive pressure setting, this reduction in gage pressures will be in
the same electrical current. the range of 60 - 80 psig (current range of 120 - 160 psig).

The MCV coils are arranged on a T-bar-style armature. If no change is made to the motor control threshold, and/or
This allows the coils to be physically separated by a small ramp in a one-line controlled motor, the motor shift will not
air gap. The KVE coils are arranged on a stand-up style occur until coil current reaches much higher levels. In fact, it
armature (which is the same used on all other dual coil may not even be possible to fully shift the motor with any coil
EDCs and servovalves) and they are stacked one atop current level. Therefore, any applications phasing a one-line
the other. In some rare instances, this may induce current hydraulically controlled motor with a Series 90 pump with one
changes resulting from the magnetic effects of one coil on of the above controls, the motor threshold and/or ramp levels
another (see Precautions When Driving Dual Coil PCPs must be changed, and coordinated with the timing of the
With A PWM Drive). Contact Sauer-Danfoss for applica- Series 90 pump EDC change. In the case of Series 51 motors
tions concerns. with one line controls, the threshold setting, and likely the
threshold spring and ramp spring will have to be changed.
KVEBXXXXX REPLACES KVEAXXXXX Please contact Sauer-Danfoss Applications Engineering for
assistance in determining the new motor specifications re-
The new control will be identified by a new letter in the control quired.
part number. The control will be designated KVEB, whereas
the previous control p/n was designated as KVEA. Since the delta pressure versus coil current relationship is not
affected by this nozzle change, the phasing of motors with
When servicing the new EDC, a different pilot valve part two line controls (controls which change motor displacement
number will be required (as compared to the existing EDC) based on the difference between X1 and X2) are not affected.
when replacement is necessary.

As a product improvement, design changes to the Series 90


Electric Displacement Control have been made:
1. Improvements in the area of the control spool and feed-
back mechanism.
2. Revisions in the nozzle area/clearance with related parts
of the pilot valve.

BLN-95-9060-4
6
APPLICATION (continued)

C2
EDC Pilot
Stage
(PCP)
C1

Lock Nut
13 mm

Pump Neutral
Adjust with
4 mm Wrench
X 1 Port X 2 Port
EDC Second
Stage 2139

Note: C1/X1 are internally connected

PCP New Pressure Where Used PCP Replaces Pressure Where Used
Part Number Range psig EDC P/N Part Number Range psig EDC P/N
MCV116G4201 60-80 KVEBXXXXX MCV116F4201 120-160 KVEAXXXXX
MCV116G4204 60-80 KVEBXXXXX MCV116F4204 120-160 KVEAXXXXX
MCV116G4211 60-80 KVEBXXXXX MCV116F4211 120-160 KVEAXXXXX
MCV116H4201 60-80 MCV114XXXXX MCV116A4201 120-160 MCV114XXXXX
MCV116H4204 60-80 MCV114XXXXX MCV116A4204 120-160 MCV114XXXXX

CURRENT VS. SWASHPLATE ANGLE OF THE SINGLE COIL KVEA (B & E CONFIGURATION)

15

10

5
100 mA 80 60 40 20

20 40 60 80 100 mA
5

10

15
1390

BLN-95-9060-4
7
CONTROL OPTIONS
In the many industrial processes where flammable materials are handled, any leak or spillage may lead to an explosive
atmosphere. To protect both property and personnel, precautions must be taken to ensure that this atmosphere cannot be
ignited. The areas at risk are known as hazardous areas and the materials that are commonly involved include crude oil and
its derivatives, alcohol, natural and synthetic process starch, grain, fibers and flyings.

Intrinsic safety is based on the principle of restricting the electrical energy available in hazardous-area circuits such that any
sparks or hot surfaces that may occur as a result of electrical faults are too weak to cause ignition. Factory mutual Research
(FM) has approved the following model listed below for use in Class I, II, or III, Division 1, Group C, D, F, and G hazardous
locations as defined by the National Electrical code, NFPA-70 when used with approved barriers. This device is also factory
Mutual certified for use in Division 2, Group C, D, F, G. If a given application requires only Division 2 approval, an inline barrier
may bot be required.

Part Number Series 90 Frame Size Current Range (mA)


KVEBS0599 30, 42, 55 cc 4 - 20
KVEBS0799 75 cc 4 - 20
KVEBS1099 100 cc 4 - 20
KVEBS1499 130 cc 4 - 20
KVEBS1899 180/250 cc 4 - 20

WIRING

A suppression circuit is incorporated in the PCP torque motor cover but by itself does not insure intrinsic safety. An additional
suppression circuit (Zener barrier) must be connected in series with the valve coils. The Zener barrier and electrical controller
must be isolated from the hazardous area either through use of a purge enclosure or mounted in a safe area. The intrinsically
safe device enclosure grounding terminal is shown in the illustration of the KVEBS 1499 on the first page. Electrical connections
and suggested barrier model numbers are shown the connection diagram below.

UNIDIRECTIONAL CONTROL, SELECT ONE OF THE FOLLOWING DC CURRENT BARRIERS


Stahl Barrier 9001/01-158-150-10 (12V) Impedence 127 1
Groups A, B, C, D, F and G (maximum voltage 15.8V)

A 3 (+)1
CONTROLLER
MCV BARRIER
B 4 2 OUTPUT

HAZARDOUS LOCATION EARTH


CLASS I, II, AND III GROUND
DIVISION 1
GROUPS C OR D, F AND G NON-HAZARDOUS LOCATION

BIDIRECTIONAL CONTROL, SELECT ONE OF THE FOLLOWING BARRIERS


Stahl Barrier 9001/02-175-200-10 (12V) Impedence 110 1
Groups A, B, C, D, F and G (maximum voltage 17.2V)

A 3 ()1
CONTROLLER
MCV BARRIER
B 4 2 OUTPUT

HAZARDOUS LOCATION EARTH


CLASS I, II, AND III GROUND
DIVISION 1
GROUPS C OR D, F AND G NON-HAZARDOUS LOCATION

To obtain a barrier or specific information about a barrier, contact R. Stahl, Inc. at 1-800-782-4357 or
e-mail at http://www.rstahl.com.

NO CHANGES TO THIS DRAWING WITHOUT PRIOR WRITTEN AUTHORIZATION FROM FACTORY MUTUAL.

BLN-95-9060-4
8
PRECAUTIONS WHEN DRIVING DUAL COIL PCPS WITH A PWM DRIVER
Sauer-Danfoss dual coil PCPs are constructed in such a 3. Some controllers are designed to diagnose shorts or
manner that magnetic flux generated in the circuit flows opens in the output circuit. The PWM-induced voltage
through the windings of both coils. This phenomenon is basic can affect some common detection schemes.
to the torque motor technology used. This is different from
some magnetic actuators, such as most proportional valves, 4. In the case of the PCP, a PWM signal is just like an
that have two distinctly separate magnetic circuits. alternating current applied to the primary of a trans-
former. A voltage is induced in the secondary coil
Since the flux generated in one coil flows through the other proportional to the turns ratio of the coils less losses in
coil, the device operates like, and in fact is, a transformer. the magnetic circuit. If the secondary coil is open cir-
cuited, there is no effect since no current flows, and
This fact is generally insignificant when the coils are driven hence no magnetic field is generated. However, if cur-
with dc currents, such as when the device is driven from a rent is allowed to flow in the secondary coil, it flows in a
potentiometric control handle or from dc current drivers such direction which will reduce the output of the actuator.
as the valve drivers in Sauer-Danfoss DC2 and SUSMIC
microcontrollers. 5. Most electronic drivers will conduct current when back
driven with excessive voltages. One example is a drive
Many controllers are set up to drive proportional solenoids that contains non-linear devices such as diodes or zener
through Pulse Width Modulation (PWM). Sometimes the diodes for re-circulatory currents. The induced voltages
scheme is used with the FET outputs of DC2s or SUSMIC may be sufficient to cause these devices to conduct,
controllers. These controls send an oscillating pulse width thereby causing current flow in the non-driven coil.
modulated dc current to the coil. This scheme has the
In position control systems where the control drives
advantages of providing dither to the actuator and, in some
toward null this generally is not a problem. However, in
cases, can simplify the electronics since they operate in a
propel systems, especially dual path propel systems,
digital mode. This can reduce heat output from the device.
the change in output velocity could be severe limitation.
In some cases filters can be designed to correct the
As with most things there are trade-offs or unwanted side
problem. A limitation of filters is this adds a lag in the
effects: Items 1 through 3 apply to all electrohydraulic
circuit which will adversely affect high response sys-
actuators. Items 4 and 5 relate more specifically to PCPs.
tems. Also it is impossible to design one filter to fit all
applications.
1. The pulsing current generates unwanted electromag-
netic radiation, which can interfere with related devices. In summary, the ability to drive the Sauer-Danfoss PCP
depends on many circumstances which must be understood
2. The actuators are generally responsive to current. PWM and accounted for by the user.
valve drivers are generally low impedance voltage
drives. As the coils heat up the resistance changes
(typically by as much as 50%), thus altering the re-
sponse of the device. For given PWM frequency and
duty cycle, both peak and average current into the driven
coil may strongly affect the coil's L/R (inductance/resis-
tance) time constant, potentially reducing both accuracy
and linearity. The effects vary considerably with valve
type and with temperature and are quite different be-
tween Sauer-Danfoss MCV116 and MCV110. PWM
drivers often require "current feedback" to maintain
sufficient accuracy as the temperature varies over the
operating range.

BLN-95-9060-4
9
PERFORMANCE

HYSTERESIS pressure limiters inoperative)


Less than 7 psi divided by the scale factor. Measured at Under 500-1000 psi load at 90 phase lag with 10 mA
a frequency of .01 Hz at 30% of rated current when run signal at 45 mA offset
from plus to minus 98 psi divided by the scale factor
TIME RESPONSE (75 CC PUMPS)
SYMMETRY B Configuration:
The differences in the currents to drive to either side of 0 to full stroke 0.78 seconds (0.18 seconds without PL
rated output will not exceed 15% orifices)
Full to full stroke 1.40 seconds (0.30 seconds without PL
LINEARITY orifices)
No point plotted on the current/swashplate angle curve Full to 0 stroke 0.38 seconds (0.15 seconds without PL
shall fall outside the area defined by a 10% slope orifices)
deviation from the scale factor, exclusive of the
deadband E Configuration (All models are shipped without PL orifices):
0 to full stroke 0.13 seconds
FAIL SAFETY
Full to full stroke 0.24 seconds
The spool will return to neutral if the electrical signal is
Full to 0 stroke 0.13 seconds
disconnected or if the pilot output pressure goes to case
pressure. Mechanical feedback must be present.
SENSITIVITY
FREQUENCY RESPONSE The valve will respond to a 2% change in input current
(EXCEPT FOR 130 cc PUMPS) throughout the rated current range except for the
2-3 Hz minimum with .052 pressure limiter orifices deadband region
3-4 Hz minimum without pressure limiter orifices (with

ENVIRONMENTAL
SHOCK 2. Resonance dwell for one million cycles for each
50 Gs for 11 milliseconds. Three shocks in both resonance point in each of the three axes.
directions of the three mutually perpendicular axes for a Subject to acceleration levels of 1 g to 46 Gs
total of 18 shocks Acceleration level varies with frequency

VIBRATION HUMIDITY
Withstands a vibration test designed for mobile After being placed in a controlled atmosphere of 95%
equipment control consisting of two parts: humidity at 49 C (120 F) for 10 days, the EDC will
perform within specification limits.
1. Cycling from 5 to 2000 Hz in each of the three axes. Meets MIL-STD-810B

WIRING

Common wiring styles are mentioned as follows: MS, 2. Strip back the insulation 5,5 millimeters on both wires.
Packard Weather-Pack, and Deutsch. The MS Connector
(MS3102C14S-2P) has four pins. See the MS Connector 3. Push a ribbed cable seal over each of the wires with the
Diagram for pin locations. See the Electrical Characteristics smaller diameter shoulder of the seals toward the wire
section for pump phasing. tip. Select the pair of seals that fits tightly over the wires.
The distance from the tip of the wires of the first (nearest)
Mating connectors must be ordered separately. For the MS rib should be 9.5 millimeters. Thus the insulation should
connector order part number K08106. The mating Packard just protrude beyond the seal.
connector is a bag assembly part number K03384,
comprised of : 4. Select the larger of the two sets of pins, as measured at
1. 4 14-16 gauge sleeves Dimension A (see the Dimension A drawing), if using
2. 4 18-20 gauge sleeves 14-16 gauge wire. Choose the smaller if using 18-20
3. 1 plastic housing gauge. Place the wire into the socket so that the seal
4. 4 green cable seals (accept 2 2-2, 8 mm wire diameter) edge is pushed through and extends slightly beyond the
5. 4 gray cable seals (accept 2 81-3, 49 mm wire diameter) circular tabs that hold it in place. Crimp in the locations
6. 4 blue cable seals (accept 3 50-4, 21 mm wire diameter) shown in the Packard Connector Crimp drawing with a
Packard 12014254 crimp tool. The distance from the
See Ordering Information. back of the tangs to the furthest rib may not exceed
19,5 mm.
TO ASSEMBLE THE FEMALE TOWER CONNECTOR

1. Isolate the wires that extend from the command source


to the EDC.
BLN-95-9060-4
10
WIRING (continued)

5. Manually insert the assembled wires into the back end 7. Plug the shroud connector from the valve into the tower
(large hole) of the plastic housing. Push until the wire connector just constructed. They are sealed with a
detents with an audible click, then pull back slightly to quadruple plug seal over the quadruple barrel of the
ensure proper seating (Observe the proper phasing of tower assembly. The two connector halves should
the wires when installing: Black wire to A hole, Red detent into each other. See the Packard Connector
wire to B, Black to C and Red to D). Terminals may Parts drawing.
be removed from the connector bodies with a Packard
12014012 removal tool.

6. Swing the holder down into the detented position to trap


the wires in the housing. The third rib should be sealed
into the housing.

MS CONNECTOR DEUTSCH DT SERIES PACKARD CONNECTOR

A
DEUTSCH
4 1 19,7 mm
0.78 in B
D A 3 2
C B C
D
20,8 mm
1276 1622
0.82 in
2076
Pin Orientation of the Optional MS Pin orientation of the Mating 4-pin Pin orientation of the optional
Connector. This Part is not Field Deutsch Plug DT06-4S Series Packard Weather-Pack connector.
Replaceable. Connector. Part number K23511. Part number K03384.

PACKARD CONNECTOR CRIMP PACKARD CONNECTOR PARTS

1077 1792

Crimp Location and Distance from Tang to Third Rib of Packard Weather-Pack Interlocked Connector Halves
Packard Weather-Pack Connector. with Parts Identified.

DIMENSION A

DIMENSION A

1123
Dimension A for Selecting Correct Terminal.
BLN-95-9060-4
11
MOUNTING
123456789012345678901234567890121234567890123
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123456789012345678901234567890121234567890123 TO INSTALL THE NEW CONTROL
123456789012345678901234567890121234567890123
123456789012345678901234567890121234567890123
WARNING
123456789012345678901234567890121234567890123
123456789012345678901234567890121234567890123 1. Place a new gasket on the pump housing. If a charge
pressure control orifice is used ensure that the orifice
Exercise care when placing the valve on a surface before
and spring are in the proper position in the control.
mounting on a transmission. Dropping or otherwise force-
fully setting the valve down may damage the pin.
2. While setting the control into position, engage the pin on
the control linkage into the mating hole in the link
Before mounting the KVEB, remove the manual control or the attached to the pump swashplate.
blanking plate that comes with the pump. First thoroughly
clean all external surfaces of the pump with steam or solvent. 3. With the control in position against the pump housing,
Then remove the six hex head cap screws from the housing pin engagement can be check by one of two methods:
using a 5 mm internal hex wrench. Lift the manual control or a. Move control assembly left and right from center
plate from the pump. position, slight resistance will be noted if properly
engaged.
Before the new control is installed it is recommended that a b. Place a finger under the control connector and lift
new mounting gasket be installed. If going from a manual away form pump housing.
control to an EDC the same mounting bolts can be used. If If control tilts away more than approximately 1/4 to 3/8 of
going from a blanking plate to an EDC new mounting bolts are an inch,, the pin is not engaged.
required because of the different lengths. To help avoid a
mounting problem it may be necessary to order an EDC 4. Repeat steps 2 and 3 in case of non engagement.
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mounting kit. See Ordering Information.
1234567890123456789012345678901212345678901234 1234567890123456789012345678901212345678901234
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WARNING
1234567890123456789012345678901212345678901234
1234567890123456789012345678901212345678901234 1234567890123456789012345678901212345678901234
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WARNING
1234567890123456789012345678901212345678901234
1234567890123456789012345678901212345678901234 Ensure positive pin engagement. Failure to do so may
result in pump output, and the vehicle may move.
The KVEB EDC cannot be hydraulically connected with
another device through the servo ports (X1 and X2). Do
not disconnect the SAE servo port fittings for this pur- 5. After control pin is engaged align the gasket and install
pose. Doing so may cause the EDC to go on stroke. The the cap screws (on 42 cc and 180/250 cc pumps use the
fittings are to be used only for troubleshooting purposes. included seal washer per the Seal Washer Location
When hydraulic connections are required, such as for a drawing) and torque to 16 Nm 10-12 ftlbs.
staging function, the MCV114S must be used. Also an
orifice (Sauer-Danfoss orifice fitting part number
9002875-0039) must be located in each of the hydraulic
connections. See Ames Bulletin No. 9104 for details. SEAL WASHER
(USED ON 42, 180, AND
250 cc MODELS ONLY)

1396

Location of Seal Washer on 42, 180, and 250 cc


Pump EDCs.

BLN-95-9060-4
12
PUMP NEUTRAL ADJUSTMENT
Use the following procedure to bring the pump to neutral wrench angle rotation, until charge pressure decreases
once the electrical displacement control has been mounted. again (charge pressure will rise in neutral and drop when
going into stroke).
1. Install a 600 psi gauge into the charge pressure gauge
port on the pump. See the Pump Port Location drawing. 7. If the transmission operates as indicated by motor shaft
rotation, reduce speed to idle. Using a 3 mm internal hex
2. Using a 13 mm wrench, loosen the hex lock nut on the wrench, slowly turn the null adjustment screw clockwise
null adjustment screw. See the Dimension drawings. or counterclockwise until the transmission does not
operate. Repeat step 6. Note that charge pressure
3. Disconnect the electrical source at the connector. should drop with forward or reverse stroking of the pump
swashplate due to the shifting of the shuttle valve in the
4. Start the prime mover and run at low idle.
123456789012345678901234567890121234567890123
123456789012345678901234567890121234567890123 motor manifold. Slowly turn the null adjustment screw
123456789012345678901234567890121234567890123
123456789012345678901234567890121234567890123 clockwise until charge pressure decreases.
WARNING
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123456789012345678901234567890121234567890123
8. With a 4 mm internal hex wrench, slowly turn the null
To adjust neutral requires operating the pump. Take the adjustment screw counterclockwise, observing the
necessary safety precautions, such as having wrench angle rotation, until charge pressure decreases
unnecessary personnel stand away from the machine. again (charge pressure will rise in neutral and drop when
Maximum system pressure may occur upon start-up, going into stroke).
and the machine may move. Ensure that the operator is
not in a position to be injured should the machine move. 9. Turn the adjustment screw clockwise half the amount of
the turn observed in step 8. This should be the center of
5. Warm the system up for several minutes to bleed air. neutral.

6. Slowly increase the prime mover speed to rated rpm. 10. Hold the adjustment screw and securely tighten the hex
lock nut on the adjustment screw to 14-18 foot-pounds.
7. If the transmission operates as indicated by motor shaft Note that if a motor is used that does not have a manifold,
rotation, reduce speed to idle. Using a 4 mm internal hex neutral should be adjusted (steps 8 - 10) by observing
wrench, slowly turn the null adjustment screw clockwise the motor shaft rotation without a load.
or counterclockwise until the transmission does not
operate. Repeat step 6. Note that charge pressure 11. Stop the prime mover.
should drop with forward or reverse stroking of the pump
swashplate due to the shifting of the shuttle valve in the 12. Reconnect the electrical signal source.
motor manifold. Slowly turn the null adjustment screw
13. Run the system briefly to ensure that it operates
clockwise until charge pressure decreases.
proportionally on both sides of null. Swashplate
8. With a 3 mm internal hex wrench, slowly turn the null movement can be verified by watching motor shaft
adjustment screw counterclockwise, observing the rotation without a load.

CHARGE PRESSURE
GAUGE PORT
2021

Location of Pump Ports.

BLN-95-9060-4
13
TROUBLESHOOTING
PUMP FAILS TO STROKE PROPERLY gage differential readings are greater than 10 psi with no
If the pump does not reach its expected output flow with the command signal, the Pilot Valve should be replaced
proper input electrical signal when measured across the coils because of either contamination or a null pressure shift,
(approximately 2 to 2.5 Vdc and 12 to 15 Vdc for configuration the effect of which would likely be pump creep in one
A), the following should be checked: direction. If gage readings are less than 80 psi, charge
pressure is either low or is not getting to the EDC, which
1. Ensure pump maintains approximately 270 psi could be caused by a number of things, such as a
minimum charge pressure. blockage at either the EDC Pilot Stage inlet filter or EDC
inlet (charge pressure) orifice if applicable. See Service
2. Actuate the EDC manual operator several times from Parts for Pilot Stage filter location.
side to side, but first take the necessary safety
precautions in the event the pump reaches full output. If adequate pressure is noted at X1 and X2 as stated
above, but the X1 and X2 differential pressure (psid)
Pump Phasing With EDC Manual Operator (MO) reading fails to reach a minimum 100 psid (example, X1
Pump MO Pump Flow of 35 psi and X2 of 135 psi) with either the manual
Rotation Rotation Out Port operator or with full rated electrical signal, then replace
CW Towards Connector B the PCP. Note, a small percentage of the KVEA style
CCW Towards Connector A PCPs between date codes 9549 through 9753 may
experience a condition in which the manual operator will
not bring the pump to full stroke in one direction (see
3. If the pump fails to reach full output flow with the manual
Service Bulletin 9833 for details).
operator, shut the system off and place two 0-500 psi
pressure gages in the control ports X1 and X2 of the EDC
(see Service Parts). Once the gages are in place start
the system. Observe the gage readings. X1 and X2
should read between 45 to 85 psi for the KVEB and 90
to 170 psi for the KVEA and be within 5 psi of each other.
Note, the level of these readings will vary with respect to
charge pressure and oil temperature but should always
be within approximately 5 psi or less of each other. If

EDC ASSEMBLY

1 Reference Service Parts Table (see page 15)

Manual Operator
Do not remove
cover screws (4)
Pilot Stage
Mounting screws (4)

EDC Pilot
Stage Lock Nut
(PCP) 13 mm

Pump Neutral
Adjust with
4 mm Wrench
X 1 Port X 2 Port
1 EDC Second 1
Stage
2071

BLN-95-9060-4
14
SERVICE PARTS
ITEM P/N QTY DESCRIPTION
1 K01291 5 SAE-6 Plugs
2 K07067 4 PCP Mounting Screws
3 K00860 1 PCP Cover Gasket
4 (2)(4) K02264 4 PCP Cover Screws
5* K00920 1 PCP Null Access Screw
6 (4)** K28475 1 PCP Cover Assy Replacement Kit
7 K21436 1 Silicone Oil Kit 4000 cs
8 (4) K04790 1 Connector Gasket
9 (4) K08687 4 Connector Screw for MS
10 (4) K01314 1 Connector MS
11 (4) K08688 4 Connector Screw for Packard
12 K08106 1 Mating Electrical Connector MS
13 (4) K08014 1 Feed Through Assy Cover Plate
14 (4) K07533 1 Feed Through Assy
4-pin Packard W-P
15 K03384 1 Mating Electrical Packard W-P
16 K00829 2 O-ring control port
17 K00830 1 O-ring return port
18 K08573 1 Filter Assy with O-rings
19 K08493 1 O-ring pressure port
20 KO2290 1 Spring Main Adjust
21 K17139 1 3-pin link/main adjust assy
(30 cc, 42 cc, 55 cc)
K17140 1 3-pin link/main adjust assy
(75 cc)
K17141 1 3-pin link/main adjust assy
(100 cc)
K17143 1 3-pin link/main adjust assy
(130 (long pin) (PV S/N < 92-19)
K17142 1 3-pin link/main adjust assy
(130 (short pin) (PV S/N * 92-19)
K17144 1 3-pin link/main adjust assy
(180 cc, 250 cc)
22 K16871 1 Neutral adjust screw
(thread m 8 x 45) 55 cc & down
K26150 1 Neutral adjust screw
(thread m 8 x 45) 75 cc & up
23 9003509-0008 1 EDC lock nut
24 K16887 1 1-pin link
25 K02288 1 Guide Shaft 55 cc & down
K02289 1 Guide Shaft 75 cc & up
26 K18519 1 Barrel Assy 55 cc & down (98 psi)
K18521 Barrel Assy 75 cc & up (98 psi)
27 K07066 2 Guide Shaft Screw
(all sizes)
28 (4) 2 Control Ports (meter in)
Thread Size M8
29 (3) K06041 2 Tank (PL) Orifices 0.052 in.
Thread Size M5
30 Spring
K17726 1 55 cc & down
K17727 1 75 cc & up
31 EDC Mounting Gasket
8800520 1 30/42/55 cc
8800923 1 75/100/130 cc
790345 1 180/250 cc
32 K17944 1 Plug
33 MCV116G4204 1 PCP, 14-85 mA, Packard
W-P connector
34 MCV116G4201 1 PCP, 14-85 mA, MS connector
35 (1) MCV116A3501 1 PCP, 4-20 mA, MS connector (single coil)
36 MCV116C1401 1 PCP, 4-20 mA, MS connector I. S. (single coil)
37 MCV116G4214 1 PCP, 14-85 mA, Deutsch connector
38 K25238 1 PCP Blanking Plate
* Item 5 see item 6
**Item 6 contains items 3, 5, 8
BLN-95-9060-4
15
SERVICE PARTS (continued)

7 8
6 9
5 10

3 11
12
2
1 13

14
33 34 35 19
36 17 18 16
21 16
20
15

31

22 32

23

24 25 26 27 28 29 30 2045A

REFERENCE ITEMS IN SERVICE PARTS TABLE REPLACING COVER AND/OR


(SEE PAGE 15) ELECTRICAL CONNECTOR

(1) Item 35 has an internal scale factor (psid/mA) that is 1. Wipe down external surface to ensure that loose
factory calibrated to a special second stage which yields contaminants will not fall inside the housing.
4-20 mA control.
2. Place the valve in a firm position at 45 with the electrical
(2) Item 4. connector tilted upwards (PCPs built after 1988 are filled
1234567890123456789012345678901212345678901234
1234567890123456789012345678901212345678901234 with a silicon oil). Locate and remove the four connector
1234567890123456789012345678901212345678901234
WARNING
1234567890123456789012345678901212345678901234 screws in Item 7 if MS connector, or Item 9 if Packard
connector.
DO NOT Remove Cover Screws, unless replacing cover.
3. Hold the electrical connector and untwist wires by rotating
(3) Item 28. All units are factory shipped without orifices the connector CCW two turns while gently pulling away
installed, and are not recommended. from the housing.

(4) Items 4, 6, 8, 9, 10, 11, 13, 14. The following steps are 4. Clean the solder connections inside connection of the
recommended when servicing those piece parts listed in electrical connector with degreaser. Unsolder the wires
Service Parts-Table A. (page 11). noting which pin goes to which wire color (i.e., Pin A to
black, Pin B to red, Pin C to brown, etc.). With the
Preferred service tools are: connector held firmly, place the solder iron against the
Screw driver TX 15 and TX 10 base solder cup if MS, and pin if Packard, until the wires
Solder SN62 can be gently pulled away.
Needle nose pliers, small tip
Solder iron, electronic type 5. The cover can now be removed and replaced if required.
Volt/ohm meter (VOM) Be sure the cover O-ring (Item 1) is firmly seated into the
Cleaning solvent, Chemtronics 2000 ES 1601 cover base and is in good condition before cover is
Torque wrench, 0-50 inlb (0-66 Nm) installed. Torque cover screws to 8-10 inlb (11-13 Nm).

BLN-95-9060-4
16
SERVICE PARTS (continued)
6. Verify that wire to pin connections are correct before 2. Loosen the null adjust lock nut using 13-mm wrench.
soldering wires. Also ensure that the connector gasket
(Item 3) is in place before soldering. 3. With a 4-mm internal hex wrench, turn the null adjustment
screw CCW 10 turns.
7a. For the MS style connector, ensure that the cups have
sufficient solder (approximately level). If additional 4. Move the link arm back and forth to eliminate any
solder is required, place solder iron against the base of binding. Using a bladed type screw driver, place it under
the cup and add solder. While solder is still liquid, place the main adjust and lift up until the 3-pin link/main adjust
wire in the cup, remove iron and let cool for several assembly lifts away from the housing.
seconds while holding wire firmly.
5. Note the 1-pin link, barrel, and guide shaft are also
7b. For the Packard style connector, the wire should extend removed at this time if changing them is required. When
around and contact the terminal post for at least 180 (1/ installing, ensure that the ball detents of the barrel align
2 wrap to a maximum of 270). When ready to solder, with the internal spool sections. Then tighten guide shaft
heat the terminal and add solder, remove iron, and let holddown screws to 30 3 in lbs.
cool for several seconds while holding wire firmly.
6. Before installing the new link assembly, ensure that it is
8. After soldering, ensure that terminals and wires do not the correct one for the pump frame size. The link arm
contact one another. should be stamped per its frame size.
7. Installing the link/main adjust assembly requires the
9. If silicone oil is to be added, do so at this step with the large spring to be installed at the same time. Ensure
connector not yet attached to cover. Tilt cover upward engagement of the link pin into the 1-pin link and that the
and add 45-cc of oil from container. The container (P/N spring is properly seated.
K21436) holds enough for 3 fills.
8. Turn the null adjustment screw CW the same number of
10. Before attaching the connector to the cover, rotate turns from Step 3. To help ensure a positive EDC null,
connector CW two turns. This will bundle the wires the 3-pin link should be aligned approximately with the
together, finishing with the notch up when viewed from neutral adjust screw as shown in the drawing. While
the outward side of the MS connector, and lead wires holding the null adjustment screw firmly, tighten the lock
down for Packard connector (see page 11). Insert nut.
connector screws and torque to 8-10 inlb (11-13 Nm).
9. Check for any binding by moving the 3-pin link back and
11. With a VOM, check for proper coil resistance between forth several times.
terminals A and B, and between C and D if PCP is a dual 1234567890123456789012345678901212345678901234
1234567890123456789012345678901212345678901234
coil. 1234567890123456789012345678901212345678901234
1234567890123456789012345678901212345678901234
WARNING
1234567890123456789012345678901212345678901234
CHANGING SERIES 90 EDC INTERNAL COMPONENTS EDC neutral setting is critical to ensure there is no machine
movement upon startup. Therefore, take the necessary
The following steps should be used as a guide when changing safety precautions in the event the pump builds pressure.
the 3-pin link/main adjust assembly: If pump system pressure does build, renulling the EDC
while it is mounted to the pump should restore the pump to
1. Place the control on a firm surface viewing the internal
neutral.
workings.

Fits Pump Drag Link

Main Adjust

3-pin Link

Snap Ring

Fits 1-pin Link

2070
3-pin Link/Main Adjust Assembly.

BLN-95-9060-4
17
CUSTOMER SERVICE
NORTH AMERICA EUROPE

ORDER FROM ORDER FROM

Sauer-Danfoss (US) Company Sauer-Danfoss (Neumnster) GmbH& Co.


Customer Service Department Order Entry Department
3500 Annapolis Lane North Krokamp 35
Minneapolis, Minnesota 55447 Postfach 2460
Phone: (763) 509-2084 D-24531 Neumnster
Fax: (763) 559-0108 Germany
Phone: +49 4321 871-0
DEVICE REPAIR Fax: +49 4321 871-284

For devices in need of repair or evaluation, include a


description of the problem and what work you believe
needs to be done, along with your name, address and
telephone number.

RETURN TO

Sauer-Danfoss (US) Company


Return Goods Department
3500 Annapolis Lane North
Minneapolis, Minnesota 55447

BLN-95-9060-4
18