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Vickers® Proportional Pressure Relief Valve Technical Catalog KBCG5-3 10 Design

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Vickers®Proportional Pressure Relief ValveTechnical Catalog

KBCG5-3 10 Design

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2 EATON Vickers Proportional Pressure Relief Valve KBCG5-3, V-VLPO-MC012-E November 2009

Contents

Introduction

General Description ............................................................................................................................................................ 3

Basic Characteristics .......................................................................................................................................................... 3

Features and Benefits ........................................................................................................................................................ 3

Typical Section .................................................................................................................................................................... 3

Functional Symbols ............................................................................................................................................................ 3

Model Code............................................................................................................................................................................ 4

Operating Data ...................................................................................................................................................................... 5

Performance Data .................................................................................................................................................................. 6

Installation Dimensions ........................................................................................................................................................ 9

Elettrical Information ............................................................................................................................................................ 10

Application Data .................................................................................................................................................................... 12

This product has been designedand tested to meet specific standards outlined in the

European Electromagnetic CompatibilityDirective (EMC).For instructions on installation requirementsto achieve effective protection levels, seethis leaflet and the Installation WiringPractices for Vickers™ Electronic Productsleaflet 2468. Wiring practices relevant to

this Directive are indicated byElectromagnetic Compatibility (EMC).

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3EATON Vickers Proportional Pressure Relief Valve KBCG5-3, V-VLPO-MC012-E November 2009

Introduction

General Description

These compact two-stagepressure relief valves offerextensive applicationpossibilities through theirability to control the pressuresetting in proportion to anapplied electrical input.

The integral amplifier allowsthe pressure to be controlledfrom a low power commandsignal: either a voltage orcurrent command.

The amplifier is mounted in arobust metal housing andelectrical connections are viaan industry standard 7-pinplug. Factory-setadjustments ensure highreproducibility valve-to-valve.

Basic Characteristics

Max. pressure350 bar (5000 psi)

Max. flow rate40 L/min (10.6 USgpm)

Mounting face to ISO 6264-03-04

Note: Port B must beblocked by the mountinginterface - see installationdiagram for port postions.

Port A is used for pilot drainflow on external drainmodels.

External drain models shouldbe selected for applicationswhere a high T port pressureis required (up to 210 bar) orwhere T port pressuredisturbances are present..

Features and Benefits

• Remote electricalproportional control ofpressure from a choice offive pressure ranges.

• Excellent repeatability andstable performance.

• Low installed cost andspace requirement fromhigh power/size ratios.

• On-board rampadjustment.

• Model code selectableramp times.

Typical Section

Functional Symbols

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Model Code

Va l ve Ty p eKB – Proportional valve withintegral amplifier, B series

C o n t rol Ty p eC – Pressure Relief Valve

M o u n t i n gG – Subplate mounted

O p e ra t i o n5 – Pilot operated

Mounting Inte r fa c e3 – ISO 6264-03-04

P re s s u re Rating40 – 40 bar

100 – 100 bar

160 – 160 bar

250 – 250 bar

350 – 350 bar

Da m p e rD – Standard Damper

Manual Ove rri d eZ – No manual override

D rain OptionT – Internal drain

Blank – External drain

Amplifier Control SignalM1 – ±10 V control signal

M2 – 4 to 20 mA control signal

Ramp Option4 – Fast▼

5 – Damped ▲

Amplifier Ty p eA – Standard

E l e c t rical Connection

PC7 – 7 pin connector,without plug supplied

PE7 – 7 pin connector, withplug supplied

PH7 – As PE7 but with pin 'C'used for enable signal

PR7 – As PC7 but with pin 'C'used for enable signal

Coil IdentificationH – 24VDC

T port pre s s u re1 – 10 bar. Internal drain (T models)

7 – 210 bar. External drain(non-T models)

Design Number 1* series. Subject to change

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

WARNING

Valves with integralamplifiers are

supplied with or without themetal 7-pin plug.The Vickers TM plug, part no. 934939, must be

correctly fitted to ensure thatEMC and IP67 ratings areachieved. The plug retaining nut mustbe tightened with a torqueof 2-2,5 Nm (1.5-2.0 lbf ft) toeffect a proper seal.

▼ Typically 160 ms for 0-100%/100-0% signal(system dependent)

▲ Typically 420 ms for 0-100%/100-0% signal(system dependent)

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Standard test conditions are with antiwear hydraulic oil at 36 cSt (168 SUS) and 50°C (122°F)Maximum pressures:

Internal drain External drainModel code [9] = T Model code [9] = blank

Port P 350 bar (5000 psi) 350 bar (5000 psi)Port T 10 bar (145 psi) 210 bar (3000 psi)Port A* — 10 bar (145 psi)*External drain port

Rated flow at Δp = 5 bar (73 psi):KBCG5V-3 40 L/min (10.6 USgpm)

Pilot flow 0,4 - 1,0 L/min (0.1 - 0.26 USgpm)Coil or amplifier rating 24V x 36W max. (22 to 34V including 10% peak-to-peak max. ripple)Command signal:

Volts (see model code - [10] M1) 0 to +10V or 0 to -10VInput impedance 47 kΩCommon mode voltage to pin B 4VCurrent (see model code - [10] M2) 4 to 20 mAInput impedance 100Ω

Valve enable signal:Enable >9.0V (36V max)Disable <2.0VInput impedance 36 kΩ

7-pin plug connector Pin Description

A Power supply positive (+)B Power supply 0V and current command returnC Valve enable (PH7 & PR7)D Command signal (+V or current in)E Command signal (-V or current GND)F Output monitor G Protective ground

View of pins of fixed halfElectromagnetic compatibility (EMC):

Emission EN 50081-2Immunity (10 V/m) EN 50082-2

Monitor signal (pin F) 1.52 V/amp solenoid currentOutput impedance 10 kΩPressure gain See graphsFactory setting: maximum with 100% command signalPressure override when relieving and when off-load See graphsLinearity, between 10% and 100% of rated pressure <5%Hysteresis <5% (with factory-set dither)Repeatability +/-2% of rated pressureReproducibility, valve-to-valve (at factory settings):Pressure at 100% command signal +/-3% of rated pressureProtection:

Electrical Reverse polarity protectedEnvironmental IE C60529, Class IP67

Mass (weight) 3,45 kg (7.61lb)Mounting attitude No restriction, provided that the valve is kept full of fluid through port T.

5EATON Vickers Proportional Pressure Relief Valve KBCG5-3, V-VLPO-MC012-E November 2009

Operating Data

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Performance Data

Data is typical with oil at 36 cSt (168 SUS) and at 50°C (122°F)

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7EATON Vickers Proportional Pressure Relief Valve KBCG5-3, V-VLPO-MC012-E November 2009

Performance Data

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Performance Data

MODEL CODE STEP SIZE: RESPONSE TIME PRESSURE DEMAND (ms)

M*-4 0-100%/100-0% 16025 - 75%/75-25% 10010-90%/90-10% 140

M*-5 0-100%/100-0% 42025-75%/75-25% 26010-90%/90-10% 360

Step Response

The step response data inthe attached table should beused as a guideline only asresponse time in anyapplication will be systemdependant.

The response will besignificantly influenced bythe valve operating flow rateas well as the volume of oilbeing controlled.

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9EATON Vickers Proportional Pressure Relief Valve KBCG5-3, V-VLPO-MC012-E November 2009

InstallationDimensions

WARNING

Valves with integralamplifiers are

supplied with or without themetal 7-pin plug.The Vickers TM plug, part no. 934939, must be

correctly fitted to ensure thatEMC and IP67 ratings areachieved. The plug retaining nut mustbe tightened with a torqueof 2-2,5 Nm (1.5-2.0 lbf ft) toeffect a proper seal.

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Electrical Information

WARNING

All power must beswitched off before

connecting or disconnectingany plugs.

▲ In valves with PH7 or PR7 type electrical connection.

Block Diagram

Wiring

Connections must be madevia the 7-pin plug mountedon the amplifier. See thisleaflet and Installation WiringPractices for Vickers™Electronic Products leaflet2468. Recommended cablesizes are:

Power cables:

For 24V supply:

0,75 mm2 (18 AWG) up to20m (65 ft)

1,00 mm2 (16 AWG) up to40m (130 ft)

Signal cables:

0,50 mm2 (20 AWG)

Screen (Shield):

A suitable cable should haveat least 6 cores with pairs ofconductors individuallyscreened and an overallscreen.

Cable outside diameter 8,0-10,5 mm (0.31- 0.41 inches).

See connection diagrams onnext page.

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Electrical Information

Typical ConnectionArrangements

WARNING

ElectromagneticCompatibility (EMC)

It is necessary to ensure thatthe valve is wired up asabove. For effective protection theuser electrical cabinet, thevalve subplate or manifold

and the cable screens shouldbe connected to efficientground points. The metal 7-pin connectorpart no. 934939 should beused for the integralamplifier. In all cases bothvalve and cable should bekept as far away as possiblefrom any sources of

electromagnetic radiationsuch as cables carryingheavy current, relays andcertain kinds of portableradio transmitters, etc. Difficult environments couldmean that extra screeningmay be necessary to avoidthe interference.

It is important to connect the0V lines as shown above.The multi-core cable shouldhave at least two screens toseparate the demand signaland monitor output from thepower lines.

■ Pin C may be connectedto ground or leftunconnected.

● Output monitor voltagepin F) will be referenced tothe power 0 volts (pin B).

▲ Note:

In applications where thevalve must conform toEuropean RFI/EMCregulations, the outer screen(shield) must be connectedto the outer shell of the 7-pin connector, and thevalve body must be fastenedto the earth ground. Properearth grounding practicesmust be observed in thiscase, as any differences incommand source and valveground potentials will resultin a screen (shield) groundloop.

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Application Data

Hydraulic Fluids

Materials and seals used inthese valves are compatiblewith:

Anti-wear petroleum oils ................................L-HM

Non-alkyl based phosphate esters ........L-HFD

The extreme operating rangeis 500 to 13 cSt (270 to 70SUS) but the recommendedrunning range is 54 to 13 cSt(245 to 70 SUS). For furthertechnical information aboutfluids see 694.

Contamination Control

RequirementsRecommendations oncontamination controlmethods and the selection of products to control fluidcondition are included inpublication 9132 or 561,“Guide to SystemicContamination Control”.

The book also includesinformation on the conceptof “ProActive Maintenance”.The following recommenda-tions are based on ISOcleanliness levels at 2 μm, 5 μm and 15 μm.

For products in this catalogthe recommended levels are:

Up to 210 bar (3000 psi)18/16/13

Above 210 bar (3000 psi)17/15/12

Installation and Start-upGuidelines

The proportional valves inthis catalog can be mountedin any attitude but it may benecessary, in certaindemanding applications, toensure that the solenoids arekept full of hydraulic fluid.

If this proves to be the caseany accumulated air can bebled from the solenoid bleedscrew. This task is easier ifthe valve has been mountedbase downwards. Goodinstallation practice dictatesthat the tank port, and anydrain port, are piped so as tokeep the valve full of fluidonce the system start-up hasbeen completed.

Temperatures

For petroleum oil:Min......................-20°C (-4°F)Max ................+70°C (158°F)

For fluids where limits areoutside those of petroleumoil, consult fluidmanufacturer or Eatonrepresentative. Whatever theactual temperature range,ensure that viscosities staywithin those specified under“Hydraulic Fluids”.

Ambient for:Valves at full performancespecification: -20 to +70°C (-4 to +158°F).

Valves, as above, will operateat temperatures of 0 to -20°C(32 to -4°F) but with areduced dynamic response.

Storage:-25 to +85°C (-13 to +185°F)

Seal Kits

6022633-001

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© 2008 Eaton CorporationAll Rights ReservedPrinted in USADocument No. V-VLPO-MC012-ENovember 2009

Eaton Hydraulics Operations USA14615 Lone Oak RoadEden Prairie, MN 55344USATel: +1 952 937 9800Fax: +1 952 294 7722www.eaton.com/hydraulics

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