PVE-EX Ex eb mb version, Group II Electro-hydraulic Actuator Installation Guide

Revision History

General Information

Literature Reference

Literature reference for PVG and PVE products:

PVE-EX Introduction

The Danfoss PVE-EX is an actuator for PVG 32/128/256, PVG 100, and PVG 120. 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 DNV GL Presafe.

Product Certification

The PVE-EX eb mb 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 IEC 60079-0:2018 Explosive atmospheres - Part 0: Equipment - General requirements
• EN IEC 60079-7: 2015/A1:2018 Part 7: Equipment protection by increased safety "e"
• EN IEC 60079-18: 2014/A1:2017 Part 18: Equipment protection by encapsulation "m"

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

⚠️ Originally supplied "Danfoss cable gland" may not provide sufficient clamping. User shall provide additional clamping of the cable to ensure that pulling and twisting is not transmitted to the terminations.

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

Oil Flow Direction for Standard Assembled Groups

Diagram illustrating oil flow direction for standard assembled groups. It shows the PVE-EX, PVP, PVB, and PVS components connected, with arrows indicating flow paths labeled P, A, and B. Torque specifications for connections are also shown: 6 ± 1 N•m [53 ± 9 lbf•in].

Installation

PVE-EX Dimensions

Diagram showing the physical dimensions of the PVE-EX actuator in millimeters [inches]. Key dimensions include height, width, and depth, with specific measurements provided for various points of the unit.

Mounting of PVE-EX

1. Protect the LVDT pin (for PVEH-EX and PVES-EX actuators).
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, with a minimum tensile strength of 600 N/mm² and a minimum 0.2% proof stress of 450 N/mm².

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

Mounting of Cable

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

1. Remove insulation of an appropriate length to expose wires. If connecting to the earth terminal, ensure enough insulation for crimping into the cable shoe and proper attachment to the chassis. Cable material must meet specifications.
2. Strip wires to expose a suitable length of copper.
3. Insert wires and cable through the gland and grommet.
4. Insert wires into screw terminals and tighten screws.
5. Pull the cable back to the position where the cable insulation is still going through the grommet.
6. Mate the male and female connector after immersing the terminal compartment.
7. Ensure the O-ring is properly seated in its groove and that excess wires are not trapped between the two elements.
8. Tighten the screws (M6 x 12 mm) to the specified torque of 6 ± 1 N•m.
9. Tighten the gland to the specified torque, ensuring the cable is locked correctly, then fix the safety wire (not included). Use screws made from stainless steel grade A4 or stronger.

Cable Gland

The PVE-EX requires installation with a cable specified for the surrounding conditions and the given cable gland diameter. Two options are available:

• Supplied built-in cable gland (certified with the product).
• Pre-certified standard cable gland (M20 x 1.5 mm threaded entry and 20 x 1.5 mm O-ring).

Supplied Built-in Cable Gland

The PVE-EX features a built-in cable gland for installation. The gland and grommet prevent internal components from being exposed and retain any flame or pressure within the PVE-EX. Choose grommets delivered with the PVE-EX for different cable diameters (see table below). The cable gland must match the cable diameter and the PVE-EX requirements.

2. Screw the cable gland at least 5 full threads.
3. Tighten the cable gland to the specified torque.

PVE-EX eb mb Pre-certified Cable Gland

For cable diameter specifications, refer to the supplier's instructions for the pre-certified cable gland. To comply with product certification, the pre-certified cable gland must bear the following markings:

⚠️ Warning: Pre-certified cable glands must have an M20 x 1.5 mm 6g/6H thread and be sealed with an O-ring ø20 x 1.5 mm at the spotface of the threaded entry. The allowed surface roughness of the spotface is a maximum of Ra 6.3.

Mounting of PVG

For mounting information regarding PVG products, refer to the Literature Reference.

Mounting Options and Guidelines

The PVE-EX can be installed as either a standard or optional assembly.

Standard Assembly: Diagram showing the PVE-EX mounted to a PVG valve assembly in a standard configuration, illustrating connections and torque specifications (6 ± 1 N•m).

Optional Assembly: Diagram showing the PVE-EX mounted to a PVG valve assembly in an optional configuration, illustrating connections and torque specifications (6 ± 1 N•m).

Direction of Cable Exit

The PVE-EX design allows the customer to choose the cable exit direction, either towards or away from the PVG group. Diagrams show cable exiting towards the PVG (left) and away from the PVG (right).

Specifications

4-Pin Layout

Diagram of a 4-pin connector (Group II) with pin assignments. Minimum wire size is 0.75 mm²/AWG18, and maximum wire size is 2.5 mm²/AWG14. A table details pin assignments for different PVE-EX versions (PVEO, PVEH, PVES).

Radiometric Control Signal

Details the radiometric control signal for PVEH/PVES actuators. A table lists PIN functions (Demand signal, Supply voltage, Ground, Error) and corresponding versions.

Control signal (Us) is described with neutral, Q: P→A, and Q: P→B states, with corresponding Us values.

Ratiometric Fixed Control Signal (0-10 V)

Details the ratiometric fixed control signal (0-10 V) for specific versions. A table lists PIN functions (Demand signal, Supply Voltage, Ground, Error, Not in use) and corresponding versions. A note specifies that pins 2 and 7 shall be connected together for PVE modules without the DI function.

Adjustment/Calibration

The PVE-EX is pre-calibrated from the factory to operate within the proportional valve's dead band. The position sensor is not user-adjustable. Any biasing must be incorporated into the demand signal.

Earth Connection

Diagram showing the connector terminal with internal and external earth terminals indicated.

Internal Earth Connection

Enables an earth wire connection to the chassis. Steps involve removing insulation, crimping or soldering the wire to a cable shoe, attaching the shoe to the chassis with an M4 screw, washer, and spring washer, and tightening to 2.5 ± 0.5 N•m (M4 x 8 mm, Property class 70).

External Earth Connection

Provides a supplementary earth wire connection to the PVE-EX, required by local codes or authorities. Steps involve crimping or soldering the wire to a cable shoe, attaching the shoe to the chassis with an M4 screw, washer, and spring washer, and tightening to 2.5 ± 0.5 N•m (M4 x 8 mm, Property class 70).

Fault Monitoring

PVE-EX Fault Monitoring

Overview of fault monitoring capabilities for different PVE types (PVEH, PVEH-U, PVES, PVES-U, PVEO), including delay before error out, memory reset requirements, and error modes (Input signal fault, Transducer fault, Close loop fault).

⚠️ Caution: The installation must be performed as intended to ensure a safe system. Please refer to this manual for assistance or consult a professional.

Technical Data

Fluid Specification

Based on typical test results using mineral-based hydraulic oil with a viscosity of 21 mm²/s [102 SUS] at 50 °C [122 °F].

⚠️ Warning: The PVE is designed for pilot oil supply. Operation without oil can damage the system. Intermission should not exceed 5 seconds or occur more than once per minute.

Oil Consumption

Oil Viscosity, Oil Temperature and Pilot Pressure

Filtering in the hydraulic system: Required operating cleanliness level (ISO 4406, 2017 version): 18/16/13

PVE-EX Electrical Data

Reaction Times

Reaction Time for PVES/PVEH Versions

Reaction Time for PVEO Versions

Maintenance, Service and Troubleshooting

PVE-EX Installation, Start-up and Operation

Inspection intervals and definitions are in accordance with EN/IEC 60079-17 and inspection schedules. Operators must not attempt to repair or open a PVE-EX; a failing or damaged unit must be replaced. The PVE-EX module has a built-in thermal fuse that disconnects power if the temperature exceeds 102°C ±3°C. This fuse is not replaceable, and the actuator requires replacement.

⚠️ Warning: Installation must be performed as intended for a safe and functional application. If the enclosure, plug, or cable is damaged, the PVE-EX actuator must be replaced. Seek assistance from this manual or a professional.

⚠️ Warning: All national safety regulations must be followed for installation, start-up, and operation of Danfoss PVE-EX electrical actuators. Compliance with the Declaration of Conformity and national regulations for installations in potentially explosive atmospheres is also required. Disregarding these regulations poses a risk of serious personal injury or material damage.

⚠️ Warning: Electrical work must only be performed by professionals and qualified persons.

Safety Guidelines

• If failure, damage, or defect occurs, the PVE-EX must be replaced.
• A failing PVE-EX must not be repaired under any circumstances.
• No modifications that could compromise explosion safety or protection are permitted on the PVE-EX, cable gland, or cable.
• Demounting a PVE-EX must occur in an atmosphere free from explosion hazards.
• Machine and system approval must be obtained before using the PVE-EX in potentially explosive atmospheres.
• The manufacturer holds application responsibility and is solely liable for system safety.
• Deviations from recommended torques during part mounting can negatively affect performance and the PVE-EX.
• Do not adjust, bend, or damage the position transducer (LVDT), as this impacts safety and performance.
• When replacing the PVE-EX, ensure the electrical and hydraulic systems are turned off and oil pressure is released.
• Hydraulic oil can cause environmental damage and personal injury.
• Actuator replacement may introduce contamination and errors; maintain a clean work area and handle components with care.

Warnings

PVE-EX Warnings

⚠️ Warning: All types of directional control or proportional valves can fail and cause serious damage under various operating conditions. A risk assessment is mandatory. The machine builder/system integrator is solely responsible for product selection and ensuring all performance, safety, and warning requirements are met. Control system and safety level selection is governed by the Machinery Directive 2006/42/EC and EN 13849.

⚠️ Warning: Installation must be performed as intended for a safe and functional application. If the enclosure, plug, or cable is damaged, the PVE-EX actuator must be replaced. Consult the manual or a professional for assistance.

⚠️ Warning:

• Non-compliance with Operational Conditions can compromise safety.
• The PVG with PVE-EX operates according to specifications only if conditions in this Installation Guide are met.
• In exposed applications, shielding is recommended for protection.
• In fault mode, PVE-EX performance quality and feedback validity are limited by the fault type.
• Error signals from multiple PVE-EX units must not be connected together. Inactive error pins are grounded and disable active signals; they are signal pins with very limited power consumption.
• After actuator or cable replacement, verify wiring quality with a performance test.
• Actuation outside the specified supply voltage range reduces PVG performance.
• The PVE-EX is not designed for use with supply voltages outside the nominal range.
• Obstacles to pilot oil flow can directly influence spool control.
• Reduced pilot oil pressure limits spool control.
• Pilot oil pressure outside specifications can damage the PVE-EX.
• The PVE-EX must be installed so that flanged joints are not within 0.5 mm of a solid object not part of the PVG.

Certificates

EU Declaration of Conformity

Danfoss A/S declares under its sole responsibility that the product(s) / component(s) Ex certified PVE Series 4 - PVE-Ex eb mb T4 Gb, including various type designations (PVEO32-EX, PVEH32-EX, PVES32-EX, etc.), conform to Directive 2014/34/EU and relevant standards (EN ISO 4413, EN IEC 60079-0, EN IEC 60079-7, EN IEC 60079-18). The product bears CE marking, Notified Body identification 0470, and Presafe 16ATEX8699X.

EU-Type Examination Certificate

Issued by DNV Product Assurance AS (Notified Body 2460), this certificate (Presafe 16 ATEX 8699X, Issue 5) confirms that the Electrohydraulic actuator for proportional valve (Product Intended for use in Potentially Explosive Atmospheres Directive 2014/34/EU) complies with Essential Health and Safety Requirements. Compliance is assured by adherence to EN IEC 60079-0:2018, EN 60079-7:2015, and EN 60079-18:2014. The product marking includes II 2 G, Ex eb mb IIB T4 Gb, -40°C ≤ Tamb ≤ +60°C. Specific conditions of use may apply if indicated by an 'X'.

IECEx Certificate of Conformity

Issued by DNV Product Assurance AS for the IECEx Certification System, this certificate (IECEX PRE 16.0060X, Issue 5) verifies that the Electrohydraulic actuator for proportional valve, with Type of Protection Ex e, m, and marking Ex eb mb IIB T4 Gb, -40°C ≤Tamb≤ 60°C, complies with IEC standards (IEC 60079-0:2017, IEC 60079-18:2017, IEC 60079-7:2017). It covers the product's construction, testing, and quality system requirements. The certificate is subject to conditions outlined in IECEx Scheme Rules.

China Compulsory Product Certificate

This certificate (No: 2020322307000966) confirms that the product 'Explosion Proof Electric Control Module' (Product Name: 防爆电控模块), specifically the PVE Series (型号规格: PVE 系列), complies with Chinese standards GB 3836.1-2010, GB 3836.3-2010, and GB 3836.9-2014. It is valid from September 2, 2020, until September 1, 2025. The certificate is issued by Shanghai Inspection and Testing Institute of Instruments and Automation Systems Co., Ltd.