Danfoss 72400 Electronic Proportional Control Installation Guide

Installation Guide for Danfoss models including: 72400 Electronic Proportional Control, 72400, Electronic Proportional Control, Proportional Control, Control

Installation guide Danfoss electronic proportional control for medium duty 72400 piston pumps

File Info : application/pdf, 20 Pages, 346.92KB

AN481360937078en-000101

Danfoss® Electronic Proportional (EP) Control for Medium Duty 72400 Piston Pumps
Installation Guide
AN425863868388en-000101

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Identification of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 R equired Tools for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 EP Control Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 R eassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Interconnect Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Troubleshooting Reference Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Information contained in this installation booklet is accurate as of the publication date and is subject to change without notice. Performance values are typical values. Customers are responsible for selecting products for their applications using normal engineering methods.
2

Introduction
The following information describes the installation of the Electronic Proportional (EP) Control for Danfoss ® Medium Duty 72400 piston pumps. Review this information to become familiar with the procedures required before beginning any installation.
CAUTION In order to assure the most reliable installation and operation of any electronic control, proper component selection and installation procedures must be followed with respect to interconnection wiring harnesses, input command signal devices, fusing, and input power switching. Appropriate industry practices must be followed to prevent damage of and shorting of all electrical and electronic components caused by environmental hazards and application specific hazards. Typical hazards that damage the wiring harnesses or other components are abrasion, moving objects, and heat from the engine or exhaust system. Moisture can damage poorly sealed connectors and/or components, causing short circuits and other problems like corrosion. A switch must be installed in line with (+ battery) power to the electronic module, so that power may quickly be disconnected in case of emergency (component failure or inadvertent commands). A fuse rated at the maximum module operating current (3 Amp) must be installed in the + battery line to the electronic module. All the electrical connections to the EP Control electronic module must be disconnected prior to performing any electrical welding on the vehicle or machine. The electronic module and/or the hydraulic pump are not to be used as a connection point for electrical welding equipment. During initial start-up and/or checkout of the machine after service, the machine must be placed on jack stands to prevent inadvertent movement. The reliable operation and suitability of this product is dependent upon how it is applied and the other components used in the system. The system integrator must review all aspects of the application and all of the components used to assure proper operation and reliability.
3

Identification of Components
4 ea. 1.75" 10-24 Button Head Cap Screws 4 ea. #10 Lockwashers
Electronic Module
2 ea. Electronic Module Bracket

2 ea. 1.25" - 5/32" 10-24 Hex Head Cap Screws Torque to 60-68 lbf-in.

2 ea. 1.25" - 5/32" 10-24 Hex Head Cap Screws Torque to 60-68 lbf-in.
Control Valve Gasket

Solenoid Tibe Subassembly
Solenoid Coil Subassembly
Valve Assembly

Solenoid Coil Subassembly
Solenoid Tube Subassembly

6 ea. 2.75" - 5/32" 10-24 Hex Head Cap Screws Torque to 60-68 lbf-in.

Required tools f or Installation:
· 1/8" Bit Socket or Hex Key · 5/32" Bit Socket or Hex Key · 9/16" Open End Wrench · 3/4" Open End Wrench · Flat Blade Screwdriver · 1 2 VDC Power Supply or Battery · V oltage Ohm Meter (VOM) · Charge Pressure Gauge

EP Control Kits

KIT NO.

MODEL CODE REF. KIT DESCRIPTION

INPUT

VALVE

SIGNAL ASSEMBLY MODULE

ELECTRONIC VOLTAGE

9900015-000 EE 9900016-000 EC 9900017-000 ED 9900018-000 EL 9900019-000 EG 9900020-000 EL 9900021-000 EG

EP Ctrl Kit MD 72400: 1-6 V input, w/o brackets
EP Ctrl Kit MD 72400: 12 V coils w/o electronics
EP Ctrl Kit MD 72400: 24 V coils w/o electronics
EP Ctrl Kit MD 72400: ±100 mA input, w/o brackets
EP Ctrl Kit MD 72400: ±4-20 mA input, w/o brackets
EP Ctrl Kit MD 72400: ±100 mA input
EP Ctrl Kit MD 72400: ±4-20 mA input

1-6 V 4993057-012 111520-016 12/24 V

4993057-012

12 V

4993057-024

24 V

±100 mA 4993057-012 111520-100 12/24 V

±4-20 mA 4993057-012 111520-020 12/24 V

±100mA 4993057-012 111520-100 12/24 V ±4-20 mA 4993057-012 111520-020 12/24 V

9900022-000 EE 990830-000 990831-000

EP Ctrl Kit MD 72400: 1-6 V input
EP Crtl Electronic Module 1-6 V
EP Crtl Electronic Module ±100 mA

1-6 V 1-6 V ±100 mA

4993057-012 111520-016 12/24 V

111520-016 --

111520-100 --

990832-000 72400-942

EP Crtl Electronic Module ±4-20 mA

±4-20 mA --

Brackets and Screws

111520-020 --

Note: All kits using Danfoss Electronic Modules use 12 V coils.

Installation
Disassembly
Step 1 Clean the pump thoroughly. If conversion will be performed without removing pump from machine, case fluid level will need to be lowered below EP Control mounting surface. Step 2 R emove the manual displacement control. Using a 5/32" hex key or bit socket, remove the cap screws and discard.
Step 3 Carefully lift the manual displacement control away from the pump to disengage the feedback link from the servo piston land.
6

Step 4 R emove the control valve gasket from the pump housing and discard. W ith a 5/32" hex key or bit socket, remove the two top hex head cap screws on each side of the servo piston cap so the "L" brackets for the electronic module can be mounted.
Remove top hex head cap screws on each side.
7

Reassembly
Step 6 Locate the EP Control valve assembly, electronic module, bolts, washers and control valve gasket. Clean the control mounting surface and install a new control valve gasket by aligning with bolt and porting holes.
Step 7 Carefully install the EP Control valve assembly on the pump housing, making sure the feedback link is installed in the appropriate servo piston land. Note: There is a narrow land on the servo piston for the EP Control feedback link and a wide land for the swashplate link. Step 8 Use a 5/32" hex key or bit socket to install the six 10-24 hex head cap screws. Torque to 60-68 lbf·in.
8

Step 9
Neutral Adjustment
Caution: All hoses and fittings must be connected, and the pump ready for operation before attempting to check neutral adjustment. Electrical wiring harnesses for the solenoid coils and command input should be left disconnected while adjusting neutral. A. Disengage the input drive to vehicle or elevate wheels. B. Install charge pressure gauge. A 0-1000 psi or 0-1500 psi pressure gauge is
recommended. C. Start the prime mover. D. Loosen the locknut holding the neutral adjustment screw until it is just snug
enough that the threaded screw can be rotated. Use a 9/16" end wrench to hold the locking nut while rotating the neutral adjustment screw. E. Note the number stamped on the cap of the low pressure relief valve. -022 is 220 psig (15 bar), -030 is 305 psig (21 bar), etc. This will be the high setting. Settings can vary from 155 psig (11 bar) to 325 psig (22.4 bar).
9

300

200

400

100
PSI
0

500 600

300

200

400

100
PSI
0

500 600

High Setting Range

Low Setting Range

F. Slowly rotate the neutral adjustment screw clockwise until charge pressure drops to its low setting. Mark the neutral adjustment screw location.
Note: The charge pressure low setting is usually 40-60 psig lower than the high setting.
G. Rotate the neutral adjustment screw counterclockwise. The charge pressure will rise. Continue turning counterclockwise until the pressure drops again to its low setting. Mark the neutral adjustment screw location.
H. Rotate the neutral adjustment screw to the position between the two marks.
I. Carefully hold adjustment screw while torquing locknut. Torque locknut to 10±1 lbf·ft. Neutral adjustment is completed.

Solenoid

Spool

Solenoid

Alignment slot to be towards control spool± 90°

Step 10 Install the two "L " brackets on each end of the servo piston cap with the flat end facing up to hold the electronic module. Replace the 10-24 cap screws on the pump and torque with 5/32" hex key or bit socket to 60-68 lbf·in.
Step 11 Connect the four-pin connector between the EP Control electronic module and the solenoid coils. The connectors must be latched securely.
11

Step 12 Carefully position the EP Control electronic module. Tuck all cables under the module. Caution: Av oid pinching cables at mounting points. Install the four lockwashers and four 10-24 button head cap screws. Place two of the screws through the "L" brackets. Using a 1/8" hex key or bit socket, torque the four screws to 60-68 lbf·in.
Step 14 If applicable, disconnect power to the input device. Connect the command input device to the three-pin connector on the EP Control electronic module. Step 15 Disconnect electrical power to the vehicle or system. Connect the electrical power source to the two-pin connector on the EP Control electronic module. Install a 3 Amp SLO-BLO® fuse per the Interface Diagram on page 15. Step 16 The pump is now ready to return to operation.
12

Interconnect Schematic

POWER SUPPLY CONNECTOR (2-Pin) see chart

A + On/Off Switch
B +-

FUSE Battery or Power Supply

Customer

Supplied

Components

Electronic Module

COMMAND INPUT SIGNAL CONNECTOR (3-Pin) see chart

Solenoid Connector
A B C D
Proportional Solenoid 1
Servo Orifices (Optional)
S1 S2
Proportional Solenoid 2

Valve Assembly

Supply Orifice (Optional)
P

Mechanical Swashplate Feedback

Command Input Signal Connector

C OMMAND INPUT SIGNAL PINS

WIRE COLOR

SIGNAL

Black

Ref Low - 1 Vdc

1 to 6 Vdc Potentiometric B

Green

Command (wiper)

Red

Ref Hi - 6 Vdc

Orange

Loop Return

4 to 20 mA Current Loop

White

Loop In

No Connection Required*

Blue

Loop Return

±100 mA Differential

White

Loop In

No Connection Required

*EP Control Electronic Module Mating Connector Kit 990762-000 contains plug used to seal mating end connector.

Power Supply Connector

Fuse Rating

PINS WIRE COLOR SIGNAL

A Red B Black

+ Supply Voltage Supply Return

3 Amp SLO-BLO® (Time Delay) fuse for 12-24 Vdc system - customer supplied

Pump Displacement vs. Input Signal

Full Stroke Port B Flow*

Minimum Neutral Range
A

BC D

Full Stroke Port A Flow*

*Note: Actual flow direction depends on pump type and rotation

Typical Control Characteristics

(MAX) (MIN)

D (MIN)

E (MAX)

Command Input Signal

1-6 Vdc

1.5 Vdc 3.3 Vdc 3.5 Vdc 3.7 Vdc 5.5 Vdc

±4-20 mA

-20 mA -4.5 mA 0 mA +4.5 mA +20 mA

±100 mA

-100 mA -7.5 mA 0 mA +7.5 mA +100 mA

Shaft Rotation

CCW

Solenoid #2

Neither Solenoid #1

Flow OUT port "B" No flow Flow OUT port "A"

Solenoid #2

Neither Solenoid #1

Flow OUT port "A" No Flow Flow OUT port "B"

Note: The +20 mA command input signal configuration operates the pump in one direction. The customer has to change the polarity on the -20 mA signal to operate the pump in the opposite direction.

Troubleshooting

S YMPTOM

CAUSE

ACTION

No Flow in Either Direction

Defective Power Connection, or Loose Wires

Check Power Input. Disconnect the two-pin power supply connector from the EP Control electronic module. Inspect the two connectors for corrosion, loose wires or broken wires. Measure the DC voltage across pins "A" and "B" at the connector. The reading should be between 9 to 30 Vdc.

Command Signal Missing

Check Command Input Signal. Disconnect the three-pin command input device connector from EP Control electronic module. Inspect the two connectors for corrosion, loose contacts, loose wires and broken wires.

If joystick or potentiometer is used, measure the DC voltage across pins "A" and "B" at the connector. Move the joystick or potentiometer position. The voltage reading will be approximately 2.5 volts DC at joystick neutral or the half range position of the potentiometer. The DC voltage will be approximately 5 volts at one end of the joystick or potentiometer travel. At the opposite end of travel the DC voltage will be approximately zero.

If ±100 mA differential input is used, measure the DC voltage across pins "A" and "B" at the connector The DC voltage reading should be approximately zero at zero input current which occurs at command input neutral. The DC voltage reading should be approximately ±2.8 volts for input command currents of ±100 mA respectively.

Defective Solenoid Coil

Check Solenoid Coil. Disconnect the two-pin power supply and the three-pin command input device connectors from the EP Control electronic module. Inspect the connectors for corrosion, loose contacts, loose wires and broken wires. Remove the EP Control electronic module. Reverse Steps 11 and 12 on pages 11 and 12. Disconnect the two mating four-pin connectors. Measure the coil resistance across the designated pins at the solenoid four-pin connector. Refer to the Solenoid 4-pin Connector chart on page 19 for typical readings.

Defective

Check Electronic Module. Disconnect the two-pin power

Electronic Module supply and the three-pin command input device

connectors from the EP Control electronic module.

Inspect the connectors for corrosion, loose contacts,

loose wires and broken wires. Remove the EP Control

electronic module. Reverse Steps 11 and 12 on pages 11

and 12. Caution:The engine or motor driving the pump

should not be running. Connect command input device

and power to the module. Measure the current to the

coil at the four-pin connector. Activate the input device

end to end and at neutral. Monitor the current on one

coil, and then on the other. Refer to Command Input

Device chart on page 19 for typical readings.

S YMPTOM

CAUSE

ACTION

No FLow in Either Direction (con't)

Manual Override Check Manual Override. Disconnect two-pin power Does Not Function supply and the three-pin command input device
connectors from the EP Control electronic module. Inspect the connectors for corrosion loose contacts, loose wires and broken wires. Remove the valve assembly. Reverse instructions on page 8. Use a small Phillips screwdriver to push on the manual override of the solenoid tube's solenoid tube actuator pin.

Flow Only in One Direction

Command Signal Missing

Check Command Input Signal. Disconnect the three-pin command input device connector from the EP Control electronic module. Inspect the two connectors for corrosion, loose contacts, loose wires and broken wires.

Defective Solenoid Coil

Check Solenoid Coi.l Disconnect the two-pin power supply and the three-pin command input device connectors from the EP Control electronic module. Inspect the connectors for corrosion, loose contacts, loose wires and broken wires. Remove the EP Control electronic module. Reverse Steps 11 and 12 on pages 11 and 12. Disconnect the two mating four-pin connectors. Measure the coil resistance across the designated pins at the solenoid four-pin connector. Refer to the Solenoid 4-pin Connector chart on page 19 for typical readings.

Defective Solenoid Check Solenoid Tube Subassembly. Disconnect the twoTube Subassembly pin power supply and the three-pin command input device connectors from the EP Control electronic module. Inspect the connectors for corrosion, loose contacts, loose wires and broken wires. Remove the two solenoid tube subassemblies. Visually inspect the actuator pin in the tube subassembly. The pin should be free to move.

S YMPTOM

CAUSE

ACTION

Flow Only in One Direction (con't)

Defective

Check Electronic Module. Disconnect the two-pin power

Electronic Module supply and the three-pin command input device

connectors from the EP Control electronic module.

Inspect the connectors for corrosion, loose contacts,

loose wires and broken wires. Remove the EP Control

electronic module. Reverse Steps 11 and 12 on pages 11

and 12. Caution:The engine or motor driving the pump

should not be running. Connect command input device

and power supply to the electronic module. Measure the

current to the coil at the four-pin connector. Activate the

input device end to end and at neutral. Monitor the

current on one coil, and then on the other. Refer to

Command Input Device chart on page 19 for typical

readings.

Flow in Neutral

Command Signal Incorrect

Neutral Out of Adjustment

Check Neutral Adjustment. Disconnect the two-pin power supply and the three-pin command input device connectors from the EP Control electronic module. Inspect the connectors for corrosion, loose contacts, loose wires and broken wires. Remove the EP Control electronic module. Reverse Steps 11 and 12 on pages 11 and 12. Disconnect the two four-pin solenoid connectors. Follow instructions for setting neutral on page 9 Step 9.

Flow Limited, Cannot Achieve Full Pump Stroke

Command Signal Incorrect

S YMPTOM

CAUSE

ACTION

Flow Limited, Cannot Achieve Full Pump Stroke (con't)

Command Signal Incorrect

If ±100 mA differential input is used, measure the DC voltage across pins "A" and "B" at the connector. The DC voltage reading should be approximately zero at zero input current which occurs at command input neutral. The DC voltage reading should be approximately ±2.8 volts for input command currents of ±100 mA respectively.

Defective

Check Electronic Module. Disconnect the two-pin power

Electronic Module supply and the three-pin command input device

connectors from the EP Control electronic module.

Inspect the connectors for corrosion, loose contacts,

loose wires and broken wires. Remove the EP Control

electronic module. Reverse Steps 11 and 12 on pages 11

and 12. Caution: The engine or motor driving the pump

should not be running. Connect command input device

and power supply to the electronic module. Measure the

current to the coil at the four-pin connector. Activate the

input device end to end and at neutral. Monitor the

current on one coil, and then on the other. Refer to

Command Input Device chart on page 19 for typical

readings.

Manual Override Check Manual Override. Disconnect the two-pin power Does Not Function supply and the three-pin command input device
connectors from the EP Control electronic module. Inspect the connectors for corrosion loose contacts, loose wires and broken wires. Remove the valve assembly. Reverse instructions on page 8. Use a small Phillips screwdriver to push on the manual override of the solenoid tube's actuator pin should move the spool.

Does Not Return to Neutral

Command Signal Incorrect

S YMPTOM

CAUSE

ACTION

Does Not Return to Neutral (con't)

Command Signal Incorrect
Neutral Out of Adjustment

If ±4-20 mA current loop input is used, measure the DC voltage across pins "A" and "B" at the connector. The DC voltage reading should be approximately zero at zero input current which occurs at command input neutral. The DC voltage reading should be approximately ±5 volts for input command currents of ±20 mA respectively.
If ±100 mA differential input is used, measure the DC voltage across pins "A" and "B" at the connector The DC voltage reading should be approximately zero at zero input current which occurs at command input neutral. The DC voltage reading should be approximately ±2.8 volts for input command currents of ±100 mA respectively.
Check Neutral Adjustment. Disconnect the two-pin power supply and the three-pin connectors from the EP Control electronic module. Inspect the connectors for corrosion, loose contacts, loose wires and broken wires. Remove the EP Control electronic module. Reverse Steps 11 and 12 on pages 11 and 12. Disconnect the two solenoid four-pin connectors. Follow instructions for setting neutral on page 9 Step 9.

Troubleshooting Reference Settings

Solenoid 4-Pin Connector

PINS

SOLENOID

12 VOLT COIL

24 VOLT COIL

A & B Coil 1

5 ohms

21 ohms

C & D Coil 2

5 ohms

21 ohms

Note: Only 12 volt coils are used with EP Control electronics module

Joystick Position
DC VOLTAGE MEASURED ACROSS DESIGNATED PINS ATTHE CUSTOMERTHREE-PIN CONNECTOR

Full-Forward Neutral Full-Reverse

A to B 5 Vdc 2.5 Vdc 0 Vdc

Command Input Device 12/24 Volt Systems (5

coils)

CURRENTTO COIL 1 PINS A & B YELLOW & WHITE WIRES

CURRENTTO COIL 2 PINS C & D ORANGE & BLACK WIRES

Max command in one direction
Neutral
Max command in the same direction

Minimum 1.5 A Maximum 2.0 A
0 A
0 A 0 A

0 A 0 A
0 A
Minimum 1.5 A Maximum 2.0 A

· Cartridge valves
· DCV directional control
valves
· Electric converters
· Electric machines
· Electric motors
· Gear motors
· Gear pumps
· Hydraulic integrated
circuits (HICs)
· Hydrostatic motors
· Hydrostatic pumps
· Orbital motors
· PLUS+1® controllers
· PLUS+1® displays
· PLUS+1® joysticks and
pedals
· PLUS+1® operator
interfaces
· PLUS+1® sensors
· PLUS+1® software
· PLUS+1® software services,
support and training
· Position controls and
sensors
· PVG proportional valves
· Steering components and
systems
· Telematics

Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and electric components. We specialize in providing state-of-the-art technology and solutions marine sector. Building on our extensive applications expertise, we work closely with you to ensure exceptional performance for a broad range of applications. We help you and other customers around the world speed up system development, reduce costs and bring vehicles and vessels to market faster. Danfoss Power Solutions your strongest partner in mobile hydraulics and mobile Go to www.danfoss.com for further product information. outstanding performance. And with an extensive network of Global Service Partners, we also provide you with comprehensive global service for all of our components.
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References

Danfoss A/S GPL Ghostscript 10.03.1