MCV116

Pressure Control Pilot (PCP) Valve

BLN-95-9033-5 Issued: October 2003

DESCRIPTION
The MCV116 Pressure Control Pilot (PCP) Valve is an inex-
pensive control valve for use in electrohydraulic systems which
control machines used in construction, farming, material han-
dling, marine, mining and industrial applications. The device is
designed to control pilot-operated flow control valves (propor-
tional main spool valves in the 5—50 gpm range), pilot-
operated variable displacement pumps and motors and any
other device which is pilot differential pressure actuated.

The PCP is a torque-motor actuated, double-nozzle flapper

valve that produces a differential output pressure proportional
to the applied electrical input signal. It is a single-stage, stand-
alone, closed loop pressure control valve which uses internal
hydraulic pressure reactions to achieve its closed loop control
characteristics.

THEORY OF OPERATION INTERNAL WORKINGS SCHEMATIC

The PCP accepts a dc current and produces a proportional CENTERING

SPRINGS
hydraulic differential pressure output. See the Internal
Workings Schematic. Input current controls the torque ARMATURE
motor stage, a bridge network consisting of an armature
POLE POLE
mounted on a torsion pivot and suspended in the air gap of PIECE PIECE
a magnetic field. Two permanent magnets polarized in
parallel and a connecting plate form a frame for the magnetic
bridge. At null the armature is centered in the air gap
between the magnets’ opposing poles by the equivalence of MAGNET MAGNET
their magnetic forces and the null-adjust centering springs.
As input current rises, the end of the armature becomes
biased either north or south, depending on the direction of
the current. The resulting armature movement is deter-
mined by the amperage of control current, the spring con-
FLAPPER
stant and the differential pressure feedback forces (which PIVOT

seek a torque balance, as explained below). Linearity of the

input/output relationship is less than 10% through 80% of
ORIFICE ORIFICE
rated current.
P
The magnetic bridge output, the flapper torque, in turn S

controls the hydraulic bridge ratio. At null, the flapper is

centered between two nozzles. Upstream from each nozzle NOZZLE NOZZLE

is an orifice which provides a nominal pressure drop when C

1
P
R
C
2
the system is at null. Between the nozzle and the orifice on
each side is a control port. As the torque shifts the flapper 1025
away from one nozzle towards the other, a differential
control pressure results, the high side being the one nearer Pressure Control Pilot (at null).
the flapper.

The PCP is a closed-loop pressure control valve using

internal hydraulic pressure reactions to effect an intrinsic
feedback. With a step input from the current source, the
flapper initially moves towards full stroke to close the (com-
manded) high-side nozzle. Fluid pressure rises on this side
and moves the flapper back towards null. When the torque
output from the motor equals the torque output from the
pressure feedback, the system is in equilibrium. Deferential
pressure is then proportional to command current.
.
© Danfoss, 2013-09 BLN 95-9033-5 .
1
 FEATURES

• Standard manual override • Optional environmental electrical connector (see PCP

Mating Connectors, page 10)
• Withstands mobile equipment vibration and shock con-
ditions • Self-contained pressure feedback

• Controls both pilot-operated pumps/motors and main • Constant scale factor with varying pilot pressure
spool valves
• Can be used in either closed loop or open loop systems

MCV116 DIMENSIONS

MS CONNECTOR
MANUAL OPERATOR

NULL 2
2 CONNECTOR ADJUST
OPTIONS ACCESS
SHOWN SCREW

PACKARD 78,7
(3.10)
CONNECTOR ASSY
INTRINSICALLY
(see page 10 for SAFE DEVICE 56,1
additional connector ENCLOSURE (2.21)
options) GROUNDING
TERMINAL

12,7 OUTPUT PORT - C1 4,8 (0.19) DIA

(0.50) 12,8 (0.50) O.D. X 1,78 (0.07) O-RING 17,5 DIA (2)
(0.69)
PRESSURE PORT THRU FILTER 5,6 (0.22) DIA
12,8 (0.50) O.D. X 1,78 (0.07) O-RING
5,5 (0.217) DIA (4) RETURN PORT 4,8 (0.19) DIA
12,8 (0.50) O.D. X 1,78 (0.07) O-RING
OUTPUT PORT - C2 4,8 (0.19) DIA 1
50,8 12,8 (0.50) O.D. X 1,78 (0.07) O-RING
(2.00) 34,9
MAX (1.375)
38,1 19,0
(1.50) (0.75)

6,3 38,1
2,5 (0.10) (2) (1.50)
(0.25)
3,0 (0.12) 70,1 (2.76)
9,5 (0.38) 76,2 (3.00)
95,2 (3.75)

1 Phasing-
Positive voltage to either red lead (Pins B or D on either
the Packard or MS Connector; or pins 2 or 4 of the Duetsch Connector)
produces a pressure rise at Output Port-C2.
2 Null Adjust-
Remove screw, make null adjustment with 3/32 inch hex key,
replace screw. Adjust only for special offset considerations, or
when adjusting neutral for the Flow Control Servovalve (KVF). 1640C
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CAUTION
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If the pilot is used as the first stage of electrical displacement
control (EDC), pump or motor, do not adjust the pilot null.
Adjust the second stage valve null.

Dimensions of the MCV116 Pressure Control Pilot (PCP) Valve in Millimeters (Inches).
BLN 95-9033-5
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PERFORMANCE FREQUENCY RESPONSE

FREQUENCY RESPONSE

PHASING LAG (DEGREES)

Defined at -90° phase lag using a sine wave equal to
±30% input amplitude of the test current loaded into a TYPE 1
0

AMPLITUDE (DECIBLES)
34.5 bar differential pressure transducer (load capaci-
30
tance 0.000143 cubic centimeters/bar) and 8 cubic
centimeters of oil on each side between the valve and 60
the transducer. Response bandwidth will decrease with
increasing flow demanded by the driven load. See 90
Frequency Response.
0 120
OUTPUT SYMMETRY -6 150
Defined as the difference of the differential output
pressure obtained over the test current high and low -12 180
end divided by the larger number, expressed as a 1 10 50 100 200
FREQUENCY (HERTZ)
percentage.

PHASING LAG (DEGREES)

TYPE 2
0

AMPLITUDE (DECIBLES)
MINIMUM OUTPUT RANGE
Rated at saturation current. 30

LINEARITY 60
Defined by measuring the deviation of the center of a
90
test hysteresis loop from the best straight line between
the positive and negative extremes of the test current 0 120
range, expressed as a percentage of the range.
-6
150
THRESHOLD -12 180
Defined as the input signal to produce a detectable 1 10 50 100 200
FREQUENCY (HERTZ)
pressure change.

PHASING LAG (DEGREES)

TYPE 3 & 4
HYSTERESIS 0
AMPLITUDE (DECIBLES)

Defined at 0.01 Hz cycled through the test current 30

range.
60
TYPICAL NULL AS SHIPPED
Defined as the output offset at the center of the hyster- 90
esis loop at zero input current.
0 120

LOAD FLOW -6 150

Defined across a 6.9 bar (100 psi) load pressure drop at
180
saturation current. See Load Pressure Droop Slope, -12
1 10 50 100 200
page 4. FREQUENCY (HERTZ) 1076A

LOAD PRESSURE DROOP SLOPE These curves demonstrate the amplitude and phase response
Defined at 17.23 bar (250 psi) supply and 50 mA input. of the valve tested over a given frequency range with a supply
pressure of 17.23 bar. Frequency response curves are on the
See Load Pressure Droop Slope, page 4.
bottom of the graph, phase lag on top. The amplitude at low
frequency was ±30 mA and the load was a 34.47 bar transducer.
PRESSURE NULL SHIFT Frequency response varies with the applied load. Curves are
Defined as a percentage of supply pressure change shown with a current driver.
when supply pressure is varied from 10.3 bar to 34.5
bar.

TEMPERATURE NULL SHIFT

Defined as the maximum temperature null shift per
55.6°C (100°F) from -29° to 121°C (-20° to 250°F).

SATURATION CURRENT
Defined as the magnetic saturation of the torque motor.

SCALE FACTOR
See Scale Factor in the table MCV116 Specifications,
page 5.

BLN 95-9033-5
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 LOAD PRESSURE DROOP SLOPE SCALE FACTOR

TYPE 1 15 bar TYPE 1

1L
750 ccm 1
10 bar 1D
500 ccm
A

50 mA

25 mA
75 mA
250 ccm
m

5 bar
0
10

5 bar 10 bar 15 bar

100 mA 50mA
15 bar 10 bar 5 bar

75 mA
50 mA
25 mA

A
m
250 ccm 50mA 100mA

0
10
5 bar
500 ccm

750 ccm
10 bar

15 bar
TYPE 2
1250 ccm

1000 ccm

750 ccm 15 bar TYPE 2

2
500 ccm 2D
10 bar
A

100 mA

75 mA

25 mA
50 mA
m

250 ccm
5
12

5 bar 10 bar 15 bar 5 bar

75 mA

15 bar 10 bar 5 bar 200 mA 100mA

100 mA
25 mA

50 mA

A
m

250 ccm
5
12

100mA 200mA
500 ccm
5 bar
750 ccm

1000 ccm 10 bar

1250 ccm
15 bar

TYPE 3 & 4
1000 ccm
175 mA
750 ccm
15 bar TYPE 3 & 4
200 mA
225 mA 3&4
250 mA 500 ccm 10 bar
50 mA
100 mA
125 mA
150 mA

3D & 4D
75 mA

250 ccm
25 mA

5 bar
5 bar 10 bar 15 bar
200 mA 100mA
25 mA

15 bar 10 bar 5 bar

A
125 mA
100 mA
75 mA
50 mA

150 m

250 ccm 100mA 200mA

500 ccm 250 mA 5 bar
225 mA
750 ccm 200 mA
175 mA 10 bar
1000 ccm

15 bar
1075A 1074C

These curves demonstrate the output impedance characteris- These curves demonstrate the typical relationship between
tics of the valve. Output flow versus output differential pres- input current and output differential pressure. Curve slopes are
sure are shown at various positive and negative constant input insensitive to input pressure, temperature and load. Supply
currents. The slopes of these curves indicate the output pressure is 17.23 bar.
conductance (load pressure droop slope) or impedance of the
valve. Supply pressure is 17.23 bar. Dual coil and low current
coil devices have similar load pressure droop slope curves at
proportionally different steady current levels.

ENVIRONMENTAL DATA

SHOCK 2. Resonance dwell for one million cycles for each

50 G for 11 ms. Three shocks in both directions of the resonance point in each of the three axes.
three mutually perpendicular axes for a total of 18 Run from 1 to 46 G. Acceleration level varies with
shocks. frequency.

VIBRATION HUMIDITY
Withstands a vibration test designed for mobile equip- After being placed in a controlled atmosphere of 95%
ment controls consisting of two parts: humidity at 49°C (120°F) for 10 days, the pilot will
1. Cycling from 5 to 2000 Hz in each of the three axes. perform within specification limits.
BLN 95-9033-5
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MCV116 SPECIFICATIONS
Type 1 Type 2
U/M A11XX A12XX A13XX A14XX A15XX A21XX A22XX
Scale Factor Delta bar/mA .165 ± .014 .101 ± .010 .282 ± .028 .378 ± .034 .866 ± .082 .107 ± .010 .069 ± .007
Delta psi/mA 2.4 ± .2 1.47 ± .15 4.1 ± .4 5.5 ± .5 12.6 ± 1.2 1.55 ± .15 1.00 ± .1
Typical Supply bar 34.4 34.4 34.4 34.4 34.4 17.2 17.2
Pressure psi 500 500 500 500 500 250 250
Coil Resistance ohms 23 (32) 19/15.5 (25/22) 69 (92) 106 (145) 643 (900) 23 (32) 19/15.5 (25/22)
Coil Inductance henries 0.078 0.062/0.047 0.25 0.399 2.25 0.078 0.062/0.047
Test Current mA ± 85 ± 125 ± 42 ± 40 ± 13 ± 85 ± 125
Saturation Current mA 250 350*/175** 150 110 50 250 350*/175**
Minimum Pressure Delta bar ± 20.7 ± 20.7 ± 20.7 ± 20.7 ± 20.7 ± 11.0 ± 11.0
Output Range Delta psi ± 300 ± 300 ± 300 ± 300 ± 300 ± 160 ± 160
Typical Null as Delta bar 0 ± 0.35 0 ± 0.35 0 ± 0.35 0 ± 0.35 0 ± 0.35 0 ± 0.35 0 ± 0.35
Shipped Delta psi 0±5 0±5 0±5 0±5 0±5 0±5 0±5
Pressure Null Shift % ±2 ±2 ±2 ±2 ±2 ± 1.5 ± 1.5
Temperature Null Delta bar ± 0.28 ± 0.28 ± 0.28 ± 0.28 ± 0.28 ± 0.21 ± 0.21
Shift Delta psi ±4 ±4 ±4 ±4 ±4 ±3 ±3
C1/C2 Null Pressure at bar 11.0 ± .68 11.0 ± .68 11.0 ± .68 11.0 ± .68 11.0 ± .68 7.9 ± .34 7.9 ± .34
Typical Supply Pressure psi 160 ± 10 160 ± 10 160 ± 10 160 ± 10 160 ± 10 115 ± 5 115 ± 5
Internal Leakage LPM < 3.44 < 3.44 < 3.44 < 3.44 < 3.44 < 3.44 < 3.44
cis < 3.5 < 3.5 < 3.5 < 3.5 < 3.5 < 3.5 < 3.5
Load Flow LPM > 0.73 > 0.73 > 0.73 > 0.73 > 0.73 > 0.73 > 0.73
cis > 0.75 > 0.75 > 0.75 > 0.75 > 0.75 > 0.75 > 0.75
Load Pressure LPM/bar > 0.285 > 0.285 > 0.285 > 0.285 > 0.285 > 0.428 > 0.428
Droop Slope cis/psi > 0.02 > 0.02 > 0.02 > 0.02 > 0.02 > 0.03 > 0.03
Hysteresis % <9 <9 <9 <9 <9 <7 <7
Symmetry % < 10 < 10 < 10 < 10 < 10 < 10 < 10
Linearity % <5 <5 <5 <5 <5 <5 <5
Threshold mA <1 <1 <5 < 0.2 < 0.05 <1 <1
Resonant Frequency Hz > 300 > 300 > 300 > 300 > 300 > 350 > 350
Frequency Response Hz (min.) 150 150 150 150 150 150 150
with Current Driver
Maximum Voltage Volts 7.5 6 12 12 30 7.5 6
Maximum Current mA 375 375 175 115 46 375 375

Type 3 Type 4
A31XX A32XX A35XX F31XX A42XX F42XX G42XX
Scale Factor .079 ± .007 .054 ± .005 .428 ± .043 .079 +/-.007 .079 +/-.007 .079 +/-.007 .079 +/-.007
1.15 ± .1 .78 ± .08 6.2 ± .6 1.15 +/-.1 1.15 +/-.1 1.15 +/-.1 1.15 +/-.1
Typical Supply 17.2 17.2 17.2 24 24 24 24
Pressure 250 250 250 350 350 350 350
Coil Resistance 23 (32) 19/15.5 (25/22) 643 (900) 23 (32) 19/15.5 (25/22) 19/15.5 (25/22) 19/15.5 (25/22)
Coil Inductance 0.078 0.062/0.047 2.25 0.078 0.062/0.047 0.062/0.047 0.062/0.047
Test Current ± 85 ± 125 16 85 85 85 85
Saturation Current 250 350*/175** 50 250 250/125 250/125 250/125
Minimum Pressure ± 12.4 ± 12.4 ± 12.4
Output Range ± 180 ± 160 ± 180 ± 180 ± 180 ± 160 ± 160
Typical Null as 0 ± 0.138 0 ± 0.138 0 ± 0.138 0.1 ± 0.138 0.1 ± 0.138 0.1 ± 0.138 0.1 ± 0.138
Shipped 0±2 0±2 0±2 1.5 ± 2 4.5 ± 2 1.5 ± 2 1.5 ± 2
Pressure Null Shift ±1 ±1 ±1 <1 < 1.5 < 1.5 < 1.5
Temperature Null ± 0.14 ± 0.14 ± 0.14 0.14 0.21 0.21 0.21
Shift ±2 ±2 ±2 2 3 3 3
C1/C2 Null Pressure at 3.8 ± .34 3.8 ± .34 3.8 ± .34 3.5-4.1 10.3-11.7 10.3-11.7 3.5-4.1
Typical Supply Pressure 55 ± 5 55 ± 5 55 ± 5 50-60 120-160 120-160 60-80
Internal Leakage < 2.46 < 2.46 < 2.46 < 2.46 < 3.44 < 3.44 < 3.44
< 2.5 < 2.5 < 2.5 < 2.5 < 3.5 < 3.5 < 3.5
Load Flow > 0.49 > 0.49 > 0.49 > 0.49 > 0.49 > 0.49 > 0.49
> 0.5 > 0.5 > 0.5 > 0.5 > 0.5 > 0.5 > 0.5
Load Pressure > 0.570 > 0.570 > 0.570 > 0.570 > 0.570 > 0.570 > 0.570
Droop Slope > 0.04 > 0.04 > 0.04 > 0.04 > 0.04 > 0.04 > 0.04
Hysteresis <7 <7 <7 <7 <7 <7 <7
Symmetry < 10 < 10 < 10 < 10 < 10 < 10 < 10
Linearity <3 <3 <3 <3 <3 <3 <3
Threshold <1 <1 <1 <1 <1 <1 <1
Resonant Frequency > 400 > 400 > 400 > 400 > 300 > 300 > 300
Frequency Response 150 150 150 150 150 150 150
with Current Driver
Maximum Voltage 7.5 6 30 7.5 6 6 6
Maximum Current 375 375 46 375 375 375 375

* Individual coils; **Coils in series; See Pressure Control Pilot Valve (PCP) Part Number Reference Guide, page 6,
for difference between F42XX and G42XX.

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 PRESSURE CONTROL PILOT (PCP) VALVE PART NUMBER REFERENCE GUIDE

Unit P/N Where Used Electrical Mating Coil Scale Factor Replaces C1 & C2 Pressure C urrent mA
MCV116 C onnector Conn Ohms psid/mA MCV101 at null, typical, psi Typical max.
1 A1100 Special 10 None 23 2.4 A1016 150 to 170 0 to 150
2 A1101 Servo V. KVF 1 K08106 23 2.4 A1289 150 to 170 0 to 150
3 A1102 Servo V. KVF 3 K03383 23 2.4 A1065 150 to 170 0 to 150
4 A1201 Servo V. KVF 1 K08106 15.5 & 19 1.47 A1388 150 to 170 0 to 220
5 A1203 Servo V. KVF 3 K08106 15.5 & 19 1.47 150 to 170 0 to 220
6 A1204 Servo V. KVF 2 K03384 15.5 & 19 1.47 A1354 150 to 170 0 to 220
7 A1301 Servo V. KVF 3 K08106 69 4.1 A1396 150 to 170 0 to 42
8 A1302 Servo V. KVF 3 K03383 69 4.1 A1362 150 to 170 0 to 42
9 A1307 Servo V. KVF 2 K08106 69 4.1 A1370 150 to 170 0 to 42
10 A1401 Servo V. KVF 1 K08106 106 5.5 A1402 150 to 170 0 to 42
11 A1402 Servo V. KVF 3 K03383 106 5.5 A1404 150 to 170 0 to 42
12 A1407 KVF Special 1 K08106 106 5.5 A1412 150 to 170 0 to 42
13 A1501 Servo V. KVF 1 K08106 643 12.6 A1420 150 to 170 0 to 13
14 A2100 Special 10 None 23 1.55 A1024, A1032, 110 to 120 < 150
A1107
15 A2101 Servo V. MCV102 1 K08106 23 1.55 A1297 110 to 120 0 to 150
16 A2102 Servo V. MCV102 3 K03383 23 1.55 A1040 110 to 120 0 to 150
17 A3101 EDC S-20,M-46 1 K08106 23 1.15 A1313, A1347 50 to 60 0 to 90
18 A3102 EDC S-20,M-46 3 K03383 23 1.15 A1214, A1255 50 to 60 0 to 90
19 A3105 EDC Special 5 K10552 23 1.15 50 to 60 0 to 90
20 A3201 EDC S-20,M-46 1 K08106 15.5 & 19 0.78 A1339 50 to 60 0 to 130
21 A3203 Servo V. KVF 3 K03383 15.5 & 19 0.78 A1456 50 to 60 0 to 220
22 A3204 EDC S-20,M-46 2 K03384 15.5 & 19 0.78 A1248 50 to 60 0 to 130
23 A3206 Special 4 K12812 15.5 & 19 0.78 50 to 60 0 to 150
24 A3501 EDC all 4-20 mA 1 K08106 643 6.2 50 to 60 4 to 20
25 A3502 Special 3 K03383 643 6.2 50 to 60 4 to 20
26 A3602 Servo V. KVF 3 K03383 34.5 1.56 50 to 60 < 150
27 A4201 EDC S-90 MCV114 1 K08106 15.5 & 19 1.15 120 to 160 0 to 90
28 A4204 EDC S-90 MCV114 2 K03384 15.5 & 19 1.15 120 to 160 0 to 90
29 F3112 EDC S-90 Special 8 K22569 23 1.15 120 to 160 0 to 90
30 F3113 EDC S-90 Special 7 K26500 23 1.15 120 to 160 0 to 90
31 F4201 EDC S-90 KVEA 1 K08106 15.5 & 19 1.15 120 to 160 0 to 90
32 F4204 EDC S-90 KVEA 2 K03384 15.5 & 19 1.15 120 to 160 0 to 90
33 F4211 EDC S-90 Special 6 K22254 15.5 & 19 1.15 120 to 160 0 to 90
34 G4201 EDC S-90 KVEB 1 K08106 15.5 & 19 1.15 60 to 80 0 to 90
35 G4204 EDC S-90 KVEB 2 K03384 15.5 & 19 1.15 60 to 80 0 to 90
36 G4211 EDC S-90 Special 6 K22254 15.5 & 19 1.15 60 to 80 0 to 90
37 G4213 EDC S-90 Special 7 K26500 15.5 & 19 1.15 60 to 80 0 to 90
38 G4214 EDC S-90 Special 9 K23511 15.5 & 19 1.15 60 to 80 0 to 90
39 C1101 Intrinsically Safe 1 K08106 23 2.4 C1014 150 to 160 < 100
40 C1201 Intrinsically Safe 1 K08106 15.5 & 19 1.47 C1030 150 to 160 < 100
41 C3101 Intrinsically Safe 1 K08106 23 1.15 C1006, C1063 150 to 160 0 to 100
42 C3201 Intrinsically Safe 1 K08106 15.5 & 19 0.78 C1055 150 to 160 0 to 130
43 C1401 Intrinsically Safe 1 K08106 106 5.5 150 to 170 0 to 20
Units 5 & 21 are configured with two 2-pin connectors, one for the A/B coil and one for the C/D coil.
Unit 24 is used on all EDCs with a current range of 4-20 mA, with the exception of the Series 42, which has no removable PCP.
Unit 30 has only 2 lead wires terminating into the 4-pin connector
Units 33, 36 & 37 do not have a manual override.
Units 34 - 37 are the result of a product improvement (see PIB 9810 & SB 99001) and should be used with the KVEB style of EDC.
Unit 43 is used on Series 90 EDCs that are Intrinsically Safe with a current range of 4-20 mA.

ELECTRICAL CONNECTOR 1 MS 2 Packard Weather-pack 4-pin shroud 3 Packard Weather-pack 2-pin shroud
4 Packard Metri-pack 4-pin (5 cavity) 280 series male 5 Packard Metri-pack 2-pin 280 series male
6 Packard Metri-pack 4-pin 150 series female 7 Packard Metri-pack 4-pin 150 series male 8 Packard Metri-pack 2-pin 150 series male
9 Deutsch 4-pin plug DT series 10 Lead wires only, 4 inch NOTE: See PCP Mating Connectors, page 10 for mating connector information.

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SPECIFICATIONS (continued)

AMBIENT OPERATING TEMPERATURE FLUID

-40°—93°C (-40°—200°F) The valve is designed for use with petroleum based
hydraulic fluids. Other fluids may be used provided that
OIL TEMPERATURE compatibility with viton and fluorosilicone seals is main-
-29°—107°C (-20°—225°F) tained.

OIL VISCOSITY SYSTEM FILTRATION

40 SSU—1400 SSU The system hydraulics will have a filtration rating of B10
or better.
LIFE
10,000 hours or 10,000,000 cycles minimum ELECTRICAL

WEIGHT PULSE WIDTH MODULATION

0.73 kg (1.6 lb) When using a pulse width modulated current input, do
not exceed rated currents for single coil devices or the
HYDRAULIC algebraic sum of the rated currents in coils A and B for
dual coil devices. Pulse width modulated frequencies of
OPERATING SUPPLY PRESSURE greater than 200 Hz are recommended.
10.3—68.9 bar (150—1000 psi)

OPERATING RETURN PRESSURE

Less than 13.8 bar (200 psi)

WIRING

Optional wiring styles are available: pigtail, MS, Packard 3. Push a ribbed cable seal over each of the wires with the
Weather Pack, Packard Metri-Pack, and Deutsch DT Series. smaller diameter shoulder of the seals toward the wire
The pigtail connector is 89 mm (3.5039 in) long and is either tip. Select the seals that fit tightly over the wires. The
two or four wire. distance from the tip of the wires of the first (nearest) rib
should be 9.5 mm (.37401 in). Thus, the insulation
As with all PCP connectors, phasing is such that a should just protrude beyond the seal.
positive voltage to either red wires causes a pressure
rise at the C2 port. 4. Select the appropriate set of terminals for the gauge
wire used. Place the wire into the socket so that the seal
The MS connector, MS3102C14S-2P (Danfoss part edge is pushed through and extends slightly beyond the
number K01314), has four pins, two of which (A and B) are circular tabs that hold it in place. Crimp with a Packard
used on single coil devices. See MS Connector Pin Orien- 12014254 crimp tool. See Connector Crimp (Metri-
tation, page 8. For single and dual coil wiring schemes see Pack 280 Series), page 8. The distance from the back
Connection Diagram, page 8. of the tangs to the furthest rib may not exceed 19.5 mm
(.7677 in) on the Weather-Pack connector,18 mm (.7087
The mating connector for MS connectors is part number in) on the Metri-Pack connector.
K08106 (right angle).
5. Insert the assembled wires into the back end (large
The mating connector for Weather Pack PCPs is part num- hole) of the plastic housing. Push until the wires detent
ber K03384 (four terminal) or K03383 (two terminal). The with an audible click, then pull back slightly to ensure
mating connector for Metri-Pack PCPs is part number K12812 proper seating. Observe the proper phasing of the
(four terminal) or K10552 (two terminal). For twin two- wires when installing: black wire to “A”, red wire to “B”,
terminal PCPs, order two K03383 bag assemblies. black to “C” and red to “D” (red to “E” if Metri-Pack).
Included in the Weather Pack and Metri-Pack bag assembly:
2 (or 4): 14—16 gauge terminals 6. Swing the holder down into the detented position to trap
2 (or 4): 18—20 gauge terminals the wires in the housing.
1: plastic housing
2 (or 4): green cable seals (for small gauge wires) 7. Plug the two connector halves together , see Connector
2 (or 4): gray cable seals (for medium gauge wires) Parts (Metri-Pack 280 Series), page 8.
2 (or 4): blue cable seals (for large gauge wires)

To assemble the Weather Pack and Metri-Pack mating

connector:

1. Isolate the wires that extend from the command source

to the PCP.

2. Strip back the insulation 5.5 mm (2.21653 in) on these

wires.
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 CONNECTION DIAGRAM

Fig. 1: Single Coil Fig. 2: One of Dual Coils Fig. 3: Dual Coils in Series Fig. 4: Dual Coils in Parallel
A B A B C D A B C D A B C D

Fig. 1 (common) Figure 3 (uncommon)

For potentiometer type inputs signals where the voltage is Wiring coils in series may only be required when multiple
divided to achieve a change in direction; it is a common MCV116XXXXX devices are being controlled, thus reducing
practice to use only one of the coils. the total current.

Figure 2 (common) Figure 4 (uncommon)

Both coils are required when the input current is a PWM Wiring coils in parallel reduces the electrical load, thus
signal from such devices as either an analog driver board or reducing the voltage required.
digital controller. A common wiring practice for controlling in
both directions is to connect pins B and C to ground, and For a listing of MCV116 valves that are either single or
connect pin A to the forward command and pin B to the dual coil see MCV116 Specifications, page 5.
reverse command.

DEUTSCH DT SERIES MS CONNECTOR PIN ORIENTATION

DEUTSCH

4 1 19,7
(.78) D A
3 2 C B

20,8
(.82)
2076 1276
Pin orientation of the Mating 4-pin Deutsch Plug DT Pin orientation of the optional MS Connector, part num-
(Danfoss Part No.Part
Series Connector. (Sauer-Danfoss K23511).
No. K23511). ber MS3102C14S-2P (K01314). (Not field replaceable).

CONNECTOR CRIMP (WEATHER-PACK) CONNECTOR PARTS (WEATHER-PACK)

SIDE "B" D
RE
K
AC
BL
CABLE
SEALS

SIDE "A"

SHROUD
CONNECTOR

DOUBLE-PLUG SEAL
TOWER CONNECTOR

1077 1078A

Crimp location and distance from tang to third rib of Packard Weather-Pack interlocked connector halves
Packard Weather-Pack Connector. with parts identified.

CONNECTOR CRIMP CONNECTOR PARTS

(METRI-PACK 280 SERIES) (METRI-PACK 280 SERIES)

FEMALE
CONNECTOR
CABLE ASSY
SEALS
CRIMP

18 mm MAX.
MALE
CONNECTOR

1724 1725

Crimp location and distance from tang to third rib of Packard Metri-Pack connector halves with parts identi-
Packard Metri-Pack Connector. fied.
BLN 95-9033-5
8
DEUTSCH ASSEMBLY CONTACT INSERTION AND CONTACT REMOVAL

CONTACT INSERTION CONTACT REMOVAL

1. Grasp crimped contact approximately 25.4 mm (1 in) 1. Remove orange wedge using needlenose pliers or a
behind the contact barrel. hook shaped wire to pull wedge straight out.

2. Hold connector with rear grommet facing you. 2. To remove the contacts, gently pull wire backwards,
while at the same time releasing the locking finger by
3. Push contact straight into connector grommet until a moving it away from the contact with a screwdriver.
click is felt. A slight tug will confirm that it is properly
locked in place. 3. Hold the rear seal in place, as removing the contact will
displace the seal.
4. Once all contacts are in place, insert orange wedge with
arrow pointing toward exterior locking mechanism. The
orange wedge will snap into place. Rectangular wedges
are not oriented. They may go in either way.

Note: Use the same procedure for the receptacle and plug.

DT SERIES

CONTACT SIZE & TYPE A MAX B MIN C MAX D MIN WIRE GAGE RECOMMENDED HAND
PART NUMBER RANGE STRIP LENGTH CRIMP TOOL
0460-202-16141 16 PIN .821 .066 .103 .250 16 and 18 .250 to .312 HDT-48-00
0462-201-16141 16 SOC .759 .066 .103 .250 16 and 18 .250 to .312 HDT-48-00
0460-215-16141 16 PIN .821 .076 .103 .250 14 and 16 .250 to .312 HDT-48-00
0462-209-16141 16 SOC .757 .076 .103 .250 14 and 16 .250 to .312 HDT-48-00

BLN 95-9033-5
9
 PCP MATING CONNECTORS

D
B C
A B
A
2-pin Packard Weather-Pack Tower
Mating Connector Kit: K03383 4-pin Packard Weather-pack Tower
Packard Crimping and Extracting Tools: 12014254 Mating Connector Kit: K03384
and 12014012 Packard Crimping and Extracting tools: 12014254
and 12014012

A D
B C A

2-pin Packard Metri-Pack Female 280 Series

4-pin MS Mating Connector Kit: K10552
Mating Connector Kit: K08106 Packard Crimping and Extracting tools: (two crimp-
Wiring Assembly Tool: ing tools required) 12085271/12085270 and 12094429
Soldering Iron

A B
B
A
C
D
E 2-pin Packard Metri-Pack Female 150 Series
Mating Connector Kit: K22569
4-pin Packard Metri-Pack Female 280 Series Packard Crimping and Extracting Tools
Mating Connector Kit: K12812
Packard Crimping and Extracting tools
D
C
A
B
B
A
C
D 4-pin Packard Metri-Pack Female 150 Series
Mating Connector Kit: K22254
Packard Crimping and Extracting Tools
4-pin Packard Metri-Pack Female 150 Series
Mating Connector Kit: K26500
Packard Crimping and Extracting Tools

4 1
3 2
4-pin Deutsch Plug DT Series
Mating Connector Kit: K23511
Deutsch Crimping and Extracting Tools: HDT-48-00 and DT/RT1
BLN 95-9033-5
10
SPECIAL APPROVAL

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 PCPs for Class I, II, and III Division 1, applicable Group C, D, F, and G hazardous
locations in accordance with the appropriate installation drawings: MCV116C1101 Single Coil; MCV116C1401 Single Coil,
typically used with Series 90 EDC's with a current range of 4-20 mA; MCV116C2101 Dual Coil; MCV116C3101 Single Coil,
typically used with EDC; MCV116C3201 Dual Coil, typically used with EDC.

Example of a typical electrical wiring diagram (unidirectional control).

UNIDIRECTIONAL CONTROL, SELECT ONE OF THE FOLLOWING BARRIERS
• Stahl Barrier 9001/01-158-270-10 (12V)
Groups A, B, C, D, F and G (maximum voltage 15.8V)
• Stahl Barrier 9001/01-280-280-10 (26V)
Groups D, E, F and G (maximum voltage 31.5V)

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

HAZARDOUS LOCATION EARTH

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

3007

The intrinsically safe PCP valve body is made from steel and has a zinc dichromate finish to prevent corrosion. Suppression
circuit is incorporated in the torque motor cover, but by itself does not insure intrinsic safety. An additional suppression circuit
(Zenier barrier) must be connected in series with the valve coils. The Zenier barrier and electrical controller must be isolated
from the hazardous area either through use of a purge enclosure or mounted in a safe area.

Example of Zener barrier options (which are manufactured by R. Stahl, Inc., 1-800-782-4357).

UNIT R. STAHL INC. MAX INTERNAL UNIT R. STAHL INC. MAX INTERNAL
PART NUMBER VOLTAGE RESISTANCE PART NUMBER VOLTAGE RESISTANCE
1 9001/01-158-270-10 15.8 74 ohm 4 9001/01-308-230-10 31.8 158 ohm
2 9001/02-172-270-10 17.2 80 ohm 5 9001/01-158-150-10 15.8 127 ohm
3 9001/01-280-280-10 31.51 124 ohm 6 9001/02-175-200-10 17.2 110 ohm

APPLICATION
The MCV coils are arranged on a T-bar-style armature. This manner that magnetic flux generated in the circuit flows
allows the coils to be physically separated by a small air gap. through the windings of both coils, a phenomenon basic to
MCV116 dual coils are arranged on a stand-up style arma- the torque motor technology used. This is different from
ture (which is the same used on all other dual coil EDCs and some magnetic actuators, such as most proportional valves,
servovalves) and they are stacked one atop the other. In that have two distinctly separate magnetic circuits.
some rare instances, this may induce current changes result-
ing from the magnetic effects of one coil on another (see the Since the flux generated in one coil flows through the other
following Precautions When Driving Dual Coil PCPs With A coil, the device operates like, and in fact is, a transformer.
PWM Drive). Contact Danfoss with applications conFHUQV
This fact is generally insignificant when the coils are driven
PRECAUTIONS WHEN DRIVING DUAL COIL PCPS with dc current, such as when the device is driven from a
WITH A PWM DRIVER potentiometric control handle or from dc current drivers such
Danfoss dual coil PCPs are constructed in such a as the valve drivers in Danfoss DC2 and SUSMIC
 microcontrollers.
BLN 95-9033-5
11
 APPLICATION (continued)
Many controllers are set up to drive proportional solenoids FREQUENTLY ASKED QUESTIONS
through pulse width modulation (PWM). Sometimes the The following questions and answers cover those applica-
scheme is used with the field effect transistor (FET) outputs tions that use the PCP as the pilot stage to a second stage.
of DC2s or SUSMIC controllers. These controls send an For example: Electrical Displacement Control (EDC) for
oscillating pulse width modulated dc current to the coil. This Danfoss Variable Pumps and Danfoss FlowDQG
scheme has the advantages of providing dither to the actua- Pressure Control Servovalves.
tor and, in some cases, can simplify the electronics since
1. Question: Is the PCP a 12 or 24 volt dc device (i.e.,
they operate in a digital mode, potentially reducing heat
direct battery voltage)?
output from the device.
Answer: Do not apply 12 or 24 volts dc directly to the
As with most things there are trade offs or unwanted side PCP for several reasons, the most important being the
effects: Items 1 through 3 apply to all electrohydraulic coil will be permanently damaged. And voltage levels
actuators. Items 4 and 5 relate more specifically to PCPs. beyond 3 volts dc are out of the control range. The
exceptions are: (1) the low current (4-20 mA) models,
1. The pulsing current generates unwanted electromag-
which have a maximum voltage ratting of 36 V DC, and
netic radiation, which can interfere with related devices.
(2) when applying a PWM signal from an amplifier.
2. The actuators are generally responsive to current.
2. Question: Why are some PCP configurations single
PWM valve drivers are generally low impedance volt-
coil and some dual coil?
age drives. As the coils heat up, the resistance changes
Answer: The original design was a single coil, and the
(typically by as much as 50%), thus altering the re-
dual coil design followed as the standard configuration.
sponse of the device. For a given PWM frequency and
duty cycle, both peak and average current into the 3. Question: When should either a dual coil or single coil
driven coil may strongly affect the coil's L/R (induc- be specified?
tance/resistance) time constant, potentially reducing Answer: When uncertain, specify a dual coil. The
both accuracy and linearity. The effects vary consider- second coil does not have to be used to be bi-directional
ably with valve type and with temperature and are quite when using a potentiometer type inputs. The dual coil
different between the Danfoss MCV116 and configuration can simplify the switching logic when
MCV110. PWM drivers often require "current feedback" required. The one exception in which a dual coil is not
to maintain sufficient accuracy as the temperature var- offered are EDCs and Servovalves that have a current
ies over the operating range. range of 4-20 mA.
3. Some controllers are designed to diagnose shorts or 4. Question: When is it a must to use a dual coil?
opens in the output circuit. The PWM-induced voltage Answer: When using a Control Handle (MCH) that has
can affect some common detection schemes. a circuit board built into the housing (e.g., MCHxxxLxxx),
because the output is switched forward and reverse
4. In the case of the PCP, a PWM signal is like an
between two output terminals. This switched output
alternating current applied to the primary of a trans-
current is approximately 0—3 volts. With this type of
former. A voltage is induced in the secondary coil
output scheme, use one coil for reverse and the other
proportional to the turns ratio of the coils less losses in
coil for forward. However, most MCH models have a
the magnetic circuit. If the secondary coil is open
voltage/current output based on a bridge circuit, which
circuited, there is no effect since no current flows, hence
uses approximately a 6 volt reference on each of the two
no magnetic field is generated. However, if current is
outputs terminals. As the MCH is moved between
allowed to flow in the secondary coil, it flows in a
forward and reverse, the voltage swings up and down
direction which will reduce the output of the actuator.
from 6 volts. Also, when using either an analog amplifier
5. Most electronic drivers will conduct current when back or a microcontroller both coils would be used to achieve
driven with excessive voltages. One example is a drive bi-directional control.
that contains non-linear devices such as diodes or
5. Question: Can the PCP alone be changed on an EDC
zener diodes for re-circulatory currents. The induced
to achieve 4-20 mA control?
voltages may be sufficient to cause these devices to
Answer: Simply changing the PCP is not a solution,
conduct, thereby causing current flow in the non-driven
because the second stage (i.e., EDC) is calibrated
coil.
using different internal spring forces to match a specific
In position control systems where the control drives high gain (psid/mA) PCP (MCV116A3501).
toward null this generally is not a problem. However, in
6. Question: What is the purpose of having silicone oil
propel systems, especially dual path propel systems,
inside the cover?
the change in output velocity could be a severe limita-
Answer: The original PCP Valves design did not have
tion. In some cases filters can be designed to correct the
silicone oil, but shortly thereafter it was added to all PCP
problem. A limitation of filters is this adds a lag in the
models to reduce the effects of the environment. The
circuit which will adversely affect high response sys-
loss of silicone oil to those PCP's that are used on the
tems. Also, it is impossible to design one filter to fit all
Servovalve (KVF models) may cause a loss in valve
applications.
performance, and therefore it is recommended to re-
In summary, the ability to drive the Danfoss PCP place the silicone oil in the event it is removed or lost.
depends on many circumstances which must be understood See item 6 on page 13 for replacement kit.
and accounted for by the user.
BLN 95-9033-5
12
SERVICE PARTS

123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
12345678901234567890123456789012123456789012345678901
WARNING 2
123456789012345678901234567890121234567890123456789012
Regarding Service Parts List, Item 3:
DO NOT Remove Cover Screws unless replacing cover.

Service Parts List.

ITEM P/N QTY DESCRIPTION

1 K01291 2 SAE-6 Plugs
2 K07067 4 PCP Mounting Screws
3 K02264 4 PCP Cover Screws
4 K26275 1 3/8-24 PCP Null Access Screw
K00920 1 1/4-28 PCP Null Access Screw
5 K28475 1 PCP Cover Kit
6 K21436 1 Silicone Oil Kit 4000 cs
7 K04790 1 Connector O-ring
8 K08687 4 Connector Screw for MS
9 K01314 1 Connector MS
10 K08688 4 Connector Screw for Packard
11 K08106 1 Mating Electrical Connector MS
12 K08014 1 Feed Through Assy Cover Plate
13 K07533 1 Feed Through Assy 4-pin Packard W-P
K24223 1 Feed Through Assy 4-pin Deutsch
14 K03384 1 Mating Electrical Packard W-P 4-pin
K23511 1 Mating Electrical Deutsch 4-pin
15 K00829 2 O-ring Control Port
16 K00830 1 O-ring Return Port
17 K08573 1 Filter Assy with O-rings
18 K08493 1 O-ring Pressure Port

5 6 7 8
4 9

10
11
2
1 12

13
18
16 17 15
15

14

3001B

Note: The Deutsch electrical connectors are not shown. See Item 4, a change was made in January 2000 that
increased the null access opening thread size from 1/4-28 to 3/8-24, therefore part number K00920 only fits
those covers with a 1/4-28 thread size. See Item 5, the preferred part number K28475 includes the cover,
gaskets, null access screw, and all the cover seals.
BLN 95-9033-5
13
 SERVICE PARTS (continued)
The following steps are recommended when servicing those 9. If silicone oil is to be added, do so at this step with the
parts listed in the Service Parts List, page 13. connector not yet attached to cover. Tilt cover upward
and add 45 cc of oil from container. The container (see
Preferred service tools are: page 13, Item 6) holds enough for 3 fills.
• Screw driver: TX 15 and TX 10
• Solder: SN62 10. Before attaching the connector to the cover, rotate
• Needle nose pliers, small tip connector clockwise two turns. This will bundle the wires
• Solder iron: electronic type together, finishing with the notch up when viewed from
• Multimeter the outward side of the MS connector and lead wires
• Cleaning solvent: Chemtronics 2000 ES 1601 down for Packard connector (see MS Connector Pin
• Torque wrench: 0—25 in.lb (0—33 N.m) Orientation, page 8). Insert connector screws and
torque to 8—10 in.lb (11—13 N.m).
REPLACING COVER AND/OR
ELECTRICAL CONNECTOR 11. With a multimeter, check for proper coil resistance
between terminals A and B, and between C and D if PCP
1. Wipe down external surface to ensure that loose is a dual coil.
contaminants will not fall inside the housing.

2. Place the valve in a firm position at 45° with the electrical

connector tilted upwards. Pressure control pilot valves
(PCP) built after 1988 are filled with a silicone oil. Locate
and remove the four connector screws (see page 13,
Item 8 if MS connector, or Item 10 if Packard connector).

3. Hold the electrical connector and untwist wires by rotating

the connector counterclockwise two turns while gently
pulling away from the housing.

4. Clean the solder connections inside connection of the

electrical connector with degreaser. Unsolder the wires,
noting which pin goes to which wire color (e.g., Pin A to
black, Pin B to red, Pin C to brown, etc.). With the
connector held firmly, place the solder iron against the
base solder cup if MS, and pin if Packard, until the wires
can be gently pulled away.

5. The cover can now be removed and replaced if required.

Be sure the PCP cover gasket is firmly seated into the
cover base and is in good condition before cover is
installed. Torque cover screws to 12—15 in.lb (16—20
N.m).

6. Verify that wire to pin connections are correct before

soldering wires and the connector O-ring (see page 13,
Item 7) is in place before soldering.

7a. For the MS style connector, ensure that the cups have
sufficient solder (approximately level). If additional
solder is required, place solder iron against the base of
the cup and add solder. While solder is still liquid, place
wire in the cup, remove iron and let cool for several
seconds while holding wire firmly.

7b. For the Packard style connector, the wire should extend
around and contact the terminal post for at least 180° (1/
2 wrap to a maximum of 270°). When ready to solder,
heat the terminal and add solder, remove iron, and let
cool for several seconds while holding wire firmly.

8. After soldering, ensure that terminals and wires do not

contact one another.

BLN 95-9033-5
14
MANIFOLDING

Applications in which manufacturers have not provided for direct sub-plate mounting will require a manifold mount. See the
Manifold dimension drawing below. To mount the manifold, drill two holes in the machine’s panel (or other suitable location)
as determined by the dimensions drawing (see MCV116 Dimensions, page 2) and attach with two M8X1.25 screws.

1 7,92 DIA. (4) 1

(0.31)

107,7 7,14 DIA. THRU (4)

(4.24) 70,1 (0.28)
(2.76)
127,0 76,2
(5.0) (3.0)
38,1
(1.5)
63,5
(2.50)
15,7
3,05 (0.12) (0.62)
9,7 (0.38)

1 VALVE 12,7 (0.50)

25,4
(1.0)

138,3 MAX (5.44) 191,6 (7.54)

121,3 (4.78)
174,6 (6.87)

2 3

RETURN PORT RETURN PORT

PRESSURE PORT PRESSURE PORT

2 VALVE 3 VALVE

244,9 MAX (9.64) 3/4 - 16 PER SAE

J514
(1/2 IN. STRAIGHT TUBE FITTING)
227,9 (8.97) 4-PL.
C2 OUTPUT SIDE
4
30,6
(1.20)
1
RETURN PORT
2
35,0
(1.38)
1 3
PRESSURE PORT
2

14,0 DIA. 2-PL

(0.55)

C1 OUTPUT SIDE 17,5

(0.69)
4 VALVE
30,76
MAX
SEALED WITH 3/4 - 16 STRAIGHT THREAD O-RING PLUG (1.21)
1 (SAE 090109 REF.), UNFURNISHED
1 SINGLE–VALVE MANIFOLD PART NUMBER KK02501
2 CHOICE OF PLUGGED END OPTIONAL PER USER REQUIREMENTS
2 2–VALVE MANIFOLD PART NUMBER KK01502
C1 AND C2 OUTPUTS ARE ACCESSED BY REMOVING THE
3 3 3–VALVE MANIFOLD PART NUMBER KK01503
PILOT VALVE SAE PLUGS, REFER TO THE SPARE PARTS SECTION (ITEM 9)

C1 AND C2 PORTS ALLOW DIRECT ACCESS 4 4–VALVE MANIFOLD PART NUMBER KK01504
4
WITHOUT REMOVING PILOT VALVE SAE PLUGS.

All manifolds include PCP MOUNTING SCREWS m5 x o.8 x 16 long (K07067) 1027E

Optional MCV116 1, 2, 3, and 4 Stack Manifold Dimensions in Millimeters (Inches).

BLN 95-9033-5
15
 TROUBLESHOOTING

1. If the pressure control pilot valve (PCP) does not reach each other, restoring the valve null is an option. Pro-
its expected output flow or pressure when applying an ceed to step 4. Observe the gage readings while strok-
electrical signal, actuate the manual operator several ing the valve manually, then stroke it electrically. If
times from side to side, but first take the necessary either case fails to reach the proper minimum differen-
safety precautions in the event full output pressure is tial pressure (psid) level, replace the valve (see Typical
reached. If output pressure is reached with the manual Supply Pressure in the table MCV116 Specifications,
operator the problem may be electrical, in which case, page 5). The minimum psid can be calculated by multi-
skip to step 5. plying the rated current by the scale factor (see Scale
Factor in the table MCV116 Specifications, page 5).
2. If the manual operator fails to achieve full output in both
directions, ensure that a minimum supply pressure is 4. To restore the PCP null requires the hydraulic system to
getting to the PCP (e.g., pump charge pressure, be running and a gage in each control port. Locate and
servovalve supply). If supply pressure is sufficient, remove the null access screw. A small amount of
there may be a problem within the PCP such as a lodged silicone oil likely will escape from this opening, which is
particle. Move to step 3 and check for the proper internal acceptable. Then insert a 3/32" Allen wrench just be-
pressure reactions. yond this opening into the adjustment set screw and
very slowly adjust clockwise and/or counterclockwise
3. Checking the PCP internal pressures at neutral (null) until gages are reading the same. Replace the access
and with a full rated electrical command can help isolate screw when finished.
a problem. First shut off the hydraulic system then
locate the two #6 SAE plugs in the sides of the PCP and 5. Checking for the proper electrical voltage or current
place a 0—500 psi gage into each of these control ports. requires a Volt Ohm Meter (VOM). To check voltage set
If the PCP is attached to the Series 90 EDC, then check meter to the Volt dc scale and place meter leads across
pressure at the EDC second stage housing, which has the two wires going to the PCP coil. Voltage require-
the same size ports as the PCP. The ports are identified ments may vary from one PCP model to another (see
as X1 and X2. Once the gages are in place start the Test Current, Table A - MCV116 Specifications, page
system. The gage reading will rise to approximately the 5). When checking current, place the VOM in series
specification for a given model (see C1/C2 Null Pres- between the electrical controller and the valve. Set the
sure at Typical Supply Pressure in the table MCV116 meter to the dc amp scale and set the range to read
Specifications, page 5). Readings should be within 10 milliamperes. The current level should reach the mini-
psi or less of each other with no command signal (e.g., mum. If the proper internal pressures are reached with
65 and 75 psi). If they are greater than 15 psi apart, the electrical signal, there is likely a problem with the
replace the PCP. If the problem is a creep in one second stage upon which the PCP is mounted, and it
direction from either the pump or servovalve and the should be replaced.
gage readings are relatively close to within 10 psi of

MANUAL OPERATOR

NULL ADJUST ACCESS SCREW-

REMOVE SCREW, MAKE NULL
ADJUSTMENT WITH 3/32-INCH
KEX KEY, REPLACE SCREW

C1 C2

3002A
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1234567890123456789012345678901212345678901234567890
1234567890123456789012345678901212345678901234567890
CAUTION
1234567890123456789012345678901212345678901234567890
If the pilot is used as the first stage of an electrical
displacement control (EDC), pump or motor, do not adjust
the pilot null. Adjust the second stage valve null.

BLN 95-9033-5
16
CUSTOMER SERVICE

When ordering a MCV116 Pressure Control Pilot Valve EUROPE

refer to the table MCV116 Pressure Control Pilot (PCP)
Valve Part Number Reference Guide, page 6. ORDER FROM

NORTH AMERICA Danfoss (Neumünster) GmbH & Co. OHG

Order Entry Department
ORDER FROM Postfach 2460, D-24531 Neumünster
Krokamp 35, D24539 Neumünster, Germany
Danfoss (US) Company Phone: +49 4321 871-0
Customer Service Department Fax: +49 4321 871 122
3500 Annapolis Lane North
Minneapolis, Minnesota 55447
Phone: (763) 509-2084
Fax: (763) 559-0108

DEVICE REPAIR

For devices in need of repair, include a description of the

problem, a copy of the purchase order and your name,
address and telephone number.

RETURN TO

Danfoss (US) Company

Return Goods Department
3500 Annapolis Lane North
Minneapolis, Minnesota 55447

BLN 95-9033-5
17