Danfoss Series 90 User manual

eries 90 Intrinsically Safe Contr

Installation, Maintenance

This line of Intrinsically Safe Pressure Control Pilots receives a low current input signal from a variety of machine controllers and

converts the current signal into a proportional dierential pressure signal suitable to control larger hydraulic equipment in hazardous

locations. The Intrinsically Safe Controls can be added to a Series 90 pump as a standard option or purchased separately.

Danfoss oers ﬁve dierent models of Intrinsically Safe Pressure Control Pilots to accommodate a variety of standard industrial

process controllers. Various combinations of hydraulic nozzle sizes and coil resistances yields a relationship between electrical current

(input) and hydraulic dierential pressure (output).

Refer to the Unit Speciﬁcations tables on pages three and four for proper selection.

Ensure that the four supplied O-rings are in place on the bottom of the unit. These pressure control pilots are fastened to the second

stage of the control with four M5 x 0.8 x 16 mm socket head screws. Torque to 5 Nm (44 in-lb).

A Mil-Spec Connector (MS3102C-14S-2P) provides the means for electronic signal input to the device. Proper selection of the mating

connector to ensure safe operation in a hazardous environment is required (Recommended MS3108E-14S-S, Danfoss Kit number

K08106). A suppression circuit is incorporated in the PCP torque motor cover but by itself does not insure intrinsic safety. An additional

safety barrier used to connect intrinsically safe circuits with non-intrinsically safe circuits must be connected in series between the

PCP and controller. The safety barrier and electrical controller must be isolated from the hazardous area either through use of a purge

enclosure or mounted in a safe area. The intrinsically safe device enclosure grounding terminal must be connected to a robust chassis

ground. The connection must be in accordance with applicable standards where required.

Refer to the following wiring diagrams for proper connections.

Wiring diagram for 11101116 Wiring diagram for 11101126, 11101118, 11101115, 11101106

No adjustment is possible.

Do not attempt to disassemble or adjust the control.

For instructions on putting a pump with the Intrinsically Safe Control in service, refer to Initial Startup Procedure in the Series 90 Pumps

Service Manual, .

Prior to installation, inspect packaging and unit for any damage. Do not continue installation if unit has visible signs of damage.

Danfoss is not responsible for the design of the control input circuit outside of the installed Mil-Spec connector. Proper design

on the entire system as noted in the applicable standards is required for safe usage in hazardous environments.

The EDC is designed to be controlled from a DC current source or voltage source. Pulse width modulation (PWM) is not required. But, if

a PMW signal is used, use a carrier frequency between 200 Hz and 4000 Hz. Do not use a pulse current of more than 120% of that

required for full output(refer to unit speciﬁcations below).

2 © Danfoss A/S, 202

• •

Hazardous location Non-hazardou location

V = 8.6 V

I = 250mA

P = 537.5mW

C = 0.4 µF

L = 0 mH

V = 8.6 V

I = 250mA

P = 537.5mW

C = 0.4 µF

L = 0 mH

PCP

Single coil

Dual coil

Hazardous location Non-hazardous location

PCP

Exi Cl I, Div 1, Gp CD T4

Ex ia / AEx ia IIB T4 Ga

FM12ATEX0031X II 1 G Ex ia IIB T4 Ga

IECEx FMG 15.0008X Ex ia IIB T4 Ga

= 16.0 V

I= 110mA

P= 440mW

C= 0.4 µF

L= 0 mH

Coil resistance

Dual coil

Single coil

A B

P108 686E

ﬁ

(PWM) The PCP is designed to be controlled from a dc current source or voltage source. If a PWM signal is used, do not use a pulse

current of more than 120% of that required.

Single Coil

Coil Resistance

A-B 23 Ω at 70° F,

A-B 29 Ω at 200° F

A-B 23 Ω at 70° F,

A-B 29 Ω at 200° F

A-B 106 Ω at 70° F,

A-B 130 Ω at 200° F

Dual Coil

Coil Resistance

A-B 20 Ω at 70° F,

A-B 25 Ω at 200° F

C-D 16 Ω at 70° F,

C-D 20 Ω at 200° F

A-B 20 Ω at 70° F,

A-B 25 Ω at 200° F

C-D 16 Ω at 70° F,

C-D 20 Ω at 200° F

Phasing

Positive voltage to pin

A produces a pressure

rise at output port C1

Positive voltage to pin

B produces a pressure

rise at output port C2

Positive voltage to pin

A produces a pressure

rise at output port C1

Positive voltage to pin

B produces a pressure

rise at output port C2

Positive voltage to pin

A produces a pressure

rise at output port C1

Positive voltage to pin

B produces a pressure

rise at output port C2

Positive voltage to

pin A or C produces a

pressure rise at output

port C1 Positive

voltage to pin B or D

produces a pressure

rise at output port C2

Positive voltage to

pin A or C produces a

pressure rise at output

port C1 Positive

voltage to pin B or D

produces a pressure

rise at output port C2

Current/Voltage Range up to 145 mA at 3.90

Vdc (linear range)

up to 190 mA at 4.75

Vdc (linear range)

4 mA at 0.50 Vdc

to 20 mA at 2.2 Vdc

(linear range)

up to 205 mA at 4.50

Vdc (linear range)

up to 170 mA at 4.50

Vdc (linear range)

Scale Factor 0.165 ± 0.013 Bar/mA

2.4 ± 0.2 psid/mA

0.079 ± 0.007 Bar/mA

1.15 ± 0.1 psid / mA

0.379 ± 0.034 Bar/mA

5.5 ± 0.5 psid / mA

0.101 ± 0.010 Bar/mA

1.47 ± 0.15 psid / mA

0.054 ± 0.006 Bar/mA

0.78 ± 0.08 psid / mA

• •

4 © Danfoss A/S, 202

ﬁ

Oil Viscosity must be in the 40 – 6000 SSU [cSt] range.

Oil Cleanliness of ISO 4406 class 22/18/13 (SAE J1165) or better, under normal operating conditions.

For detailed information on lubricants and cleanliness refer to Hydraulic Fluids and Lubricants, and Design

Guidelines for Hydraulic Fluid Cleanliness

Maximum supply pressure: 69 bar

1000 psid

69 bar

1000 psid

69 bar

1000 psid

69 bar

1000 psid

69 bar

1000 psid

Recommended range: 27.6 - 41.4 bar

400 - 600 psid

20.7 - 34.5 bar

300 - 500 psid

20.7 - 34.5 bar

300 - 500 psid

34.5 - 41.4 bar

500 - 600 psid

20.7 - 34.5 bar

300 - 500 psid

Maximum return pressure: 13.8 bar

200 psid

13.8 bar

200 psid

13.8 bar

200 psid

13.8 bar

200 psid

13.8 bar

200 psid

Maximum internal leakage:

at 500 psid supply

3.41 lpm

0.90 gpm

2.46 lpm

0.65 gpm

2.46 lpm

0.65 gpm

2.46 lpm

0.65 gpm

2.46 lpm

0.65 gpm

Maximum linear psid output

pressure:

24.1 bar at

34.5 bar supply

350 psid at

500 psid supply

15.2 bar at

20.7 bar supply

220 psid at

300 psid supply

15.2 bar at

20.7 bar supply

220 psid at

300 psid supply

21.4 bar at

34.5 bar supply

350 psid at

500 psid supply

13.8 bar at

20.7 bar supply

220 psid at

300 psid supply

Load ﬂow: the output

di rential ﬂow across a 100

psid load pressure drop at

maximum current:

>0.738 l/m

> 45 cim

>0.0492 l/m

> 30 cim

>0.0492 l/m

> 30 cim

>0.738 l/m

> 45 cim

>0.0492 l/m

> 30 cim

• •

11101116

Part of the enclosure is constructed from plastic. To prevent the risk of electrostatic sparking the plastic surfaces should

only be cleaned with a damp cloth.

No other maintenance is required.

For overhaul or repair return to: Danfoss

Power Solutions

2800 East 13th Street

Ames IA, 50010

Labels

11101126, 11101118, 11101115, 11101106

2809

Intrinsically Safe / Sécurité intrinséque

Exi, Cl I, Div 1, Gp CD T4

Ex ia / AEx ia IIB T4 Ga

FM12ATEX0031X II 1 G Ex ia IIB T4 Ga

IECEx FMG 15.0008X Ex ia IIB T4 Ga

Install per control drawing:

Input: 8.6 VDC; 250mA

MODEL NO.

XXXXXXXXXXX

DANFOSS POWER SOLUTIONS (US) COMPANY, 2800 E. 13th St. Ames, IA 50010

S/N: A123456789

Made in USA

IP66

• •

MODEL NO.

XXXXXXXXXXX

DANFOSS POWER SOLUTIONS (US) COMPANY, 2800 E. 13th St. Ames, IA 50010

Intrinsically Safe / Sécurité intr

inséque

FM12ATEX0031X

Install per control drawing: DWG00019589

Input: 16 VDC; 110mA

2809

IP66

11101126, 11101118, 11101115, 11101106

11101116

Part of the enclosure is constructed from plastic. To prevent the risk of electrostatic sparking the plastic surfaces should

only be cleaned with a damp cloth.

6 © Danfoss A/S, 202

• •

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