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Propvalve e
Propvalve e
Propvalve e
Contents
Figure 1
Figure 2
General Notes
Proportional valve technology is now an established concept in the field of hydraulic pilot control systems for mobile cranes. This
handbook will be a source of information for this technique.
A common sequence chart is shown in Figure 1.
Follow the course of the signal:
A voltage signal is connected to an amplifier and there converted to a current signal corresponding to the voltage level, e.g. 1mV
1mA.
This electric current signal is connected to a proportional solenoid with stroke to current or force to stroke relationship.
Proportionally with respect to this current, which is the input variable, the proportional solenoid generates force -or travel- as the
output variable.
This proportional solenoid is mounted on a proportional pressure control valve which again is connected -or directly mounted- on a
hydraulic control block.
According to the oncoming pressure, this control block is giving way for the oilflow to a hydraulic motor or cylinder resp.
For the consumer, a hydraulic motor or a hydraulic cylinder, that means that force and speed are influenced in a stepless manner.
At the same time is also controlled:
the change in volume flow with respect to time, i.e. acceleration or deceleration of revs. of a hydraulic motor or speed of a piston.
Proportional valves and proportional pumps also make freely programmable control possible.
Technical advantages of proportional devices are
continuously variable control of set-point values
simpler, more rapid movements
improvement of the switching process
controlled switching transition, pressure peaks thus avoided
thus extended service life
fewer and simpler valves, e.g. directional control valves
installation location optimised, thus more dynamic response of the control system
Corresponding amplifiers are assigned to the various proportional devices.
From Figure 2 various applications of proportional hydraulics can be seen, while we are using the pressure function (force) with
pressure reducing valves.
Pressure Reducing Pressure Reducing The minimum and maximum current signals of the proportional amplifier can be set
Valve Valve independently of each other, e.g. 300mA and 900mA.
The proportional amplifier has further an adjustable ramp former. This forms a
slowly increasing or decreasing output signal from the input signal.
The durations of the increase or decrease of the output signal - the ramp - can be ad-
justed independently of each other.
b a This ramp cannot be influenced by moving the lever so as to oppose it or by rapidly
pulling or releasing it.
Control The proportional solenoid adjusts the piston of a pressure reducing valve proportion-
Block
ally with respect to the current and thus controls the pressure in the hydraulic pilot
circuit.
Hydraulic New designed cranes do have proportional valve control systems without ca-
Motor pacitor and power supply modules resp. As this control system is continuously
improved, see corresponding electric circuit diagrams for details.
This units are mechanically very complicated built and are used in AC1600 type
Joystick Figure 4 cranes only. Changing to joysticks of more recent design is possible only with exten-
sive rewiring work.
Electronic Signal Transmitter
Types VT 10468 and VT 10406 resp. They have one -X = VT 10468- or
Manufacturer: Mannesmann Rexroth two operating directions -X and Y = VT 10406-.
The mark of the direction is stamped on top side of the mounting
flange.
Supply is 15V from the stabilised power supply module.
The output signal is processed according to operating direction:
+ or -, 0 to 10V;
Level Direction Output Amplifier output
XA forward 0 to +10V B X12
XB backwards 0 to 10V A X10
YC to the left 0 to +10V B X12
YD to the right 0 to 10V A X10
X- and Y-directions can be driven simultaneously - diagonally.
The lever travel in each operating direction is 20:
after approximately 1% of the latter, one directional contact
switches per axis half;
after approximately 10%, the downstream-connected proportional
amplifier starts to transmit a current signal to the proportional
solenoid
The unit has two cable harnesses. One of these is screened and con-
tents the
15V supply lines
0 to 10V signal lines
earth line for the housing.
The second, non-screened cable harness contents the
24V supply lines, directional signal lines and deadman's contact
lines.
Cable colours and assignment can be found in the applicable circuit
diagram.
\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 7
Technical Manual Proportional Valve Technology
Components
5. Zero contact
Checking of Joysticks Type FSG 2000 i set multimeter to resistance range and connect poles to terminals
6 and 7, operate joystick:
Crane Functions
after the click of the microswitch the resistance must drop to 0
CC1400/CC2800/CC12600/ X and Y-level, deadman switch, two 6. Manually operated switches
CC3800/AC665/AC535 switches, vibrating pin set multimeter to resistance range and connect poles to terminals
CC1400/CC2800/CC3800/ Y1 and Y2-level, deadman switch, two 15/16 for deadman switch, terminals 17/18 for left switch and ter-
CC12600 switches, vibrating pin minals 18/19 for right switch:
after operating the according switch the resistance must drop
CC12600/CC2800/CC3800 Y-level, deadman switch, two switches, to 0
vibrating pin
7. Vibrating pin (rotating indicator)
CC3800 Y-level, round joystick check with very short supply (tip) of 24 volt to terminals 13 and
14.
The unit converts the set-point value signal coming from the
Proportional Amplifier Type VT 11165 Figure 12
signal transmitter into a current signal corresponding to the
used on AC665/AC535/CC1400/1800/CC12600 force required by the proportional solenoid.
The maximum current signal can be reduced with the set-point
adjuster (potentiometer) so that pilot pressure and thus working
speed are also reduced.
The integrated ramp generator
produces a slowly, gradually increasing or decreasing output
signal (the ramp) from a step input signal.
The gradient (ramp time) of increase and decrease can be set
independently of each other.
The control is thus adapted to requirements of crane functions.
The difference between types VT 11165 and VT 11032 is in the
design of the set-point adjuster:
VT 11165 gives maximum reduction with zero voltage signal,
while
VT 11032 gives maximum reduction with maximum voltage sig-
nal (10V).
Therefore the units are not interchangeable without extensive
changes in the wiring
Some precautions
Connect or disconnect terminals only in de-energised state
Measurements with multimeter in DC-position
Distance to operated radio equipment at least 1 meter
Proportional Amplifier Type VT 11550 Figure 15 this amplifier converts the set-point value signal coming from
used on CC/TC1400/1800 the signal transmitter into a current signal corresponding to the
force required by the proportional solenoid.
Terminals Function
X1 +24V supply, UB solenoids
X2 0 (+24V)
X3 Switched Output B, 24V
X4 GND - measuring point
X5 Signal Input 10V from Joystick
X6 24V Operating Voltage for Amplifier
X7 - Proportional output B, direction X-/Y-,
forward/left
X8 + Proportional output A, direction X+/Y+,
backwards/right
X9 Switched Output A, 24V
X10 not connected
X11 24V Input Interlock
X12 not connected
Setting
Amplifier VT 11165
1. Ensure that pots for the ramp (T/down - T/up) are not
on min (left stop position). The ramp former is con- Signal of setpoint value adjustment
nected upstream of the electronics for the proportional 0V for max reduction and
10V for no reduction
outputs and malfunction may possibly follow
Setting Instructions
Measurements
with malfunctions in the electronic system for AC535
for telescopic boom cranes 455 649 40/3, Page 1 - 3
Switch off voltage. Switch it on again after about 2 minutes. If this has not
for lattice boom cranes 552 530 40/, Page 26
rectified the malfunction, continue to check in the following sequence:
1. Check all belonging fuses, if you find failures check for short circuit
2. At cranes with power supply module, check supply of crane voltage
first, then + and 15V supply to the joystick Remember always:
at cranes without power supply module check 24 Volt supply to joy- Hydraulic pressure is adjusted with help
stick of the current signal from the amplifier
3. At the proportional amplifier check supply voltage on all terminals, to the proportional solenoid.
switches and relays according to electric circuit diagram, then
4. Supply to set-point reducer (potentiometer) and its signal to amplifier
5. Supply to joystick and signal from same to amplifier
6. Current signal and lines from amplifier to proportional solenoid
7. On proportional solenoid check for short-circuits and coil resistance:
12 at 20 celsius, 18 at 70 celsius.
Derricking Circuit 2 A II
raise Output A Y II 5,5 - 27 bar 1 s R11 2) 0,5 s R12 2)
lower Output B Y II 5,5 - 27 bar 1 s R13 2) 0,5 s R14 2)
Telescopic Boom
Circuit 1 AI
extend Output A YI 5,5 - 27 bar 1 s R11 2) 0,5 s R12 2)
retract Output B YI 5,5 - 27 bar 1 s R13 2) 0,5 s R14 2)
D28 (~18 bar) 0,2 - 0,25 m/s 1)
pinning R35 12 bar
locking R35.3 10,5 bar
Telescopic Boom
Circuit 2 A II
extend Output A Y II 5,5 - 27 bar 1 s R11 2) 0,5 s R12 2)
retract Output B Y II 5,5 - 27 bar 1 s R13 2) 0,5 s R14 2)
D28 (~18 bar) 0,2 - 0,25 m/s 1)
pinning R35 12 bar
locking R35.3 10,5 bar
1) Normal speed
2) Resistors in Amplifier
Source: e-anw_01.doc/8315
\3PROPVALVE_E2.DOC TECHNICAL TRAINING SWR - 24
Technical Manual Proportional Valve Technology
Measurements and Adjustments
Function Amplifier Propvalve Checkpoint P min I min P max I max T up T down Remarks
Hoist 1 raising B 215.1 Y215.2 19 6 bar --- 26 bar --- 2 sec 1.5 sec -
Hoist 1 lowering B 215.1 Y215.1 23 6 bar --- 26 bar --- 2 sec 1.5 sec 1
Hoist 2 raising B 216.1 Y 216.2 20 5 bar --- 26 bar --- 2 sec 1.5 sec 1
Hoist 2 lowering B 216.1 Y 216.1 24 6 bar --- 26 bar --- 2 sec 1.5 sec 1
Tele extend B 217.1 Y 217.1 21 6 bar --- 26 bar --- 0 sec 0 sec 3
Tele retract B 217.1 Y 217.2 26 6 bar --- 26 bar --- 0 sec 0 sec 3
Luffing Cylinder B 218.1 Y 218.1 21 6 bar --- 26 bar --- 2 sec 1.5 sec -
raising
Luffing Cyl. lowering B 218.1 Y 218.2 25 6 bar --- 26 bar --- 2 sec 1.5 sec -
Slewing right B 219.1 Y 219.1 --- --- 300 mA --- 800 mA 3 sec 3 sec 2
Slewing left B 219.1 Y 219.2 --- --- 300 mA --- 800 mA 3 sec 3 sec 2
Remarks
1: to reach maximal speed the sensitivity is influenced; with normal operation use set point aduster
2: no pressure checkpoints provided
3: time ramps not required
10 V
RV Joystick 4.7 k
Joystick 2k
0 - 20 mA 0 - 20 mA
4.7 k Ramp
AC 535 AC535
Opera t ion a l Dia gr a m Operational Diagram
Crane voltage Slewin g Gea r Crane voltage Hoist, Luffing and
Telescopic Boom
10 V
Joystick 2k
0 - 20 mA Joystick 4.7 k
0 - 20 mA
4.7 k Ramp
10 V
Function
0 - 10 V Function
4.7 k Crane voltage is connected to a joystick
0 - 10 V Crane voltage is connected to a joystick
which is producing a current signal
corresponding to the movement of its control which is producing a current signal
Prop-Amplifier lever. This current signal is converted to corresponding to the movement of its control
1k voltage with an 1k potentiometer and Prop-Amplifier lever. This current signal is converted to
connected to a proportional amplifier. From voltage with an 1k potentiometer and
1k
there the amplified signal is connected to a connected to a proportional amplifier. From
prop. solenoid valve which is directly there the amplified signal is connected to a
mounted on a hydraulic control block. This prop. solenoid valve which is controlling the
proportional solenoid valve is reducing the hydraulic pressure in the pilot control circuit
pressure in the pilot circuit corresponding to affecting the control of hydraulic pumps I
2 Prop-Valves, the signal from the joystick.
left & right turn and/or II. This signal is corresponding to the
Prop-Valves signal from the joystick.
Checking & Adjustment
operate joystick full stroke into one direction Checking & Adjustment
and check on X5 of amplifier: 10 V must operate joystick full stroke into one direction
Controlblock be the reading, + or depending on direction and check on X5 of amplifier: 10 V must
of control lever. be the reading, + or depending on direction
Voltage to be adjusted with 1 k pot. of control lever.
Joystick in neutral 0 V. The ramptime is Voltage to be adjusted with 1 k pot.
adjusted with a 4.7 k pot which is supplied Joystick in neutral 0 V.
with 8 V from an adjustable 2 k pot. Hydraulic
The ramptime is adjusted with a
Pump
4.7 k pot which is supplied with 10 V
from an adjustable 2 k pot.
Hydraulic
Motor
CC1400
Operating Diagram
CC1400 Slewing
Operating Diagram Crane Voltage
Crane Voltage Derricking/Luffing/
Crawlers
Controlblock
Controlblock
Hydraulic
Motor
Hydraulic
Motor
\4PROPVALVE_E3.DOC TECHNICAL TRAINING SWR - 32
Technical Manual Proportional Valve Technology
Action Charts
CC1400
CC1400 Operating Diagram
Crane Voltage Hoist 1 & 2 raising
Operating Diagram
Crane Voltage Hoist 1 & 2 raising
22...32 VDC
Checking & Adjustment
Joystick 1. Signal from joystick to prop-
22...32 VDC Function
Crane voltage is connected to 0 - 20 mA amplifier:
Joystick 12...14 VDC
0 - 20 mA joystick, amplifiers and voltage turn rotating potentiometer to
12...14 VDC converter. The current signal from position 5, operate joystick full
the joystick is changed to a voltage stroke into direction raising and
1k
signal with a potentiometer; 1k check on X5 of amplifier:
After a 10% part of joystick 10 volt must be the reading,
movement the amplifier is 10 V Voltage to be adjusted with 1k-
operating a relay (K1) which is K1 potentiometer.
connecting the signal from joystick Joystick in neutral 0 volt.
K1 to a second amplifier, which to 1 - 10 V 4.7k After a 10% part of joystick
follow is operating a relay to movement the amplifier is
1 - 10 V operate the prop. solenoid valve on 0 to -10 V
operating a relay (K1) which is
0 to -10 V the control block (black/white- 5 Rot. Pot connecting the signal from joystick
5
control) to a second amplifier, which to
Rot. Pot Control of hydraulic pump is Prop- Prop-
Amplifier Amplifier follow is operating a relay to
Prop- Prop- according to position of joystick operate the prop. solenoid valve on
Amplifier Amplifier and position of rotating the control block (black/white-
potentiometer. This rotating control)
potentiometer is supplied with K1
K1 power from an voltage reducer and Relay 2. Supply and Signal for rotating
Relay an additional potentiometer. potentiometer:
Proportional solenoid valve turn rotating potentiometer to
for adjustment of pump has position 5 and adjust voltage on
Relay Prop-
ground-return wiring to prop. input of same to 10 volt, using
Prop- Solenoid Valve
Relay amplifier 1k-potentiometer. Control range
Solenoid Valve from rotating potentiometer to
amplifier is 10 volt to 1 volt.
Proportional solenoid valve
for adjustment of pump has
Prop- ground-return wiring to amplifier
Prop- Solenoid Valve
Solenoid Valve
Controlblock
Controlblock
Hydraulic
Pump
Hydraulic
Hydraulic Hydraulic Motor
Motor Pump
Hydraulic
Hydraulic motor
pump P1 Hydraulic
P2.1 pump P1
Hydraulic
P2.1
motor
Prop- Prop-
Solenoid Valve
Solenoid Valve
Controlblock Controlblock
Hydraulic
Hydraulic Hydraulic Hydraulic
Motor
Pump Motor Pump
CC1400
Operating Diagram
Crane Voltage Hydraulic Pump
Adjustment
22...32 VDC
12...14 VDC
Checking & Adjustment
1. Supply and signal of rotating
potentiometer on lh armrest
console:
1k turn rotating potentiometer to
position 5 and set voltage on input
of potentiometer to 10 volt, using
10 V 1k potentiometer. Control range
to proportional amplifier X6 10
volt to 1 volt.
4.7k Proportional solenoid valve
for adjustment of pump has
ground-return wiring to amplifier.
Rot. Pot
10- 1 V
6
Proportional-
Amplifier
Prop-
Solenoid Valve
Hydraulic
Pump
12...14VDC
Signal processing to the
proportional amplifier
Cranevoltage is connected to the Joystick 1k
22...32VDC joystick which is sending a current 0 20 mA
Joystick signal corresponding to its +10V
0 20 mA excursion; this is converted with the
12...14VDC 1 k pot into voltage. From the 4.7k rot. Pot
amplifier a current signal is
0 10 V
connected to the prop-solenoid
valve which is reducing the 0 10 V
1k hydraulic pressure in the pilot
0 10 V system accordingly.
The amplifier switches also the 1k
+10V 24V-signal for the relays which to Prop-Amplifier
Signal processing to the proportional
follow are switching the amplifier
Prop-Amplifier black/white solenoid valves. A = 10V B = +10V Cranevoltage is connected to the joystick
1k With the voltage converter and the 0V/24V which is sending a current signal
1 k pot 10 Volt are constantly 0V/24V corresponding to its excursion; this is
A = 10V B = +10V 0 V/24 V connected to the terminal of the 200 900mA converted with the 1 k pot into voltage.
command value input as the speed From the amplifier a current signal is
0 V/24 V 200 900mA connected to the prop-solenoid valve which
control is carried out with the pump
adjustment. Prop- Prop- is reducing the hydraulic pressure in the pilot
Valve Valve system accordingly.
Prop-Valve Prop-Ventil The amplifier switches also the 24V-signal
Prop-Valve
for the relays which to follow are switching
the black/white solenoid valves.
Voltage converter and 1 k pot are
generating 10 Volt which are used from the
4.7 k pot to adjust the command value
Checks/Adjustments
signal.
Operate joystick to its full stroke and check on
Checks/Adjustments Hint:
amplifier terminal X5 10 Volt is required there,
Operate joystick to its full stroke and in the control line between joystick and
+ oder , according to direction of excursion of
check on amplifier terminal X5 10 Volt joystick; this voltage is to be adjusted with the 1
amplifier is a chain of relays installed which
is required there, are not shown on this diagram for
k pot. simplification.
+ oder , according to direction of Joystick in neutral = 0 Volt.
excursion of joystick; this voltage is to be
adjusted with the 1 k pot.
Joystick in neutral = 0 Volt.