02-octubre, 2004 cartridge valve and hic products

02-Octubre, 2004

CARTRIDGE VALVE AND HIC PRODUCTS

CARTRIDGE VALVEBUSINESS UNIT

FACILITIES

Hillsboro, Oregon

Easley, South Carolina

Nordborg, Denmark

Reggio Emilia, Italy

NORTH AMERICAN HISTORY

1947 Fluid Controls introduces cartridge relief valve.

1965 Fluid Controls introduces HIC manifolds.

1968 Fluid Controls introduces spreader control valves.

1981 Sta-Rite acquires Fluid Controls.

1985 Sta-Rite relocates to Easley, SC.

1992 Danfoss Fluid Power acquires Sta-Rite.

2000 Sauer-Sundstrand and Danfoss Fluid Power merge to become

Sauer- Danfoss.

1977 Compact Controls founded to design and manufacture HIC’s.

1979 Compact Controls introduces pressure and flow control valves.

1982 Compact Controls introduces solenoid and proportional valves.

1995 Compact Controls relocates to 60,000 sq. ft. building in

Hillsboro, Oregon

2001 Sauer-Danfoss acquires Compact Controls.

VALVE ENGINEERING

• Hillsboro & Easley combined engineering resources:

- 8 engineers

- 6 designers

- 5 lab technicians

- 6 machinists for prototypes

- 1 buyer/planner for prototypes

• Solid model design capability:

- Inventor and AutoCad 2000 used for design.

- Translation to many formats (ProE, Unigraphics, others) available.

• Engineering Data Management System (EDMS) used to share drawings and BOM’s between multiple plant sites.

R & D LAB

• Performance test stand for 100 gpm.

• Fatigue and burst test capabilites.

• Computerized data acquisition to record and analyze data.

VALVE MANUFACTURING

• Cellular Assembly Approach:

- 7 assembly cells.

- Cartridges 100% tested on computerized test stands.

• Hard-Turning Capability:

- Ensures leak-free poppet/seat sealing.

- 4 Hardinge Conquest and 1 American Way turning centers.

- Poppet/seats matched and 100% vacuum tested.

MANIFOLD MANUFACTURING

• In-House CNC milling

- 15 flexible machining centers for “lights out” operation.

- Capacity for 240,000 manifolds/year.

• Experience with many manifold materials:

- Aluminum 6061-T6 (standard for <3000 psi), anodizing available.

- Aluminum 7075-T6 (standard for 3000-4000 psi), anodizing available.

- Ductile iron (standard for >4000 psi or on request) with zinc plating standard.

- Steel (on request).

MANIFOLD MANUFACTURING

• In-house automated thermal de-burr and automated wash systems.

• 3 HIC assembly cells with automated computerized testing.

• Utilize advanced quality planning tools as part of normal product release and manufacturing processes:

- Design for Manufacturability (DFM)

- Failure Modes and Effects Analysis (FMEA)

- Process Failure Mode and Effects Analysis (PFMEA)

- Statistical Process Control (SPC)

• Supplier audit system is used to build alliances with critical suppliers.

• All plants are ISO 9001 registered.

• Sauer-Danfoss goal is 250 dpm as measured on the customer’s production line.

QUALITY STATEGY

CARTRIDGE VALVEPRODUCT LINE

• Cartridge valves are compact, low-cost, no-leak, screw-in components suitable for mobile and industrial hydraulic control functions.

• Cartridge valves are available for flow, pressure, and directional control up to 5000 psi and 50+ gpm.

• Almost any circuit can be quickly created using standard catalog valves.

CARTRIDGE VALVES

• All valves have a model code in this format:CPABC-D-E-F-G-H

• CP = “cartridge product”

• A = type of valve: 1=check, 2=pressure control, 3=flow control, 4=motion control, 5=solenoid, 6=manual, 7=differential sensing

• B = description depends on type of valve, for example 0=poppet, 1=spool

• C = cavity size: 4=4 series, 8=8 series, 0=10 series, 1=12 series, 2=16 series, 3=20 series

• D = description depends on type of valve, for example 1=open, 2=closed

• E = type of o-ring seal: B=Buna-N (nitrile), V=Viton, U=Urethane

• F = port options: 0=cartridge only, other nomenclature describes port sizes if cartridge is ordered in a body

• G,H,… = description depends on type of valve, may specify pressure setting for relief valve, flow setting for flow control, coil voltage, etc.

CATALOG NOMENCLATURE

To specify a size 8 differential area relief valve set internally at 2500 psi crack pressure installed in an aluminum body with SAE 6 ports and viton seals, use model code:

CP208-1-V-6S-A-C250

HOW TO READ THE CATALOG

HOW TO INTERPRET THE RATINGS

• Cavity – Each valve fits a Sauer-Danfoss standard cavity.

• Pressure Rating – Based on NFPA one million cycle fatigue test standard and a burst test with a 4:1 safety factor.

• Flow Rating -

Directional Valves – Based on a pressure drop of 100 psid with 32 cSt fluid.

Pressure Relief & Reducing Valves – Based on a pressure rise or droop of 100 psid with 32 cSt fluid.

(flow rating can be exceeded for the above valves if the penalties of higher pressure drop and associated heat generation are acceptable)

Solenoid Spool Valves – Based on a pressure drop of 100 psid with 32 cSt fluid but also indicates a performance limit based on maximum solenoid force.

(do not exceed flow ratings for solenoid spool valves without consulting factory)

• Crack Pressure – Is set at 0.25 gpm with 32 cSt fluid.

HOW TO INTERPRET THE RATINGS

• Leakage –

Pressure Control Valves – measured at 70-80% of crack pressure with 32 cSt fluid.

All Other Valves – measured at maximum rated pressure with 32 cSt fluid.

• Solenoid Voltage – Is a nominal value. All solenoid valves are designed to operate with continuous duty at 140°F ambient temperature with rated flow and pressure.

• Temperature Rating – Varies by model and options. Seal materials have the following limits:

Buna N and Polyurethane – -40°F to +250°F

Viton – -15°F to +400°F

The recommended minimum fluid viscosity is 12 cSt which will override the seal temperature limit for most fluids.

• Valves use industry-standard “SAE” cavities.

• Cavities highlighted in red do not match the proposed new NFPA/3.50.200X spec. These cavities and valves will be redesigned upon formal approval of the new standard.

• Port numbering standard is as shown.

VALVE CAVITIES

• Check valves allow free flow in one direction and block flow in the opposite direction.

• Used to hold loads, separate systems, provide load-sensing “logic”, or as low pressure relief valves.

- Sizes: 4, 8, 10, 12, 16, 20

- Drop-in check valves available.

- In-line check valves available.

- Flow Ratings: to 100 gpm

- Pressure Ratings: to 5000 psi

CHECK VALVES

IN

OUT

CHECK VALVESLOAD SENSING APPLICATION

CHECK VALVESANTI-CAVITATION APPLICATION

CHECK VALVESLOAD HOLDING APPLICATION

PILOT PISTON CHECK

VALVE

• Shuttle valves connect the higher of two input pressures to the output port.

• Used for load-sense logic, pressure compensation for multiple functions, or for brake application or release.

- Sizes: 4, 8, 10

- Flow Ratings: to 5 gpm

- Pressure Ratings: to 3000 psi

SHUTTLE VALVES

IN

OUT

IN

SHUTTLE VALVESLOAD SENSING APPLICATION

SHUTTLE VALVESBRAKE RELEASE APPLICATION

• Shuttle valves connect the lower of two input pressures to the output port.

• Used for filtering and/or cooling in closed-circuit hydrostatic transmissions.

- Sizes: 10, 12

- Flow Ratings: to 50 gpm

- Pressure Ratings: to 5000 psi

HOT OIL SHUTTLES

OUT

IN

IN

HOT OIL SHUTTLESHYDROSTATIC TRANSMISSION APPLICATION

• Relief valves limit system pressure.• Direct acting valves are available with

“direct acting” and “differential area” designs as shown.

• Both designs are lower-cost, faster-acting, and more contamination tolerant than pilot operated relief valves.

• The “differential area” type has flatter pressure regulation.

• The “direct acting” type has better reseat and hysteresis characteristics.

- Sizes: 8, 10, 12- Flow Ratings: to 40 gpm- Pressure Ratings: to 3000 psi

DIRECT ACTING RELIEF VALVES

DIRECT ACTINGDIFFERENTIAL AREA

IN

OUT IN

OUT

DIRECT ACTING RELIEF VALVESTYPICAL PERFORMANCE COMPARISON

PRESSURE VS. FLOW

FLOW (GPM)

PR

ES

SU

RE

(P

SID

)

DIFFERENTIAL AREA

DIRECT ACTING

• Relief valves limit system pressure.

• Pilot operated relief valves provide flatter pressure rise for more accurate pressure control, lower hysteresis, and higher operating pressures than direct acting relief valves.

- Sizes: 10, 12

- Flow Ratings: to 50 gpm

- Pressure Ratings: to 5000 psi

PILOT OPERATED RELIEF VALVES

IN

OUT

INLET

TANK

REG. PRESSURE

• Reducing/relieving valves provide reduced downstream pressure while system pressure is unaffected.

• Direct-acting designs are lower cost, faster-acting, and more contamination tolerant than pilot operated pressure reducing valves.

- Size: 10

- Flow Rating: 10 gpm

- Pressure Rating: 3000 psi

DIRECT ACTINGPRESSURE REDUCING/RELIEVING VALVES

PILOT OPERATEDPRESSURE REDUCING/RELIEVING VALVES

• Reducing/relieving valves provide reduced downstream pressure while system pressure is unaffected.

• Pilot operated designs provide more accurate pressure control and higher operating pressures than direct acting designs.

- Size: 10

- Flow Rating: 10 gpm

- Pressure Rating: 5000 psi IN

OUT

REG

PRESSURE REDUCING/RELIEVING VALVESTYPICAL PERFORMANCE COMPARISON

PRESSURE VS. FLOW

FLOW (GPM)

PR

ES

SU

RE

(P

SI) PILOT OPERATED

DIRECT ACTING

0

REDUCINGRELIEVING

• Sequence valves ensure that one operation is complete before another is performed, for example:

- Ordered sequence of operations, e.g. clamp then lift.

- Pump unloading.

- Accumulator charging.

• Available with a variety of spool, porting, spring options, etc.

- Size: 10

- Flow Ratings: to 14 gpm

- Pressure Ratings: to 5000 psi

SEQUENCE VALVES

IN

TANK

SEQ

CP240-1 Sequence Valve ensures full force is applied to clamp cylinder before lift function begins:

Clamp

Lift

CP240-1

SEQUENCE VALVESCLAMP AND LIFT CIRCUIT

CP240-22 Kick-Down Sequence Valve opens at a pre-determined pressure and stays open until flow is stopped. Can be used to sequence operations (see example, no manual valve operation until solenoid is energized) or as a safety shut-off valve.

CP240-22

SEQUENCE VALVESKICK-DOWN SAFETY CIRCUIT

CP240-30 Unloading-Type Sequence Valve unloads pump to tank when accumulator reaches a pre-determined pressure setting and re-charges accumulator when pressure drops to 75, 80, or 85% of pre-determined level.

CP240-30

SEQUENCE VALVESACCUMULATOR CHARGING CIRCUIT

• Pressure compensated flow control valves provide constant flow regardless of system pressures.

• Restrictive-type flow controls can be used to control cylinder raise or lower speeds, motor speeds, etc.:

- Sizes: 8, 10, 12

- Flow Ratings: to 12 gpm

- Pressure Ratings: to 3000 psi

RESTRICTIVE-TYPE FLOW CONTROL VALVES

IN

OUT

.8GPM

TANK

P1 G1 P2 L1 L2LEVEL

TR1ROTATE

TR2 SC1CYLINDER

SC2CYLINDER

PC1 PC2 EXTCYLINDER

RET

TURNTABLE SECONDARY PRIMARY EXT/RET

ACAD

only for purpose which loaned.

information. Borrower of print agrees to use

Property of C.C.I. containing confidential

Controls, Inc.

CP11920

FUNCTION MANIFOLDPART NO.

USED ON

CSIZE

ROSENTHALTITLE

DR SCALE

N/A

REV

OFPAGE

1 1

2

04-22-98DATE

Compact

A B CE

Q

R O

I J

F G H

K L M

GPM1.5Y

3200 PSI

T2

3000PSI

1100PSI

1600PSI

1400PSI

1800PSI

ST

T3

CP300-1 Restrictive-Type, Pressure-Compensated Flow Control Valves provide fixed speed for each function regardless of load:

RESTRICTIVE TYPE FLOW CONTROL VALVESSPEED CONTROL APPLICATION EXAMPLE

• Pressure compensated flow control valves provide constant flow regardless of system pressures.

• Priority-type flow control can be used to provide constant flow to a priority function (e.g. steering) while allowing excess flow to be used for auxiliary functions.

• Can be used as a restrictive-type flow control with the excess flow port plugged.

- Sizes: 10, 12

- Flow Ratings: to 12 gpm

- Pressure Ratings: to 3000 psi

PRIORITY-TYPE FLOW CONTROL VALVES

IN

REG.FLOW

EXCESSFLOW

CP310-1 Priority-Type, Pressure-Compensated Flow Control provides 2.5 gpm constant flow to steering with excess available for auxiliary function:

CP310-1

2.5 gpm

PRIORITY TYPE FLOW CONTROL VALVESSTEERING PRIORITY CIRCUIT

• Flow divider/combiner valves provide pressure compensated flow division or combination at a pre-set ratio regardless of system pressures.

• Often used for cylinder synchronization or in traction circuits.

• Note: S-D flow dividers do not have a “re-phase” feature for cylinder synchronization.

• Flow divider/combiner sizing can be very important!!!• Undersizing leads to extremely high pressure drops and

associated heat generation.

• Oversizing leads to poor dividing and combining accuracy

- Sizes: 10, 12, 16

- Flow Ratings: to 40 gpm.

- Pressure Ratings: to 3000 psi

FLOW DIVIDER/COMBINER VALVES

IN/OUT

IN/OUT

OUT/IN

CP341-1 Flow Divider/Combiner Valves in four-wheel-drive circuit:

ACAD

only for purpose which loaned.

information. Borrower of print agrees to use

Property of C.C.I. containing confidential

Controls, Inc.

CP11464

TRACTION CONTROL 4PART NO.

USED ON

ASIZE

A.WOLFLINGTITLE

DR SCALE

N/A

REV

OFPAGE

1 1

05-24-94DATE

Compact

M7M3

M5

M1

B A

M2

M6

M4M8

TD

AB

C

E

67% 33%

PSI

CP

F

G

H

ACAD

only for purpose which loaned.

information. Borrower of print agrees to use

Property of C.C.I. containing confidential

Controls, Inc.

CP11464

TRACTION CONTROL 4PART NO.

USED ON

ASIZE

A.WOLFLINGTITLE

DR SCALE

N/A

REV

OFPAGE

1 1

6

05-24-94DATE

Compact

M7M3

M5

M1

B A

M2

M6

M4M8

TD

AB

C

E

.070

.070

.052

67% 33%

210PSI

CP

F

G

H

BP

EP#

19038

M6 X 1.0

T1

Rear Wheels

Left

Right

Front Wheels

Left

Right

FLOW DIVIDER/COMBINER VALVESFOUR WHEEL DRIVE TRACTION CIRCUIT

PILOT

LOAD

VALVE

• Motion control valves are used to control moving loads and prevent loads from running ahead of a pump. There are two basic types, pilot-operated check valves and counterbalance valves.

• Pilot-operated check valves are non-modulating valves that provide load holding and “hose break” protection.

• In a HIC manifold it is more economical to use a standard check valve with a pilot piston than a pilot-operated check valve cartridge.

- Sizes: 8, 10, 12, 16

- Flow Ratings: to 60 gpm

- Pressure Ratings: to 5000 psi

PILOT OPERATED CHECK VALVES

CP108-1 Check Valves in load-holding circuit application:

- Provides free-flow check for load lifting.

- Provides leak-free check for load holding.

- Prevents cavitation if the load runs away from the pump and acts as a “hose break” safety valve – but does not provide smooth deceleration or load lowering.

PILOT OPERATED CHECK VALVESLOAD HOLDING CIRCUIT

PILOT

LOAD

VALVE

• Motion control valves are used to control moving loads and prevent loads from running ahead of a pump. There are two basic types, pilot-operated check valves and counterbalance valves.

• Counterbalance valves perform the same function as pilot-operated check valves and also provide modulated load lowering and smooth braking/deceleration of large inertial loads.

- Sizes: 8, 10, 12

- Flow Ratings: to 30 gpm

- Pressure Ratings: to 5000 psi

COUNTERBALANCE VALVES

CP440-1 Counterbalance Valve in Cylinder Circuit:

- Provides free-flow check for load lifting.

- Provides leak-free check for load holding.

- Acts as a pressure relief valve for the load.

- Provides cavitation-free load lowering (matches cylinder speed to pump flow to prevent load from “running away”, acts as a “hose break” safety valve, and provides smooth deceleration and load lowering.

COUNTERBALANCE VALVESLOAD HOLDING CIRCUIT

• Relief setting to be 1.3 X maximum expected load. Don’t overlook return line backpressure which is additive to this setting.

• Low pilot ratios (3:1 to 4.5:1) require higher pilot pressure but provide smoother, more stable control. They are best for variable and high inertia loads (e.g. cylinders).

• High pilot ratios (8:1 to 10:1) require lower pilot pressure and provide faster speeds, but with less stability. They are best for constant and smooth loads (e.g. motors).

• Always mount counterbalance valves in or on the cylinder, not at the directional control valve.

• Use counterbalance valves with normally open or motor spools—never with normally closed spools.

CP440-2 Dual Counterbalance Valve for “overcenter load”:

COUNTERBALANCE VALVESAPPLICATION NOTES

• Needle valves are non-pressure compensated manually adjustable flow controls.

- Sizes: 8, 10, 12, 16

- Flow Ratings: to 50 gpm

- Pressure Ratings: to 3000 psi

NEEDLE VALVES

• Hydraulically pilot-operated spool valves that provide directional control based on pilot pressure.

• Often used with solenoid valves to create high flow directional valves.

• Available with a variety of spool, porting, and spring options.

- Sizes: 10, 16, 20

- Flow Ratings: to 70 gpm

- Pressure Ratings to 3000 psi

DIRECTIONAL CONTROL VALVES

CP72X-5

CP72X-5 Directional Control Valve Circuit:

- Creates a high-flow 4 way / 3 position directional control valve w/motor spool (up to 70 gpm).

- Pilot-operated with small solenoid cartridge valve for low electrical power requirement.

- Provides compact and low-cost alternative to on-off D03, D05, or PVG valve.

DIRECTIONAL CONTROL VALVESHIGH FLOW SOLENOID VALVE CIRCUIT

• Different spool and porting options can be used as “logic valves” in conjunction with other valves to provide:

- Restrictive-type pressure compensation for external fixed or variable orifices.

- Priority-type pressure compensation for external fixed or variable orifices.

- High flow pressure relief or reducing valve functions.

- Pilot-to-close directional valves.

• Available with a variety of spool, porting, and spring options.

- Sizes: 10, 12, 16

- Flow Ratings: to 50 gpm

- Pressure Ratings: to 3000 psi

DIFFERENTIAL SENSING VALVES

CP30X-4 Differential Sensing Valve:

- Use with fixed orifice, manually variable orifice (needle valve), or electrically variable orifice (proportional valve) to provide restrictive-type pressure compensation.

CP30X-4

DIFFERENTIAL SENSING VALVESPRESSURE COMPENSATION CIRCUIT

CP31X-4 Differential Sensing Valve:

- Use with fixed orifice, manually variable orifice (needle valve), or electrically variable orifice (proportional valve) to provide priority-type pressure compensation.

CP31X-4

Steering Cylinder (priority)

DIFFERENTIAL SENSING VALVESPRESSURE COMPENSATION CIRCUIT

Closed-center system:

- All flow dumps at 3000 psi when no function is operating.

- Excess flow dumps at 3000 psi when any function is operating.

DIFFERENTIAL SENSING VALVESPUMP UNLOADING CIRCUIT

Closed-center system with 70X-1 Differential Sensing Valve:

- All flow dumps at 150 psi when no function is operating.

- Excess flow dumps at 150 psi above load pressure when any function is operating.

- Always use bleed orifice or flow control with tandem or closed-center spools.

CP70X-1

DIFFERENTIAL SENSING VALVESPUMP UNLOADING CIRCUIT

CP70X-2 Differential Sensing Valve:

- Use with small relief valve to create high flow (50 gpm) cartridge pressure relief valve.

CP70X-2

DIFFERENTIAL SENSING VALVESHIGH FLOW RELIEF VALVE

CP70X-3 Differential Sensing Valve:

- Use with small relief valve to create high flow (50 gpm) cartridge pressure reducing valve.

CP70X-3

Full Pressure Function Reduced Pressure Function

DIFFERENTIAL SENSING VALVESHIGH FLOW PRESSURE REDUCING VALVE

• Used as 2W / 2P on-off directional control valves.

• Poppet-style provides high flow and low leakage.

• Available in normally-open and normally closed versions with free-reverse flow available as an option.

- Sizes: 8, 10, 12, 16, 20

- Flow Ratings: to 60 gpm

- Pressure Ratings: to 3000 psi

2-WAY SOLENOID POPPET VALVES

CP50X-X Solenoid Poppet Valves:

- Typical application is load-holding and directional control for lowering. CP50X-X

2-WAY SOLENOID POPPET VALVESLOAD HOLDING CIRCUIT

• Used as 2W / 2P on-off directional control valves.

• Available in normally open and normally closed versions.

- Sizes: 8, 10

- Flow Ratings: to 6 gpm

- Pressure Ratings: to 3000 psi

2-WAY 2-POSITION SOLENOID SPOOL VALVES

CP51X-X Solenoid Poppet Valves:

- One application is control of two-speed motors.

CP51X-X

2-WAY 2-POSITION SOLENOID SPOOL VALVES2-SPEED CIRCUIT

• Used as 3W / 2P on-off directional control valves.

• Available with a variety of porting and flow direction options.

- Sizes: 8, 10, 12

- Flow Ratings: to 15 gpm

- Pressure Ratings: to 3000 psi

3-WAY 2-POSITION SOLENOID SPOOL VALVES

CP52X-X Solenoid Spool Valves:

- Typical applications are directional controls for single acting cylinders, clutches, or brakes; pilot valves for large directional spools; or selector valves for different circuit functions.

CP52X-X

Fwd. Clutch Rev. Clutch

3-WAY 2-POSITION SOLENOID SPOOL VALVESCLUTCH ENGAGEMENT CIRCUIT

CP521-1 Solenoid Valve Circuit:

- Use CP521-1 (size 12) as shown to create high flow 4 way / 3 position motor spool solenoid valve (up to 16 gpm).

- Provides compact and low-cost alternative to D03, D05, or on-off PVG valves.

CP521-1

3-WAY 2-POSITION SOLENOID SPOOL VALVESDIRECTIONAL CONTROL CIRCUIT

• Used as 4W / 2P on-off directional control valves.

• Available with normally-open, normally closed, reversing, and single-acting spools.

- Sizes: 8, 10, 12

- Flow Ratings: to 15 gpm

- Pressure Ratings: to 3000 psi

4-WAY 2-POSITION SOLENOID SPOOL VALVES

CP53X-X Solenoid Spool Valves:

- Typically used as directional controls for motors or cylinders.

CP53X-X

4-WAY 2-POSITION SOLENOID SPOOL VALVESDIRECTIONAL CONTROL CIRCUIT

• Used as 4W / 3P on-off directional control valves.

• Available with normally-open, normally closed, motor, and tandem spools.

- Sizes: 8, 10

- Flow Ratings: to 5 gpm

- Pressure Ratings: to 3000 psi

4-WAY 3-POSITION SOLENOID SPOOL VALVES

• 4W / 2P and 4W / 3P on-off directional control valves.

• Use industry standard D03 and D05 subplate mounting patterns and can be bolted to custom HIC’s for high flow applications.

- D03 Flow Rating: to 8 gpm

- D05 Flow Rating: to 25 gpm

- Pressure Rating: to 4,641 psi

SUBPLATE-MOUNT DIRECTIONAL VALVES

CP53X-3P and D03 Solenoid Spool Valves:

- Typically used as on-off directional controls for motors or cylinders, or to pilot directional control valve spools.

CP53X-3P

SUBPLATE MOUNT DIRECTIONAL VALVESDIRECTIONAL CONTROL CIRCUIT

• Normally-closed non-compensated electrically variable flow control valves.

• Used with differential sensing valves to create restrictive-type or priority-type pressure compensated proportional flow control valves.

- Sizes: 8, 10, 12

- Flow Ratings: to 20 gpm

- Pressure Ratings: to 3000 psi

PROPORTIONAL FLOW CONTROL VALVES

• Different spool & sleeve options can be used for different flow rates and customized flow vs. current curves.

• Computer-controlled test stand tests valve against specification and records data for future reference.

PROPORTIONAL FLOW CONTROL VALVES

• Controls relief pressure as a function of electric current.

• Spool options available for different pressure vs. current curves.

• Often used to pilot differential sensing valves for high flow applications.

- Size: 8

- Flow Rating: to 0.5 gpm

- Pressure Rating: to 3000 psi

PROPORTIONAL RELIEF VALVES

CP558-20 Motor Speed Control Circuit:

- CP558-20 used as shown with CP70X-2 creates a high flow (up to 50 gpm), normally-open proportional relief valve.

CP558-20

CP70X-2

PROPORTIONAL RELIEF VALVESMOTOR SPEED CONTROL CIRCUIT

INLET

TANK

REG. PRESSURE

• Controls reduced pressure as a function of electric current.

• Spool options available for different pressure vs. current curves.

• Often used to pilot differential sensing valves for high flow applications.

- Size: 8

- Flow Rating: 0.5 gpm

- Pressure Rating: to 300 psi

PROPORTIONAL PRESS. REDUCING VALVES

CP558-23 Pilot Valve Circuit:

- CP558-23 used as shown with large spool (e.g. stack valve) creates a high flow proportional directional valve.

CP558-23

PROPORTIONAL PRESS. REDUCING VALVESPROPORTIONAL DIRECTIONAL VALVE CIRCUIT

CP558-23 Pilot Valve Circuit:

- Use CP124-1 Shuttle Valve and CP702-4 Differential Sensing Valve to add pressure compensation to high flow proportional directional valve.

- Provides compact and low-cost alternative to proportional D03, D05, or PVG valves. CP558-23

CP702-4

CP124-1

PROPORTIONAL PRESS. REDUCING VALVESPROPORTIONAL DIRECTIONAL VALVE CIRCUIT

• Used as proportional directional control valves.

• Available with normally-closed and motor spools.

• Uses industry standard D03 mounting pattern and can be bolted to custom HIC’s for high flow applications.

- Flow Rating: to 8 gpm

- Pressure Rating: 4,641 psi

PROPORTIONAL DIRECTIONAL VALVES

D03 Proportional Directional Valves:

- Typically used with or without pressure compensation for proportional speed control of cylinder or motor functions.

Left Front Right Front Left Rear Right Rear

Proportional Directional Valves used for electronic all-wheel-steering with crab-steer available:

PROPORTIONAL DIRECTIONAL VALVESALL WHEEL STEER CIRCUIT

• A Sauer-Danfoss standard micro-controllers is available to drive proportional cartridge valves.

• MC-200 micro-controller:- Full-featured dual output driver.

- “On the fly” choice of two input characterization curves.

- Independent acceleration and deceleration rates.

- Adjustable PWM frequencies from 80 to 200 Hz.

PROPORTIONAL VALVE CONTROLLER

• Power: 16 Watts• Temperature Rating: Continuous duty at 140°F• Environmental Rating: IP65• Voltages:

- DC: 6, 10*, 12*, 20*, 24*, 36, 48, 72- AC: 120, 240

• Connectors:- Integrally molded Deutsch (DT), Amp Jr. Timer, and

Metripak 150 (shown)- DIN- Lead Wires- Dual Spade- Single and Dual Post

• Integral diodes available

D08 & D10 SOLENOID COILS

* Standard voltages

• Power: 30 Watts

• Temperature Rating: Continuous duty at 140°F

• Environmental Rating: IP65

• Voltages:- DC: 10*, 12*, 20*, 24*, 36, 48

- AC: 120, 240

• Connectors:- DIN

- Lead Wires

- Dual Spade (shown)

• Integral diodes available

D12 & D14 SOLENOID COILS

* Standard voltages

CURRENT PROJECTS

• Rationalize North American Product Lines (Fluid Controls / Compact Controls):

- Eliminate overlap.

- Increase economies of scale.

- Lower manufacturing costs.

• Integrate Global Product Line (Fluid Controls / Compact Controls / Comatrol):

- Combine technologies so that global product offering is “best of the best”.

- Use European valves to fill gaps in North American product line and vice versa.

CURRENT PROJECTS

Pump/Valve Integration

- Pilot-operated proportional relief valve integrated into gear pump or motor.

- Provides one part and compact package for motor speed control.

- Proposed for AP1055 fan drive system.

CURRENT PROJECTS

Environmentally-Sealed Coil

- New design to meet IP-69 and major OEM environmental ratings.

- Will offer additional connection options.

- “D14” coil currently being tested; expected in production by fall 2002.

- “D10” and “D08” coils to follow.

HYDRAULICINTEGRATED

CIRCUITS

• HIC is an acronym for Hydraulic Integrated Circuit.

• HIC’s are compact packages with reduced plumbing, easier installation, easier service, and fewer leak points than traditional hydraulic systems.

• Custom HIC’s can be cost effective in any volume by using standard valves and cavities, standard manifold materials and sizes, and standard porting.

HYDRAULIC INTEGRATED CIRCUITS

1. Identify opportunity.2. Define circuit to meet customer requirements and select

components.3. Compile all necessary detail information (manifold material, coil

voltage and connector, port sizes, etc.) – use HIC data sheet.4. Submit request for quotation through account manager.5. Design created and outline drawing supplied for approval after

receipt of prototype order – lead time 1 week.6. Prototype manifold supplied after approval of design – lead time 2

weeks.

Sauer-Danfoss account managers and applications engineers available to assist with all of the above steps!!!

CUSTOM HIC PROJECTS

HIC PROJECT DATA SHEET

• Sauer-Danfoss Account Managers, Systems Engineers, and Applications Engineers are all available to provide circuit design and component selection expertise.

• Hillsboro and Easley Product Engineers are available for consultation.

• Hillsboro and Ames test and analysis resources are available for up-front system evaluation so we “do it right the first time”.

CIRCUIT DESIGN

• Manifold design is done with Inventor or AutoCad 2000 solid modeling.

• Fast lead times for product development:

- One week lead time for manifold design (after circuit approval).

- Two week lead time for prototype manifold (after design approval).

• Value-added options available:

- Fittings supply and installation.

- Electrical wire harness design and installation for one-point “bulkhead” connection.

- Brand labeling

PRODUCT DEVELOPMENT

TYPICAL APPROVAL DRAWING

1. Price & Availability – Hillsboro Customer Service• Brian Munks 503-207-7213• Susan Urbanski 503-207-7292• Nancy McBeth 503-207-7214

2. Warranty & Returns – Hillsboro RGA Administrator• Susan Urbanski 503-207-7292

3. Special Pricing & Commercial Issues – S-D Account Mgr.4. Technical Issues – Applications Engineering

• Bruce Gunzenhauser 515-239-6312

or customer-assigned application engineer:• Stan Crull 515-239-6590 (northwest region)• Jason Keck 515-239-6589 (east region)• Wenling Li 515-239-6635 (southwest region)• Misty Metschke 515-239-6500 (south region)• Stew Scott 515-239-6558 (north central region)

WHO TO CALL

May 7, 2002

CARTRIDGE VALVE AND HIC PRODUCTS