This product has been designed and tested to meet specific standards outlined in the European Electromagnetic

Compatibility Directive (EMC) 89/336/EEC, amended by 91/263/EEC, 92/31/EEC and 93/68/EEC, article 5. For

instructions on installation requirements to achieve effective protection levels, see this leaflet, the Installation

Wiring Practices for Vickers Electronic Products leaflet 2468 and leaflet 02-123931A which is packed with every

KA valve. Wiring practices relevant to this Directive are indicated by Electromagnetic Compatibility (EMC).

P ABT

KCG-3

Typical Section: KCG-3 Valve with Type “U” Coil Connection

P ABT

KACG-3

7-pin plug

GB-2162ERevised 10/97

KCG-3, 1* Series; KACG-3, 1* series

Basic Characteristics

Max. pressure 350 bar (5075 psi). . . . . .

Max. flow 5 L/min (1.3 USgpm). . . . . . . .

Mounting face to ISO 4401 size 03

General Description

An electro-hydraulic proportional relief

valve designed to regulate pressure in a

hydraulic system in proportion to an

applied electrical input.

These open-loop, single-stage valves

can be used for direct control of

pressure in low flow systems, or for pilot

control of larger pressure controls, and

for such applications as pressure-

controlled pumps.

KCG-3

The valve responds to variations in

current supply to its solenoid; separate

Vickers amplifiers, with PWM output

stage and output current control, are

available for driving this model, see

“Operating Data”.

KACG-3

The addition of an integral amplifier

allows the pressure to be controlled from

a 0 to +10V, or 0 to –10V command

signal range. The amplifier is mounted in

a robust metal housing and electrical

connections are via an industry standard

7-pin plug. Factory-set adjustments

ensure high reproducibility valve

-to-valve.

Other Models

For proportional pressure relief valves

with flow ratings up to 400 L/min

(106 USgpm), see catalog 2324 (model

types KCG, sizes 6 and 8)

Features and Benefits

F Valve design ensures low hysteresis

and good repeatability.

F Self-bleeding design simplifies

installation and ensures consistent

performance.

F When used for piloting a large

pressure relief or reducing valve, a

low minimum pressure is obtainable

combined with fast and stable

response to step input signals.

Functional Symbol

Proportional Pressure Relief Valves

Vickers

Proportional Valves

Valves supplied with type HJ1 coils

will be stamped with the applicable

maximum controlled pressure.

Model code Max. pressure

position with HJ1 coil

40 35 bar (500 psi)

100 85 bar (1230 psi)

160 140 bar (2000 psi)

250 210 bar (3000 psi)

350 315 bar (4500 psi)

Design number, 1* series

Subject to change. Installation

dimensions unaltered for design

numbers 10 to 19 inclusive.

Special features

EN46 used with P-type coil

connection and Uniplug connector.

Omit if not required.

KCG-3 *** -1*

-D-Z-M-*****

***

(-EN46)

Valve type

KC = Proportional pressure relief

KAC = Proportional pressure relief with

integral amplifier

Mounting type

G = Subplate mounted

Interface

3 = ISO 4401, size 03 (NFPA D03)

Solenoid location

Blank = At port B end

L = At port A end

Controlled pressure range

(All coils except type HJ, see position

footnoteB)

At rated flow of 1 L/min (0.26 USgpm)

40 = 2-40 bar (29-580 psi)

100 = 3-100 bar (44-1450 psi)

160 = 4-160 bar (58-2300 psi)

250 = 5-250 bar (73-3625 psi)

350 = 6-350 bar (87-5000 psi)

Standard features

DZM = For KCG-3

DZM2 = For KACG-3

Coil connections (KCG only)

U = ISO 4400 (DIN 43650)

interface

FW = Flying-leads in wiring box

tapped

I NPT

FTW= As “FW” plus terminal strip

FJ = Flying-leads in wiring box

tapped M20

FTJ = As “FJ” plus terminal strip

P = Plug-in coil (type “H” only)

Use with “EN46”

Connections (KACG only)

PD7 = 7 pin connector with plastic plug.

See Warning note below.

Coil rating

Code = amps x ohmsY

G1 = 3,5 x 1,65

GP1 = 3,0 x 2,0

H1 = 1,6 x 7,3 F

HA1 = 0,94 x 22

HJ1 = 1,00 x 14,25B

HL1 = 0,80 x 29 z

Y Resistance at 20_C (68_F).

FKACG valves must have H1 coils

z For valves replacing ECG-02 models.

B This low power coil is limited to the

following maximum controlled

pressures.

(-L)-

KACG-3 *** -1*-D-Z-M- H1(-L)-

Models requiring separate amplifier

Models with integral amplifier

2- PD7-

Features in brackets () may be omitted. All other features must be specified.

Model Code

7 11

1 32 4 5 6 10

Warning

To conform to the EC Electromagnetic Compatibility directive (EMC) this KACG valve must be fitted with a metal 7-pin

plug. The screen of the cable must be securely connected to the shell of the metal connector. A suitable IP67 rated

connector is available from Vickers, part no. 934939. Alternatively a non IP67 rated connector is available from

ITT-Cannon, part no.CA 02 COM-E 14S A7 P.

Additionally the cable must be fitted with a ferrite EMC suppression core not more than 4cm from the connector

referred to above. Suitable types include Farnell 535-898 or Farnell 535-904 which snap fit over the cable.

The plastic plug, part number 694534, is only suitable for use in a sealed electromagnetic environment or outside of

the European Community.

Operating Data

Standard test conditions are with antiwear hydraulic oil at 36 cSt (168 SUS) and 40_C (104_F)

Maximum pressures:

Port P:

Operating

Static

Port T:

Operating

Static

See  in “Model Code”

350 bar (5075 psi)

2 bar (29 psi). See “Back pressure at port T” under “Installation

and start-up” on next page.

210 bar (3000 psi)

Flow limits:

Rated flow

Maximum flow

1 L/min (0.26 USgpm)

5 L/min (1.3 USgpm)

Coil or amplifier rating:

KCG models

KACG models

See  in “Model Code”

24V x 40W max. (22 to 36V including 10% pk.-to-pk. max. ripple

Command signal ranges, KACG models 0 to +10V DC, or 0 to –10V DC

Dither, KACG models Factory set, not user adjustable

Monitor point signal, KACG models 0,5V per amp. solenoid current

Power stage PWM, KACG models 2kHz nominal

7-pin plug connections, KACG models:

Power supply +ve

Power 0V

Signal 0V

+ve voltage command signal

–ve voltage cpommand signal

Monitor output

Protective ground

Electro-magnetic compatibility (EMC)

KACG models only:

Emission (10V/m)

Immunity (10V/m)

EN 50081-2

EN 50082-2

Pressure gain

Factory setting - Maximum with 10V command signal.

User adjustment - 30 to 120% of factory setting.

Note that altering this setting will affect valve to valve

interchangeability.

See graph

Pressure override See graph

Minimum-pressure adjustment 50% of maximum pressure limit of model

Pressure step response:

KCG-3-250-D-Z-M-*****-H1 model using

EEA-PAM-513-A-1* amplifier:

0 to 100% step

100 to 0% step

25 to 100% step

100 to 25% step

KACG-3-250 model:

0 to 100% step

100 to 0% step

25 to 100% step

100 to 25% step

Typical times to reach 90% of commanded step:

48 ms

9 ms

37 ms

18 ms

40 ms

18 ms

26 ms

30 ms

Linearity, between 10% and 100% of controlled pressure

range

<4%

Hysteresis

KCG models

KACG models

<4% (with 100 mA pk.-to-pk. dither)

<5% (with factory-set dither)

Repeatability

KCG models

KACG models

<"0,5% of rated pressure for a constant coil current

<"1.0% of rated pressure for a constant amplifier supply voltage

and constant command signal

Reproducibility (valve to valve) KACG models only <3% at factory settings

Protection, Electrical (KACG models) Reverse-polarity protected

Mass (weight)

KCG

KACG

1,7 kg (3.8 lb)

2,1 kg (4.6 lb)

Supporting products:

Amplifiers for KCG valves with “H” type coils only:

EHH-AMP-724-C/D-10 (Uniplug)

EHH-AMP-7*2 series (power plug)

EEA-PAM-513-A-14 (1 adjustable ramp)

EEA-PAM-513-A-3* (2 adjustable ramps)

Auxilliary electronic modules (Din-rail mounting) for

KACG models:

EHA CON 201 A 2* signal converter

EHD DSG 201 A 1* command signal generator

EHA RMP 201 A 2* ramp generator

EHA PID 201 A 2* PID controller

EHA PSU 201 A 1* power supply

ISO 4400 (DIN 43650) electrical connector:

Black, marked “B”

Gray, marked “A”

Subplates, size 03

Mounting boltsJ

J Note: If not using Vickers recommended bolt kits, bolts

must be to ISO 898 grade 12.9 or stronger.

See catalog 2367

See catalogs 2114, 2115 and 2282

See catalog 2137

See catalog 2464

See catalog 2410B

See catalog 2470

See catalog 2410B

See catalog 2427

See catalog 2410B

Part number 710775

Part number 710776

See catalog 2425

See catalog 2314A

Installation and start-up (commissioning):

Installation and start-up (commissioning) guide

Electrical data

Electromagnetic capability

Mounting attitude

Back pressure at port T

ML-B-9133B (Multi-lingual English, German, French and Italian),

shipped with each product and also available separately on

request.

See under that heading on previous page.

No restriction, provided that the valve is kept full of fluid through

port T.

Port T should be piped directly to reservoir with minimum

restriction. Any back pressure at this port is additive to the

controlled pressure at port P. The recommended max. pressure

at port T when the valve is controlling pressure is 2 bar (29 psi);

the max. pressure at T under static conditions is 210 bar

(3000 psi).

Ordering procedure Valves, subplates, bolt kits and Vickers amplifiers should be

ordered by full model code designation. Order ISO (DIN)

electrical connectors by part number.

Performance Data

Typical pressure v. command signal

response of K(A)CG-3-250 models

Test conditions:

Fluid = Antiwear hydraulic oil at 36 cSt

(168 SUS)

100

150

200

250

bar

1000

2000

3000

psi

Pressure

1.5 1.6

1.00.50

2.0 3.51.0 3.0

Amps

KCG-3(-L)-250 models

with 24V supply

KCG-3(-L)-250 models

with 12V supply

3 L/min (0.8 USgpm)

1 L/min (0.26 USgpm)

Pressure Override, Typical

Test conditions:

Fluid = Antiwear hydraulic oil at 36 cSt

(168 SUS)

bar

0 (At valve cracking

pressure)

200

400

600

800

1000

psi

Rated flow;

see in

“Model Code”

0.2 0.4 0.6 0.8

L/min

USgpm1.0

1 2 345

1.2 1.32

K(A)CG-3(-L)-350 models

K(A)CG-3(-L)-250 models

K(A)CG-3(-L)-160 models

K(A)CG-3(-L)-100 models

K(A)CG-3(-L)-40 models

Pressure override

(Rise above valve cracking pressure)

246810

K(A)CG-3(-L)-250 models

Volts

Amps

Pressure Gain, Typical

Wiring

Connections must be made via the 7-pin

plug mounted on the amplifier.

Recommended cable sizes are:

Power cables:

For 24V supply

0,75 mm

(18 AWG) up to 20m (65 ft)

1,00 mm

(17 AWG) up to 40m (130 ft)

Signal cables:

0,50 mm

(20 AWG)

Screen:

A suitable cable would have 7 cores, a

separate screen for the signal wires and an

overall screen.

See wiring connection diagram on page 7

Gain

Modulator

+15V

Valve envelope

7-pin plug con-

nections

+24V

Power 0V

Signal 0V

Protective ground

Minimum

Pressure

Positive

Monitor output

Negative

Command

signal

voltage

(see table)

–15V

Solenoid drive

Dither

Warning

All power must be switched

off before connecting or

disconnecting any plugs.

KACG-3 Electrical Block Diagram

KACG-3 Typical Connection Arrangements

Warning

Do not ground pin C. If the

local ground (pin C) is not used for

differential monitor electronics, do not use.

Read monitor pin F with respect to ground.

User panel

Outer

Screen

“KA” valve

D or E

E or D

+24V

Demand

Signal

Solenoid

Current

Monitor

Power

Supply

Enclosure

Valve must

be connected

to ground via

subplate

Input

+/– 10V

Connector shell

J Solenoid current monitor voltage (pin F)

will be referenced to the KA valve local

ground. A “local ground” (pin C) is

provided for optional use by differential

input customer supplied electronics.

Wiring Connections for Valves with integral Amplifier

Y Note: In applications where the valve

must conform to European RFI/EMC

regulations, the outer screen (shield) must

be connected to the outer shell of the

7-pin connector and the valve body must

be fastened to the earth ground. Proper

earth grounding practices must be

observed in this case, as any differences

in command source and valve ground

potentials will result in a screen (shield)

ground loop.

0V must be

connected

to ground

Warning

Electromagnetic Compatibility (EMC)

It is necessary to ensure that the valve is wired-up as above. For effective protection, the user

electrical cabinet, the valve subplate or manifold, and the cable screens should be connected to

efficient ground points. The metal 7-point connector, part no. 934939, should be used for the

integral amplifier.

In all cases, both valve and cable should be kept as far as possible from any sources of

electromagnetic radiation such as cables carrying heavy current, relays and certain kinds of

portable radio transmitters, etc. Difficult environments could mean that extra screening may be

necessary to avoid the interference.

It is important to connect the 0V lines as shown above. The multi-core cable should have at least

two screens to separate the demand signal and monitor output from the power lines.

Drain wire

Inner screen

Installation Dimensions in mm (inches)

3rd angle

projection

KCG-3-***-D-Z-M-U-10 models

For KCG-3-L-***-D-Z-M-U models the solenoid

is mounted at port A-end of body, which then has

C and D dimensions as in table.

46,0

(1.8)

Port P

Port T

Port A YPort B Y

41,75

(1.64)

51,0

(2.0)

max.

155,0

(6.1)

61,0 (2,4) for

coil removal

74,4

(3.0) J

13,0 (0.5) for plug removal J

Port B Port A

Orientation pin

88 (3.52)

(1.54)

Alternative Power Plugs

See “Supporting products”

on page 4.

Model

C D

KCG-3-*** 57,3 (2.26) 20,5 (0.81)

KCG-3-L-*** 61,2 (2.41) 16,8 (0.66)

J KCG-3-(L)-***-D-Z-M-U models.

Dimensions may vary according to

source of plug.

Y Ports A and B are blind holes with

O-ring recesses.

B The cable entry on this plug can be

repositioned at 90_ intervals by

reassembly of the contact holder

relative to the plug housing. The

cable entry is Pg 11 for cables

Ø6-10 mm (0.24-0.4I dia).

KCG-3-(L)-***-D-Z-M-F**-**1-10 models

For dimensions not shown see previous page

163,0 (6.42): KCG-3-L

93,0 (3.7)

93,5 (3.7)

69,5 (2.7)

163,0 (6.42): KCG-3

Conduit entry both ends, see

“Model Code” for thread

type. Closure plug fitted to one

end.

Ground (earth) connection

Ø4,0 (0.16 dia) self-tapping screw

Y Ref. Model Code :

Codes “FJ” and “FW”: 2 lead wires approx. 150,0 (6.0) long.

M3 terminals provided for customer connection.

Codes “FTJ” and “FTW”: Lead wires connected into terminal

strip suitable for M3 terminals on customer connection.

87,5 (3.44)

164,0 (6.46): KCG-3

KCG-3-(L)-***-D-Z-M-P-H1-10-EN46

For use with Vickers single-cable UNIPLUG connectors:

For “Soft Switch” Control:

Use UNIPLUG model type EHH-AMP-724-C**-1*

For Proportional Control:

Use UNIPLUG model type EHH-AMP-724-D**-1*

UNIPLUG connectors should be ordered separately;

see catalog 2367.

UNIPLUG connector

correctly assembled to

KCG-3 valve

9,0 (0.35)

To fit UNIPLUG connector to KCG-3 valve:

Unscrew coil retention nut and remove coil.

Slide UNIPLUG connector onto dummy pins (at non-solenoid

end) then replace coil, ensuring pins are fully engaged.

Replace and tighten coil retention nut.

For dimensions not shown see previous page.

164,0 (6.46): KCG-3-L

50,0 (2.0) max.

over wiring box

Remove plug for

access to

minimum-pressure

potentiometer.

16,8 (0.66)

21,75

(0.86)

98,87 (3.89)

227,0 (8.9)

7-pin plug

128,0 (5.1)

max.

200,0 (7.9) max.

Remove plug for

access to the gain

potentiometer

Do not

remove

this plug.

24,0

(0.94

)

To bleed air, loosen plug

in end of core tube;

re-tighten after bleeding

is complete.

48,0

(1.9)

40,0

(1.6)

KACG-3-** models

For KACG-3-L-*** models the solenoid is mounted at port

A-end of body (both versions have C and D dimensions as in

table on page 8 ) and the amplifier turned through 180°

Metal plug 934939

Cable outside diameter 8,0 to 10,5 (0.31 to 0.41)

Must be used for full EMC protection. See also warning

note on page 2

Plastic plug 694534

PG11. Cable maximum outside diameter 11,0 (0.43)

25,0

(1.0)

See Warning note on page 2 regarding the use of 7-pin plugs.

Further Information

Hydraulic Fluids

Materials and seals used in these valves

are compatible with:

Anti-wear petroleum oils L-HM. . . . . . . .

Non-alkyl based

phosphate esters L-HFD. . . . . . . . . . . . .

The extreme operating range is 500 to

13 cSt (270 to 70 SUS) but the

recommended running range is 54 to

13 cSt (245 to 70 SUS). For further

technical information about fluids see

694.

Contamination Control Requirements

Recommendations on contamination

control methods and the selection of

products to control fluid condition are

included in Vickers publication 9132 or

561, “Vickers Guide to Systemic

Contamination Control”. The book also

includes information on the Vickers

concept of “ProActive Maintenance”.

The following recommendations are

based on ISO cleanliness levels at

2 mm, 5 mm and 15 mm.

For products in this catalog the

recommended levels are:

Up to 210 bar (3000 psi) 18/16/13. . . . .

Above 210 bar (3000 psi) 17/15/12. . . .

Installation and Start-up Guidelines

The proportional valves in this catalog

can be mounted in any attitude but it

may be necessary, in certain demanding

applications, to ensure that the

solenoids are kept full of hydraulic fluid.

If this proves to be the case any

accumulated air can be bled from the

solenoid bleed screw. This task is easier

if the valve has been mounted base

downwards. Good installation practice

dictates that the tank port, and any drain

port, are piped so as to keep the valve

full of fluid once the system start-up has

been completed.

Temperatures

For petroleum oil:

Min. –20°C (–4°F). . . . . . . . . . . . . . . . . .

Max.* +70°C (158°F). . . . . . . . . . . . . . . .

* To obtain optimum service life from both fluid and

hydraulic system, 65°C (150°F) normally is the

maximum temperature.

For other fluids where limits are outside

those of petroleum oil, consult fluid

manufacturer or Vickers representative.

Whatever the actual temperature range,

ensure that viscosities stay within those

specified under “Hydraulic Fluids”.

Ambient for:

Valves at full performance specification:

–20 to +60_C (–4 to +140_F).

Valves, as above, will operate at

temperatures of 0 to –20_C (32 to –4_F)

but with a reduced dynamic response.

Storage:

–25 to +85_C (–13 to +185_F)

Eurocard electronics:

0 to 50_C (32 to 122_F)

Seal Kits

K(A)CG-3 (KA + DIN) 02-138201. . . . .

KCG-3 (’F’ & ’P’ versions) 02-145869. .