Proportional Pressure Relief Valves
Technical Catalog
KBCG-6-1*
KBCG-8-1*
2
Contents
General Description Page 3
Typical Section Page 3
Functional Symbol Page 4
Model Codes Page 5
Operating Data Page 6
Performance Data
Pressure Override, Off-Load Page 8
Pressure Override when Relieving Page 9
Pressure Gain Page 9
Step Response Page 9
Installation Dimensions
KBCG-6/8 Models Page 10
Mounting Surfaces Page 11
CGVM-6-10-R Subplate Page 11
Electrical Information
Block Diagram Page 12
Typical Connection Arrangements Page 13
Further Information Page 14
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
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 and the Installation Wiring Practices for
Vickers™ Electronic Products leaflet 2468. Wiring practices relevant to this
Directive are indicated by Electromagnetic Compatibility (EMC).
3
General
Description
These two-stage pressure relief
valves offer extensive
application possibilities through
their ability to control the
pressure setting in proportion
to an applied electrical input (up
to a pressure limit which is
manually adjustable and
lockable).
The integral amplifier allows the
pressure to be controlled from
a low power command signal:
either a voltage or current
command. 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.
Basic Characteristics
Max. pressure................350 bar
(5000 psi)
Max. flow rate...........400 L/min
(106 USgpm)
Mounting face to ISO 6264:
For KBCG-6............... AR-06-2-A
For KBCG-8............... AS-08-2-A
Features and Benefits
• Remote electrical proportional
control of pressure from a
choice of five pressure ranges
per valve size.
• Excellent repeatability and
stable performance results
from cartridge design of
mainstage elements.
• Low installed cost and space
requirement from high
power/size ratios (more than
double that of many
conventional designs).
• On-board ramp adjustment.
Typical Section
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
Functional
Symbols
4
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
P T
TP
X
7-pin plug
P T
7-pin plug
PX
◆ Tapped port on side of pilot head.
T
Side
drain
port ◆
Side
drain
port ◆
P
PX
◆ Tapped port on side of pilot head.
7-pin plug
T
P
T
Manual and electrical
pilots internally
drained to port T.
Model code = Blank
Manual and electrical
pilots drained to side
drain port ◆.
Model code = 1
Manual pilot internally
drained to port T;
electrical pilot drained
to side drain port ◆.
Model code = 3
7
7
7
5
Model Codes
Valve Type
KB - Proportional valve
with integral amplifier,
B series
Type
C- Pressure relief
Mounting
G - Subplate mounted
Interface - ISO 6264
With B port high pressure inlet,
A port reduced pressure outlet
6- AR-06-2-A
8- AS-08-2-A
Manual Adjustment
K- Micrometer with keylock
M- Micrometer without
keylock
W- Screw/locknut
Controlled Pressure
Range
Based on inlet pressure of 350 bar
(5000 psi).
Note, with 100 bar (1450 psi) inlet
the lower limits will be 2-3 bar
(30-43 psi) lower
40 - 6-40 bar (87-580 psi)
100 - 7,75-100 bar (112-1450 psi)
160 - 8,5-160 bar (125-2300 psi)
250 - 8,5-250 bar (125-3625 psi)
350 - 9-350 bar (139-5000 psi)
Drain
Blank - Manual and electrical
pilots drain internally
to T port
1- Manual and electrical
pilots drained to side port
drain
3 - Manual pilot internally
drained to T port,
electrical pilot drained to
side port drain
Standard Features
ZM - for KBC
Electrical Command
Options
1 - +/- 10 volts control signal
2- 4-20 mA control signal
Ramps
3 - Standard ramp for KBCG-
6/8 valve types
Command/Pressure
Characteristic
A - Standard
Electrical Connection
PC7 - 7 pin connector, without
plug supplied
PE7 - 7 pin connector, with
plug supplied
PH7 - As PE7 but with pin ‘C’
used for enable signal
PR7 - as PC7 but with pin ‘C’
used for enable signal
Coil Rating
H1 - 24V DC amplifier supply
Design Number, 1* Series
Subject to change. Installation
dimensions unaltered for design
numbers 10 to 19 inclusive.
Warning
To conform to the EC
Electromagnetic
Compatibility directive (EMC) this
KBCG 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 Eaton, part no.
934939. Alternatively a non IP67
rated connector is available from
ITT-Cannon, part no. CA 02 COM-E
14S A7 P.
1
2
3
4
5
6
8
9
7
10
11
12
13
14
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
Standard test conditions are with antiwear hydraulic oil at 36 cSt (168 SUS) and 50˚C (122˚F)
Maximum pressures:
Ports P and X▲ 350 bar (5000 psi)
Port T▲ in KBCG-*-****-Z valves 2 bar (30 psi)
Port T▲ in KBCG-*-****-1/3-Z valves 350 bar (5000 psi)
Side drain port▲ 2 bar (30 psi)
▲ Back pressure at these ports additive to the pressure
setting of the valve.
Rated flow at ∆p = 6 bar (87 psi):
KBCG-6 200 L/min (52.8 USgpm)
KBCG-8 400 L/min (105.7 USgpm)
Vent ◆ flow with valve at rated flow 1 L/min (0.26 USgpm)
◆ See “Venting”, page 8.
Pilot control drain flow, when valve is limiting system
pressure, i.e. flow P to T occurring:
KBCG-6 1,3 L/min (0.34 USgpm)
KBCG-8 2,0 L/min (0.53 USgpm)
Coil or amplifier rating 24V x 40W max. (22 to 36V including 10% pk.-to-pk.
max. ripple)
Command signal:
Volts (see model code - 1) 0 to +10V or 0 to -10V
Input impedance 47 kΩ
Common mode voltage to pin B 4V
Current (see model code - 2) 4 to 20 mA
Input impedance 100Ω
Valve enable signal:
Enable >9.0V (36V max)
Disable <2.0V
Input impedance 36 kΩ
7-pin plug connector Pin Description
A Power supply positive (+)
B Power supply 0V and current command return
CValve enable (PH7 & PR7)
D Command signal (+V or current in)
E Command signal (-V or current GND)
F Output monitor
View of pins of fixed half G Protective ground
Electromagnetic compatibility (EMC):
Emission (10 V/m) EN 50081-2
Immunity (10 V/m) EN 50082-2
Monitor signal (pin F) 1.7 V/amp solenoid current
Output impedance 10 kΩ
Pressure gain See graph
Factory setting - Maximum with 100% command signal.
Pressure override when relieving and when off-load See graphs
Linearity, between 10% and 100% of rated pressure:
KBCG-6 models at 100 L/min (26 USgpm) <6%
KBCG-8 models at 200 L/min (52 USgpm) <6%
Hysteresis <6% (with factory-set dither)
Repeatability <1.3% of rated pressure
Operating Data
F
AG
B
C
D
E
6
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
9
9
7
Reproducibility, valve-to-valve (at factory settings):
Pressure at 100% command signal ≤5%
Protection:
Electrical Reverse polarity protected
Environmental IEC 529, Class IP67
Mass (weight):
KBCG-6 5,36 kg (11.8 lb)
KBCG-8 6,26 kg (13.8 lb)
Supporting products:
Auxiliary electronic modules (DIN-rail mounting):
EHA-CON-201-A-2* Signal converter See catalog 2410B
EHD-DSG-201-A-1* Command signal generator See catalog 2470
EHA-RMP-201-A-2* Ramp generator See catalog 2410B
EHA-PID-201-A-2* PID controller See catalog 2427
EHA-PSU-201-A-10 Power supply See catalog 2410B
Subplates, size 03 See catalog 2425
Mounting bolts ■ See catalog 2314A
■ Note: If not using Vickers™ recommended bolt kits, bolts
must be to ISO 898 grade 12.9 or stronger.
Mounting attitude No restriction, provided that the valve is kept full of
fluid through port T.
Operating Data
(continued)
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
Performance
Data
Data is typical with oil at
36 cSt (168 SUS) and at
50°C (122°F)
Pressure Override,
Off-Load
Graphs show the minimum
pressures obtainable:
a) With 0 mA current to the
solenoid coil
b) When the valve is vented
(see following explanation).
Venting
When the vent port X (or
alternative vent port in the
valve body) is connected to the
reservoir via a suitable 2-way
pilot valve, the mainstage of
the relief valve opens to allow
full flow from P to T at low
pressure drop. The minimum
pressure drop is obtained
when the pilot valve is also de-
energized. The total pressure
drop through the venting 2-way
valve and pipework is additive
to the pressure at P.
While the valve is vented the
system pressure cannot be
controlled via the proportional
solenoid.
This control feature is
frequently used during off-load
periods in machine cycle times.
If lower off-load system
pressures are required then
additional full flow unloading
valves are recommended, e.g.
Vickers™ CV series cartridge
valves.
Note: All valves are with pilot
valve de-energized.
0
2
4
8
10
bar
6
0
25
50
75
100
125
150
psi
1
3
5
7
9
KBCG-6
Valve pressure drop
50 100 150 200 L/min
KBCG-6*-160/250/350
KBCG-6*-100
KBCG-6*-40 (also KBCG-6*-350 vented)
KBCG-6*-40 vented
02040USgpm503010
Flow rate
0
2
4
8
10
bar
6
0
25
50
75
100
125
psi
KBCG-8
150
9
7
5
3
1
Valve pressure drop
200 300 L/min400
KBCG-8*-350
KBCG-8*-160/250
KBCG-8*-100 KBCG-8*-40
(also KBCG-8-350 vented)
0406080
100
20
Flow rate
100
USgpm
KBCG-8*-40
vented
8
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
9
Pressure Gain
Typical pressure versus
command signal response of
KBCG-6-250 model.
Step Response
KBCG models with factory-set
gain.
Test method
1. Trapped volume between
pump and test valve, as in
table.
2. Flow rate set at pump, as in
table.
3. Response = time from step
input signal until pressure
reaches 90% of step change,
as measured by transducer.
0102030405060708090100%
50
100
150
200
250
300
bar
0
1000
2000
3000
4000
psi
% max. solenoid current
Pressure
VALVE SIZE TEST CONDITIONS: STEP SIZE: RESPONSE
TRAPPED VOLUME FLOW RATE PRESSURE DEMAND TIME (ms)
6 2,0 liters 100 L/min 0 to 100% 100
(0.53 USg) (26 USgpm) 100% to 0 70
25 to 100% 40
100 to 25% 50
8 4,0 liters 200 L/min 0 to 100% 110
(1.06 USg) (52 USgpm) 100% to 0 70
25 to 100% 50
100 to 25% 65
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
0
50
100
150
200
250
300
350
bar
0
1000
2000
3000
4000
5000
psi
KBCG-8
KBCG-6
0
0
100 200
400
20 40 60 80
L/min
USgpm
Flow rate
0
010203040
L/min
USgpm
40 80 120
160
300
100
200
50
1
2
3
4
5
7
8
9
Pressure
6
Pressure Override
when Relieving
MODEL CURVE NUMBER
123456789
KBCG-**-40
•
KBCG-**-100
••
KBCG-**-160
••••
KBCG-**-250
• • • ••••••
KBCG-**-350
• • • ••••••
To bleed air,
loosen plug in
end of core
tube; re-tighten
to
2,4 +/- 0,2 Nm
(1.85 +/- 0.15 lbf ft)
after bleeding
is complete.
B
C
D
62
E
G
H
F
J
45,0 (1.8) for
removal of
protective cap
7,5 (0.29) A/F
Turn clockwise
to increase
pressure setting
Locknut 17,0
(0.67) A/F
16,0 (0.63)
G
1
/4 (
1
/4" BSPF) alternative vent
port. Remove plug for access.
Port X
(vent port)
Port P
pressure
inlet
Port T
outlet to
reservoir
77,5
(3.1)
196,5
(7.74)
K
203,0 (8.12) for KBCG-6
209,0 (8.23) for KBCG-8
20,0 (0.79) for
connector
removal
Side drain port
G
1
/4 (
1
/4" BSPF)
(see "Functional
Symbols" section)
AA
View "A-A"
Type K only:
43,0 (1.7) for
key removal
Micrometer Adjustment Options
"K" or "M" in Model Code
"K" Feature:
To adjust pressure setting, insert key and turn clockwise.
Turn micrometer knob clockwise to increase pressure
setting; counter-clockwise to decrease setting. When the
key is removed the knob can spin freely without affecting
the pressure setting.
Mainstage overall dimension
with adjuster knob fully out:
196,0 (7.7) for KBCG-6 models
203,0 (8.0) for KBCG-8 models
L
A
10
Installation
Dimensions
3rd angle
projection
KBCG-6/8 Models
Dimensions are shown in mm
(inches)
MODEL A B C D E RAD ØF (DIA)
KBCG-6 58,0 35,0 68,0 35,0 12,0 20,0
(2.3) (1.4) (2.7) (1.4) (0.5) (0.78)
KBCG-8 42,0 39,0 83,0 30,0 16,0 26,0
(1.7) (1.54) (3.3) (1.2) (0.63) (1.02)
MODEL G H ØJ (DIA) K L
KBCG-6 79,0 82,0 13,5 176,0 20,0
(3.1) (3.23) (0.53) (7.0) (0.78)
KBCG-8 103,0 106,0 17,0 183,0 25,0
(4.1) (4.2) (0.7) (7.2) (1.0)
Warning
To conform to the EC Electromagnetic Compatibility directive (EMC)
this KBCG 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 Eaton, part no. 934939.
Alternatively a non IP67 rated connector is available from ITT-Cannon, part no.
CA 02 COM-E 14S A7 P.
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
11
Installation
Dimensions
(continued)
Mounting Surfaces,
ISO 6264
AR-06-2-A
AS-08-2-A
When a subplate is not used, a
raised pad must be provided for
mounting. The pad must be flat
within 0,001 mm/100 mm
(0.0001”/10”) and smooth within
0,8 µm (32 µin). Dimensional
tolerances are ±0,2 mm
(±0.008”) except where
indicated.
Port functions:
P = Pressure inlet
T = Outlet to reservoir
X = Vent, or remote control port
SIZE A B C D E F H J K L
AR-06 80 (3.2) 13,1 (0.5) 53,8 (2.12) 13,1 (0.5) 47,5◆ (1.87) 22,1 (0.87) 22,1◆ (0.87) 0 13,1 (0.5) 53,8 (2.12)
AS-08 118 (4.7) 35,0 (1.4) 66,7 (2.63) 16,3 (0.7) 55,6 (2.19) 33,4 (1.35) 11,1 (0.44) 23,8 (0.94) 16,0 (0.63) 70,0 (2.76)
SIZE M N ØP (DIA) Q ØT (DIA) ØX (DIA) Y THREAD x MIN. FULL THREAD DEPTH
AR-06 13,1 (0.5) 26,9 (1.06) 14,7 (0.58) 80 (3.2) 14,7 (0.58 4,8 (0.19) M12 x 21 (7/16” UNF x 0.83) ●
AS-08 16,0 (0.63) 35,0 (1.38) 23,4 (0.92) 102 (4.0) 23,4 (0.92) 6,3 (0.25) M16 x 30 (5/8” UNF x 1.2) ●
▲
Tolerance on bolt and pin locations ±0,1 mm (±0.004”).
◆ These ISO standard dimensions can be used, but improved flow paths to and from valve are obtained by using 48,0
(1.89) instead of 47,5 (1.87), and 22,6 (0.89) instead of 22,1 (0.87).
● ISO standard does not give UNC bolt sizes. These are recommended equivalents to metric sizes specified in the
standard.
M (min.)
A (min.)
B (min.)
D (min.)
K (min.)
C
▲
L
▲
E
H
J
N
Ø 7,5 (0.29 dia) x 6,0
(0.24) deep min.
P
T
X
F
▲
Y
Plug or omit if this vent / hydraulic
remote port is not to be used
Q (min.)
21,0 (0.83)
2 ports, G1 (1" BSPF) x 19,0 (0.75)
min. depth full thread, from underside
Ø 7,5 (0.29 dia) x 6,0 (0.24)
deep, for valve locating pin
4 holes, Ø 11,0 (0.43 dia) through,
Ø 17,5 (0.68 dia) spotface
G
1
/4 (
1
/4" BSPF) x 12,0 (0.47)
min. depth full thread, from
underside
4 holes tapped M12 x 21,0
(0.82) min. depth full thread
24,0
(0.95)
26,9
(1.06)
7,0
(0.27)
P
T
X
21,7
(0.85)
20,0 (0.79)
125,0 (5.0)
56,0 (2.2)
68,5
(2.7)
101,0
(4.0)
55,0
(2.2)
150,0 (6.0)
132,0 (5.2)
80,0
(3.15)
CGVM-6-10-R Subplate
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
12
+5V
Solenoid drive
PWM
modulator
GainRamp
7-pin plug connections
A+24V
BPower 0V
CEnable ▲
DNon-inverting
EInverting
Command
signal
FCurrent monitor
GProtective ground
▲ In valves with PH7 or PR7 t
yp
e electrical connection.
+24V
Electrical
Information
Wiring
Connections must be made via
the 7-pin plug mounted on the
amplifier. See this leaflet and
Installation Wiring Practices for
Vickers™ Electronic Products
leaflet 2468. Recommended
cable sizes are:
Power Cables
For 24V supply:
0,75 mm
2
(18 AWG) up to 20m
(65 ft)
1,00 mm
2
(16 AWG) up to 40m
(130 ft)
Signal Cables
0,50 mm
2
(20 AWG)
Screen (Shield)
A suitable cable should have at
least 6 cores with pairs of
conductors individually
screened and an overall
screen. Cable outside diameter
8,0-10,5 mm (0.31- 0.41
inches). See connection
diagrams on next page.
Warning
All power must be
switched off before connecting
or disconnecting any plugs.
Block Diagram
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
13
User Panel
Power
Supply
Demand
Signal
Solenoid
Current
Monitor
0V must be
connected to
ground
Enclosure
+/-10V
Valve must be
connected
to ground
via subplate
▲
Connector
shell
Outer Screen
KB..PC7/PE7 valve
+24V
A
0V
B
D or E
0V
0V
C ■
Drain Wire
Inner Screen
G
Input
F●
User Panel
Power
Supply
Demand
Signal
Solenoid
Current
Monitor
Valve must be
connected to
ground via
subplate
▲
Connector
shell
Outer Screen
+24V
A
0V
0V
C
Drain Wire
Inner Screen
E or D
G
Input
F●
0V
B
KB..PR7/PH7 valve
0V must be
connected to ground
Enable
Signal
+8.5V
to 36V
D or E
E or D
Typical Connection
Arrangements
Wiring Connections
▲ 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.
■ Pin C may be connected to
ground or left unconnected.
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-pin
connector part no. 934939
should be used for the integral
amplifier.
In all cases both valve and
cable should be kept as far
away 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.
Wiring Connections for Valves with “Enable” Feature
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
● Output monitor voltage
(pin F) will be referenced to the
power 0 volts (pin B).
14
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 publication 9132 or
561, “Guide to Systemic
Contamination Control”. The
book also includes information
on the concept of “ProActive
Maintenance”. The following
recommendations are based on
ISO cleanliness levels at
2 µm, 5 µm and 15 µm.
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.
Te m peratures
For petroleum oil:
Min.........................-20°C (-45°F)
Max.....................+70°C (158°F)
For fluids where limits are
outside those of petroleum oil,
consult fluid manufacturer or
Eaton 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 +70°C
(-4 to +158°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)
Seal Kits
Pilot valve:
KBCG-3.....................02-352521
Mainstage valves:
KBCG-6..........................614824
KBCG-8..........................614931
EATON Vickers Proportional Pressure Relief Valves V-VLPO-MC003-E May 2003
© 2003 Eaton Corporation
All Rights Reserved
Printed in USA
Document No. V-VLPO-MC003-E
May 2003
Eaton
14615 Lone Oak Road
Eden Prairie, MN 55344-2287
USA
Tel: (+1) 952 937-9800
Fax: (+1) 952 974-7722
www.hydraulics.eaton.com
Eaton
20 Rosamond Road
Footscray
Victoria 3011
Australia
Tel: (+61) 3 9319 8222
Fax: (+61) 3 9318 5714
Eaton
Dr.-Reckeweg-Str. 1
D-76532 Baden-Baden
Germany
Tel: +49 (0) 7221 682-0
Fax: +49 (0) 7221 682-788
