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11 Service

Repair

© Moog GmbH User Manual "D633-A Series" (CA80942-001; Version 1.0, 12/08) 62

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Summary of Contents for D633-A Series

Page 1: ...DIRECT DRIVE SERVOVALVES SIZE 03 NG6 Original User Manual CA80942 001 Version 1 0 12 08 USER MANUAL D633 A SERIES...

Page 2: ...er manual may be reproduced in any form print photocopies microfilm or by any other means or edited duplicated or distributed with electronic systems without our prior written consent Offenders will b...

Page 3: ...ctural modifications 8 2 6 Occupational safety and health 9 2 7 General safety instructions 9 2 8 Pressure limitation 10 3 Product Description 11 3 1 Function and mode of operation 11 3 1 1 Representa...

Page 4: ...aracteristic Curves 29 5 1 Dependency of flow and pressure drop 29 5 2 Flow signal characteristic curve 29 5 3 Spool stroke signal characteristic curve 30 5 4 Pressure signal characteristic curve 30 5...

Page 5: ...2 1 1 Tools and materials required 58 11 2 1 2 Checking and replacing the O rings 58 11 3 Troubleshooting 59 11 3 1 Leaks 59 11 3 1 1 Leak at the valve connecting surface 59 11 3 1 2 Leak at the line...

Page 6: ...Table of Contents Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 iv For your notes...

Page 7: ...20 Table 8 Bushing spool identification in the type designation 21 Table 9 Linear force motor identification in the type designation 21 Table 10 Fail safe identification in the type designation 22 Ta...

Page 8: ...gure 8 Flow signal characteristic curve 29 Figure 9 Setup for measuring the flow signal characteristic curve 29 Figure 10 Spool stroke signal characteristic curve 30 Figure 11 Pressure signal characte...

Page 9: ...e full contents have been generated to the best of the authors knowledge However the possibility of error remains and improvements are possible Please feel free to submit any comments about possible e...

Page 10: ...nger to life and limb or possible serious damage to property Failure to comply with these safety instructions may result in fatalities serious personal injuries disablement or serious damage to proper...

Page 11: ...Moog and Moog Authentic Repair are registered trademarks of Moog Inc and its subsidiaries Microsoft and Windows are either registered trademarks or trademarks of the Microsoft Corporation in the USA...

Page 12: ...nterna tional regulations standards and guidelines such as e g the EU Machin ery Directive the regulations of the trade association and of T V or VDE in the configuration construction and operation of...

Page 13: ...of T V or VDE The valves and all of the other installed components are in a technically fault free and operationally reliable state No signals which can lead to uncontrolled movements in the machine a...

Page 14: ...rtaining to the safety of machinery DIN EN ISO 12100 DIN EN 982 DIN EN 563 EN 60204 Observing the safety instructions and the safety and accident prevention regu lations standards and guidelines will...

Page 15: ...chin ery Directive the regulations of the trade association and of T V or VDE in the configuration construction and operation of the machine with all of its installed components Installation of suitab...

Page 16: ...onversant with automation safety concepts Warranty and liability claims for personal injury or damage to property are among others excluded if such injury or damage is caused when the valves are worke...

Page 17: ...le safety equipment such as e g safety shoes must be worn to provide protection against injury CAUTION Valves and hydraulic port lines can become very hot during op eration Suitable safety equipment s...

Page 18: ...xcessive pressure at the hydraulic ports damages the valve and can cause unsafe states in the machine and per sonal injury Pressure limiting valves for example or other comparable safety devices must...

Page 19: ...r electrohydraulic position speed pressure and force con trol even for high dynamic requirements They control flow 3 1 1 Representative depiction of the valve Representative depiction of the valve Fig...

Page 20: ...per manent magnets Some of the magnetic force is already provided by the per manent magnets The linear force motor s power demand is thus significantly lower than is the case with comparable proporti...

Page 21: ...hanical fail safe functions are available Fail safe function F Fail safe function D Fail safe function M WARNING It is essential to observe the notes information on han dling in accordance with safety...

Page 22: ...ion Chapter 3 5 Nameplate page 18 Fail safe function Position of spool F Defined position of spool approx 10 valve opening PtB and AtT D Defined position of spool approx 10 valve opening PtA and BtT M...

Page 23: ...by applying the command signal in accordance with the technical data Type designation 1 2 3 4 5 6 7 8 9 10 A K 5 Ident Valve configuration Bushing spool version O 4 way Linear characteristic curve ze...

Page 24: ...ay operation page 17 3 way operation Chapter 3 3 2 1 4 way and 3 way operation page 16 4 way operation Chapter 3 3 2 1 4 way and 3 way operation page 16 2x2 way operation Chapter 3 3 2 2 2 way and 2x2...

Page 25: ...ation i e the 7th position in the valve type designation indi cates how leakage port Y is configured in the valve Overview of type designation Chapter 3 5 Nameplate page 18 Leakage port Y must always...

Page 26: ...number page 18 2 Type designation Chapter 3 5 2 Type Designation page 19 3 Serial number 4 Optional customer specific designation 5 Hydraulic symbol 6 Date of manufacture in MM YY format 7 Optional ve...

Page 27: ...mum pressure identification page 20 command signal identification Chapter 3 5 2 10 Command signal identification page 23 valve connector identification Chapter 3 5 2 9 Valve connector identification p...

Page 28: ...ification i e the 3rd position in the valve type designation indicates what maximum operating pressure is permissible Overview of type designation Chapter 3 5 Nameplate page 18 Type designation 1 2 3...

Page 29: ...hich linear force motor is integrated in the valve Overview of type designation Chapter 3 5 Nameplate page 18 Type designation 1 2 3 4 5 6 7 8 9 10 A K 5 Ident Valve configuration Bushing spool versio...

Page 30: ...sition in the valve type desig nation indicates the sealing material of the port O rings of the valve Overview of type designation Chapter 3 5 Nameplate page 18 Type designation 1 2 3 4 5 6 7 8 9 10 A...

Page 31: ...e Data matrix code The data matrix code is a two dimensional code The code on the nameplate contains a character string which is set out as follows If there is no optional version identification a bla...

Page 32: ...3 Product Description Nameplate Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 24 For your notes...

Page 33: ...tion In any position fixed or moving Observe the relevant safety instructions when mounting the valve Chapter 7 Mounting and Connection to the Hydraulic System page 35 Permissible ambient conditions A...

Page 34: ...2 l min 0 04 0 08 0 16 0 32 gpm model dependent Maximum operating pressure Ports P A and B 350 bar 5 075 psi Chapter 3 5 2 3 Maximum pressure identification page 20 Port T without Y 50 bar 725 psi Ch...

Page 35: ...nector with pin contacts as per MIL DTL 5015 14S 2P Chapter 8 2 Valve connector X1 page 43 Chapter 3 5 2 9 Valve connector identification page 23 Power consumption Pmax 9 W at I 600 mA and R 25 Table...

Page 36: ...4 Technical Data Emissions Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 28 For your notes...

Page 37: ...Chapter 3 3 1 Open loop flow control Q control page 16 5 2 Flow signal characteristic curve 1 Flow signal characteristic curve Q l min gpm actual flow QN l min gpm rated flow p bar psi actual pressur...

Page 38: ...ignal characteristic curve of the valves with zero lap 1 Typical characteristic curves measured at operating pressure pP 140 bar 2 030 psi viscosity of hydraulic fluid 32 mm2 s and temperature of hy d...

Page 39: ...gure 13 Step response of the spool stroke Frequency response of the spool stroke Figure 14 Frequency response of the spool stroke 1 Typical characteristic curves measured with Mini DDV Amplifier G123...

Page 40: ...5 Characteristic Curves Step response and frequency response Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 32 For your notes...

Page 41: ...ervicing and when handling the valves accessories tools or hydraulic fluids Chapter 2 6 Occupational safety and health page 9 CAUTION The valve shipping plate may only be removed from the valve hydrau...

Page 42: ...upplier 6 2 Scope of delivery of the valve Scope of delivery of the valve The scope of delivery of the valve consists of Valve with mounted oilproof shipping plate at the hydraulic port 4 O rings ID 9...

Page 43: ...ransducers or programming units Secure the machine without fail against restarting Examples of suitable securing measures Lock the main command device and remove the key Attach a warning sign to the m...

Page 44: ...3 Grounding screw page 44 3 Installation screw or attachment screw of the shipping plate Chapter 7 3 2 Specification for installation screws page 38 Chapter 7 2 2 Mounting pattern of mounting surface...

Page 45: ...ed on the valve side 2 Bore G for positioning pin must be at least 4 mm 0 16 in deep If the valve is mounted on the mounting surface it projects over the mounting surface Valve dimensions Chapter 7 1...

Page 46: ...socket head cap screws WAF 4 for mounting the valve Installation screws Chapter 7 3 2 Specification for installation screws page 38 If necessary replacement for port O rings to be replaced Chapter 13...

Page 47: ...valve The shipping plate attachment screws must not under any circumstances be used to mount the valve Se cure valve mounting cannot be guaranteed in such a case Specification for installation screws...

Page 48: ...7 Mounting and Connection to the Hydraulic System Mounting the valves Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 40 For your notes...

Page 49: ...vice and remove the key Attach a warning sign to the master switch DANGER Hydraulic fluid squirting out under high pressure can cause serious personal injuries burns and fires Depressurize all hydraul...

Page 50: ...d TN 494 CAUTION Do not misuse the connectors mating connectors plugs and connection cables of the valves e g as a tread or transport fixture CAUTION Do not lay valve connection cables in the immediat...

Page 51: ...nector X1 is available as accessories Chapter 13 1 Accessories page 65 valve view of valve connector X1 guides for proper mating Pin Assignment Description 1 Command signal Iin 600 mA Rin 16 at coil t...

Page 52: ...nding screw The valve is controlled via a shielded connection cable If the equipotential bonding current flowing over the shield of the connection cable is too high this may interfere with the valve o...

Page 53: ...with a leaking hydraulic system is dangerous and not permitted Before starting up or operating the valve check the higher level machine including all of its installed components for dam age and defec...

Page 54: ...uences of motions Destruction Malfunction CAUTION The valve shipping plate may only be removed from the valve hydraulic ports directly prior to mounting and must be re mounted directly after the valve...

Page 55: ...ate No signals which can lead to uncontrolled movements in the machine are transmitted to the valves Chapter 2 1 Intended operation page 5 9 2 Start up of the valves Procedure for start up Procedure 1...

Page 56: ...in accordance with the instructions of the manufacturer and the operator of the machine Observe the following when doing so In order to obtain the best possible flushing effect make sure the hy draul...

Page 57: ...the operator of the machine 3 Check the hydraulic system for external leaks 9 4 1 Venting the hydraulic system CAUTION Air trapped in the hydraulic system particularly in the case of high pressure pea...

Page 58: ...9 Start up Start up of the hydraulic system Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 50 For your notes...

Page 59: ...or with a leaking hydraulic system is dangerous and not permitted Before starting up or operating the valve check the higher level machine including all of its installed components for dam age and def...

Page 60: ...nformation given on the valve nameplate Chapter 4 Technical Data page 25 WARNING Prior to start up the valves must be checked for correct mechanical design Wrong mechanical design of the valves will r...

Page 61: ...ing the valve page 15 DANGER Hydraulic pressure and electrical supply voltage are still normally applied after the valve has been shut down The machine is not automatically put out of operation when t...

Page 62: ...10 Operation Shutting down the valve Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 54 For your notes...

Page 63: ...with a leaking hydraulic system is dangerous and not permitted Before starting up or operating the valve check the higher level machine including all of its installed components for dam age and defect...

Page 64: ...ized repairs or other unauthorized interventions Chapter 1 5 Warranty and liability page 4 CAUTION To provide protection against injuries or other damaging influ ences on health suitable protective me...

Page 65: ...ve from the mounting surface 4 Check for presence elasticity integrity and correct seating of the O rings in the valve ports A B P T etc 5 Replace hardened and damaged O rings with new O rings 6 Mount...

Page 66: ...terials required Tools and materials required for checking and replacing the O rings The following are required for checking and replacing the port O rings Torque wrench for hexagon socket head cap sc...

Page 67: ...g surface Measures Check for presence elasticity integrity and correct seating of the O rings in the valve ports A B P T etc If necessary install O rings replace or correct the seating Check the valve...

Page 68: ...he fault state If necessary correct the fault and then restart the valve by switching the command signal off and then on again Typical fault causes Control error e g due to the spool sticking which ca...

Page 69: ...e can be guaranteed even after repairs Repair quality seal Figure 20 Repair quality seal Our repair seal is a guarantee that an authentic Moog repair has been per formed 11 4 1 Contact persons for rep...

Page 70: ...11 Service Repair Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 62 For your notes...

Page 71: ...ndividual materials and placed in the correspond ing waste system or earmarked for recycling The valve contains among others the following materials Adhesives and casting compounds Parts with electro...

Page 72: ...12 Disposal Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 64 For your notes...

Page 73: ...ad cap screw as per DIN EN ISO 4762 quality class 10 9 tightening torque 6 8 Nm 5 0 lbf ft 10 A03665 050 055 Mating connector metal IP65 for M12 valve connector X1 1 As per IEC 60947 4 2 usable cable...

Page 74: ...x 0 071 in HNBR 90 Shore FKM 90 Shore B97009 013 42082 013 for port Y 1 ID 7 65 x 1 8 mm ID 0 301 x 0 071 in HNBR 90 Shore FKM 90 Shore B97009 012 42082 012 Shipping plate 1 B46035 001 Fastening eleme...

Page 75: ...ers WAF width across flats for wrenches Accessories ordering information 65 Acronyms 75 Activation 18 Address of Moog GmbH A Air humidity permissible relative air humidity for storage 25 Ambient condi...

Page 76: ...mounting surface 37 Exclusion of liability 4 Exclusion of warranty 4 Explosive environment potentially explosive environment 5 25 F F1 F4 position of the bores for installation screws or attachment s...

Page 77: ...the valves 5 Interfaces see Signal interface IP international protection see Protection type by enclosure ISO International Organization for Standardization see Standards Item numbers see Order number...

Page 78: ...packaging 33 34 Part numbers see Order numbers PELV protective extra low voltage see SELV PELV power supply Permanent magnet linear force motor see Linear force motor Permanent magnets of the linear...

Page 79: ...ety and health 33 35 41 46 52 56 63 safe distances for cardiac pacemakers and similar devices due to magnetic fields 9 27 safety equipment 9 sound insulation measures 9 27 open connectors 42 46 52 ope...

Page 80: ...Ra average roughness Rin input resistance T temperature t time V volume Symbols used 2 T T symbol for temperature see Temperature T tank port see Ports t symbol for time Table of contents i Tank port...

Page 81: ...in the type designation 9th position in the type designation 23 Valve connector X1 see Connector X1 Valve construction type 26 Valve version identification in the type designation 1st position in the...

Page 82: ...14 Index Moog GmbH User Manual D633 A Series CA80942 001 Version 1 0 12 08 74 For your notes...

Page 83: ...or attachment screws of the shipping plate in the mounting pattern of the valve mounting surface FKM Fluorocarbon rubber material for seals such as e g O rings G Bore for positioning pin in the mount...

Page 84: ...T V Technischer berwachungsverein German technical inspection agency UV Ultraviolet V Symbol for volume such as e g tank capacity VDI Verein Deutscher Ingenieure e V association of German engineers ht...

Page 85: ...nts DIN 51524 2 Pressure fluids Hydraulic oils HLP hydraulic oils Minimum requirements DIN 51524 3 Pressure fluids Hydraulic oils HVLP hydraulic oils Minimum require ments 15 3 2 DIN EN Quoted standar...

Page 86: ...ticular requirements for safety isolating transformers for general use 15 3 5 IEC Quoted standards IEC IEC 60947 4 2 Low voltage switchgear and controlgear Part 4 2 Contactors and mo tor starters AC s...

Page 87: ......

Page 88: ...and 353 21 451 9000 info ireland moog com Italy 39 0332 421 111 info italy moog com Japan 81 463 55 3615 info japan moog com Luxembourg 352 40 46 401 info luxembourg moog com Netherlands 31 252 462 00...

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