Safety for Hydraulics

User’s information about proportional valves in subplate design

motion and progress

Replace for: 7.4.0 1/10 Classification: 430.40.60.

Reference: 301−P−9050028−E−02/03.05
Contents Page
1. Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Figure: proportional directional control valve PV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Figure: pressure compensator type PU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Figure: pressure compensator type PD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Figure: valve variant type PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Table: tightening torques MA (µges=0.125) or fastening screws, ISO4762(DIN912)−12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 View of a proportional valve (here for example: subplate valve size 12 with electro−hydr. or hydr. actuation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Figure: View of the pressure compensators PU/PL/PR and the pressure relief valve PL
(here for example: subplate valve size 12 with electro−hydr. or hydr. actuation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Adjustment instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Adjusting the maximum pressure−relief device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Adjusting the maximum flow via the main spool stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Adjusting the maximum flow via pressure compensator adjustment (item E2 in fig. 3.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. Storage notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

301−P−9050028−E−02/03.05 2/10
1. Functional description
Bucher proportional valves in subplate
design control the flow load−indepen-
dently to the actuator. The directional
control valve (PV), the pressure com-
pensators (PD, PU, PR) as well as the
piloted pressure relief valve (PL) as
each a single unit make up a compact
design. The main part is the proportio-
1.1 Figure: proportional directional control valve PV
a b
LA T A P B
Pressure compensator type PU
(see Fig. 1.2) besides the 3−way flow
control function this type of pressure
compensator enables also the function
of a piloted pressure relief valve (only
when directional control valve is ope-
ned) as well as the function of a unloa-
ding valve (when directional control
valve is closed). In neutral position of
the directional control valve, the spring
chamber of the pressure compensator
will be relieved by 2 jets (
DUE2
).
Pressure compensator type PR
(without figure) this type of pressure
compensator is similar to the PU−type
with 3−way flow control function. The
difference is the high loadable port T1
(up to 350 bar) for the excess pump
flow. The relieve by 2 jets (
DUE2
) of
the pressure relief valve and the spring
chamber of the pressure compensator
is separately made by port Y.
The return flow (A/B−T) of the directio-
nal control valve is separately collected
by port T of the subplate.
301−P−9050028−E−02/03.05
nal directional control valve − selective
with electrical, hydraulic, manual ac-
tuation or any combination thereof. The
combination of the pressure compen-
sator or of the pressure relief valve with
the directional control valve is realized
by one subplate. The subplate also inc-
T LB
Pressure compensator type PD
(see fig. 1.3) this type of pressure com-
pensator enables the pressure redu-
cing function besides the 2−way flow
control function − but only when direc-
tional control valve is opened and the
preset pressure set is passed over. The
relieve of the pressure compensator
spring chamber in actuated position is
effected by 2 sets ("DUE2
). This re-
lieve is necessary because normally
there are existing check valves in the
load feed back bores of the directional
control valve. The relieve is made by
channel L to Y and is not shown in fig.
1.3 (similar is fig. 1.2 from L to T).
ludes the pipe ports for pump (P), tank
(T), load signal port (XL) and actuator
(A/B). All directional control valves −
which are combined with one 2−way
pressure compensator − can be actua-
ted simultaneously, load−indepen-
dently.
Valve variant type PL
(see fig. 1.4) this variant only has the
function of a piloted pressure relief
valve (e.g. max. pressure setting for
load sensing pumps or fixed displace-
ment pressure systems). A flow control
is not possible. Standardly there are 2
jets (
DUE2
) assigned to relieve the
load feed back channels in neutral po-
sition of the spool.
3/10
1.2 Figure: pressure compensator type PU

Adjustment of maximum pressure

P = Pump
Adjustment of pressure T = Tank
difference of main spool L = Load signal

Spring
L P T
Pressure compen- Filter Relieve jets DUE 2 Pressure compensator spool
sator jet DUE 1

1.3 Figure: pressure compensator type PD

Adjustment of maximum pressure

PN = Low pressure
PH = High pressure
Adjustment of pressure
difference of main spool L = Load signal
Y = External tank

Spring
Y L PN PH
Pressure compensator jet DUE 1 Pressure compensator spool

1.4 Figure: valve variant type PL

Adjustment of maximum pressure

P = Pump
T = Tank
L = Load signal

Spring
L P T
Filter Relieve jets DUE 2 Jet DUE 3 Main stage

2. Safety instructions
S Use the valves only for their intended
purpose.
S The valves may only be adjusted by
specialized personnel.
S The hydraulic system must be de-
pressurized before work can be per-
formed on the system.
S The unit may only be opened with the
manufacturer’s authorization..
S Ensure that the pump provides an
adequate flow for the supply of all ac-
tuators during parallel operation of
multiple actuators. If this is not obser-
ved, the motion of the actuator with
the highest load pressure may inad-
vertently change its direction.
S In general there is a risk of sticking
spool often caused by contamination
of the pressure fluid. A risk assess-
ment with regard to the safety of the
machine/system must be performed
during the design of the hydraulic
control system and suitable safety
measures must be implemented,
which may be defined in categories
as per EN 954.

301−P−9050028−E−02/03.05 4/10
3. Installation instructions
S Never lift the valve by the solenoids,
displacement transducers or similar
sensitive components.
S The valve ports are not marked. The
position of the ports are shown in fig.
3.2 and 3.3.
S Do not exceed the maximum tighte-
ning torque of threaded connections;
see Table 3.1.
S Attach the valve only at the four
points mounting holes "B" (see fig.
3.2/3.3).
S Ensure that the mounting surface is
clean. The mounting surface must be
level within 0.01 mm per 100 mm (in
accordance with DIN ISO 1101)
S Pipeline systems must not be subjec-
ted to stress during installation.

3.1 Table: tightening torques MA (mges=0.125) or fastening screws, ISO4762(DIN912)−12.9

Size Thread Wrench size MA [Nm]

8 M6 5 11.4
12 M8 6 28
18 M12 10 94
25 M16 14 232

3.2 View of a proportional valve (here for example: subplate valve size 12 with electro−hydr. or
hydr. actuation)

"B"

TB B A TA
P
Port surface
LB Y LA
X

Check valve B "B" Check valve A

b a

Side view of an electrically

operated valve

Item 33
Item 32 Item 31
Item 31 Item 32
Item 33

Item E3 Item E3
Sets max. valve stroke Sets max. valve stroke
(max. flow) for P!B (max. flow) for P!B
(para. 4.3) (para. 4.3)

Side view of a hydraulic

operated valve

bY aX
Top view of a hydraulic
operated valve

301−P−9050028−E−02/03.05 5/10
3.3 Figure: View of the pressure compensators PU/PL/PR and the pressure relief valve PL
(here for example: subplate valve size 12 with electro−hydr. or hydr. actuation)

"B"

T P
L
Port surface PU/PL

"B

"B

PH PN
L
Port surface PD/PR
Y
(T1) (P)

Item E2
(only at PU, PR and PD)
Sets pressure compensator (para. 4.4)
Item 23
Item 22
Item 21

Side view

Item 11 Item 12
Item12 Item 13
Item 13 Item 14
tem E1 Item E1.1
sets pressure valve Sets pressure relief
valve with stroke limiter

(only at PU/PL/PR)

F1
DUE2 Top view
DUE1

(only at PU/PD/PR)

4. Adjustment instructions
4.1 General safety instructions
The valves are adjusted according to Adjustment should be made only in ex-
the order datas of the customer. ception and by specialized personnel

Caution: The setting range of the adjustment units is not limited mechanically! Changes to the pressure or flow must
be made with extreme care, in small steps and in accordance with the adjustment instructions (para. 4.2 and 4.3)!
Uncontrolled adjustments and non−observance of the adjustment instructions can lead to a failure of the maximum
pressure−relief device!

301−P−9050028−E−02/03.05 6/10
4.2 Adjusting the maximum pressure−relief device
Changes of the maximum pressure set-
ting may only be made with a pressure
gauge connected to the measurement
points MP or XL (measurement point
XL = load, measurement point MP =
pump pressure; please refer to fig.3.3
for the locations of the measuring
points).
Caution: Do not mistake maxi-
mum pressure−relief device
with set screw of the pressure
compensator spring (item E2)!
1. Maximum−pressure measurements circa 5 to 10 bar higher than the pres-
may only be performed with an actu− sure of XL.
ated directional control valve and blok-
3. The measured pressure at XL corres-
ked actuator (cylinder at stop, closed
ponds to the load pressure of port A or
mechanical brake or things like that).
B when directional control valve is ac-
Because − in that case − the flow to port
tuated. The measured pressure at MP
A or B is zero, the measured pressures
corresponds to the pressure at port P of
at measurement points MP and XL are
the valve variants PU, PR, PL and to the
identical.
reduced pressure PN of the valve va-
2. As soon as a flow to port A or B is riant PD (reduced by the 2−way pres-
available the measured operating sure compensator) − see fig. 1.3.
pressure at meassurement point MP is

4.2.1 Procedure:
S Remove the protective cap (item 11).
S Stick the hexagon socket screwdri-
ver (according to DIN 911) into the
set screw (item 12).
S When loosen the lock nut (item 13),
hold set screw at its home position.
S During turning the set screw check
the pressure gauge:
S Maximum pressure reduction:
turn adjustment screw counter clock-
wise
S Maximum pressure increase:
turn adjustment screw clockwise
S Standard value:
1/4 turn ~40 bar pressure change
S For standard valves the maximum
permissible set value is 350 bar.
S For special designed valves with
permissible set value under 350 bar
the set screw must be fitted with a
mechanical stop (item 14) (see item
E1.1, fig. 3.3).
Caution: This special set screw
may never be changed!
S After adjustment is finished hold set
screw (item 12) with the hexagon
socket screwdriver and tighten lock
nut (item 13) (tightening torque:
20Nm).
S Put on the protective cap (item 11).

4.3 Adjusting the maximum flow via the main spool stroke

Note: Uncontrolled movement of the adjustment screw by several clockwide turns can lead to the failure of the fail−
safe position; i.e. the spool of the directional control valve may not be able to return to its neutral position!

Adjustment is effected with the adjustment screw inthe main spool cover; see item E3, fig. 3.2.

4.3.1 Procedure:

S Check that the pump flow is ade-
quate.
S Ensure that the directional control
valve has reached its maximum
stroke:
S manual lever adjustment:
~20º adjustment angle
S hydraulic adjustment:
control pressure difference > 18 bar
S electrical adjustment:
control current (24V) > 700 mA
control current (12V) > 1400 mA
control current (EEx ia l) > 270 mA
S Do not actuate valve.
S Remove the protective cap (item 31)
from the side to be adjusted (actuator
A/B).
S Loosen the lock nut (item 33) (wrench
size see table 4.3.2).
S Turn the adjustment screw (item 32):
S clockwise to reduce the flow.
S counterclockwise to increase the
flow.
S turn adjustment screw by ~1/2 turn.
S Tighten lock nut (item 33) with the
correct tightening torque; see table
4.3.2.
S Actuate valve, check the change in
actuator speed.
S If actuator speed is o.k. − put on the
protective cap (item 31).

Note: If a change will not be achieved, the adjustment of the pressure compensator can be changed.

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4.3.2 Table: tightening torques and wrench sizes for the stroke adjustment of the directional control valve spool and of
the pressure compensator (para. 4.4)

Allen key/Spanner size Torque

Compensator adjuster Spool−stroke limiter
Setscrew Capscrew Hexagonal Setscrew Sealing nut Hexagonal
(old) (new) nut ’Seal−Lock’ nut
and
ISO4026 ISO4762 DINEN24032 ISO4026
sealing nut
(DIN913) (DIN912) (DIN934) (DIN913)
Item 22 Item 22 Item 23 Item 32 Item 33 Item 22/32
Size Thread
[mm] [mm] [mm] [mm] [mm] [Nm]
8 M6 3 5 10 3 10 8.5
12 M8 4 6 13 4 13 20
18 M10 5 8 16 (17) 5 17 40
25 M12 6 10 18 (19) 6 19 65

4.4 Adjusting the maximum flow via pressure compensator adjustment (item E2 in fig. 3.2)
This protecting can only be performed on PU, PD, PR versions!

Caution: Do not mistake the set screw of pressure compensator spring with maximum pressure−relief device
(fig. 1.2/1.3)!

4.4.1 Procedure:
S Depressurize the system! (stop
pump).
S Remove the protective cap (fig.
1.2/1.3/item 21, fig. 3.2).
S Stick the hexagon socket screwdri-
ver (according to DIN 911) into the
set screw (item 22).
S Turn the adjustment screw clockwise
until a hard stop is felt.
S Set the adjustment screw counter-
clockwise by the number of turns
mentioned in table 4.4.2 (with this ad-
justment the maximum possible
speed will be reached).
S To check the speed, start pump and
control actuator.
S If speed is to high, set the adjustment S Tighten lock nut (item 23) with the
screw counterclockwise (reduction correct tightening torque; see table
of the spring force) until the correct 4.3.2.
speed (flow rate) for the actuator is S Put on the protective cap (item 21).
reached. Note: If a change will not be
Caution: Never overturn the achieved please contact the
maximum set of the pressure valve manufacturer.
compensator spring, other-
wise the pressure compensa-
tor is unable to close and there
will be no flow control− and-
pressure relief function an-
ymore!

301−P−9050028−E−02/03.05 8/10
4.4.2 Table: pressure compensator adjustment (minimum number of turns back from the stop = maximum spring force)

Pressure compensator Pressure compensator

PU/PR PD
Size Number of turns Number of turns
8 3 3.5
12 3.5 4
18 4 4.5
25 5 4

4.4.3 New adjuster on the 2−way compensator (hydrostat)

The previous ISO4026 (DIN 913) setscrew adjuster for the 2−way compensator has been superseded by a modified
ISO4762 (DIN912) cap screw adjuster. This change is an improved engineering solution.
Cover
Compensator spool Spacer pin (adjuster side)

New Lock nut

Modified
ISO4762 (DIN912) cap screw

Old Lock nut

ISO4026 (DIN 913) setscrew

This change does not alter in any way the effect produced by the adjuster.

The change merely simplifies the pro-
cedure for setting the maximum com-
pensator spring force.
To set the maximum compensator
spring force with the previous adjuster,
it was necessary to first screw the sets-
crew in to its end stop and then to un-
screw it by the number of turns speci-
fied in the User information leaflet.
To set the maximum compensator
spring force with the new adjuster, it is
only necessary to screw the cap screw
complete with lock nut into the cover as
far as it will go.
The maximum compensator spring
force is identical in both cases. The
spring force can be subsequently re-
duced by unscrewing the adjuster in
the same way as before.
Advantages of the new adjuster:
S the maximum compensator spring
force can be set reliably
S the spring force can be changed ea-
sily
Fot technical reasons, it is unfortunately
not possible to retrofit any valve sy-
stems already supplied.
Warning: Replacing the modi-
fied cap screw by any other
screw is not permitted and can
result in failure of the pressure
relief function.

5. Storage notes
The maximum permissible storage period in closed, dry rooms is six months. Longer storage periods (up to 3 years) may
be achieved by using suitable packaging materials and preservation.

301−P−9050028−E−02/03.05 9/10
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We reserve the right of modification without notice.
301−P−9050028−E−02/03.05
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