ECV85R (Reversely Proportional Electro-hydraulic Converter)

Product Guide
ECV85R (Reversely Proportional Electro-hydraulic Converter)
ECV85R Operating Scheme
The ECV85R is a “direct command” electro-hydraulic
converter, designed for a typical power oil pressure in
the range of 6 to 15 bars.
Although it operates with a relatively low-pressure
range, no special settings or adjustments are
required, however it still ensures a reliable and
uninterrupted performance in a wide range of
operating conditions.
ECV85R is used as a current to pressure transducer
to drive hydraulic servo actuators and provides a
regulated output pressure proportional to the control
current.
The flow rate is regulated by means of a “swing-disk”,
whose positioning is established, on one end, by the
solenoid’s mechanical force which is proportional to
the control current and on the other end by the
opposing force due to a spring.
The pressure drop across an internal calibrated
orifice, that depends on the oil flow discharged,
establishes the pressure under the swing disk thus
regulating the output oil pressure.
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Product Guide
In case of zero current, the pressure drops below the
minimum of the regulating range.
From the structural point of view, ECV85R consists of
a manifold fitted with a solenoid, a valve seat, an input
orifice, connections for the pipes, as well as
connections for the control instruments.
The resulting structure is compact and easy to install,
and the need of connecting pipes is reduced to a
minimum.
The ECV85R is equipped with magnets captors,
located in an easy accessible zone for inspection
purposes. The magnets attract the metal dust, floating
in the oil, that could penetrate through the solenoid
gaps.
ECV85R is normally used in a closed loop system; the
feedback signal is in this case a modulated oil
pressure, provided by a transducer, directly fitted in
the converter casing.
In this configuration, all the static errors (non-linearity,
hysteresis, and insensitivity) are cancelled without
impairing the dynamic performances.
ECV85R (Reversely Proportional Electro-hydraulic Converter)
Product Guide

Driven with pressure feedback

FEATURE
NO YES

Oil Supply pressure (typical) 6. ÷ 15. bar

Modulated oil pressure range 0.9 ÷ 4.2 bar

Current full range (*) 0 ÷ 1100 mA

Linearity range – modulated Oil pressure 1.1 ÷ 4.0 bar =

Linearity range – current 200 ÷ 1100 mA =

Maximum regulated flow rate 60 l/min

Non linearity <4% Zero

Average hysteresis <2.5% max. Zero

Frequency with phase shift at 90 degrees 10 Hz

Noise (bandwidth 0 - 10Hz) < 1.0%

Insensitivity <0.4% Zero

Short term drift <0.2% Zero

o
Long term drift (from 30 to 50 C) <2% 0.1% / year

Ambient operating temperature –25 ÷ +70°C

Dimensions max. ( W x D x H) 145 x 145 x 331.5 mm

Oil supply input connection ¾” NPT

Modulated oil output connection 1” NPT

Oil discharge connection 1¼” NPT

Fast pressure measuring connections SMA-3

(*) The driving current signal must have a superimposed dither of about 10-15% @ 75 Hz.

ITEM CODE
ECV85R CONVERTER, 225656000
Pressure Transducer 534069000
Calibrated Orifice blind 225664000
Φ = 2.5 mm 225658000
Φ = 3.0 mm 225659000
Φ = 3.5 mm 225660000

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ECV85R (Reversely Proportional Electro-hydraulic Converter)
Product Guide

8 7
6

10

2
1

FIGURE 1

1. Solenoid connector 6. Fast lock for flexible pipe for regulated pressure meter

2. Pressure transmitter connector 7. Fast lock for flexible pipe for inlet pressure meter

3. Inlet pressure, (P), ¾” NPT 8. Fastening holes

4. Exhaust, (T), 1¼” NPT 9. Fastening screws, M14

5. Regulated pressure (A), 1“ NPT 10. Spring adjustment screw

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ECV85R (Reversely Proportional Electro-hydraulic Converter)
Product Guide

The converter must be mounted in vertical position,
higher or lower than the servo actuator, to allow the
discharge of possible gas “pockets” through the
converter or the servo actuator.
The pipes should be installed with a minimal slope to
avoid gas “pockets” generation. The converter must
be fastened to an anchor plate by means of dedicated
screws.
When the difference between the servo actuator and
the converter height is greater than 0.5 m, the
hydrostatic pressure should be taken into account.
The overall dimensions and the placement of the
connections are shown in Figure 1.
Figure 2 shows the typical flow diagram of the
converter.

FIG. 2 – BLOCK DIAGRAM WITH SERVO ACTUATOR

IMPORTANT

«» EACH ECV85R CONVERTER IS FACTORY ADJUSTED AND THEN SEALED IN EACH CLOSURE POINT.

«» ANY OPERATION OF PRODUCT DISASSEMBLY AND OPENING MUST BE PERFORMED ESCLUSIVELY BY

ABB QUALIFIED PERSONEL. ANY EXCEPTION AND ALTERATION, FOR EXAMPLE IN CASO OF SEAL
BREAKAGE, WILL VOID THE PRODUCT GUARANTEE.

NOTE: The plastic caps should not be removed before the fitting of the pipes to prevent the internal accumulation of
dust or particles inside the unit.

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ECV85R (Reversely Proportional Electro-hydraulic Converter)
Product Guide

The connecting pipes shall be pickled before Use a mineral oil with a viscosity ranging from 1.2 to
assembling. 50°E (2.8 to 380 cSt). The physical and chemical
properties of the fluid must be unimpaired and it must
The use of flexible pipes should be avoided. If this is be free from impurities; a degree of filtration of at least
not possible, their length shall be limited to a 100 microns is recommended.
minimum.

The cleaning of the conduit shall be performed without

the converter that should be replaced by a by-pass
pipe, sized for the double of the typical operating flow.
The following diameters and other layout topics are
recommended:
- INLET PRESSURE (inlet P): ¾” NPT connection
- MODULATED OIL (inlet A): 1” NPT connection
The values of maximum flow rate are given in Fig. 3
as a function of the pressure of the inlet oil supply and
the diameter of the orifice.
The orifice diameters must be chosen to keep oil flow
rate in operation below the limit of 60 l/min.

- The horizontal sections must have a slope of at

least 5% in order to prevent air pockets Orifice diameter Ordering code
generation.
BLIND 225664000
- DISCHARGE (outlet T): 1 ¼” , NPT connection
Φ = 2.5 mm 225658000
- The piping must discharge directly into the tank
or into an empty pipe to avoid the risk of possible Φ = 3.0 mm 225659000
back pressures
Φ = 3.5 mm 225660000
- If the horizontal layout of the piping is more than
1.5 m or if there are more than 3 elbows, proceed
with a pipe having a diameter of 1½”.
NOTE: The converters are assembled with a standard
orifice of 3.5 mm and a blind one.

FIG. 3 - FLOW DIAGRAM

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ECV85R (Reversely Proportional Electro-hydraulic Converter)
The wiring of the solenoid must be carried out with
adjustable and insulated connectors (pin 1 – 2: coil
connections; pin 3 free) type DIN 43650, and cable
clamp with degree of protection IP 65.
The pressure transducer wiring must be carried out
with adjustable and insulated connectors, pin 1 (+)
and 2 (-), pin 3 free, type DIN 43650, and cable clamp
with degree of protection IP 65.
The connection cables for both coil supply and
pressure transducer must be shielded, bipolar. It is not
possible to use a single shielded multi polar cable.
The shield shall extend as close as possible to the
connectors.
To properly drive the ECV85R, ABB Energy
Automation has developed a special module
(UTAC01) that optimizes both static and dynamic
performances ensuring the perfect efficiency of the
system.
It is mandatory that the electrical driver provides a
control current signal with a superimposed dither of
about 10-15% @ 75 Hz.
The converter is normally used with a closed loop
pressure regulation. The pressure transducer,
supplied as a separate part, has the following
characteristics:
Output signal 4–20 mA
Pressure range 0–10 bars
Linearity better than 0.25%
Zero drift 0.01% °C
Bandpass 0–1 kHz
Outlet ½” gas
Ordering code 534070000
1) Check to ensure that the calibrated orifice matches
the one designed for the particular system (for its
placement, refer to Fig.1)
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Product Guide
2) Check that the input pressure measured before the
orifice is within the range foreseen for the system
in question (normally 5 –10 bars).
3) Check to ensure that the driver module is correctly
installed and powered.
4) Activate the hydraulic inlet supply of the converter
and check to be sure that there is no leakage.
5) Change the drive current value. Check to ensure
that for 200 and 1200 mA the pressure values are
similar to those shown in diagram A.
In order to ensure the complete opening of the valve
at max current, during the commissioning it is possible
to operate on the spring adjustment screw below the
converter. The adjustment screw acts on the opposite
spring, shifting the pressure/current characteristics as
in fig. 7. The above operation must be performed by
ABB personnel only.
Neither adjustment nor periodic maintenance are
required by the converter.
It is advisable every six months of operation to scrub
the magnet captors. During the maintenance, with the
oil circuit not pressurized, unscrew the magnetic cover
bolts (fig. below). It is suggested to use brush or
suitable cleaning cloth to remove the build up of
ferrous residues and particles from the surface of the
magnet rods.
After cleaning, replace the covers, and tighten with
care.
In the event of irregular operation, check to ensure
that:
a) The calibrated orifice is not clogged;
b) The filter on the oil inlet pipe is operating properly;
c) The characteristics of the oil are conform with
those indicated.
Every 20.000 working hours, it is recommended a
complete overhaul for the ECV85R.
For the converter repairing or revision, the unit shall
be replaced by a spare part and sent back to ABB.
ECV85R (Reversely Proportional Electro-hydraulic Converter)
Product Guide

FIG. 4 – SCHEME FOR THE TEST RIG

NOTE

(i) the following diagrams refer to the typical operating characteristic of the converter

(ii) the tests where carried out using mineral oil with a viscosity of 30°E and a temperature of 50 °C, with an
inlet supply pressure of 10 bars

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ECV85R (Reversely Proportional Electro-hydraulic Converter)
Product Guide

FIG. 5 – TYPICAL OPEN LOOP P- I CHARACTERISTIC W/O PRESSURE COMPENSATION

ECV85R Current/Pressure

4.5
4.0
3.5
3.0
2.5
Bar

2.0
1.5
1.0
0.5
0.0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2
Amp

FIG. 6 – CLOSED LOOP STANDARD P- I CHARACTERISTIC WITH PRESSURE COMPENSATION

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ECV85R (Reversely Proportional Electro-hydraulic Converter)
Product Guide

ECV85R Current/Pressure - Spring Adjustment

5.0
4.5
4.0
3.5 Adjustment screw
3.0
Bar

2.5
2.0
1.5
1.0
0.5
0.0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2
Amp

FIG. 7 –P- I CHARACTERISTIC ADJUSTEMENT

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ECV85R (Reversely Proportional Electro-hydraulic Converter)
Product Guide

ECV85R– Product Guide

ABB Business Unit Power Generation

Via Hermada, 6
16154 Genova NOTE:

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ITALY of this document without prior notice. With regard to purchase orders,
the agreed particulars shall prevail. ABB does not accept any
Phone: +39 (0) 10 607.3351 responsibility whatsoever for potential errors or possible lack of
information in this document.
Fax: +39 (0) 10 607.3533
We reserve all rights in this document and in the subject matter and
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Internet: http://www.abb.com/powergeneration
Copyright© 2005 ABB
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