2002-05-07 Cartridge Valve RAP Training

CARTRIDGE VALVE AND HIC PRODUCTS
02-Octubre, 2004
CARTRIDGE VALVE
BUSINESS UNIT
FACILITIES
Hillsboro, Oregon Nordborg, Denmark
Easley, South Carolina Reggio Emilia, Italy

NORTH AMERICAN HISTORY
1947 Fluid Controls introduces cartridge

relief valve. 1977 Compact Controls founded to design
and manufacture HIC’s.
1965 Fluid Controls introduces HIC
manifolds. 1979 Compact Controls introduces
pressure and flow control valves.
1968 Fluid Controls introduces spreader
control valves. 1982 Compact Controls introduces
solenoid and proportional valves.
1981 Sta-Rite acquires Fluid Controls.
1995 Compact Controls relocates to
1985 Sta-Rite relocates to Easley, SC.
60,000 sq. ft. building in
1992 Danfoss Fluid Power acquires Sta- Hillsboro, Oregon
Rite.
2001 Sauer-Danfoss acquires Compact
2000 Sauer-Sundstrand and Danfoss Fluid Controls.
Power merge to become
Sauer- Danfoss.
VALVE ENGINEERING
• Hillsboro & Easley combined engineering resources:

- 8 engineers
- 6 designers
- 5 lab technicians
- 6 machinists for prototypes
- 1 buyer/planner for prototypes
• Solid model design capability:

- Inventor and AutoCad 2000 used for design.
- Translation to many formats (ProE, Unigraphics, others) available.
• Engineering Data Management System (EDMS) used to share

drawings and BOM’s between multiple plant sites.
R & D LAB
• Performance test stand for 100

gpm.
• Fatigue and burst test

capabilites.
• Computerized data acquisition

to record and analyze data.
VALVE MANUFACTURING
• Cellular Assembly Approach:
- 7 assembly cells.
- Cartridges 100% tested on

computerized test stands.
• Hard-Turning Capability:
- Ensures leak-free poppet/seat sealing.
- 4 Hardinge Conquest and 1 American

Way turning centers.
- Poppet/seats matched and 100%

vacuum tested.
MANIFOLD MANUFACTURING
• In-House CNC milling

- 15 flexible machining centers for “lights out”
operation.
- Capacity for 240,000 manifolds/year.
• Experience with many manifold

materials:
- Aluminum 6061-T6 (standard for <3000
psi), anodizing available.
- Aluminum 7075-T6 (standard for 3000-
4000 psi), anodizing available.
- Ductile iron (standard for >4000 psi or on
request) with zinc plating standard.
- Steel (on request).
MANIFOLD MANUFACTURING
• In-house automated thermal

de-burr and automated wash
systems.
• 3 HIC assembly cells with

automated computerized
testing.
QUALITY STATEGY
• Utilize advanced quality planning tools as part of normal product

release and manufacturing processes:
- Design for Manufacturability (DFM)
- Failure Modes and Effects Analysis (FMEA)
- Process Failure Mode and Effects Analysis (PFMEA)
- Statistical Process Control (SPC)
• Supplier audit system is used to build alliances with critical suppliers.
• All plants are ISO 9001 registered.
• Sauer-Danfoss goal is 250 dpm as measured on the customer’s

production line.
CARTRIDGE VALVE
PRODUCT LINE
CARTRIDGE VALVES
• Cartridge valves are compact, low-cost, no-leak, screw-in

components suitable for mobile and industrial hydraulic control
functions.
• Cartridge valves are available for flow, pressure, and directional
control up to 5000 psi and 50+ gpm.
• Almost any circuit can be quickly created using standard catalog
valves.
CATALOG NOMENCLATURE
• All valves have a model code in this format:

CPABC-D-E-F-G-H
• CP = “cartridge product”
• A = type of valve: 1=check, 2=pressure control, 3=flow control, 4=motion control,
5=solenoid, 6=manual, 7=differential sensing
• B = description depends on type of valve, for example 0=poppet, 1=spool
• C = cavity size: 4=4 series, 8=8 series, 0=10 series, 1=12 series, 2=16 series, 3=20
series
• D = description depends on type of valve, for example 1=open, 2=closed
• E = type of o-ring seal: B=Buna-N (nitrile), V=Viton, U=Urethane
• F = port options: 0=cartridge only, other nomenclature describes port sizes if
cartridge is ordered in a body
• G,H,… = description depends on type of valve, may specify pressure setting for
relief valve, flow setting for flow control, coil voltage, etc.
HOW TO READ THE CATALOG
To specify a size 8 differential area relief valve set internally at 2500 psi
crack pressure installed in an aluminum body with SAE 6 ports and viton
seals, use model code:
CP208-1-V-6S-A-C250
HOW TO INTERPRET THE RATINGS
• Cavity – Each valve fits a Sauer-Danfoss standard cavity.

• Pressure Rating – Based on NFPA one million cycle fatigue test standard and a
burst test with a 4:1 safety factor.
• Flow Rating -
Directional Valves – Based on a pressure drop of 100 psid with 32 cSt fluid.
Pressure Relief & Reducing Valves – Based on a pressure rise or droop of 100 psid
with 32 cSt fluid.
(flow rating can be exceeded for the above valves if the penalties of higher pressure
drop and associated heat generation are acceptable)
Solenoid Spool Valves – Based on a pressure drop of 100 psid with 32 cSt fluid but
also indicates a performance limit based on maximum solenoid force.
(do not exceed flow ratings for solenoid spool valves without consulting factory)
• Crack Pressure – Is set at 0.25 gpm with 32 cSt fluid.
HOW TO INTERPRET THE RATINGS
• Leakage –
Pressure Control Valves – measured at 70-80% of crack pressure with 32 cSt fluid.
All Other Valves – measured at maximum rated pressure with 32 cSt fluid.
• Solenoid Voltage – Is a nominal value. All solenoid valves are designed to operate
with continuous duty at 140°F ambient temperature with rated flow and pressure.
• Temperature Rating – Varies by model and options. Seal materials have the
following limits:
Buna N and Polyurethane – -40°F to +250°F
Viton – -15°F to +400°F
The recommended minimum fluid viscosity is 12 cSt which will override the seal
temperature limit for most fluids.
VALVE CAVITIES
• Valves use industry-standard

“SAE” cavities.
• Cavities highlighted in red do not
match the proposed new
NFPA/3.50.200X spec. These
cavities and valves will be
redesigned upon formal approval
of the new standard.
• Port numbering standard is as
shown.
CHECK VALVES
• Check valves allow free flow in one direction and block flow in the
opposite direction.
• Used to hold loads, separate systems, provide load-sensing “logic”, or

as low pressure relief valves.
- Sizes: 4, 8, 10, 12, 16, 20
- Drop-in check valves available.
- In-line check valves available.
- Flow Ratings: to 100 gpm OUT
- Pressure Ratings: to 5000 psi IN

CHECK VALVES
LOAD SENSING APPLICATION
CHECK VALVES
ANTI-CAVITATION APPLICATION
CHECK VALVES
LOAD HOLDING APPLICATION
PILOT
PISTON CHECK
VALVE
SHUTTLE VALVES
• Shuttle valves connect the higher

of two input pressures to the
output port.
• Used for load-sense logic, IN

pressure compensation for
multiple functions, or for brake
application or release.
OUT
- Sizes: 4, 8, 10
- Flow Ratings: to 5 gpm

IN
- Pressure Ratings: to 3000 psi
SHUTTLE VALVES
LOAD SENSING APPLICATION
SHUTTLE VALVES
BRAKE RELEASE APPLICATION
HOT OIL SHUTTLES
• Shuttle valves connect the lower

of two input pressures to the
output port.
• Used for filtering and/or cooling

in closed-circuit hydrostatic
transmissions. IN
- Sizes: 10, 12
- Flow Ratings: to 50 gpm OUT

IN
HOT OIL SHUTTLES
HYDROSTATIC TRANSMISSION APPLICATION
DIRECT ACTING RELIEF VALVES
DIFFERENTIAL AREA DIRECT ACTING
• Relief valves limit system pressure.
• Direct acting valves are available with
“direct acting” and “differential area”
designs as shown.
• Both designs are lower-cost, faster-
acting, and more contamination tolerant
than pilot operated relief valves.
• The “differential area” type has flatter
pressure regulation.
• The “direct acting” type has better IN
reseat and hysteresis characteristics. OUT
- Sizes: 8, 10, 12
- Flow Ratings: to 40 gpm OUT IN
DIRECT ACTING RELIEF VALVES
TYPICAL PERFORMANCE COMPARISON
PRESSURE VS. FLOW
DIRECT ACTING
PRESSURE (PSID)
DIFFERENTIAL AREA
FLOW (GPM)
PILOT OPERATED RELIEF VALVES
• Relief valves limit system pressure.
• Pilot operated relief valves provide flatter

pressure rise for more accurate pressure
control, lower hysteresis, and higher
operating pressures than direct acting
relief valves.
- Sizes: 10, 12

OUT
IN
DIRECT ACTING
PRESSURE REDUCING/RELIEVING VALVES
• Reducing/relieving valves provide reduced
downstream pressure while system pressure is
unaffected.
• Direct-acting designs are lower cost, faster-acting,

and more contamination tolerant than pilot operated
pressure reducing valves.
- Size: 10
TANK
- Flow Rating: 10 gpm
- Pressure Rating: 3000 psi INLET
REG. PRESSURE
PILOT OPERATED
• Reducing/relieving valves provide reduced
downstream pressure while system pressure is
unaffected.
• Pilot operated designs provide more accurate

pressure control and higher operating pressures
than direct acting designs.
OUT
- Size: 10
- Flow Rating: 10 gpm
- Pressure Rating: 5000 psi IN
REG
TYPICAL PERFORMANCE COMPARISON
PRESSURE VS. FLOW
PILOT OPERATED
PRESSURE (PSI)
DIRECT ACTING
RELIEVING REDUCING
FLOW (GPM)
SEQUENCE VALVES
• Sequence valves ensure that one operation is

complete before another is performed, for example:
- Ordered sequence of operations, e.g. clamp then lift.
- Pump unloading.
- Accumulator charging.
• Available with a variety of spool, porting, spring

options, etc. TANK
- Size: 10 SEQ
IN
SEQUENCE VALVES
CLAMP AND LIFT CIRCUIT
CP240-1 Sequence Valve ensures

full force is applied to clamp
cylinder before lift function begins:
Clamp
Lift
CP240-1
SEQUENCE VALVES
KICK-DOWN SAFETY CIRCUIT
CP240-22 Kick-Down Sequence

Valve opens at a pre-determined
pressure and stays open until
flow is stopped. Can be used to
sequence operations (see
example, no manual valve
operation until solenoid is
energized) or as a safety shut-off
valve.
CP240-22
SEQUENCE VALVES
ACCUMULATOR CHARGING CIRCUIT
CP240-30 Unloading-Type Sequence

Valve unloads pump to tank when
accumulator reaches a pre-
determined pressure setting and re-
charges accumulator when pressure
drops to 75, 80, or 85% of pre-
determined level.
CP240-30
RESTRICTIVE-TYPE FLOW CONTROL VALVES
• Pressure compensated flow control valves

provide constant flow regardless of system
pressures.
• Restrictive-type flow controls can be used to

control cylinder raise or lower speeds, motor
speeds, etc.:
- Sizes: 8, 10, 12
OUT
IN
RESTRICTIVE TYPE FLOW CONTROL VALVES
SPEED CONTROL APPLICATION EXAMPLE
CP300-1 Restrictive-Type, Pressure-
Compensated Flow Control Valves
provide fixed speed for each function
regardless of load:
TURNTABLE SECONDARY PRIMARY EXT/RET
LEVEL ROTATE CYLINDER CYLINDER CYLINDER
ST P1 G1 P2 L1 L2 TR1 TR2 SC1 SC2 PC1 PC2 EXT RET
3000 1600 1400 1800

PSI PSI PSI PSI
3200 PSI A B C 1100 F G H
E PSI
Q I J K L M
R O Y
.8 1.5
GPM GPM
T3
TANK T2
PRIORITY-TYPE FLOW CONTROL VALVES
• Pressure compensated flow control valves

provide constant flow regardless of system
pressures.
• Priority-type flow control can be used to
provide constant flow to a priority function
(e.g. steering) while allowing excess flow to
be used for auxiliary functions. REG.
FLOW
• Can be used as a restrictive-type flow
control with the excess flow port plugged. EXCESS
FLOW
- Sizes: 10, 12
- Pressure Ratings: to 3000 psi IN
PRIORITY TYPE FLOW CONTROL VALVES
STEERING PRIORITY CIRCUIT
CP310-1 Priority-Type, Pressure-

Compensated Flow Control provides
2.5 gpm constant flow to steering with
excess available for auxiliary function:
2.5 gpm
CP310-1
FLOW DIVIDER/COMBINER VALVES
• Flow divider/combiner valves provide pressure

compensated flow division or combination at a pre-
set ratio regardless of system pressures.
• Often used for cylinder synchronization or in traction
circuits. IN/
OUT
• Note: S-D flow dividers do not have a “re-phase” feature for
cylinder synchronization.
OUT
• Flow divider/combiner sizing can be very important!!! /IN
• Undersizing leads to extremely high pressure drops and
associated heat generation.
IN/
• Oversizing leads to poor dividing and combining accuracy OUT
- Sizes: 10, 12, 16
- Flow Ratings: to 40 gpm.
FLOW DIVIDER/COMBINER VALVES
FOUR WHEEL DRIVE TRACTION CIRCUIT
B A
CP341-1 Flow
Divider/Combiner M7 M8
Valves in four-wheel- M3 M4
drive circuit:
210 T1
E PSI
D
CP T
M5 M6
Left Left
A C
.070 B
Rear Wheels F Front Wheels
67% 33% H
M6 X 1.0
.052
Right .070 G
Right
M1 M2
BP
Property of C.C.I. cont

information. Borrower o
only for purpose which l
PILOT OPERATED CHECK VALVES
• Motion control valves are used to control moving

loads and prevent loads from running ahead of a
pump. There are two basic types, pilot-operated
check valves and counterbalance valves.
• Pilot-operated check valves are non-modulating
valves that provide load holding and “hose break”
LOAD
protection.
• In a HIC manifold it is more economical to use a VALVE
standard check valve with a pilot piston than a pilot-
operated check valve cartridge.
- Sizes: 8, 10, 12, 16
- Flow Ratings: to 60 gpm PILOT
PILOT OPERATED CHECK VALVES
LOAD HOLDING CIRCUIT
CP108-1 Check Valves in load-holding

circuit application:
- Provides free-flow check for load

lifting.
- Provides leak-free check for load

holding.
- Prevents cavitation if the load runs

away from the pump and acts as a
“hose break” safety valve – but does
not provide smooth deceleration or
load lowering.
COUNTERBALANCE VALVES
• Motion control valves are used to control moving

loads and prevent loads from running ahead of a
pump. There are two basic types, pilot-operated
check valves and counterbalance valves.
• Counterbalance valves perform the same function

as pilot-operated check valves and also provide
modulated load lowering and smooth
PILOT
braking/deceleration of large inertial loads.
- Sizes: 8, 10, 12 VALVE
- Pressure Ratings: to 5000 psi LOAD

CP440-1 Counterbalance Valve in Cylinder Circuit:
- Provides free-flow check for load lifting.
- Provides leak-free check for load holding.
- Acts as a pressure relief valve for the load.
- Provides cavitation-free load lowering (matches

cylinder speed to pump flow to prevent load from
“running away”, acts as a “hose break” safety valve,
and provides smooth deceleration and load lowering.
APPLICATION NOTES
• Relief setting to be 1.3 X maximum
expected load. Don’t overlook return line CP440-2 Dual Counterbalance Valve
backpressure which is additive to this for “overcenter load”:
setting.
• Low pilot ratios (3:1 to 4.5:1) require higher
pilot pressure but provide smoother, more
stable control. They are best for variable
and high inertia loads (e.g. cylinders).
• High pilot ratios (8:1 to 10:1) require lower
pilot pressure and provide faster speeds,
but with less stability. They are best for
constant and smooth loads (e.g. motors).
• Always mount counterbalance valves in or
on the cylinder, not at the directional
control valve.
• Use counterbalance valves with normally
open or motor spools—never with normally
closed spools.
NEEDLE VALVES
• Needle valves are non-pressure

compensated manually adjustable flow
controls.
- Sizes: 8, 10, 12, 16

DIRECTIONAL CONTROL VALVES
• Hydraulically pilot-operated spool valves that provide

directional control based on pilot pressure.
• Often used with solenoid valves to create high flow

directional valves.
• Available with a variety of spool, porting, and spring

options.
- Sizes: 10, 16, 20
- Pressure Ratings to 3000 psi

DIRECTIONAL CONTROL VALVES
HIGH FLOW SOLENOID VALVE CIRCUIT
CP72X-5 Directional Control Valve Circuit:
- Creates a high-flow 4 way / 3 position

directional control valve w/motor spool (up
to 70 gpm).
- Pilot-operated with small solenoid cartridge

valve for low electrical power requirement.
CP72X-5
- Provides compact and low-cost alternative
to on-off D03, D05, or PVG valve.
DIFFERENTIAL SENSING VALVES
• Different spool and porting options can be used as “logic

valves” in conjunction with other valves to provide:
- Restrictive-type pressure compensation for external fixed or variable
orifices.
- Priority-type pressure compensation for external fixed or variable orifices.
- High flow pressure relief or reducing valve functions.
- Pilot-to-close directional valves.
• Available with a variety of spool, porting, and spring options.

- Sizes: 10, 12, 16
PRESSURE COMPENSATION CIRCUIT
CP30X-4 Differential Sensing Valve:
- Use with fixed orifice, manually variable

orifice (needle valve), or electrically
variable orifice (proportional valve) to
provide restrictive-type pressure
compensation.
CP30X-4
PRESSURE COMPENSATION CIRCUIT
Steering Cylinder (priority)
- Use with fixed orifice, manually variable

orifice (needle valve), or electrically
variable orifice (proportional valve) to
provide priority-type pressure
compensation.
CP31X-4
PUMP UNLOADING CIRCUIT
Closed-center system:
- All flow dumps at 3000 psi when

no function is operating.
- Excess flow dumps at 3000 psi

when any function is operating.
PUMP UNLOADING CIRCUIT
Closed-center system with 70X-1
Differential Sensing Valve:
- All flow dumps at 150 psi when

no function is operating.
- Excess flow dumps at 150 psi

above load pressure when any
function is operating.
- Always use bleed orifice or flow

control with tandem or closed-
center spools.
CP70X-1
HIGH FLOW RELIEF VALVE
- Use with small relief valve to create high

flow (50 gpm) cartridge pressure relief
valve.
CP70X-2
HIGH FLOW PRESSURE REDUCING VALVE
Full Pressure Function Reduced Pressure Function
- Use with small relief valve to create high

flow (50 gpm) cartridge pressure
reducing valve.
CP70X-3
2-WAY SOLENOID POPPET VALVES
• Used as 2W / 2P on-off directional control valves.
• Poppet-style provides high flow and low leakage.
• Available in normally-open and normally closed versions

with free-reverse flow available as an option.
- Sizes: 8, 10, 12, 16, 20

2-WAY SOLENOID POPPET VALVES
CP50X-X Solenoid Poppet Valves:
- Typical application is load-holding and

directional control for lowering. CP50X-X
2-WAY 2-POSITION SOLENOID SPOOL VALVES
• Available in normally open and normally closed versions.
- Sizes: 8, 10

2-SPEED CIRCUIT
CP51X-X Solenoid Poppet Valves:
- One application is control of two-speed

motors.
CP51X-X
• Available with a variety of porting and flow direction

options.
- Sizes: 8, 10, 12

CLUTCH ENGAGEMENT CIRCUIT
Fwd. Clutch Rev. Clutch
CP52X-X Solenoid Spool Valves:
- Typical applications are directional

controls for single acting cylinders,
clutches, or brakes; pilot valves for large
directional spools; or selector valves for
different circuit functions.
CP52X-X
DIRECTIONAL CONTROL CIRCUIT
CP521-1 Solenoid Valve Circuit:
- Use CP521-1 (size 12) as shown to create

high flow 4 way / 3 position motor spool
solenoid valve (up to 16 gpm).
- Provides compact and low-cost alternative

to D03, D05, or on-off PVG valves.
CP521-1
• Available with normally-open, normally closed, reversing,

and single-acting spools.
- Sizes: 8, 10, 12

CP53X-X Solenoid Spool Valves:
- Typically used as directional controls for

motors or cylinders.
CP53X-X
• Available with normally-open, normally closed, motor, and

tandem spools.
- Sizes: 8, 10

SUBPLATE-MOUNT DIRECTIONAL VALVES
• 4W / 2P and 4W / 3P on-off directional control valves.
• Use industry standard D03 and D05 subplate mounting patterns and
can be bolted to custom HIC’s for high flow applications.
- D03 Flow Rating: to 8 gpm
- D05 Flow Rating: to 25 gpm
- Pressure Rating: to 4,641 psi

SUBPLATE MOUNT DIRECTIONAL VALVES
CP53X-3P and D03 Solenoid Spool Valves:
- Typically used as on-off directional controls

for motors or cylinders, or to pilot directional
control valve spools.
CP53X-3P
PROPORTIONAL FLOW CONTROL VALVES
• Normally-closed non-compensated electrically

variable flow control valves.
• Used with differential sensing valves to create

restrictive-type or priority-type pressure
compensated proportional flow control valves.
- Sizes: 8, 10, 12

PROPORTIONAL FLOW CONTROL VALVES
• Different spool & sleeve

options can be used for
different flow rates and
customized flow vs. current
curves.
• Computer-controlled test
stand tests valve against
specification and records
data for future reference.
PROPORTIONAL RELIEF VALVES
• Controls relief pressure as a function of electric

current.
• Spool options available for different pressure vs.

current curves.
• Often used to pilot differential sensing valves for high

flow applications.
- Size: 8
- Flow Rating: to 0.5 gpm
- Pressure Rating: to 3000 psi

PROPORTIONAL RELIEF VALVES
MOTOR SPEED CONTROL CIRCUIT
CP70X-2
CP558-20 Motor Speed Control Circuit:
- CP558-20 used as shown with CP70X-2

creates a high flow (up to 50 gpm),
normally-open proportional relief valve.
CP558-20
PROPORTIONAL PRESS. REDUCING VALVES
• Controls reduced pressure as a

function of electric current.
• Spool options available for different

pressure vs. current curves.
• Often used to pilot differential

sensing valves for high flow
applications.
TANK
- Size: 8
INLET
- Flow Rating: 0.5 gpm
REG. PRESSURE
- Pressure Rating: to 300 psi
PROPORTIONAL DIRECTIONAL VALVE CIRCUIT
CP558-23 Pilot Valve Circuit:
- CP558-23 used as shown with large spool

(e.g. stack valve) creates a high flow
proportional directional valve.
CP558-23
PROPORTIONAL DIRECTIONAL VALVE CIRCUIT
CP558-23 Pilot Valve Circuit:
- Use CP124-1 Shuttle Valve and

CP124-1
CP702-4 Differential Sensing Valve
to add pressure compensation to
high flow proportional directional
valve.
- Provides compact and low-cost

alternative to proportional D03, D05,
or PVG valves. CP558-23
CP702-4
PROPORTIONAL DIRECTIONAL VALVES
• Used as proportional directional control valves.
• Available with normally-closed and motor spools.
• Uses industry standard D03 mounting pattern and can be bolted to

custom HIC’s for high flow applications.
- Flow Rating: to 8 gpm
- Pressure Rating: 4,641 psi

PROPORTIONAL DIRECTIONAL VALVES
ALL WHEEL STEER CIRCUIT
D03 Proportional Directional Valves:
- Typically used with or without pressure compensation for proportional speed control of
cylinder or motor functions.
Left Front Right Front Left Rear Right Rear

Proportional Directional
Valves used for electronic all-
wheel-steering with crab-
steer available:
PROPORTIONAL VALVE CONTROLLER
• A Sauer-Danfoss standard
micro-controllers is available to
drive proportional cartridge
valves.
• MC-200 micro-controller:
- Full-featured dual output driver.
- “On the fly” choice of two input
characterization curves.
- Independent acceleration and
deceleration rates.
- Adjustable PWM frequencies from 80
to 200 Hz.
D08 & D10 SOLENOID COILS
• Power: 16 Watts
• Temperature Rating: Continuous duty at 140°F
• Environmental Rating: IP65
• Voltages:
- DC: 6, 10*, 12*, 20*, 24*, 36, 48, 72
- AC: 120, 240
• Connectors:
- Integrally molded Deutsch (DT), Amp Jr. Timer, and
Metripak 150 (shown)
- DIN
- Lead Wires
- Dual Spade
- Single and Dual Post
• Integral diodes available
* Standard voltages
D12 & D14 SOLENOID COILS
• Power: 30 Watts
• Temperature Rating: Continuous duty at 140°F
• Environmental Rating: IP65
• Voltages:
- DC: 10*, 12*, 20*, 24*, 36, 48
- AC: 120, 240
• Connectors:
- DIN
- Lead Wires
- Dual Spade (shown)
• Integral diodes available
* Standard voltages
CURRENT PROJECTS
• Rationalize North American Product Lines (Fluid Controls / Compact

Controls):
- Eliminate overlap.
- Increase economies of scale.
- Lower manufacturing costs.
• Integrate Global Product Line (Fluid Controls / Compact Controls /

Comatrol):
- Combine technologies so that global product offering is “best of the best”.
- Use European valves to fill gaps in North American product line and vice versa.
CURRENT PROJECTS
Pump/Valve Integration
- Pilot-operated proportional relief valve

integrated into gear pump or motor.
- Provides one part and compact

package for motor speed control.
- Proposed for AP1055 fan drive

system.
CURRENT PROJECTS
Environmentally-Sealed Coil
- New design to meet IP-69 and major

OEM environmental ratings.
- Will offer additional connection

options.
- “D14” coil currently being tested;

expected in production by fall 2002.
- “D10” and “D08” coils to follow.

HYDRAULIC
INTEGRATED
CIRCUITS
HYDRAULIC INTEGRATED CIRCUITS
• HIC is an acronym for Hydraulic

Integrated Circuit.
• HIC’s are compact packages with

reduced plumbing, easier
installation, easier service, and
fewer leak points than traditional
hydraulic systems.
• Custom HIC’s can be cost effective

in any volume by using standard
valves and cavities, standard
manifold materials and sizes, and
standard porting.
CUSTOM HIC PROJECTS
1. Identify opportunity.
2. Define circuit to meet customer requirements and select
components.
3. Compile all necessary detail information (manifold material, coil
voltage and connector, port sizes, etc.) – use HIC data sheet.
4. Submit request for quotation through account manager.
5. Design created and outline drawing supplied for approval after
receipt of prototype order – lead time 1 week.
6. Prototype manifold supplied after approval of design – lead time 2
weeks.
Sauer-Danfoss account managers and applications engineers

available to assist with all of the above steps!!!
HIC PROJECT DATA SHEET
CIRCUIT DESIGN
• Sauer-Danfoss Account
Managers, Systems Engineers,
and Applications Engineers are
all available to provide circuit
design and component selection
expertise.
• Hillsboro and Easley Product
Engineers are available for
consultation.
• Hillsboro and Ames test and
analysis resources are available
for up-front system evaluation so
we “do it right the first time”.
PRODUCT DEVELOPMENT
• Manifold design is done with Inventor or

AutoCad 2000 solid modeling.
• Fast lead times for product development:
- One week lead time for manifold design (after
circuit approval).
- Two week lead time for prototype manifold (after
design approval).
• Value-added options available:

- Fittings supply and installation.
- Electrical wire harness design and installation for
one-point “bulkhead” connection.
- Brand labeling
TYPICAL APPROVAL DRAWING
WHO TO CALL
1. Price & Availability – Hillsboro Customer Service

• Brian Munks 503-207-7213
• Susan Urbanski 503-207-7292
• Nancy McBeth 503-207-7214
2. Warranty & Returns – Hillsboro RGA Administrator
• Susan Urbanski 503-207-7292
3. Special Pricing & Commercial Issues – S-D Account Mgr.
4. Technical Issues – Applications Engineering
• Bruce Gunzenhauser 515-239-6312
or customer-assigned application engineer:
• Stan Crull 515-239-6590 (northwest region)
• Jason Keck 515-239-6589 (east region)
• Wenling Li 515-239-6635 (southwest region)
• Misty Metschke 515-239-6500 (south region)
• Stew Scott 515-239-6558 (north central region)
CARTRIDGE VALVE AND HIC PRODUCTS
May 7, 2002

2002-05-07 Cartridge Valve RAP Training

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2002-05-07 Cartridge Valve RAP Training

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CARTRIDGE VALVE AND HIC PRODUCTS

Hillsboro, Oregon Nordborg, Denmark

Easley, South Carolina Reggio Emilia, Italy

1947 Fluid Controls introduces cartridge

• Hillsboro & Easley combined engineering resources:

• Solid model design capability:

• Engineering Data Management System (EDMS) used to share

• Performance test stand for 100

• Fatigue and burst test

• Computerized data acquisition

• Cellular Assembly Approach:

- Cartridges 100% tested on

- Ensures leak-free poppet/seat sealing.

- 4 Hardinge Conquest and 1 American

- Poppet/seats matched and 100%

• In-House CNC milling

• Experience with many manifold

• In-house automated thermal

• 3 HIC assembly cells with

• Utilize advanced quality planning tools as part of normal product

- Failure Modes and Effects Analysis (FMEA)

- Process Failure Mode and Effects Analysis (PFMEA)

- Statistical Process Control (SPC)

• Supplier audit system is used to build alliances with critical suppliers.

• All plants are ISO 9001 registered.

• Sauer-Danfoss goal is 250 dpm as measured on the customer’s

• Cartridge valves are compact, low-cost, no-leak, screw-in

• All valves have a model code in this format:

• Cavity – Each valve fits a Sauer-Danfoss standard cavity.

• Valves use industry-standard

• Used to hold loads, separate systems, provide load-sensing “logic”, or

- Sizes: 4, 8, 10, 12, 16, 20

- Drop-in check valves available.

- In-line check valves available.

- Flow Ratings: to 100 gpm OUT

- Pressure Ratings: to 5000 psi IN

• Shuttle valves connect the higher

• Used for load-sense logic, IN

- Flow Ratings: to 5 gpm

• Shuttle valves connect the lower

• Used for filtering and/or cooling

- Flow Ratings: to 50 gpm OUT

- Pressure Ratings: to 5000 psi

• Relief valves limit system pressure.

• Pilot operated relief valves provide flatter

- Flow Ratings: to 50 gpm

• Direct-acting designs are lower cost, faster-acting,

- Pressure Rating: 3000 psi INLET

• Pilot operated designs provide more accurate

- Flow Rating: 10 gpm

- Pressure Rating: 5000 psi IN

• Sequence valves ensure that one operation is

- Ordered sequence of operations, e.g. clamp then lift.

• Available with a variety of spool, porting, spring

CP240-1 Sequence Valve ensures

CP240-22 Kick-Down Sequence

CP240-30 Unloading-Type Sequence

• Pressure compensated flow control valves

• Restrictive-type flow controls can be used to

- Pressure Ratings: to 3000 psi

3000 1600 1400 1800

• Pressure compensated flow control valves

CP310-1 Priority-Type, Pressure-

• Flow divider/combiner valves provide pressure