Aventics CONTROLAIR H-4 Instructions d'utilisation et d'installation

H-4 CONTROLAIR® VALVE

Service Information

SM-800.6516

The user of these devices must conform to all applicable

electrical, mechanical, piping and other codes in the

installation, operation or repair of these devices.

INSTALLATION! Do not attempt to install, operate or

repair these devices without proper training in the

technique of working on pneumatic or hydraulic systems

and devices, unless under trained supervision.

Compressed air and hydraulic systems contain high

levels of stored energy. Do not attempt to connect,

disconnect or repair these products when a system is

under pressure. Always exhaust or drain the pressure

from a system before performing any service work.

Failure to do so can result in serious personal injury.

MOUNTING! Devices should be mounted and

positioned in such a manner that they cannot be

accidentally operated.

WARNING: INSTALLATION AND

MOUNTING

DESCRIPTION OF MODELS

The H-4 Type CONTROLAIR Valves are knob

operated 3-way pressure graduating valves. The knob

actuates the pressure graduating portion to increase,

decrease or maintain graduated air pressure to a

separate delivery line.

In knob “release” position the delivery line is connected

to exhaust. Knob rotation from release position

actuates the graduating portion to deliver graduated

pressure to a delivery line according to the value of

control spring being used. The knob is self holding in

all positions.

The H-4 CONTROLAIR Valve is available with either

clockwise rotation or counterclockwise rotation of the

knob increasing pressure.

Table of Contents Page

Description of Models .................................. 1

Technical Data .............................................. 2

Installation ..................................................... 2

Maintenance and Repair ............................... 2

Outline Dimensions ....................................... 3

Description of Operation................................ 4

Symbol .......................................................... 4

Diagrammatic View ....................................... 4

Identity Schedule ........................................... 5

Exploded Views ............................................. 6

Parts List ....................................................... 7

Repair Kit List ................................................ 8

Maintenance and Repair ............................... 9

Testing:

Function ................................................. 10

Pressure Range ..................................... 10

Leakage ................................................. 10

Flow Capacity ........................................ 10

Response ............................................... 10

Test Set-up ............................................ 10

Test Diagram ................................................. 11

Warnings and Warranties .............................. 12

Installation and General Maintenance Recommendations

Installation

Before installing the Controlair® Valve, all air lines in

the system should be blown clean to remove any

moisture, dirt, or harmful contamination. Strainers are

furnished in the Inlet and Outlet ports to protect the

valve from large particles of foreign matter in the line.

To further ensure long, trouble-free service, a 10

Micron or better filter should be installed in the supply

line to the valve.

The H-4 type Controlair is designed for either side or

panel mounting, and may be mounted in any position

convenient for operation. Refer to installation view,

page 3, for panel thickness and opening dimensions.

Allow suitable clearance for removal of the pipe

bracket screws which are 1 ¾” (44 mm) long.

General Maintenance

Maintenance periods should be scheduled in

accordance with frequency of use and working

environment of the Controlair Valve. All valves must

be visually inspected for wear and given an “in

system” operating performance and leakage test at

least once a year. If these visual observations

indicate valve repair is required, the valve must be

removed, repaired and tested.

A major overhaul is recommended at one million

cycles. However, where frequency of use is such that

it would require more than two years to obtain one

million cycles, the valve must be overhauled at the

two-year period.

When it is determined that the Controlair Valve

requires a major repair as a result of the one million

cycles, one year routing inspection, or the two year

service period has elapsed, the device must be

disassembled, cleaned, inspected, parts replaced as

required, rebuilt and tested for leakage, and proper

operation prior to installation. Refer to MAJOR

REPAIR AND MAINTENANCE INSTRUCTION, page

9, and TEST PROCEDURES, page 10.

One complete Controlair Valve should be kept in

stock for each four valves in service. During the

maintenance period, replace the complete valve with

the “stand-by” unit. This will reduce production time

loss and afford inspection and replacement of worn

parts at a more appropriate or opportune time and

favorable location.

Notice that the operating portion of a valve can be

removed without disturbing the pipe connections.

Remove the valve from the pipe bracket by loosening

(2) screws and lift the unit free.

No special tools are required to maintain the

Controlair Valve.

Technical Data

Maximum Operating Pressure.... 200 psi (13.8 Bar)

Admissible Medium .................... Air, clean and dry

Operating Temperature .............. -40°F to +160°F

(-40°C to 71°C)

Hysteresis .................................. 1 ½ PSI (.10 Bar)

Control Pressure Range ............. (Ref. Identity Chart, Pg 5)

Pressure Change ....................... ½ PSI Increment

(.03 Bar)

Mounting .................................... Flange Plate

Port Size .................................... ¼ - 18 NPTF

Materials

Controlair Valve

Housing and Body .................. Die Cast Aluminum

Knob ....................................... Plastic

Stop and Cam Dog ................. Sintered Steel

Internal Parts .......................... Brass, Rubber (Buna-N),

Steel

Weight ........................................ 5.5 lbs (3 kg)

approximately

Page 2

OUTLINE DIMENSIONS

Clockwise rotation of the

knob increases pressure

unless otherwise specified.

240 ° max. effective knob

rotation. (Adjustable)

Page 3

DESCRIPTION OF OPERATION

Description of Operation

When the knob is in released position, the “IN” port is

closed to supply pressure and “OUT” port is open to

exhaust.

Note in the diagrammatic, when the knob is rotated to

increase pressure, the shaft and cam are also rotated. The

rotation of the knob allows the cam to push down the

pressure control plunger, closing the lower exhaust valve

and opening the upper supply valve which permits air flow

to out port delivery and the upper diaphragm chamber. As

the pressure builds up in the delivery line it acts through

the sensing port orifice and deflects the control diaphragm

downward, compressing the control spring. When sufficient

diaphragm deflection is reached to allow the upper supply

valve in the pressure control portion to close, the pressure

in the delivery line is held to that valve. The valve of the

pressure delivered to the outlet port is proportional to the

pressure control plunger movement. This movement in turn

is controlled by the cam contour and is therefore

proportional to the knob travel.

The Controlair Valve will automatically compensate for

downstream air pressure changes in the graduated

pressure delivery line. These air pressure changes can be

caused by line leakage, temperature change or load

feedback. If air pressure at the outlet port increases over

that called for by handle position, the diaphragm in the

control portion will deflect downward opening the lower

exhaust valve and exhausting air until the original setting is

obtained. If the pressure drops below that called for by the

handle position, the decreased force on the diaphragm will

allow the control spring to force the diaphragm upward,

opening the upper supply valve to restore the set pressure.

The range of pressure is controlled by the strength of the

diaphragm spring. Various values are available as shown

on Identity Schedule, page 5.

The H-4 Controlair is factory set to provide normal 240

degree rotation of the control knob. However, the 240-

degree rotation can be reduced by changing the

relationship of the stop with the cam brake.

Outlet

VALVE

FUNCTION

Exhaust

Inlet

DIAGRAMMATIC VIEW

Exhaust Port Adjusting Screw

Range Control

Spring

Diaphragm

Exhaust Valve

Supply Valve

Inlet & Exhaust

Valve Unit

Page 4

IDENTITY SCHEDULE

* Control portion less pipe bracket with operator portion and mounting screws. (See pages 6 & 7 for item numbers and parts

description).

**Same as R431002822 (P -050967-00008) except diaphragm unit complete is R431003715 (P -055409-00002); items 10,

13, 14 and 18 are part numbers R431000486 (P -005102-00000), R431003711 (P -055406-00000), R431001923 (P -

049623-00113), and R431000489 (P -005103-00000) respectively (low temperature operation to -65°F or -54°C).

New H-4

Complete

Part

Number

Old H-4

Complete

Part

Number

Delivery

Pressure

New Valve

Portion

Part

Number

Old Valve

Portion

Part

Number

New Control

Spring

Part

Number

Old Control

Spring

Part Number &

Color Code

Remarks

R431002818

P -050967

-00001

0-65 psi R431002874 P -051133

-00001

R431003732 P -055442-00000

Brown

Clockwise knob rotation

increases pressure

R431002819

P -050967

-00002

0-100 psi R431002875 P -051133

-00002

R431000043 -526749-0000

Yellow

Clockwise knob rotation

increases pressure

R431002820

P -050967

-00003

0-125 psi R431002876 P -051133

-00003

R431000099 -540577-0000

Lt. Blue

Clockwise knob rotation

increases pressure

R431002821

P -050967

-00004

0-150 psi R431002877 P -051133

-00004

R431003731 P -055441-00000

Red

Clockwise knob rotation

Increases pressure

OBSOLETE

P -050967

-00006

0-20 psi OBSOLETE R431005473 P -060293-00000

White

Clockwise knob rotation

Increases pressure

R431002822

P -050967

-00008

0 -30 psi R431002878 P -051133

-00008

R431005475 P -060295-00000

Dk. Blue

Clockwise knob rotation

Increases pressure

OBSOLETE

P -050967

-00015

0-175 psi R431002879 P -051133

-00015

R431003311 P -054159-0000

Silver

Clockwise knob rotation

increases pressure

OBSOLETE

P -050967

-00016

0-55 psi P -051133

-00016

R431006501 P -064822-0000

Plain

Clockwise knob rotation

increases pressure

P -052742

-00008

0-30 psi P -057182

-00008

R431005475 P -060295-0000

Dk. Blue

Clockwise knob rotation

increases pressure

R431002885

P -051173

-00001

0-65 psi R431002874 P -051133

-00001

R431003732 P -055442-00000

Brown

Counterclockwise knob

pressure

rotation increases

R431002886

P -051173

-00002

0-100 psi R431002875 P -051133

-00002

R431000043 -526749-00000

Yellow

Counterclockwise knob

pressure

increases pressure

R431002037

P -051173

-00003

0-125 psi R431002876 P -051133

-00003

R431000099 -540577-00000

Lt. Blue

Counterclockwise knob

pressure

increases presssure

Page 5

EXPLODED VIEW

Note:

1. See page 5 & 7 for part

number

2. See page 8 for repair kits

3. Matched/lapped set of item

13 & 8 are in kit, P/N

R431003895

(

R431003895), page 8

33C

33A

33B

See Identity Schedule

Valve Control Portion Complete

(See Identity Schedule, Page 5)

2 4

8 (Note 3)

13 (Note 3)

6 7

Page 6

PARTS LIST

NOTE: Parts List Items 1 through 21—Control Portion

Parts List Items 22 through 33—Pipe Bracket With Operator Portion

* Kits listed on page 8.

31 2 3/8” – 16 X 1 ¾” Cap screws R431000161 -850563-00000

32 1 Pipe bracket complete R431004173 P -057557-00000

33 1 Knob assembly incl. 33a, 33b, 33c, * SEE KITS * SEE KITS

33a 1 Knob, adjustment * SEE KITS * SEE KITS

33b 2 Set screw, ¼ - 20 X ½ * SEE KITS * SEE KITS

33c 1 Position plate * SEE KITS * SEE KITS

30 1 ¼” – 20 X ½” Screw R431001873 P49592-0004

29 1 Adjustable stop * SEE KITS * SEE KITS

27 2 1/8” X ½” Key R431002108 P -049767-00002

28 1 Brake * SEE KITS * SEE KITS

26a 1 Cam (counterclockwise) R431000095 -539406-00000

26 1 Cam (clockwise) * SEE KITS * SEE KITS

24 1 Spring * SEE KITS * SEE KITS

25 1 Shaft R431003713 -055407-00000

23 1 Spring seat, washer R431002466 P -049904-00053

22 1 ¼” – 20 X ¾” Screw R431002085 P -049728-00011

20 2 Retaining ring, ¼ R431001844 P -049528-00001

21 1 Cam dog R431003014 P -052835-00000

19 1 Pin, pivot R431001563 P -048189-00000

18 2 Gasket * SEE KITS * SEE KITS

17 2 Strainers * SEE KITS * SEE KITS

16 1 Boot, dirt protector * SEE KITS * SEE KITS

15 1 Exhaust valve spring * SEE KITS * SEE KITS

14 2 ¾” O.D. “O” ring * SEE KITS * SEE KITS

13 1 Inlet and exhaust valve * SEE KITS * SEE KITS

12 1 5/16” – 18 Hex nut * SEE KITS * SEE KITS

11 1 Diaphragm follower * SEE KITS * SEE KITS

10 1 Diaphragm * SEE KITS * SEE KITS

8 1 Exhaust valve seat * SEE KITS * SEE KITS

9 1 11/16” O.D. “O” ring * SEE KITS * SEE KITS

5 1 Control Spring (See identity schedule, Pg. 4) (See identity schedule, Pg. 4)

6 1 Body with 2 studs R431000045 -526874-00000

7 2 5/16” – 18 X 1 3/8” Cap screws R431000160 -850557-00000

1 Diaphragm Unit incl. 8, 9, 10, 11, 12 * SEE KITS * SEE KITS

4 1 Spring set R431000036 -526347-00000

3 4 Nuts, 5/16” – 18 R431002419 P -049901-00020

1 1 Adjusting screw R431006770 P -066209-00000

2 1 Spring housing with nut R431006822 P -066488-00002

Ref. Qty Description New Part Number Old Part Number

Page 7

REPAIR KITS

Old Part Num-

ber

Quantity

Per

Valve

Description

P -055687-K0000* 1 Minor Graduating Valve Portion – repair kit (includes

items 8,9,10,11,12,13, 14) see note

P -059028-K0000 1 Major Graduating Valve Portion – repair kit (includes

items 15,16,17,18 and kit R431003895)

P -064421-K0000 1 Knob Kit (includes items 33a, 33b,33c)

P -064421-00006 1 Operator Kit for clockwise*

(includes items 24,26,28,29 and kit R431000132)

New Part

Number

R431003895

R431004887

R431006425

R431006420

R431006421 P -064221-00007 1 Handle operator for H-4

Notes:

1. *The inlet and exhaust valve unit item 13 and exhaust valve seat item 8 are lapped

together to form a matched set. Kit contains these items factory matched.

2. Select replacement range control spring from identity schedule page 5.

3. All repair kits above include small tubes of recommended lubricant.

4. Valve portion kits listed above contain seals and other parts that are recommended for

repair of valve portion only.

5. On severely worn or damaged components, additional parts my be required especially in

the mechanical operating portions of the valve. Select as required from parts list on pages

6 and 7.

* For counterclockwise, order this kit plus cam part no. R431000095

Page 8

Page 9

Repair and Maintenance Instructions

When it has been determined that the Controlair®

Valve requires repairs, the following general

instructions are recommended.

Disassembly, Cleaning and Lubrication

Completely disassemble the Controlair valve. Wash

all metal parts in a non-flammable solvent. Rinse

each part thoroughly and blow dry with low

pressure air.

Inspect and clean the inlet filter Item #17 and both

gaskets Item #18. Be sure all passages in the body

and pipe bracket and sensing port orifice in top of

the diaphragm chamber are clean and unrestricted.

Examine all parts carefully. Replace all rubber parts

and all worn or damaged parts. The use of repair

kits is recommended.

Reassemble

Refer to exploded Parts and Assembly Views.

Valves should always be reassembled using new

rubber parts.

Lubricate all metal to metal wear surfaces with

Lubriplate 107 Grease. Lubricate all the rubber

parts, except the diaphragm with Dow Corning

No. 55 Pneumatic Grease.

The exhaust valve and seat if not replaced should

be polished for minimum leakage using a 600 grit

lapping compound. Be sure to clean these parts

prior to installing in the valve.

Installing the knob (Item #33a), seat the knob on

the shaft, Item #25 before installing the set screw,

Item #33b.

Do not over torque the set screw.

Adjustments

There is one adjustment that can be made to the H-

4 Controlair Valves. This is the adjusting screw item

#1, that varies the output pressure.

Graduated Output Pressure Adjustments

Adjusting screw Item #1 varies the maximum

pressure setting. Turning the adjusting screw “in”

raises the maximum pressure. Turning the screw

“out” decreases the maximum pressure. The

maximum control pressure adjustment should not

exceed the maximum control pressure shown in the

Identity Schedule for that part number. (Control

Springs are color coded).

The maximum output pressure rating can be

changed by changing the control spring Item #5.

With air supplied to the valve, move handle from

start to full travel position. Adjust graduating valve

screw Item #1 to obtain the maximum control

pressure per Identity schedule. Move handle back

to neutral position and note delivery line is

exhausted to zero.

Special Preload Setting

This setting calls for a predetermined delivery

pressure.

Page 10

Testing and Test Set-Up (See Test Arrangement Diagram)

Valve

Range Fill Psi

Max.

Time-

Sec

Exhaust

Psi

Max.

Time

Test

Vol.

0 to15

psi

0 to 15

psi 2 sec 15 to 5

psi 2 sec. 450

cu.in.

0 to20

psi

0 to 15

psi 2 sec 15 to 5

psi 2 sec. 450

cu.in.

0 to25

psi

0 to 15

psi 2 sec 15 to 5

psi 2 sec. 450

cu.in.

0 to30

psi

0 to 15

psi 2 sec 15 to 5

psi 2 sec. 450

cu.in.

0 to 35

psi

0 to 15

psi 2 sec 15 to 5

psi 2 sec. 450

cu.in.

0 to 65

psi

0 to 50

psi 2 sec. 50 to 10

psi 2 sec. 225

cu. In.

0 to

100 psi

0 to 50

psi 2 sec. 50 to 10

psi 2 sec. 225

cu. In.

0 to

125 psi

0 to 50

psi 2 sec. 50 to 10

psi 2 sec. 225

cu. In.

0 to

150 psi

0 to 50

psi 2 sec. 50 to 10

psi 2 sec. 225

cu. In.

0 to 65

psi

0 to 15

psi 2 sec. 50 to 10

psi 2 sec. 225

cu. In.

35 to

85 psi

35 to

70 psi 2 sec, 70 to 40

psi 2 sec. 225

cu. In.

Flow Capacity Tests- Ports 1 & 3

Test Ranges & Times

Testing

After any repair or adjustments, the H-4 Controlair®

Valve should be tested using the following procedures

and test arrangements described in this section.

Pressure control valves need to be tested for the

following:

1. Function 4. Flow Capacity

2. Pressure Range 5. Response

3. Leakage 6. Mechanical Detents

The adjustments affecting these points were described

in the previous sections.

General instructions for accomplishing these tests are

listed below.

1. Function: The H-4 Controlair Valves are rotary

actuated 3-way pressure graduating valves.

Rotating the knob actuates the valve to increase,

decrease or maintain graduated air pressure to the

“OUT” port or delivery line.

2. Pressure Range: Supply pressure at “IN” port will

be delivered as graduated pressure to the “OUT” or

delivery port depending upon the range of the

control spring being used and the handle position.

The handle in the “OFF” or returned position the

“OUT” or delivery port is at minimum pressure

setting. Moving the handle actuates the graduating

control portion to deliver graduated

pressure to the “OUT” or delivery port. Check the

valve to confirm the Minimum Pressure of 30 psi

(2 Bar) and Maximum pressure of 70 psi (4.9

Bar).

3. Leakage: Set supply pressure to 20 psi (1.4 Bar)

above maximum delivery pressure of the valve

being tested. Using soap and water solution, coat

the valve at the pipe bracket and spring housing

parting lines. No leakage is permitted in any handle

position.

A. Port (IN)

1. On all valves with spring ranges less than 90

psi (6.2 bar), set supply line pressure to 100 psi

(6.9 bar). Move handle to full travel position

and hold (detent position on detented valves).

Close valve in supply line to “IN” port or

delivery line to isolate graduating valve.

Observe delivery pressure gage in line. A

pressure drop of no more than 2 psi (0.14 bar)

in 30 seconds is permitted.

4. Flow Capacity: Set supply line pressure to 100 psi

(6.9 bar) regardless of the control spring rating.

Moving the handle from “OFF” position to the full

travel position, the delivery volumes should start to

fill within the time limits shown in Table 1.

Move the handle quickly from full travel position to

back to “OFF” position. This should exhaust

volumes within the time limits shown on table 1.

Note: valves with less than 0 to 35 psi (2.4 bar) or

less rated springs require an additional volume as

shown in test arrangement diagram.

5. Response: Rotate the knob to full travel position

and hold. Fully open the valve at test volume so

that that the air exhausts through the choke plug.

Observe the delivery pressure gage at volume (1).

A pressure drop of no more than 3 psi (0.2 Bar) is

permitted.

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