H-1 & H-1-A CONTROLAIR VALVE

SM-800.6501

H-1 & H-1-A CONTROLAIR® VALVE Service Information

DESCRIPTION OF MODELS

The H-1 and H-1-A Type CONTROLAIR Valves are spring returned pedal actuated 3-way pressure graduating valves. A pedal actuates the valve to increase, decrease or maintain graduated air pressure to a separate delivery line. In pedal release position, the delivery line is connected to exhaust. Depressing the pedal actuates the graduating portion to deliver graduated pressure to a delivery line according to the value of control spring being used. MODELS H-1 CONTROLAIR Valve: The H-1 CONTROLAIR Valve is a pedal actuated, 3-way pressure regulating valve, suitable for applications where the valve portion extends below the floor level. Depressing the pedal increases the outlet delivery pressure, releasing the pedal decreases the delivery pressure. The pedal is self-returning from all depressed positions. H-1 CONTROLAIR Valve (light pedal force): This version of the H-1 operates identically to the standard H-1, but has a considerably lighter pedal force that makes it especially suited for throttle controls. This model also offers an alternative piping arrangement as the valve portion from the H-2 Valve version is utilized. A formed steel pedal with a rubber tread is utilized on this model. H-1-A CONTROLAIR Valve: the H-1-A CONTROLAIR Valve is a pedal actuated 3-way pressure regulating valve that is designed for installations in which its operator is standing or in which part of the valve cannot extend below floor levels. Depressing its pedal increases the outlet delivery pressure. Releasing the pedal decreases the outlet delivery pressure. The pedal is self-returning.

Table of Contents Page

Description of Models ................................... 1 Technical Data ............................................... 2 Installation ...................................................... 2 Maintenance and Repair ................................ 2 Outline Dimensions (H-1) ............................... 3 Outline View ................................................... 4-5 Description of Operation ................................ 6 Symbol ........................................................... 6 Diagrammatic View ........................................ 6 Identity Schedule ........................................... 7 Exploded Views ............................................. 8 Parts List ........................................................ 9 Repair Kit List ................................................ 10-11 Maintenance and Repair Instructions ............. 12-13 Adjustment and Repair Instructions ............... 12-13 Testing: Function .................................................. 14 Pressure Range ...................................... 14 Leakage .................................................. 14 Flow Capacity ......................................... 14 Response................................................ 14 Test Set-up ............................................. 14 Test Diagram ................................................. 15 Warnings and Warranties .............................. 16

H-1 CONTROLAIR VALVE

H-1-A CONTROLAIR VALVE

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.

WARNING: INSTALLATION AND MOUNTING

MOUNTING! Devices should be mounted and positioned in such a manner that they cannot be accidentally operated.

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 forgoing 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. All Controlair Valves utilize a pipe bracket. Piping connections made to the pipe bracket need not be disturbed when removing the operator portion for maintenance. The H-1 Controlair Valves are designed for floor mounting; the complete assembly is installed and removed from the top of the floor. The valve extends beneath the floor. Refer to page 3 & 4 for panel opening dimensions. Allow suitable clearance for pipe bracket cap screws which are 1 ¾” long. H-1-A Controlair Valve is mounted directly to a floor platform by two bolts through the lugs in the pipe bracket. The floor, or platform normally serves as a stop for the pedal. Refer to installation view on page 5 for panel opening dimensions. Allow suitable clearance for pipe bracket screws which are 1 ¾” 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 routine 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, pages 12 & 13, and Test Procedures, page 14. 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 four (4) 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 Control Pressure Range ................................. (Reference Identity Chart, Pg 7) Pressure Change ........................................... ½ psi Increment Mounting ........................................................ Flange Plate Port Size ........................................................ ¼ - 18 NPTF Materials Controlair Valve Housing and Body ............ Die Cast Aluminum Internal Parts .............................................. Brass, Rubber (buna-N), Aluminum,

Steel, Plastic and Hytrel Inlet Valve Assemblies

Weight ............................................................ 9 lbs. (4.1 Kg.) approximately

H-1 CONTROLAIR® VALVES OUTLINE DIMENSIONS

H-1 CONTROLAIR® VALVE LIGHT PEDAL FORCE

OUTLINE VIEW

H-1-A CONTROLAIR® VALVES OUTLINE VIEW

DESCRIPTION OF OPERATION

Description of Operation When the pedal 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 pedal is depressed downward to increase pressure, the pedal forces the follower to push down the pressure control plunger, closing the lower exhaust valve and opening the upper supply valve, which permits air to 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 obtained to allow the upper supply valve in the pressure control portion to close, the pressure in the delivery line is held to that value. The value 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 pedal 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 pedal 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 pedal 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 7.

*Note: H-1 Controlair Valve shown. Internal parts same on H-1 Controlair valve (light pedal force) and H-1-A Controlair Valve.

DIAGRAMMATIC VIEW

VALVE SYMBOL

H-1 & H-1-A Controlair® Valve

IN OUT

INLET & EXHAUST VALVE UNIT

SUPPLY VALVE

EXHAUST VALVE

* RANGE CONTROL SPRING

EXHAUST PORT ADJUSTING SCREW

DIAPHRAGM

IDENTITY SCHEDULE

*H-1 Control Portion part number is less pipe bracket, pedal operator portion and mounting screws. See pages 8 & 9 for control portions item numbers and parts list. See page 10 for pipe bracket and operator item numbers and parts list. Note 1: Same as H-1 Type R431002613 (P -050208-00001) except light pedal spring R431005474 (P -060294-00000), item 5, page 8 Note 2: Same as H-1 Type R431002614 (P -050208-00002) except light pedal spring R431005474 (P -060294-00000), item 5, page 8 Note 3: With full pressure feature (consult factory for (P -065316-00000) parts). Note 4: With rubber tread (light pedal force). Note 5: Same as H-1 Type R431003063 (P -052971-00001) except less pedal, items 7, 8, and 9, page 10

Model

New Complete

Part Number

Old Complete

Part Number

Control Pressure

Range (PSI)

Control Spring

New Part Number

Control Spring

Old Part Number

Valve Portion

New Number

Valve Portion Old Part Number

H-1 R431002613 P -050208-00001 0-65 psi R431003732 P -055442-00000 R431002874 P -051133-00001

H-1 R431002614 P -050208-00002 0-100 psi R431000043 -526749-00000 R431002875 P -051133-00002

H-1 R431002615 P -050208-00003 0-125 psi R431000099 -540577-00000 R431002876 P -051133-00003

H-1 R431002616 P -050208-00004 0-150 psi R431003731 P -055441-00000 R431002877 P -051133-00004

H-1 R431002617 P -050208-00008 0-30 psi R431005475 P -060295-00000 R431002878 P -051133-00008

H-1 R431002822 P -050967-00008 0-65 psi R431005475 P -060295-00000 R431002878 P -051133-00008

H-1 R431002981 P -052570-00001 0-100 psi R431003732 P -055442-00000 R431002874 P -051133-00001

H-1 R431002982 P -052570-00002 0-65 psi R431000043 -526749-00000 R431002875 P -051133-00002

H-1 P -065292-0000 0-35 psi R431005475 P -060295-00000 P -057182-00008

H-1 R431005617 P -060921-00001 0-65 psi R431003732 P -055442-00000 R431002874 P -051133-00001

H-1 R431005618 P -060921-00002 0-100 psi R431000043 -526749-00000 R431002875 P -051133-00002

H-1 R431005619 P -060921-00003 0-125 psi R431000099 -540577-00000 R431002876 P -051133-00003

H1-A R431003063 P -052971-00001 0-65 psi R431003732 P -055442-00000 R431002850 P -051085-00001

H1-A R431003064 P -052971-00002 0-100 psi R431000043 -526749-00000 R431002851 P -051085-00002

H1-A R431003065 P -052971-00003 0-125 psi R431000099 -540577-00000 R431002852 P -051085-00003

H1-A R431003066 P -052971-00004 0-150 psi R431003731 P -055441-00000 R431002853 P -051085-00004

H1-A Obsolete P -052971-00008 0-30 psi R431005475 P -060295-00000 R431002855 P -051085-00008

H1-A Obsolete P -064701-00001 0-65 psi R431003732 P -055442-00000 R431002850 P -051075-00001

Remarks

Note 1

Note 2

Note 3

Note 4

Note 4

Note 4

Note 5

See Identity Schedule

NOTE: 1. See page 9 & 10 for part numbers 2. See page 11 for repair kits 3. Match/lapped set of items 8, 11 &

13 are in kit, p/n R431003895

H-1, H-1-A

Part No. R431002608 (P -050138-00000) Spring Housing Complete (Includes No 1 and 2)

1

2

3

4

5

12

11

10

8

9

15

14

14

13

7a 6a

17

18

6

16

22

7

20

23

20

19

21

H-1 (Light Pedal) R431005617 (P -060921-00001 Series)

EXPLODED VIEW

Part No. R431003714 (P -055409-00000) Diaphragm with Exhaust Valve Seat. Complete (Includes No. 8, 9, 10 11 & 12)

PARTS LIST

*Note: Appropriate suffix from Identity Schedule, page 7 must be used to identify valve and pressure rating. + Control portion less pipe bracket, mounting screws and operator. ++ Control portion less pipe bracket, pedal portion, mounting bolts, screws, washer and boot.

Item Ref

Qty. Description

Control Portions H-1-A+New

P/N P -051085-

00000

H-1-A+ Old P/N

P -051085-0000*

Old P/N H-1++ Lt. Pedal

P -060925-00000*

Old P/N H-1+ Cast Body P -051133-

00000* 1 2 3 4 5 6 6a 7 7a * 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21a 22 23 24

1 1 4 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 2 2 1 2 1 1 1 1 1

Adjusting screw Spring housing with nut Nuts 5/16” - 18 Spring seat Control spring Body with 2 studs Body with 2 studs 5/16” – 18 x 1 3/8” Cap screws 5/16” – 18 x 1 1/8” Cap screws Dia. Unit Kit incl. 8,9,10,11,12 Exhaust valve seat 11/16” O.D. “O” ring Diaphragm Diaphragm follower 9/16” – 18 Hex nut Inlet & exhaust valve ¾” O.D. “O” ring Exhaust valve spring Boot, dirt protector Strainers Gasket Pin, pivot Retaining ring, ¼ Cam Dog Cam roller assembly (incl. 22,23,24) Lever with tip and nut Roller, cam Pin, fulcrum (eccentric)

R431006770 R431006822 R431002419 R431000036 See Page 7 R431000045

--- --- ---

R431003714 See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See 21 a See 21 a See 21 a

P -066209-00000 P -066488-00002 P -049901-00020 -526347-00000 See Page 7 -526874-00000

--- -850577-00000

--- P -055409-00000 See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See 21a See 21a See 21a

P -066209-00000 P -066488-00002 P -049901-00020 -526347-00000 See Page 7

--- --- ---

P -049842-00000 P -055409-00000 See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

--- --- --- ---

--- --- ---

P -066209-00000 P -066488-00002 P -049901-00020 -526347-00000 See Page 7

--- -526874-00000

--- P -085077-00000 P -055409-00000 See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See 21a See 21a See 21a

New H-1++ Lt. Pedal

P -060925-00000*

R431006770 R431006822 R431002419 R431000036 See Page 7

--- --- ---

R431002291 R431003714 See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

--- --- --- ---

--- --- ---

New P/N H-1+ Cast Body P -051133-

00000* R431006770 R431006822 R431002419 R431000036 See Page 7

--- R431000045

--- ---

R431003714 See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See 21a See 21 a See 21 a

Repair Kits are listed on page 11.

PARTS KITS

H-1 Type (P -050208-00000 and P-052570-00000 Series) Service

Ref Qty Description New Part No. Old Part No.

1 2 3/8” -16x1¾ Cap screws R431000161 -850563-00000

1a 2 Washer 3/8 lock R431004331 P -049982-00013

2 1 Pedal bracket complete R431007392 P -069068-00001

3 1 Pedal pin 3/8” x 2 7/8 See Repair Kits See Repair Kits

4 2 Retaining Rings See Repair Kits See Repair Kits

5 1 Pedal Return Spring See Repair Kits See Repair Kits

5a 1 Pedal Return Spring (light) R431005474 P -060294-00000

6 1 Pedal stop screw R431002231 P -049832-00076

7 1 Nut ¼ - 20 R431002442 P -049903-00015

8 1 Pedal R431007390 P -069067-00001

n/a 1 Pipe bracket R431007394 P -069069-00000


1 2 5/16 - 18 x 1¼” Cap screws R431002291 P -049842-00000

2 1 Pipe bracket R431006911 P -066888-00000

3 2 5/16” - 18 x 1 bolts R431002227 P -049832-00064

4 2 5/16” Washers R431002419 P -049901-00020

5 2 5/16” -18 Nuts R431005527 P -060397-00001

Pedal portion (incl. 6-15) P -060397-00001

6 1 Mounting bracket --- ---

7 2 Retaining rings --- ---

8 1 Pins --- ---

9 1 Spring R431005504 P -060384-00000

10 1 Screw minimum pressure --- ---

H-1 Rubber Tread Light Pedal Force (P-060921 Series) Service

11 1 Locknut --- ---

12 1 Screw minimum pressure --- ---

13 1 Locknut --- ---

14 1 Pedal --- ---

15 1 Tread R431005506 P -060387-00000

16 1 Boot, dirt protector R431000035 -526344-00000


1 2 3/8” - 16 x 3¼ Cap screws R431000167 -850763-0000

2 2 3/8” Lock washers R433014331 P -049982-00013

3 1 Pipe bracket R431004175 P -057558-00000

4 1 Lever retainer R431003101 P -053121-00000

5 1 Pedal fulcrum R431003025 P -052873-00000

6 1 5/16” x 1 5/8” Roll pin See Repair Kit See Repair Kit

Pedal complete, consisting of 7,8,& 9) R431003104 P -053123-00000

7 1 Pedal --- ---

8 1 Pedal stop screw --- ---

H-1-A Type (P -052971 Series) Service

9 1 ¼” 20 Nut --- ---

16

REPAIR KITS FOR H-1 AND H-1-A

Notes:

*1. The inlet and exhaust valve unit item 13 and exhaust valve seat item 8 must be lapped together to form a matched set. Kit contains these items factory matched.

2. Select replacement range control spring from identity schedule page 7. 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 may be required

especially in the mechanical operating portions of the valve. Select these as required from parts list on pages 8, 9 and 10.

Repair Kit Old

Part No. (Pre 1986)

Old Part No.(1987-2008)

New Part No.( 2008-)

Complete pedal kit with pipe bracket and standard springs for H-1

P -051090-00000 P -051090-K0002 R431002865

New replacement pedal and pin kit for H-1 520474 P -026205-00000 R431000597

Part Number Quantity Per Valve

Description

R431003895 (P -055687-K0000*) 1 Minor graduating valve portion - - repair kit (includes items

8,9,10,11,12,13, 14) see note R431004887 (P -059028-K0000) 1 Major graduating valve portion – repair kit (includes items

15,16,17,18, and kit P55687-K0000) R431006648 (P -065636-00000) 1 Kit, lever repair for standard H-1 and H-1-A (includes

items 19,20,21,22,23,24)

Control Portion and Lever Kits (See pages 8 & 9)

Pedal Operator Kits (See page 10)

R431006417 (P -064421-00003)

1 Operator kit for H-1-A (includes items 4,6, and kit P65636)

R431006416 (P -064421-00002)

1 Operator kit for standard H-1 (includes items 3,4,5)

Part Number Quantity Per Valve

Description

Kits for Replacing Old Style Pedal (pre-1986) to Current Design

MAJOR REPAIR AND MAINTENANCE, ADJUSTMENTS

H-1 Adjustment (reference page 15 for test set-up and page 10 for part references) With the H-1 Controlair Valve pedal fully released, turn the adjusting screw at the bottom of housing clockwise until the delivery gauge begins to move from “0” pressure setting. With pressure gauge reading from “0” to 3 psi maximum, turn the adjusting screw one full turn counterclockwise. Fully depress the pedal (8) and adjust the pedal stop screw (6) to obtain the maximum specified pressure setting as per identity schedule on page 7. Release the pedal, tighten lock nut (7). Depress the pedal again and check to see that, at full travel, the maximum specified pressure ± 3 psi is obtained. Release the pedal. PC. No. P65292 has “full pressure” feature and requires additional adjustment. Install .030-feeler gauge at pedal stop. Depress pedal fully and hold. Adjust screw in pedal to obtain 35 +3 –0 psi at delivery gauge. Release the pedal to full release position and tighten the lock nut. Depress the pedal again and check the specified pressure. With pedal depressed, screw inward the set screw in the adjusting screw at bottom of spring housing until delivery pressure gauge just begins to show pressure increase. Release the pedal, remove feeler gauge, and recheck. Valve should graduate pressure 0 to 35 psi and then go into full supply pressure. Release the pedal.

Major Repair and Maintenance Instructions

When it is determined that the Controlair Valve requires shop repairs (see page 2 for general maintenance and repair recommendations), the following general instructions are recommended: Disassembly, Cleaning and Lubrication Complete disassemble the Controlair Valve. Wash all metal parts in a non-flammable solvent. Rinse each part thoroughly and blow dry with a low-pressure air jet. Arrange the parts on a clean surface. Inspect and clean screens, item 16. Be sure all body and bracket passages are clear and unrestricted. Be sure sensing port orifice in top of diaphragm chamber is clear. Examine each part carefully. Replace all rubber parts and all other worn or damaged parts. The use of repair kits is strongly recommended, see page 11. Reassembly Refer to exploded parts and assembly views. Valve should be reassembled using new rubber parts and parts indicated by inspection. As reassembly proceeds, lubricate all metal-to-metal wear surfaces with 107 Lubriplate Grease. Lubricate all rubber parts, except diaphragm with No. 55 Dow Corning Pneumatic Grease. Do not lubricate diaphragm. The exhaust valve and seat may have to be slightly polished for minimum leakage. If necessary, use BW valve lapping compound (600+ grit).

Adjustments and Test Set Up The valve is factory set to provide the appropriate graduated pressure and mechanical operation per part number (see identity schedule on page 7). However, after the Controlair has been disassembled, repaired and reassembled it must be adjusted and tested for proper operation prior to returning to service. It is recommended that the valve should be connected in a test set up as shown on page 15.

H-1 CONTROLAIR® VALVE

8

7

6

MAJOR REPAIR AND MAINTENANCE, ADJUSTMENTS (continued)

H-1 (light pedal) Adjustment (ref. Page 15 for test set-up and page 10 for part references)

With the H-1 Controlair Valve pedal fully released, turn the adjusting screw at the bottom of housing clockwise until the delivery gauge begins to move from “0” pressure setting. With pressure gauge reading from “0” to 3 psi maximum, turn the ad-justing screw one full turn counterclockwise. Fully depress the pedal (14) and adjust the pedal top screw (12) to obtain the maximum specified pressure setting as per identity schedule, page 7, release the pedal. Tighten lock nut (13). Depress the pedal again and check to see that at full travel, the specified pressure ± 3 psi is obtained. Release the pedal.

(H-1 Light Pedal) Controlair ® Valve

H-1-A Adjustment (ref. Page 15 for test set-up and pages 8 & 10 for part references)

4. Check delivered air pressure from valve. It should be the pressure range indicated on identity schedule, page 7, for the part number valve.

5. Adjust bottom set screw (1) (adjustment C) to obtain the pressure range rating of the control spring in use. When using this adjustment to obtain the rated maximum pressure setting, always be sure the delivered pressure goes to zero upon release of the pedal.

6. The inability to complete the above adjustments on a repaired valve would indicate the following possibilities:

Pedal, cam roller and/or eccentric pin is worn past the point where step 2 can be completed. Replace as necessary. Incorrect control spring for the range desired…check the spring in use. Or the control spring has taken some permanent set and should be replaced. Valve not mounted, or in use, on a flat surface. Pedal pivot pinpoint and/or pin worn. Inlet and exhaust valve assembly and/or exhaust valve seat (items 13 & 8 on page 8 of service bulletin) have been reseated and are out of dimensional tolerance. It is recommended that these units be fully replaced with new parts when necessary.

1. Place valve with mounting feet firmly on a flat surface, bolting the valve down if necessary.

2. Adjust eccentric pin (24), page 8, (adjustment A) so that top of pedal rests about 1.75” above the flat surface as shown below.

3. Depress pedal to contact with the flat surface and adjust the travel stop bolt (8), page 10, to contact the body at this point (adjustment B). Tighten lock nut (9), page 10.

H-1-A Controlair ® Valve

Adjustment “C” Graduated Pressure Adjusting Screw (1)

Adjustment “A” Eccentric Pin (24)

Adjustment “B” Travel Stop 8 and Lock Nut 9

TESTING AND TEST SET-UP

The H-1, H-1 (light pedal) and H-1-A Controlair Valve can be tested after repair using the test arrangement shown below. Pressure control valves of this nature should be tested for the following:

1. Function 2. Pressure Range 3. Leakage 4. Flow Capacity 5. Response

The adjustment affecting these points has been described in the previous section. General instructions for accomplishing the five tests above are as follows. 1. Function: The H-1 and H-1-A type Controlair

Valves are spring returned pedal actuated 3-way pressure graduating valves. A pedal actuates the valve to increase, decrease or maintain graduated air pressure to a separate delivery line. This function should be checked using test arrangement shown.

2. Pressure Range: Supply pressure at “IN” port will be delivered as graduated pressure to “Out” port delivery line depending on value of control spring being used and pedal position. In pedal release position the out delivery line is connected to exhaust. Depressing the pedal actuates the graduating control portion to deliver graduated pressure to the out delivery line. See “Adjustments” to adjust valve. After valve is adjusted, check that the zero and maximum pressure ranges are generated in delivery line as per “Identity Schedule”.

3. Leakage: Set supply pressure to 20 psi above maxi-mum delivery pressure of valve being tested. Using soap solution, coat the valve at pipe bracket and spring housing parting lines. No leakage is permitted in any pedal position. A. On all valves with spring ranges less than 100 psi,

set supply lines pressure to 100 psi. Depress pedal to full travel position and hold. Close valve in sup-ply line to “IN” port and valve in delivery line from “OUT” delivery line pressure gage. A pressure drop of no more than 2 psi in 30 seconds is permitted.

B. On all valves with spring ranges 100 psi and above, set supply line pressure to 100 psi. Depress pedal to deliver 95 psi to delivery line from “OUT” port. Close valve in supply line to “IN” port and valve in delivery line from “OUT” port to trap the supply pressure at the valve. Observe the “OUT” delivery line pressure gage. A pressure drop of no more than 2 psi in 30 seconds is permitted.

4. Flow Capacity: Set supply line pressure to 100 psi regardless of control spring rating of valve. Depress pedal to full travel position. The delivery volume or volumes from “OUT” port should be inflated with time limits shown on Table 1. Release pedal quickly from full travel position to release position. The delivery vol-ume or volumes connected to “OUT” port should be “exhausted” within time limits shown in Table 1.

5. Response: Depress pedal to full travel position. Fully open the test valve at delivery volume from “OUT” port. Observe the delivery pressure gage. A pressure drop of no more than 3 psi is permitted. Release pe-dal.

Table 1 Flow Capacity Tests – Port “OUT”

Valve Setting PSI

Test Ranges and Time

Fill PSI

Maximum Time-Sec.

Exhaust PSI

Maximum Time-Sec.

0-30 0-15 2 0-15 2 450

0-35 0-15 2 0-15 2 450

0-65 0-50 1 50-10 2 225

0-100 0-50 1 50-10 2 225

0-125 0-50 1 50-10 2 225

0-150 0-50 1 50-10 2 225

0-175 0-50 1 50-10 2 225

Test Volume Cu. In.

TEST ARRANGEMENT DIAGRAM

Notes: 1. Taskmaster® Timing Volumes, part number R434002899 (TM-058887-000225), can be used

for the volumes indicated. 2. The supply air lines to the valves and delivery lines must be full size as shown. Line length

must not exceed 3 feet between the supply valve and “IN” port, and between the “OUT” port and delivery test volumes. The piping connections must have zero leakage, and must not restrict the flow. If quick couplers are used, be sure they are full flow or oversize.

3. It is recommended that as large of a gauge as practical be used on the delivery lines. A 6” gauge is recommended.

Test Valve (H-1 Light Pedal Shown)

H-1 and H-1-A Connected Similar

1/4” PIPE SCHEDULE 40 OR

3/8” O.D. TUBING OR

#6 SINGLE BRAID HOSE

P/N PD-020031-00191

AVENTICS P/N/ R432016359 (PR-007816-00010)

PRESSURE GAGE

IN OUT

CHOKE PLUG .032 OPTIONAL:

REQUIRED FOR LOW SPRING RANGE VALVES ONLY.

CLEAN, DRY, CHEMICAL FREE AIR SUPPLY 200 PSIG MAXIMUM (OR 20 PSIG ABOVE MAXIMUM DELIVERY PRESSURE OF ANY VALVE TESTED).

RECOMMENDED:

225 in 3

225 in 3

AVENTICS

NOTICE TO PRODUCT USERS WARNING: FLUID MEDIA AVENTICS pneumatic devices are designed and tested for use with filtered, clean, dry, chemical free air at pressures and temper-atures within the specified limits of the device. For use with media other than air or for human life support systems, AVENTICS must be consulted. Hydraulic cylinders are designed for operation with filtered, clean, petroleum based hydraulic fluid; operation using fire-resistant or other special types of fluids may require special pack-ing and seals. Consult the factory. 2. WARNING: MATERIAL COMPATIBILITY Damage to product seals or other parts caused by the use of non-compatible lubricants, oil additives or synthetic lubricants in the air system compressor or line lubrication devices voids AVEN-TICS warranty and can result in product failure or other malfunc-tion. See lubrication recommendations below. AIR LINE LUBRICANTS! In service higher than 18 cycles per minute or with continuous flow of air through the device, an air line lubricator is recommended.* (Do not use line lubrication with vacu-um products.) However, the lubricator must be maintained since the oil will wash out the grease, and lack of lubrication will greatly shorten the life expectancy. The oils used in the lubricator must be compatible with the elastomers in the device. The elastomers are normally BUNA-N, NEOPRENE, VITON, SILICONE and HYTREL. AVENTICS recommends the use of only petroleum based oils without synthetic additives, and with an aniline point between 180° F and 210° F. COMPRESSOR LUBRICANTS! All compressors (with the excep-tion of special "oil free" units) pass oil mist or vapor from the inter-nal crankcase lubricating system through to the compressed air. Since even small amounts of non-compatible lubricants can cause severe seal deterioration (which could result in component and system failure) special care should be taken in selecting compati-ble compressor lubricants. 3. WARNING: INSTALLATION AND MOUNTING 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 work-ing on pneumatic or hydraulic systems and devices, unless under trained supervision. Compressed air and hydraulic sys-tems 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. 4. WARNING: APPLICATION AND USE OF PRODUCTS The possibility does exist for any device or accessory to fail to operate properly through misuse, wear or malfunction. The user must consider these possibilities and should provide ap-propriate safe guards in the application or system design to prevent personal injury or property damage in the event of a malfunction. 5. WARNING: CONVERSION, MAINTENANCE AND REPAIR When a device is disassembled for conversion to a different configuration, maintenance or repair, the device must be tested for leakage and proper operation after being reassembled and prior to installation. MAINTENANCE AND REPAIR! Maintenance periods should be scheduled in accordance with frequency of use and working conditions. All AVENTICS products should provide a minimum of 1,000,000 cycles of maintenance free service when used and lubricated as recommended. However, these products should be visually inspected for defects and given an "in sys-tem" operating performance and leakage test once a year. Where devices require a major repair as a result of the one million cycles, one year, or routine inspection, the device must be disassembled, cleaned, inspected, parts replaced as re-quired, rebuilt and tested for leakage and proper operation prior to installation. See individual catalogs for specific cycle life estimates. 6. PRODUCT CHANGES Product changes including specifications, features, designs and availability are subject to change at any time without no-tice. For critical dimensions or specifications, contact factory. *Many AVENTICS pneumatic valves and cylinders can operate with or without air line lubrication; see individual sales catalogs for details.

LIMITATIONS OF WARRANTIES & REMEDIES

AVENTICS warrants its products sold by it to be free from defects in material and workmanship to the following: For twelve months after shipment AVENTICS will repair or replace (F.O.B. our works), at its option, any equipment which under normal conditions of use and service proves to be defective in material or workmanship at no charge to the purchaser. No charge will be made for labor with respect to defects covered by this Warranty, provided that the work is done by AVENTICS or any of its authorized service facilities. However, this Warranty does not cover expenses incurred in the removal and reinstallation of any product, nor any downtime incurred, whether or not proved defective. All repairs and replacement parts provided under this Warranty policy will assume the identity, for warranty purposes, of the part replaced, and the warranty on such replacement parts will expire when the warranty on the original part would have expired. Claims must be submitted within thirty days of the failure or be subject to rejection. This Warranty is not transferable beyond the first using purchaser. Specifically, excluded from this Warranty are failures caused by misuse, neglect, abuse, improper operation or filtration, extreme temperatures, or unauthorized service or parts. This Warranty also excludes the use of lubricants, fluids or air line additives that are not compatible with seals or diaphragms used in the products. This Warranty sets out the purchaser's exclusive remedies with respect to products covered by it, whether for negligence or other-wise. Neither, AVENTICS nor any of its affiliates will be liable for consequential or incidental damages or other losses or expenses incurred by reason of the use or sale of such products. Our liability (except as to title) arising out of the sale, use or operation of any product or parts, whether on warranty, contract or negligence (including claims for consequential or incidental damage) shall not in any event exceed the cost of replacing the defective products and, upon expiration of the warranted period as herein provid-ed, all such liability is terminated. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER FOR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE. No attempt to alter, amend or extend this Warranty shall be effective unless authorized in writing by an officer of AVENTICS Corporation. AVENTICS reserves the right to discontinue manufacture of any product, or change product materials, design or specifications with-out notice.

AVENTICS Corporation 1953 Mercer Road Lexington, KY 40511 Tel 859.254.8031 www.aventics.com/us [email protected] AVENTICS Incorporated 5515 N. Service Rd, Ste 104 Burlington, Ontario, Canada LTL 6G4 Tel 905.332.0399 www.aventics.com/ca [email protected] AVENTICS México, S. de R.L. de C.V. AV. Paseo de la Reforma 250, Esquina Niza Deleg. Cuauhtémoc 06280 México, D.F. Tel 866.873.0635 www.aventics.com/mx [email protected]

SM-800.6501/ Feb 2019 Subject to change. Printed in United States. AVENTICS Corporation. This document, as well as the data, specifications, and other information set forth in it, are the exclusive property of AVENTICS. It may not be reproduced or given to third parties without its consent.

H-1 & H-1-A CONTROLAIR VALVE

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Transcript of H-1 & H-1-A CONTROLAIR VALVE