H-2 CONTROLAIR VALVE - AVENTICS · valve from large particles or foreign matter in the supply line....

Description of Models The H-2 Type Controlair Valves are handle operated 3-way pressure graduating control valves. The handle actu-ates the pressure-graduating portion to increase, de-crease or maintain a graduated air pressure to the deliv-ery line. When the handle is in the “OFF” or release position the delivery line is connected to exhaust, except in the pre-loaded type Controlairs. Handle movement from the “OFF” or release position actuates the pressure graduat-ing portion to deliver a graduated pressure according to the value of the control spring. Models There are several models with similar valve functions, but different handle operating characteristics. H-2-X Controlair Valve -Handle is spring returned to the off position from all positions in the handle travel. Some special models exist. See notes on Identity schedule on page 9. H-2-LX Controlair Valve - Handle is spring returned to off position from all positions except at the maximum pres-sure setting. The handle is held in the extreme position by a mechanical detent. H-2-FX Controlair Valve - Handle is equipped with a friction brake that will hold the handle in any position se-lected in the handle travel. H-2-EX Controlair Valve - Handle is spring returned to “OFF” position from all other positions in the handle travel. The “OUTLET” pressure increases from 0 to 40% of the control pressure in the first 60 degrees of handle travel. The outlet pressure then increases to maximum control pressure in the remaining 32 degrees of handle travel. H-2-EFX Controlair Valve - Handle travel and valve func-tions are the same as H-2-EX except it is equipped with a friction brake that holds the handle in any position select-ed in the handle travel. H-2-ES Controlair Valve - Valve is similar to H-2-EX ex-cept no handle return spring or friction brake in the handle travel. H-2-EFS Controlair Valve- Valve is similar to H-2-EFX except is preloaded in “release” position and handle return spring is only effective in the first 28° of 86 degrees of handle travel.

Table of Contents Page Description of Models 1 Warnings 2 Technical Data 2 Installation 2 Maintenance/Repair Recommend. 2 Outline Dimensions 3 & 4 Description of Operation 5 Maintenance and Repair 6 Graphical Symbol 7 Diagrammatic View 7 Identity Schedule 8 & 9 Exploded View 10 Part List 11 & 12 Repair Kit List 13 Full Pressure Feature 14 Assembly Sectional Views 15 & 16 Testing 17 Function 17 Pressure Range 17 Leakage 17 Flow Capacity 17 Response 17 Mechanical Detents 17 Test Setup 17 Test Diagram 18

H-2 CONTROLAIR® VALVE Service Information

SM-800.6502

GENERAL MAINTENANCE AND REPAIR RECOMMENDATIONS Maintenance periods should be scheduled in accordance with frequency of use and working environment of the Con-trolair 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 immediately and repaired. A major overhaul is recommended at one million cycles. However, where frequency of use is such that it would re-quire more than two years to obtain the one million cycles, the valve must be overhauled every 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, inspect-ed, parts replaced as required. The valve then must be test-ed for leakage and proper operation prior to installation, refer to the Major Repair and Maintenance Instructions and test procedures. Notice that the operating portion of the valve can be re-moved without disturbing the pipe connections by just re-moving the (2) screws that hold the pipe bracket to the valve. No special tools are required to maintain the Controlair valves. One complete Controlair valve should be kept in stock for every (4) valves in service. During the maintenance period, replacing the complete valve with the stand-by unit reduces production down time and affords inspection and replace-ment of parts at a more appropriate time and favorable loca-tion.

WARNING: INSTALLATION AND MOUNTING

The user of these devices must conform to all appli-cable electrical, mechanical, piping and other codes in the installation, operation or repair of these devic-es. INSTALLATION! Do not attempt to install, oper-ate or repair these devices without proper train-ing 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 ex-haust 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.

Installation and General Mainte-nance Recommendations Before installing the Controlair Valve®, all air lines in the system should be cleaned to remove all dirt, moisture or contamination. A strainer is furnished on the inlet port to protect the valve from large particles or foreign matter in the supply line. To insure long, trouble-free service, a 10 micron or better filter should be installed in the sup-ply line to the valve. The H-2 Controlair Valve is designed for panel mounting. The valve less the pipe bracket can be installed from the top of the panel. Refer to the in-stallation view on pages 3 & 4 for panel opening dimension. Allow suitable clearance for installing or removing of the (2) pipe bracket screws which are 1 1/2” (38 mm) long.

Technical Data: Max. Operating Pressure 200 PSI. (13.8 Bars)

Admissible Mediums Clean & Dry Compressed Air Operating Temperature -40° to 160° F( - 40° to 71° C)

Hysteresis Control Pressure Range Ref. Identity Chart on Page 8

Pressure Change 1/2 Psi. Increments Mounting Flanged Plate Port Size 1/4-18 NPTF Materials Controlair Valve Housing & Body Die Cast Aluminum

Internal Parts Brass, Rubber, Aluminum, Steel, Plastic and Hytrel ™.

Weight 9 Lb. (4.1 Kgs.)

1 1/2 Psi

Installation and General Maintenance Recommendations

Outline View H-2 Controlair® Valve

Outline View H2-E Controlair® Valve

4.69

2.38

.34 DIA

.38 R

HOLE IN PANEL FOR MOUNTING

2.00

4.69

2.50

1.94

4.00 4.44

2.25 1.50R

1.00R 1.50R

1.00R

5.88R C

46°

92° YOKE ASSEMBLY AS SHOWN REVERSE FOR 78°

EXHAUSE OPENING

6.18

.25 MAX. THICKNESS OF PANEL

1.50

.31

A

1.63

2.66

TAP “B” (2) PLACES

IN

OU

T

.62 1.25

When the handle is in released position, the “IN” port is closed to supply pressure and the “OUT” port is open to exhaust. Note in the diagrammatic, when the handle is pushed forward to increase pressure, the cam forces the cam follower to push down on the inlet and exhaust valve unit by closing the exhaust valve and opening the supply. This permits air to flow to the “OUT” port and the upper diaphragm chamber. As the pres-sure builds up in the delivery line, it acts through the sensing port orifice and deflects the control diaphragm downward, compress-ing the control spring. When sufficient dia-phragm 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 graduating portion plunger movement. This movement in turn is controlled by the cam contour and is proportional to the handle travel. The H-2 Controlair Valve will automatically compensate for delivery (outlet) line air pres-

sures changes. These air pressure changes can be caused by line leakage, temperature change or load feedback. If air pressure at the delivery (outlet) port increases over that called for by the handle position, the dia-phragm 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 de-creased force on the diaphragm will allow the control spring to force the diaphragm up-ward, opening the upper supply valve to re-store the set pressure. The range of the de-livery (outlet) line pressure is controlled by the strength of the diaphragm spring.

Description of Operation For H-2 Controlair®

Repair and Maintenance Instructions When it has been determined that the Controlair®

Valve requires repairs, the following general instruc-tions 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.

To remove cam set screw Item #40, use of an im-pact wrench (set soft) will break it loose to remove the cam and shaft from cam housing.

Examine all parts carefully. Replace all rubber parts and all worn or damaged parts. The use of re-pair 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 cam set screw Item #40. The cam set screw must be fully seated into the drill point location on the cam shaft Item #36. When installing set screw Item #40 use a thread locker like Loctite TL242.

Installing the handle (Item #43), seat the handle into the yoke, Item #42 before installing the nut, Item #44.

Do not over torque the cap nut, Item #44. Adjustments There are 3 adjustments that can be made to the

H-2 Controlair Valves. The adjusting screw item #1 that varies the output pressure, reversing the handle yoke item #42 can effect the degrees of handle travel from 92 to 78 degrees and friction brake item #47 increases or decreases the force required to move the control handle. Graduated Output Pressure Adjustments

Adjusting screw Item #1 varies the maximum pres-

sure setting. Turning the adjusting screw in raises the maximum pressure. Turning the screw out decreases the maximum pressure. The maximum control pres-sure 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 neutral to full travel position and hold. Adjust graduat-ing valve screw Item #1 to obtain the maximum con-trol pressure per Identity schedule. Move handle back to neutral position and note delivery line is ex-hausted to zero.

Special Preload Setting This setting calls for a predetermined delivery pres-

sure. Friction Brake Adjustment The handle force of the H-2-FX, H-2-EFX and H-2-

EFS Controlair Valve can be varied by adjusting nut Item #50 on the brake shoe holder Item #47. This adjustment increases or decreases the force required to move the handle in any position of the handle trav-el. Factory setting is 8 lbs (3.6 Kgs)

This adjustment is normally made on the cam housing portion before assembling to the control por-tion.

Repair and Maintenance Instructions

DIAGRAMMATIC VIEW

FULL TRAVEL RELEASE POSITION

CAM

CAM FOLLOWER

INLET & EXHAUST VALVE UNIT

SUPPLY VALVE

EXHAUST VALVE

EXHAUST PORT

ADJUSTING SCREW

DIAPHRAGM

SENSING PORT ORIFICE

LEGEND—PIPE BRACKET IN - SUPPLY OUT - GRADUATED DELIVERY

IN

VALVE SYMBOL

OUT

H-2 CONTROLAIR® VALVE

+Model New

Complete Old

Complete Control Pressure New Control Spring

Old Control Spring

New Cam Portion

Old Cam Portion

New Valve Portion

Old Valve Portion Handle Remarks

Part Number Part Number Range (PSI.) & Color Code & Color Code Complete Complete Complete Complete Travel

R431002638 P -050493-00001 0 to 65 Psi. R431003732 BROWN P -055442-00000 R431000147 -850426-00000 R431003776 P -055510-00001 92 Deg.

R431002639 P -050493-00002 0 to 100 Psi. R431000043 YELLOW -526749-00000 R431000147 -850426-00000 R431003777 P -055510-00002 92 Deg.

R431002640 P -050493-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 R431000147 -850426-00000 R431003778 P -055510-00003 92 Deg.

R431002641 P -050493-00004 0 to 150 Psi. R431003731 RED P -055441-00000 R431000147 -850426-00000 R431003779 P -055510-00004 92 Deg.

P -050493-00005 0 to 15 Psi. R431005473 WHITE P -060293-00000 R431000147 -850426-00000 P -055510-00005 92 Deg.

R431002642 P -050493-00008 0 to 30 Psi. R431005475 DK. BLUE P -060295-00000 R431000147 -850426-00000 R431003781 P -055510-00008 92 Deg.

H-2-X P -050493-00011 10 to 65 Psi. R431003732 BROWN P -055442-00000 -850427-00000 R431003776 P -055510-00001 78 Deg.

P -065989-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 P -065990-00000 R431003778 P -055510-00003 92 Deg. Note 1

P -067191-00000 0 to 100 w/FP R431000099 LT. BLUE -540577-00000 R431000147 -850426-00000 P -063408-00003 92 Deg. Note 4

R431007252 P -067694-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 R431006748 P -065990-00001 R431003778 P -055510-00003 92 Deg. Note 2

P -068542-00007 0 to 25 Psi. R431005475 DK. BLUE P -060295-00000 R431007293 P -068454-00000 P -068453-00007 92 Deg. Note 5

R431007323 P -068543-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 P -065990-00000 R431003778 P -055510-00003 92 Deg. Note 6

R431007324 P -068544-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 P -065990-00000 R431003778 P -055510-00003 92 Deg. Note 7

P -068758-00001 0 to 65 Psi. R431003732 BROWN P -055442-00000 R431007294 P -068454-00001 R431003776 P -055510-00001 92 Deg. Note 3



R431002645 P -050494-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 R431000143 -850261-00000 R431003778 P -055510-00003 92 Deg.


R434002045 P -050494-00005 0 to 15 Psi. R431005473 WHITE P -060293-00000 R431000143 -850261-00000 R431003780 P -055510-00006 92 Deg.

P -050494-00007 0 to 25 Psi. R431005475 DK. BLUE P -060295-00000 R431000143 -850261-00000 R431003781 P -055510-00008 92 Deg.

R431002647 P -050494-00008 0 to 30 Psi. R431005475 DK. BLUE P -060295-00000 R431000143 -850261-00000 R431003782 P -055510-00010 92 Deg.

R431002648 P -050494-00010 0 to 80 Psi. R431000056 DK. GREEN -531418-00000 R431000145 -850265-00000 R431003776 P -055510-00001 92 Deg.


P -050494-00012 10 to 90 Psi. DK. GREEN -531418-00000 -850265-00000 P -055510-00010 78 Deg.

R431002651 P -050494-00015 0 to175 Psi. R431000056 DK. GREEN -531418-00000 R431000143 -850261-00000 R431003783 P -055510-00015

P -050494-00016 3 to 15 Psi. R431003311 SILVER P -054159-00000 R431000145 -850265-00000 P -055510-00016 92 Deg.

P -051248-00011 10 to 65 PSI R431006501 SILVER P -064822-00000 P -051429-00000 R431003776 P -055510-00001 78 Deg.

P -052490-00001 0 to 65 Psi. R431003732 BROWN P -055442-00000 P -051429-00000 R431003776 P -055510-00001 92 Deg. Note 9


P -052929-00002 0 to 100 Psi. R431005475 DK. BLUE P -060295-00000 P -052877-00000 R431003777 P -055510-00002 92 Deg. Note 10


P -055863-00002 0 to 100 Psi. R431000043 YELLOW -526749-00000 P -057053-00000 R431003777 P -055510-00002 78 Deg. Note 18

P -055863-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 P -057053-00000 R431003778 P -055510-00003 92 Deg. Note 18

P -055863-00010 0 to 80 Psi. R431000056 DK. GREEN -531418-00000 P -057053-00000 R431003782 P -055510-00010 92 Deg. Note 18

P -058998-00000 0 to 65 Psi. R431003732 BROWN P -05442.00000 R431000145 -850265-00000 R431003776 P -055510-00001 92 Deg. Note 18

P -063407-00002 0 to 100 Psi w/

FP R431000043 YELLOW -526749-00000 R431000143 -850261-00000 R431003777 P -055510-00002 92 Deg. Note 20

P -064092-00004 0 to 150 Psi. R431003731 RED P -055441-00000 R431000143 -850261-00000 R431003779 P -055510-00004 92 Deg. Note 19

R434001217 P -065124-00001 0 to 65 Psi. R431003732 BROWN P -055442-00000 R431006568 P -065129-00000 R431003776 P -055510-00001 92 Deg. Note 11

R434001216 P -065124-00002 0 to 100 Psi. R431000043 YELLOW -526749-00000 R431006568 P -065129-00000 R431003777 P -055510-00002 92 Deg. Note 12

H-2-FX R434001215 P -065124-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 R431006568 P -065129-00000 R431003778 P -055510-00003 92 Deg. Note 12

R434001214 P -0965124-00004 0 to 150 Psi. R431003731 RED P -055441-00000 R431006568 P -065129-00000 R431003779 P -055510-00004 92 Deg. Note 12




R431007328 P -068548-00003 0 to125 Psi. R431000099 LT. BLUE -540577-00000 R431007311 P -068522-00002 R431003778 P -055510-00003 92 Deg. Note 13

R434001171 P -068549-00001 0 to 65 Psi. R431003732 BROWN P-055442-00000 R431007310 P -068522-00001 R431003776 P -055510-00001 78 Deg. Note 22



R434001201 P -068549-00010 0 to 80 Psi. R431000056 DK. GREEN -531418-00000 R430017310 P -068522-00001 R431003782 P -055510-00010 92 Deg. Note 22

R431002652 P -050499-00001 0 to 65 Psi. R431003732 BROWN P -055442-00000 R431000149 -850428-00000 R431003776 P -055510-00001 92 Deg. Note 22


R431002654 P -050499-00003 0 to 125Psi. R431000099 LT. BLUE -540577-00000 R431000149 -850428-00000 R431003778 P -055510-00003 92 Deg.


P -050499-00009 0 to 75 Psi. R431000056 DK. GREEN -531418-00000 R431000149 -850428-00000 R431003782 P -055510-00010 92 Deg.

P -050499-00011 10 to 65 Psi. R431003732 BROWN P -055442-00000 -850428-00000 R431003776 P -055510-00001 92 Deg.

H-2-LX P -050499-00012 10 to 90 Psi. R431000056 DK. GREEN -531418-00000 -850429-00000 R431003782 P -055510-00010 78 Deg.

P -066325-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 P -066326-00000 R431003778 P -055510-00003 78 Deg.





R431002808 P -050925-00002 0 to 100 Psi. R431000043 YELLOW -526749-00000 R431002810 P -050926-00000 R431003793 P -055513-00002 92 Deg.

R431002809 P -050925-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 R4312810 P -050926-00000 R431003794 P -055513-00003 92 Deg.

P -050925-00005 0 to 15 Psi. R431005473 WHITE P -060293-00000 R431002810 P -050926-00000 P -055513-00005 92 Deg.

H-2-EX P -066322-00002 0 to 100 Psi. R431000043 YELLOW -526749-00000 P -066323-00000 R431003793 P -055513-00002 92 Deg.





R431002947 P -051846-00002 0 to 100 Psi. R431000043 YELLOW -526749-00000 R431002949 P -051847-00000 R431003793 P -055513-00002 92 Deg.

R431002948 P -051846-00003 0 to 125 Psi. R431000099 LT. BLUE -540577-00000 R431002949 P -051847-00000 R431003794 P -055513-00003 92 Deg.

H-2-EFX P -051846-00004 0 to 150 Psi. R431003731 RED P -055441-00000 R431002949 P -051847-00000 P -055513-00004 92 Deg.

P -053217-00001 0 to 65 Psi. R431003732 BROWN P-055442-00000 P -053218-00000 R431003792 P -055513-00001 92 Deg.

P -055763-00001 0 to 65 Psi. R431000043 YELLOW -526749-0000 P -053218-00000 R431003792 P -055513-00001 92 Deg. Note 29

H-2-ES P -062293-00002 0 to 100 Psi. R431000043 YELLOW -526749-00000 R431006040 P -053218-00000 R431003793 P -055513-00002 92 Deg. Note 28

P -063247-00003 10 to110 R431000099 BLUE -540577-00000 P -063298-00000 R431003794 P -055513-00003 92 Deg. H-2-EFS P -063247-00004 12 to 125 Psi. R431003731 RED P -055441-00000 P -063298-00000 P -055513-00004 86 Deg.

H-2 IDENTITY SCHEDULE

Identity Schedule

Note 1 - Same as R431002640 (P -050493-00003) except Items 23 & 42 are chrome plated. Note 2 - Same as 431002640 (P50493-00003) except cam housing and escutcheon plate, Item 23 and 25, part numbers R431007253 (P -067695-00000) or R431002638 (P -048316-00000). Note 3 - Same as R431002638 (P -050493-00001) except less yoke, handle, nut, knob and paint, Items 42,43,44 & 45. Note 4 - Same as R431002640 (P -050493-00003) except with full pressure feature (special valve portion consult factory). Note 5 - Same as R431002642 (P -050493-00008) except special non-magnetic materials (consult the factory) Note 6 - Same as R431002640 (P -050493-00003 except Items 22, 23, 35,36, 37 and 39 are replaced with part numbers (P -065690-00003), R431007255 (P -067695-00002), R431002761 (P -050800-00000), R431007035 (P -067225-00001), R431007032 (P -067223-00000) and (P -049804-00069). Note 7 - Same as (P -068543-00002) except Items 22, 23 and 25 are replaced with R431006749 (P -065990-00002), R431007253 (P -067695-00000) and R431001591 (P -048316-00000). Note 8 - Same as R431002644 (P -050494-00002) except Item 43 is part number R431002845 (P -050979-00000) (long handle shaft). Note 9 - Same as R431002649 (P -050494-00011) except special non-magnetic material (consult the factory). Note 10 - Same as (P -050494-000XX except Items 22, 23, and 25 are replaced by part numbers (P -052491-00000), (P -052492-00000) and less Item 25. Note 11 - Same as P50494-00XX except with black epoxy paint. Note 12 - Same as P50494-00XX except Items 23 & 42 are chrome plated. Note 13 - Same as R431002644 (P -050494-00002) except Items 22, 23, and 25 are replaced with part numbers R431007309 (P -068522-00000), R431007254 P -067695-00001) and R431001591 (P -048316-00000). Note 14 - Same as R431002654 (P -050499-00003) except Items 42 and 43 are chrome plated. Note 15 - Same as R431002654 (P -050499-00003) except Items 22, 23 and 25 are replaced with R431006749 (P -065990-00002), R431007253(P -067695-00000) and R431001591 (P -048316-00000). Note 16 - Same as R431002654 (P -050499-00003) except Items 22, 23, 35,36, 37 and 39 are replaced with part numbers R431006800 (P -066326-00003), (P -066237-00003), R431007336 (P -068643-00000), R431007035 (P -067225-00001), R431007032 (P -067223-00000) and R431001992 (P -049707-00004). Note 17 - Same as Note 16 except Items 22, 23 and 25 are replaced with R431006749 (P -065990-00002), R431007253 (P -067695-00000) and R431001591 (P -048316-00000). Note 18 - Same as (P -050494-000XX) except (Right Hand Pull Action) Items 22, 23, 35 and 36 are replaced with part numbers (P -057053-00000), R4317253 (P -067695-00000), R431001591 (P -048316-00000) and (P -05988-00000). Note 19 - Same as R431002644 (P -050494-00002) except with full pressure feature (special valve portion consult factory). Note 20 - Same as R431002643 (P -050494-00001) except with sprocket drive (Obsolete). Note 21 - Same as R431002643 (P -050494-00001) except has 9/16-18 straight thread “O” ring ports Note 22 - Same as (P -050494-XXXXX) except (Right or Left Hand Pull Action) Items 22, 23, 35 and 36 are replaced with part numbers R431007311(P -068522-00002), R431007255 (P -067695-00002), R431006378 (P -064198-00000), R431007034 (P -067225-00000) and (P -049804-00069). Note 23 - Same as (P -050494-XXXXX) except less Items 43,44 and 45 and Items 22 and 36 are replace with R431006645 (P -065610-0001), R431007132 (P -067459-00000) and (1) screw P/N (P -050283-00005). Note 24 - Same as R431002808 (P-050295-00002) except Items 23 & 42 are chrome plated. Note 25 - Same as R431002808 (P -050925-00002) except (Left Hand Pull Action) and Items 22 & 23 are replaced part numbers R431002811 (P -050926-00001) and R431002814 (P -050927-00002). Note 26 - Same as R431002808 (P -050925-00002) except (Left Hand Push Action) less Items 37 & 39 and Items 22, 23, 35 and 36 are replaced with part numbers R431007044 (P -067274-00001), R431002815 (P -050927-00003), R431002682 (P -050600-00002), and R431007035 (P -067225-00001) plus arbor spring R431007032 (P -067223-00000) and spacer (P -067228-00000) are added. Note 27 - Same as R431002808 (P -50925-00002) except (Right Hand Push Action) less Items 37 & 39 and Items 22, 23, 35 and 36 are replaced with part numbers R431007043 (P -067274-00000), R431002816 (P -050927-00004), R431002682 (P -050600-00002), and R431007035 (P -067225-00001) plus arbor spring R431007032 (P -067223-00000) and spacer (P -067228-00000) are added. Note 28 - Same as R431002946 (P -051846-00001) except less Item 25 with holes plugged for the escutcheon drive screws. Note 29 - Same as R431002946 (P -051846-00001) except less Item 25.

52

15

14

13 NOTE 3

14

IN

OUT

51 18

17 6

34

33

1

3

2

4

5

12

11

10

8

9

NOTE 3

7

20 19

SEE PAGE 13 FOR REPAIR KITS

30

28

27

40

35

23

21

48

49 50

32 47

44

42

43

45

41 39 38 37 36

41 16

46 36

BRAKE ASSY. PART NO.R434000130 (-850182-00000)

H-2-EFX CONTROLAIR H-2-EFS CONTROLAIR (has spring (38), arbor (37) and brake). H-2-FX CONTROLAIR

H-2-X CONTROLAIR® H-2-LX CONTROLAIR®

NOTE: 1. SEE PAGE 11 & 12 FOR PART NUMBERS 2. SEE PAGE 13 FOR REPAIR KITS 3. MATCHED/LAPPED SET OF ITEM 8 & 13

ARE IN KIT, P/N R431003895 (R431003895) PAGE 11.

EXPLODED VIEW

REF. QTY. DESCRIPTION New P/N H-2-X Old P/N H-2-X New P/N H-2-FX Old P/N H-2-FX New P/N H-2-LX Old P/N H-2-LX

Complete Device P –050493-0000X P –050494-0000X P –050499-0000X

1 1 Adjusting screw R431006770 P –066209-00000 R431006770 P –066209-00000 R431006770 P –066209-00000

2 1 Spring Housing R431006822 P –066488-00002 R431006822 P –066488-00002 R431006822 P –066488-00002

3 4 Nuts R431002419 P –049901-00020 R431002419 P –049901-00020 R431002419 P –049901-00020

4 1 Spring Seat R431000036 -526347-0000 R431000036 -526347-00000 R431000036 -526347-00000

5 1 Control Springs See page 6 See page 6 See page 6 See page 6 See page 6 See page 6

6 1 Complete Body R431000068 -534500-00000 R431000068 -534500-00000 R431000068 -534500-00000

7 2 Cap Screws R431002291 P –049842-00000 R431002291 P –049842-00000 R431002291 P –049842-00000

**1

Minor Graduating Portion R431003895 R431003895 R431003895 R431003895 R431003895 R431003895

Includes Items 8 to 14

8 *1 Exhaust Valve Seat See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

9 *1 11/16” “O” Ring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

10 *1 Diaphragm See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

11 *1 Diaphragm Follower See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

12 *1 Adjusting Screw See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

13 *1 Inlet & Exhaust Valve/Includes 14 See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

14 *2 3/4” “O” Rings See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

15 **1 Exhaust Valve Spring See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

15A 1 Complete Bottom Portion P -055510-0000X P –055510-0000X P -055510-0000X P –055510-0000X P -055510-0000X P –055510-0000X

16 1 Brake Drum R431000129 -850181-00000 R431000129 -850181-0000 R431000129 -850181-00000

17 **1 Strainers See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

18 **2 Gaskets See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

**1

Major Graduating Repair Kit R431004886 P –059028-00000 R431004886 P –059028-00000 R431004886 P –059028-00000

Includes Kit R431003895 and Items 15, 17 and 18 19 1 Pivot Pin R431001563 P –048189-00000 R431001563 P –048189-00000 R431001563 P –048189-00000

20 2 Retaining Rings R431001844 P –049528-00001 R431001844 P –049528-00001 R431001844 P –049528-00001

21 1 Cam Dog R431003014 P –052835-00000 R431003014 P –052835-00000 R431003014 P –052835-00000

22 1 Complete Top Portion

R431000147 -850426-00000 R431000147 -850426-00000 R431000147 850426 Includes items 23,33 to 50

23 1 Complete Cam Housing R431000062 -534496-00000 R431000062 -536795-00000 R431000077 536795 Includes items 24 to 32

24 1 Cam Housing (Bushed) R431002766 P –050851-00002 R431002766 P –050851-00002 R431002766 P –050851-00002

25 1 Escutcheon Plate R431000061 -534491-00001 R431000061 -534491-00001 R431000061 -534491-00001

26 1 Stop R431002767 P –050851-00003 R431002767 P –050851-00003 R431002767 P –050851-00003

27 1 Latch Spring X X X X R431000098 -539961-00000

28 1 Latch X X X X R431004002 P –057117-00000

29 2 Rivets Large R431001847 P –049533-00001 R431001847 P –049533-00001 R431001847 P –049533-00001

30 2 Rivets Small R431002293 P –049854-00004 R431002293 P –049854-00004 R431002293 P –049854-00004

31 4 Screws #6—3/16” R431002597 P –049987-00002 R431002597 P –049987-00002 R431002597 P –049987-00002

32 2 Studs R431002505 P –049906-00014 R431002505 P –049906-00014 R431002505 P –049906-00014

33 2 Mounting Nuts R431002419 P –049901-00020 R431002419 P –049901-00020 R431002419 P –049901-00020

34 2 Tooth Washers R431002409 P –049898-00009 R431002409 P –049898-00009 R431002409 P –049898-00009

35 1 Cam w/pin R431002763 P –050800-00002 R431002763 P –050800-00000 R431002763 P –050800-00002

36 1 Cam Shaft See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

37, 38 1 Return Spring & Arbor Kit R431006422 P –064421-00008 X X R431006422 P –064421-00008

39 1 Cam Shaft Sleeve R431000146 -850400-00000 X X R431000146 -850400-00000

40 1 Screw 5/16” - 18 x 5/8” R431001665 P –048746-00001 R431001665 P –048746-00001 R431001665 P –048746-00001

41 1 Cap Nut See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

42 1 Handle Yoke See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

43 1 Handle Shaft See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

44 1 Nut See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

45 1 Handle Ball See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits See Repair Kits

46 1 Key 1/8 x 5/8” X X R431002109 P –049767-00003 X X

1 Brake Shoe & Holder Kit X X R434000132 -850187-00000 X X Includes items 47, 48, 49 & 50

47 1 Brake Shoe & Holder X X See Repair Kits See Repair Kits X X

48 1 Nut X X See Repair Kits See Repair Kits X X

49 1 Washer X X See Repair Kits See Repair Kits X X

50 1 Elastic Stop Nut X X See Repair Kits See Repair Kits X X

51 1 Bracket R431006911 P –066888-00000 R431006911 P –066888-00000 R431006911 P –066888-00000

52 2 Screws 3/18-24 x 1 1/4” R431002438 P –049902-00042 R431002438 P –049902-00042 R431002438 P –049902-00042

* These items are in the minor repair kit for graduating section.

** These items are in the major repair kit for graduating section.

Includes items 1 to 15 Must specify spring range, same as last digit on valve

H-2 Controlair® Valve Parts List

See Page 13 for Repair Kits summary.

REF. QTY DESCRIPTION Old P/N H-2-EX Old P/NH-2-EFX Old P/N H-2-ES H-2-EFS

Complete Device P –050925-0000X P –051846-0000X P –062293-00003 P –063247-0000X 1 1 Adjusting Screw P –066209-00000 P –066209-00000 P –066209-00000 P –066209-00000

2 1 Spring Housing P –066488-00002 P –066488-00002 P –066488-00002 P –066488-00002

3 4 Nuts P –049901-00020 P –049901-00020 P –049901-00020 P –049901-00020

4 1 Spring Seat -526347-00000 -526347-00000 -526347-00000 -526347-00000

5 1 Control Springs See Page 6 See Page 6 See Page 6 See Page 6

6 1 Complete Body -534500-00000 -534500-00000 -534500-00000 -534500-00000

7 2 Cap Screws P –049842-00000 P –049842-00000 P –049842-00000 P –049842-00000

**1

Minor Graduating Portion R431003895 R431003895 R431003895 R431003895

Includes Items 8 to 14

8 *1 Exhaust Valve Seat See Repair Kits See Repair Kits See Repair Kits See Repair Kits

9 *1 11/16” “O” Ring See Repair Kits See Repair Kits See Repair Kits See Repair Kits

10 *1 Diaphragm See Repair Kits See Repair Kits See Repair Kits See Repair Kits

11 *1 Diaphragm Follower See Repair Kits See Repair Kits See Repair Kits See Repair Kits

12 *1 Adjusting Screw See Repair Kits See Repair Kits See Repair Kits See Repair Kits

13 *1 Inlet & Exhaust Valve/Includes 14 See Repair Kits See Repair Kits See Repair Kits See Repair Kits

14 *2 3/4” “O” Rings See Repair Kits See Repair Kits See Repair Kits See Repair Kits

15 **1 Exhaust Valve Spring See Repair Kits See Repair Kits See Repair Kits See Repair Kits

15A 1 Complete Bottom Portion P –055513-0000X P –055513-0000X P –055513-0000X P –055513-0000X

Portion includes items 1 to 15 Must specify spring range, same as last digit on valve

16 1 Brake Drum X -850181-00000 X P –063297-00000

17 **1 Strainers See Repair Kits See Repair Kits See Repair Kits See Repair Kits

18 **2 Gaskets See Repair Kits See Repair Kits See Repair Kits See Repair Kits

**1 Major Graduating Repair Kit P –059028-00000 P –059028-00000 P –059028-00000 P –059028-00000

19 1 Pivot Pin P –048189-00000 P –048189-00000 P –048189-00000 P –048189-00000

20 2 Retaining Rings P –049528-00001 P –049528-00001 P –049528-00001 P –049528-00001

21 1 Cam Dog W/ Bearing & Follow P –050140-00001 P –050140-00001 P –050140-00001 P –050140-00001

22 1 Complete Top Portion

P -050926-00000 P –051847-00000 P –062292-00000 P –063298-00000 Includes items 23,33 to 50

23 1 Complete Cam Housing

P –050927-00000 P –050927-00000 P –050927-00000 P –063299-00000 Includes items 24 to 32

24 1 Cam Housing (Bushed) P –050851-00002 P –050851-00002 P –050851-00002

25 1 Escutcheon Plate P –049197-00001 P –049197-00001 P –049197-00001 P –049197-00001

26 1 Stop P –050851-00003 P –050851-00003 P –050851-00003 P –050851-00003

27 1 Latch Spring X X X X

28 1 Latch X X X X

29 2 Rivets Large P –049533-00001 P –049533-00001 P –049533-00001 P –049533-00001

30 2 Rivets Small X X P –049854-00004 X

31 4 Screws #6—3/16” P –049987-00002 P –049987-00002 P –049987-00002 P –049987-00002

32 2 Studs P –049906-00014 P –049906-00014 P –049906-00014 P –049906-00014

33 2 Mounting Nuts P –049901-00020 P –049901-00020 P –049901-00020 P –049901-00020

34 2 Tooth Washers P –049898-00009 P –049898-00009 P –049898-00009 P –049898-00009

35 1 Cam w/pin P –050600-00003 P –050600-00002 P –050600-00002 P –050600-00002

36 1 Cam Shaft See Repair Kits See Repair Kits See Repair Kits P –063294-00001

37 1 Arbor Handle Return See Repair Kits X X P –063296-00000

38 1 Handle Return Spring See Repair Kits X X -850256-00000

39 1 Cam Shaft Sleeve -850400-00000 X X X

40 1 Screw 5/16” - 18 x 5/8” P –048746-00001 P –048746-00001 P –048746-00001 P –048746-00001

41 1 Cap Nut See Repair Kits See Repair Kits See Repair Kits P –055465-00000

42 1 Handle Yoke See Repair Kits See Repair Kits See Repair Kits P –063295-00000

43 1 Handle Shaft See Repair Kits See Repair Kits See Repair Kits -850460-00000

44 1 Nut See Repair Kits See Repair Kits See Repair Kits P –049859-00000

45 1 Handle Ball See Repair Kits See Repair Kits See Repair Kits -517026-00000

46 1 Key 1/8 x 5/8” X P –049767-00003 X P –049767-00003

1

Brake Shoe & Holder Kit X -850187-00000 X -850187-00000

Includes items 47, 48, 49 & 50

47 1 Brake Shoe & Holder X See Repair Kits X See Repair Kits

48 1 Nut X See Repair Kits X See Repair Kits

49 1 Washer X See Repair Kits X See Repair Kits

50 1 Elastic Stop Nut X See Repair Kits X See Repair Kits

51 1 Bracket P –066888-00000 P –066888-00000 P –066888-00000 P –066888-00000

52 2 Screws 3/18-24 x 1 1/4” P –049902-00042 P –049902-00042 P –049902-00042 P –049902-00042

53 1 Nut X X X P –049901-00023

54 1 Screws X X X P –049856-00046

X=NOT USED IN THIS DEVICE

* These items are in the minor repair kit for graduating section.

** These items are in the major repair kit for graduating section.

Includes Kit R431003895 and Items 15, 17 and 18

New P/N H-2-EX

R431006770

R431006822

R431002419

R431000036

See Page 6

R431000067

R431002291

R431003895

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

X

See Repair Kits

See Repair Kits

R431004866

R431001563

R431001844

R431002611

R431002810

R431002813

R431002766

R431001716

R431002767

X

X

R431001847

X

R431002597

R431002505

R431002419

R431002409

R431002683

See Repair Kits

See Repair Kits

See Repair Kits

R431000146

R431001665

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

X

X

X

X

X

X

R431006911

R431002438

X

X

New P/N H-2-EFX

R431006770

R431006822

R431002419

R43100036

See Page 6

R431000067

R431002291

R431003895

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

R431000129

See Repair Kits

See Repair Kits

R431004866

R431001563

R431001844

R431002611

R431002949

R431002813

R431002766

R431001716

R431002767

X

X

R431001847

X

R431002597

R431002505

R431002419

R431002409

R431002682

See Repair Kits

X

X

X

R431001665

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

R431002109

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

R431006911

R431002438

X

X

New P/N H-2-ES

R431006770

R431006822

R431002419

R431000036

See Page 6

R431000067

R431002291

R431003895

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

X

See Repair Kits

See Repair Kits

R431004866

R431001563

R431001844

R431002611

R431006040

R431002813

R431002766

R431001716

R431002767

X

X

R431001847

R431002293

R431002597

R431002505

R431002419

R431002409

R431002682

See Repair Kits

X

X

X

R431001665

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

X

X

X

X

X

X

R431006911

R431002438

X

X

New P/N H-2-EFS

R431006770

R431006822

R431002419

R431000036

See Page 6

R43100067

R431002291

R431003895

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

R431004886

R431001563

R431001844

R431002611

R431001716

R431002767

X

X

R431001847

X

R431002597

R431002505

R431002419

R431002409

R431002682

R431000137

X

R431001665

R431003740

R431000155

R431001871

R431000012

R431002109

See Repair Kits

See Repair Kits

See Repair Kits

See Repair Kits

R431006911

R431002438

R431002420

R431002303

H-2 Controlair® Valve Parts List

See Page 13 for Repair Kits summary.

Notes: *1. The inlet and exhaust valve unit Item 13 and exhaust valve seat Item 8 are lapped together to form a matched set. Kits that contain these items from the factory include matched sets. 2. Select replacement range control spring from identity schedule on page 8. 3. All kits above include small tubes of the recommended lubricants. 4. Valve portion kits listed above contain the seals and other parts that are needed to repair the valve portion. 5. Replace all worn or damaged components, especially in the mechanical portions of the valve. The mechanical parts are listed on pages 9, 10, 11 and 12.

Repair Kits for H-2 Controlair® Valves

Chrome plated H-2 Controlair® Valves with chrome plated parts for item numbers listed

(See notes 1, 12, 14 and 24 --Page 9)

Old Part Number Quantity Per Valve Description

* P –055687-K0000 1

Minor Graduating Valve Portion-Repair Kit

Note 1 Includes items 8, 9, 10, 11, 12, 13 and 14

* P –059028-K0000 1

Major Graduating Valve Portion-Repair Kit

Note 1 Includes items 15, 17, 18 and Kit R431003895

-850187-00000 1

Friction Brake Kit for FX, EFX and EFS models

Note 5 Includes items 47, 48, 49 and 50

P –064421-00006 1

Cam Shaft Kit for X, FX, LX, EX, EFX and ES

Note 5 Includes items 36, 41, 42, 43, 44 and 45

P –064421-00008 1

Return Spring and Arbor Kit for X and LX

Note 5 Includes items 37 and 38

P –064421-00010 Return Spring and Arbor Kit for EX

Note 5 Includes items 37 and 38 1

New Part Number

R431003895

R431004887

R431000132

R431006420

R431006422

R431006424

Model Old Complete

Part Number

Old Item 23 Cam Housing

Part Number

Old Item 42 Yoke Part

Number

Item 43 Handle Shaft Part Number

H-2-X P –065989-00003 P –065130-00000 P –066852-00001 P –050979-00001

P –065124-00001 P –065130-00000 P –066852-00001 P –050979-00001

P –065124-00002 P –065130-00000 P –066852-00001 P –050979-00001

P –065124-00003 P –065130-00000 P –066852-00001 P –050979-00001

H-2-LX P –066325-00003 P –066237-00000 P –066852-00001 P –050979-00001

H-2-EX P –066322-00002 P –066234-00000 P –066852-00001 P –050979-00001

H-2-FX

New Complete

Part Number

R431001217

R431001216

R431001215

New Item 23 Cam Housing

Part Number

R431006569

R431006569

R431006569

R431006569

R431006789

New Item 42 Yoke Part

Number

R431006897

R431006897

R431006897

R431006897

R431006897

R431006897

New Item 43 Handle Shaft Part Number

R431002846

R431002846

R431002846

R431002846

R431002846

R431002846

Full Pressure Feature for H-2 Controlair® The full pressure feature was added to H-2 Controlair Valves to provide pressure graduation for the initial engagement of a clutch and then to lock the clutch at full line pressure. It is particular-ly attractive on valves that are mounted in a vertical position. The full pressure feature makes it easier for the operator to hold the valve fully engaged for period of time. When the top pressure is critical, it compensates for valve component wear. Caution must be exercised when using this feature. The full pressure feature opens to full line pressure, so this pressure may need to be regulated to the value desired.

Full Pressure Kit P/N R431007029 (P –067190-00000) Exhaust Valve Nut Stop Rod Adjusting Screw Set Screw

Line

PR

ES

SU

RE

FULL PRESSURE POINT IS ADJUSTABLE.

HANDLE TRAVEL

GRADUATION WITH FULL PRESSURE FEATURE

HANDLE TRAVEL

Normal setting is 10 - 15 before full travel.

Nut

Adjustable Max. Travel

Rod

Adjustable Screw

Set Screw

ASSEMBLY VIEW

H-2

-X &

H-2

-LX

CO

NT

RO

LA

IR®

VA

LV

E

H-2

-FX

CO

NT

RO

LA

IR®

VA

LV

E

A

A

A

A

A A

C

92°

YO

KE

AS

SE

MB

LY

AS

SH

OW

N R

EV

ER

SE

A

SS

EM

BLY

FO

R 7

8°

ASSEMBLIES The following H-2-X, H-2-LX, and H-2-FX CONTROLAIR Valves are assembled as shown where handle location or push/pull handle action is required on special panel configuration.

Model New P/N Old P/N Configuration

H-2-X R431007252 P -067694-00003 Figure No. 1 Rev. nameplate Std. cam

H-2-X R431007323 P -068543-00003 Figure No. 2 Std. nameplate Reverse cam


H-2-X R431007324 P -068544-00003

No. 3 Rev. nameplate Reverse cam

H-2-X R431002639 P -050493-00002

Figure No. 4 Std. nameplate Std. cam


H-2-LX R431007326 P -068546-00003 Figure No. 1 Rev. nameplate Std. cam

H-2-LX --- P -065545-00003 Figure No. 2 Std. nameplate Reverse cam


H-2-X R431007327 P -068547-00003 Figure No. 3 Rev. nameplate Reverse cam

H-2-X R431002653 P -050499-00002 Figure No. 4 Std. nameplate Std. cam


H-2-FX R431007308 P -068521-00002 Figure No. 1 Rev. nameplate Std. cam

H-2-FX R431007328 P -068548-00003 Figure No. 2 Std. nameplate Reverse cam


H-2-FX R431007329 P -068549-00003 Figure No. 3 Rev. nameplate Reverse cam

H-2-FX R431002644 P -050494-00002 Figure No. 4 Std. nameplate Std. cam

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

Testing After any repair or adjustments, the H-2 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 fol-lowing: 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-2 Controlair Valves are spring returned handle actuated 3-way pressure graduating valves. The handle actuates the valve to increase, decrease or maintain graduated air pressure to the “OUT” port or delivery line. 2. 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: Move valve handle to the full travel position and hold. Fully open the valve at test vol ume 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. 6. Mechanical Detent (H-2-LX): Move handle to ex-

treme detent position. Connect a spring scale just under the knob. A minimum of 12 lbs. should be required to pull the handle out of detent.

Valve Range Fill Psi Maximum

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 to25 psi



0 to30 psi



0 to 35 psi



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


0 to 125 psi

0 to 50 psi 2 sec. 50 to 10


0 to 150 psi

0 to 50 psi 2 sec. 50 to 10


0 to 65 psi

0 to 15 psi 2 sec. 50 to 10


35 to 85 psi

35 to 70 psi 2 sec, 70 to 40


Flow Capacity Tests- Ports 1 & 3

Test Ranges & Times

Test Arrangement Diagram Notes: 1. AVENTICS Taskmaster Timing Volumes, part number R431002899 (TM–058887-00225) can be used for the volumes indicated. 2. The supply air line to the valve and the delivery lines must be full size as shown. Line must not exceed 3 Ft. (1 meter) between the supply valve and “IN” or supply port or “OUT” or delivery port. 3. It is recommended that as large of a gage as practical be used on the delivery lines. A 6” (150mm) test gage is

recommended.

R431016359 (PR-7816-10)

IDENTITY SCHEDULE

AVENTICS P/N PD-20031-0191

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

CHOKE PLUG .032

OPTIONAL: REQUIRED FOR LOW SPRING RANGE VALVES ONLY.

1/4” PIPE SCHEDULE 40 OR

3/8” O.D. TUBING OR

#6 SINGLE BRAID HOSE

PRESSURE GAGE DELIVERY

PRESSURE GAGE

IN OUT

TEST VALVE

225 in 3

225 in 3

NOTICE TO PRODUCT USERS 1. 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 packing and seals. Consult the factory. 2. WARNING: MATERIAL COMPATIBILITY Damage to product seals or other parts caused by the use of noncompatible 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 electri-cal, mechanical, piping and other codes in the installation, opera-tion 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 con-tain high levels of stored energy. Do not attempt to connect, dis-connect or repair these products when a system is under pres-sure. Always exhaust or drain the pressure from a system before performing any service work. Failure to do so can result in seri-ous 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 appropriate safe guards in the application or system design to prevent per-sonal 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 con-figuration, 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 con-ditions. 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 system" operating performance and leakage test once a year. Where devices re-quire 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 required, rebuilt and tested for leakage and proper operation prior to installation. See individ-ual 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 notice. 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 otherwise. 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 provided, 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 without notice.

AVENTICS Corporation 1953 Mercer Road Lexington, KY 40511 www.aventics.com/us [email protected] AVENTICS Incorporated 3426 Mainway Drive Burlington, Ontario CANADA L7M 1A8 www.aventics.com/ca [email protected]

SM-800.6502/May 2014 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-2 CONTROLAIR VALVE - AVENTICS · valve from large particles or foreign matter in the supply line....

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Transcript of H-2 CONTROLAIR VALVE - AVENTICS · valve from large particles or foreign matter in the supply line....