Aventics CONTROLAIR H-3 Instrucciones de funcionamiento e instalación

SM-800.6515

The H-3 TYPE CONTROLAIR Valves are 3-way

pneumatic pressure graduating valves. The operator

portion is equipped with a cam roller which can be

operated by another cam or similar mechanical

operator. The roller actuates the pressure graduating

potion to increase, decrease, or maintain graduated air

pressure to a separate delivery line.

In “release” position the delivery line is connected to

exhaust, except preload type. From “release” position,

force down on the roller actuates the graduating portion

to deliver graduated pressure to a delivery line

according to the value of control spring being used.

The roller is spring returned from all positions.

DESCRIPTION OF MODEL

Table of Contents Page

Description of Model .................................. 1

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

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

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

Outline View .................................................. 3

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

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

Diagrammatic & Assembly Views .................. 4

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

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

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

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

SH-3 Version ................................................. 9-10

Maintenance and Repair Instructions ............ 11

Adjustment and Repair Instructions .............. 11

Testing:

Function ................................................. 12

Pressure Range ..................................... 12

Leakage ................................................. 12

Flow Capacity......................................... 12

Response ............................................... 12

Test Set-up ............................................ 12

Test Diagram ................................................. 13

Warnings and Warranties .............................. 14

H-3, H-3-G & SH-3 CONTROLAIR® VALVE

Service Information

The user of these devices must conform to all applicable

electrical, mechanical, piping and other codes in the

installation, operation or repair of these devices.

INSTALLATION! Do not attempt to install, operate or

repair these devices without proper training in the

technique of working on pneumatic or hydraulic systems

and devices, unless under trained supervision.

Compressed air and hydraulic systems contain high

levels of stored energy. Do not attempt to connect,

disconnect or repair these products when a system is

under pressure. Always exhaust or drain the pressure

from a system before performing any service work.

Failure to do so can result in serious personal injury.

MOUNTING! Devices should be mounted and positioned

in such a manner that they cannot be accidentally

operated.

WARNING: INSTALLATION AND

MOUNTING

Installation and General Maintenance Recommendations

Installation

Before installing the CONTROLAIR® Valve, all air lines

in the system should be blown clean to remove any

moisture, dirt, or harmful contamination. Strainers are

furnished in the INLET and OUTLET ports to protect the

valve from large particles of foreign matter in the line. To

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

or better filter should be installed in the supply line to the

valve.

The H-3 Type CONTROLAIR is designed for side

mounting. Refer to page 3 for mounting dimensions.

Allow suitable clearance for removal of the pipe bracket

screws which are 1 ¾” (44.5 mm) long.

Travel of the cam roller and the position of the actuating

device must be considered in mounting. Refer to the

outline dimensions on page 3.

General Maintenance and Repair

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, or

every two years, whichever comes first.

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 having

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, pg.

11, and TEST PROCEDURES, pg. 12.

One complete CONTROLAIR Valve should be kept for each

four valves in service. During the maintenance period,

replace the complete valve with the “stand-by” unit. This will

reduce downtime and afford inspection and replacement of

worn parts at a more appropriate or opportune time and

favorable location.

Notice that the operating portion of a valve can be removed

without disturbing the pipe connections. Remove the valve

from the pipe bracket by loosening (2) screws and lifting the

unit free.

No special tools are required to maintain the CONTROLAIR

Valve.

Page 2

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 (0.1 Bar)

Control Pressure Range ................................. (Reference Identity Chart, Pg 7)

Pressure Change ........................................... ½ psi Increment (0.03 bar)

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

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

Materials

Controlair Valve Housing and Body ............ Die Cast Aluminum

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

Aluminum, and Steel

Weight ............................................................ 14.5 lbs (6.6. kg) approximately

H-3 CONTROLAIR® VALVES

OUTLINE DIMENSIONS

Page 3

Adjustable CAM Roller

0.031” Eccentric for total

Roller adjustment of 0.062”

to obtain 2.531” “A” Dim.

DESCRIPTION OF OPERATION

Page 4

In released position, the supply valve is closed to

supply pressure and “out” port is open to exhaust.

Note in the diagram, when the roller is forced down

to increase pressure, it pushes 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 reached to allow the upper

supply valve in 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 roller and is therefore proportional to the roller

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 roller position, the diaphragm in the control

portion will deflect downward opening the lower

exhaust valve and exhausting air until the original

setting is obtained. If the pressure drops below that

called for by the handle position, the decreased

force on the diaphragm will allow the control spring

to force the diaphragm upward, opening the upper

supply valve to restore the set pressure.

The range of pressure is controlled by the strength

of the diaphragm spring. Various values are

available as shown on Identity Schedule, page 5.

Outlet

VALVE

FUNCTION

Exhaust

Inlet

ASSEMBLY VIEW

Range Control

Spring

Exhaust Port Adjusting Screw

Diaphragm

Exhaust

Valve

Supply Valve

Inlet & Exhaust

Valve Unit

CAM Roller

Assembly

CAM Roller

Adjustment

DIAGRAMMATIC VIEW

Page 5

IDENTITY SCHEDULE

H-3 COMPLETE

DELIVERY

PRESSURE

RANGE

NEW VALVE

CONTROL*

PORTION

COMPLETE

NUMBER

OLD VALVE

CONTROL*

PORTION

COMPLETE

NUMBER

"A" DIMENSION

MAXIMUM

OUT PRES-

SURE +5/-0

PSI

NOTES

NEW PART

NO. OLD PART NO. NEW PART

NO. OLD PART NO.

NORMAL

POSITION

(1)

LAPPED

POSITION

(2)

MAXIMUM

PRES-

SURE

POSITION

(3)

R431002626 P -050382-00001 0-65 psi R431002850 P -051085-00001 R431003732 P -055442-00000 Brown 2.531" 2.469" 2.203" 65 psi

R431002627 P -050382-00002 0-100 psi R431002851 P -051085-00002 R431000043 -526749-00000 Yellow 2.531" 2.469" 2.213" 100 psi

R431002628 P -050382-00003 0-125 psi R431002852 P -051085-00003 R431000099 -540577-00000 Light Blue 2.531" 2.469" 2.205" 125 psi

R431002629 P -050382-00004 0-150 psi R431002853 P -051085-00004 R431003731 P -055441-00000 Red 2.531" 2.469" 2.205" 150 psi

R431002630 P -050382-00006 0-15 psi R431002854 P -051085-00006 R431005473 P -060293-00000 White 2.531" 2.469" 2.201" 15 psi

R431002631 P -050382-00008 0-25 psi R431002855 P -051085-00008 R431005475 P -060295-00000 Dark Blue 2.531" 2.469" 2.160" 25 psi

R431002632 P -050382-00009 0-75 psi R431002856 P -051085-00010 R431000056 -531418-00000 Dark Green 2.531" 2.469" 2.234" 75 psi

Unknown P -050382-00013 15-50 psi - - P -051085-00013 R431005471 P -060291-00000 Orange 2.531" 2.469" 2.189" 50 psi

Unknown P -050382-00015 0-65 psi R431002850 P -051085-00001 R431003732 P -055442-00000 Brown 2.531" 2.469" 2.203" 65 psi See note 1

Unknown P -050382-00016 0-175 psi - - P -051085-00015 R431003311 P -054159-00000 Silver 2.531" 2.469" 2.220" 175 psi

Unknown P -055184-00002 0-100 psi - - P -055209-00002 R431000043 -526749-00000 Yellow 2.531" 2.469" 2.213" 100 psi See note 2

Unknown P -057531-00001 0-65 psi - - P -058419-00000 R431003732 P -055442-00000 Brown 2.531" 2.469" 2.203" 65 psi See note 3

Unknown P -063107-00000 0-70 w/FP - - P -063107-00001 R431000056 -531418-00000 Dark Green - - - - - - Supply psi See note 4

R434002103 P -063234-00000 0-72 w/FP R431006208 P -063235-00000 R431000056 -531418-00000 Dark Green - - - - - - Supply psi See note 4

H-3-G

R434002033 P -052550-00001 0-65 psi R431002979 P -052551-00001 R431003732 P -055442-00000 2.531" 2.469" 2.203" - - - -

R431009131 P -052550-00008 0-25 psi R431002980 P -052551-00008 R431005475 P -060295-00000 2.531" 2.469" 2.203" - - - -

CONTROL SPRING & COLOR CODE

*Control portion less pipe bracket and mounting screws.

**Locations of "A" dimensions (1), (2) and (3) shown on Assembly Views.

Note 1: Same as R431002626 (Old P/N P -050382-00001) except ports in pipe bracket are 9/16-18 UNF thread, and Item 26 is part number unknown

(Old P/N P -059584-00000).

Note 2: Same as R431002627 (Old P/N P -050382-00002) except tapped exhaust, and Item 2 is part number P -066488-00003.

Note 3: Same as R431002626 (Old P/N P -050382-00001) except has special adjustable cam roller assembly with special parts.

Note 4: Same as R431002632 (Old P/N P -050382-00009) except with full pressure feature and body less cam dog lugs (special valve portion, and

item part numbers required, consult factory).

CAM Roller Assembly

CAM Roller Adjustment

(1) Release Position

(2) Lapped Position

(3) Maximum Pressure Position

** “A” Dimension

Page 6

Notes:

1. See page 7 for part numbers.

2. See page 8 for repair kits.

3. Matched/lapped set of items 13 and 14, and

8 - 12 are in kit, Part Number

R431003895 page 8.

Pipe Bracket

Valve Control Portion Complete

(See Identity Schedule)

20 19

EXPLODED VIEW

PARTS LIST

Page 7

H-3 & H-3-G

REF. QTY. DESCRIPTION NEW PART

NO. OLD PART NO.

1 1 Adjusting screw R431006770 P -066209-00000

2 1 Spring housing w/nut R431006822 P -066488-00002

2A 1 Spring housing H-3-G R431002975 P -052199-00000

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

4 1 Spring seat R431000036 -526347-00000

5 1 Control spring (See Identity Schedule, page 5)

6 1 Body, w/2 studs R431000045 -526874-00000

7 2 5/16"-18 x 1 3/8" Cap screws R431000160 -850557-00000

1 Diaph. Unit incl. 8, 9, 10, 11, 12 * See Kit

8 1 Exhaust valve seat * See Kit

9 1 11/16" O.D. "O" ring * See Kit

10 1 Diaphragm * See Kit

11 1 Diaphragm follower * See Kit

12 1 5/16"-18 Hex nut * See Kit

13 1 Inlet & Exhaust valve (incl. Item 14) * See Kit

14 2 3/4" O.D. "O" ring * See Kit

15 1 Exhaust valve spring * See Kit

16 1 Boot, dirt protector * See Kit

17 2 Strainers * See Kit

18 2 Gaskets * See Kit

19 1 Pin, pivot * See Kit

20 2 Retaining ring, 1/4 * See Kit

21 1 Cam roller assembly (incl. 22, 23, 24) * See Kit

22 1 Lever with Tip and nut * See Kit

23 1 Roller * See Kit

24 1 Pin, Fulcrum (eccentric) R431002950 P -051856-00000

25 2 3/8"-16 x 1 3/4 Cap screw R431000161 -850563-00000

26 1 Pipe bracket R431004175 P -057558-00000

27 1 Fulcrum Pin * See Kit

28 1 Nut * See Kit

NOTE: Parts list items (1) through (24) - Control Portion

Parts list items (1) through (26) - H-3 CONTROLAIR Valve Complete

* See repair kits on page 8.

REPAIR KITS

Page 8

OLD PART NO. QTY. PER

VALVE DESCRIPTION

P -055687-K0000* 1

MINOR GRADUATING VALVE PORTION Repair Kit

(Includes Items 8, 9, 10, 11, 12, 13, 14)

See note 1

P -059028-K0000 1 MAJOR GRADUATING VALVE PORTION Repair Kit

(Includes Items 15, 16, 17, 18, and Kit R431003895)

P –051127-K0001 1 LEVER Repair Kit

(Includes Items 19, 20, 21, 22, 23)

P –065636-00000 1 Lever Kit with Fulcrum Pin & Nut

(Includes Items 19, 20, 22, 23, 27 & 28)

NEW PART NO.

R431003895

R431004887

R431002873

R431006648

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 5.

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

4. Valve portion kits listed above contain seals and other parts that are recom-

mended 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 page 7.

SH-3 CONTROLAIR® VALVE

Page 9

Item Qty. Description New Part Number Old Part Number

1 1 Body Complete Unknown P –063148-00000

* 2 1 Valve Assembly, Inlet & Exhaust (Includes (2) “O” Ring P See Repair Kit

* 3 1 Spring, Exhaust Valve See Repair Kit

* 4 1 Seat, Exhaust Valve See Repair Kit

* 5 1 “O” Ring, 15/16 O.D. See Repair Kit

* 6 1 Diaghragm See Repair Kit

* 7 1 Follower, Diaphragm See Repair Kit

8 1 Nut, 9/16-18 R431002424 P –049901-00031

* 9 1 Protector, Dirt See Repair Kit

* 10 1 Seat, Spring See Repair Kit

11 1 Housing Complete, Spring R431006189 P –063137-00000

12 2 Screw, 5/16 x 1 3/8 R431000160 -850557-00000

13 4 Nut, 5/16 R431002419 P –049901-00020

* 14 2 Strainer See Repair Kit

* 15 2 Gasket See Repair Kit

16 1 Spring, 60 for P –063150-00001 R431000056 -531418-00000

16a 1 Spring, 60 psi for P –064920-00001 R431006547 P –065000-00000

16b 1 Spring, 15 psi for P –064920-00005 R431005475 P –060295-00000

16c 1 Spring, 25 psi for P –064920-00007 R431005472 P –060292-00000

* 17 1 Lever See Repair Kit

18 1 Pin, Fulcrum (not shown) R431002950 P –051856-00000

19 1 Bearing (not shown) R431001870 P –049585-00007

* 20 1 Roller, Cam See Repair Kit

* 21 1 Pin, Double Cotter See Repair Kit

* 22 2 Pin, 1/16 x 1/2

23 1 Bracket, Pipe R431004175 P –057558-00000

24 2 Screw, 3/8 Cap (not shown) R431000161 -850563-00000

See Repair Kit

The SH-3 has a larger diaphragm for minimum

hysteresis, better graduation and increased sensitivity.

See page 10 for additional dimensional information.

* See Repair Kits on this page.

OLD PART

NUMBERS DESCRIPTION

P –064993-K0000

(Minor Kit) Includes items 2, 3, 4, 5, 6 and 7

P –065018-00000

(Major Kit) Includes kit R431006544 plus items

9, 10, 14 and 15

P –063154-K0000

(Lever Kit) Includes items 17, 20, 21 and 22

Repair Kits for SH-3

NEW PART

NUMBER

R431006544

R431006556

R431006192

Repairs for complete devices

P -066183-00001

P -066183-00002

*P -066183-00003

*P -066183-00004

*P -066183-00006

P -066183-00008

P -066183-00009

P -066183-00015

P -066184-00002

P -066186-00001

SH-3 CONTROLAIR® VALVE

Page 10

Old Valve

Part Number

‘A’ (Factory Setting)

Full Exhaust Ex. Valve Closed 0 psi Delivery Max. Delivery

2.750” 2.625” Approx.

60 psi @2.125

-0

P –063150-00001

New Valve

Part Number

—

Old Valve

Part Number

Lever Travel ‘A’ (Factory Setting)

2.27” 2.531”

P –064920-00001 Full Exhaust 10 psi 60 psi

-1

P –064920-00005 Full Exhaust 3 psi 15 psi

-1/2

P –064920-00007 4 psi max. 10 psi 25 psi

-1

*2.114

New Valve

Part Number

R431006528

R431006529

—

* Note: Travel further than the 2.114 dimension will damage the valving seals.

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