Aventics CONTROLAIR H-1 Manual, Service Information

Manual, Service Information for Aventics CONTROLAIR H-1 Control Unit (17 pages)

Specifications:

1468/1468891-controlair_h1.pdf file (29 May 2024)
  • Manufacturer: Aventics
  • Category of Device: Control Unit
  • Document: CONTROLAIR H-1, File Type: PDF Service Information
  • Updated: 29-05-2024
  • Count of Pages: 17
Download CONTROLAIR H-1 Manual (17 pages)

Read Aventics CONTROLAIR H-1 PDF Manual Online:

Data: UPD 29th May 2024

Aventics CONTROLAIR H-1 Control Unit PDF Service Information (Updated: Wednesday 29th of May 2024 09:47:15 PM)

Rating: 4.4 (rated by 80 users)

Compatible devices: NL1, TC08, CERAM GX Series, CONTROLAIR HC-2 Series, CONTROLAIR H-4-G, CONTROLAIR THD-2-FM, VCU, R434001003.

Recommended Documentation:

Text Version of Aventics CONTROLAIR H-1 Control Unit Manual

(Ocr-Read Summary of Contents, Document's Main Page, UPD: 29 May 2024)
  • Page 1:

    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.

  • Page 2:

    Installation and General Maintenance Recommendations

    Page 2

    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

  • Page 3:

    Page 3

    H-1 CONTROLAIR

    ®

    VALVES

    OUTLINE DIMENSIONS

  • Page 4:

    H-1 CONTROLAIR

    ®

    VALVE

    LIGHT PEDAL FORCE

    OUTLINE VIEW

    Page 4

  • Page 5:

    H-1-A CONTROLAIR

    ®

    VALVES

    OUTLINE VIEW

    Page 5

  • Page 6:

    DESCRIPTION OF OPERATION

    Page 6

    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

  • Page 7:

    Page 7

    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

    Remarks

    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 Note 1

    H-1 R431002982 P -052570-00002 0-65 psi R431000043 -526749-00000 R431002875 P -051133-00002 Note 2

    H-1 P -065292-0000 0-35 psi R431005475 P -060295-00000 P -057182-00008 Note 3

    H-1 R431005617 P -060921-00001 0-65 psi R431003732 P -055442-00000 R431002874 P -051133-00001 Note 4

    H-1 R431005618 P -060921-00002 0-100 psi R431000043 -526749-00000 R431002875 P -051133-00002 Note 4

    H-1 R431005619 P -060921-00003 0-125 psi R431000099 -540577-00000 R431002876 P -051133-00003 Note 4

    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 Note 5

  • Page 8:

    Page 8

    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 & 13

    are in kit, p/n R431003892

    (P -055687-00000) page 11.

    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)

  • Page 9:

    PARTS LIST

    Page 9

    *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*

    New H-1++ Lt.

    Pedal

    P -060925-

    00000*

    New 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

    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

    ---

    ---

    ---

    ---

    ---

    ---

    ---

    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.

  • Page 10:

    PARTS KITS

    Page 10

    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

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

    Ref

    Qty Description New Part No. Old Part No.

    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 --- ---

    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

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

    Ref Qty Description New Part No. Old Part No.

    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 --- ---

    9 1 ¼” 20 Nut --- ---

    16

  • Page 11:

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

    Page 11

    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)

    Part Number Quantity

    Per Valve

    Description

    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)

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

  • Page 12:

    MAJOR REPAIR AND MAINTENANCE, ADJUSTMENTS

    Page 12

    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

  • Page 13:

    MAJOR REPAIR AND MAINTENANCE, ADJUSTMENTS

    (continued)

    Page 13

    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

  • Page 14:

    TESTING AND TEST SET-UP

    Page 14

    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

    Test Volume

    Cu. In.

    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

  • Page 15:

    Page 15

    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

  • Page 16:

    Page 16

    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.

  • Page 17:

DOC-82e4f86b:

Recommended:

CI-6.0, ASB3545WF, C3100, CE870, DLCX36SP93N-1, HP 802.11b Printer Card C8264A#A2L C8264A#A2L, Toscana 240301, 390.2532
Additional Information:
# Brand Model Document Type/File Pages File Size Last Checked
1 CD Automation
REVEX 3PH 120A
55 09/06
2 Siemens
SINAMICS DCM
44 11/03
3 LOVATO ELECTRIC
RGK900
83 17/04
4 Zte
MG2636
50 26/02
5 Jflow controls
DM4800 SERIES
5 15/01
6 urmet domus
1083
44 28/02
7 Graco
C Series
8 18/04
8 Videx
VX8800
4 16/04
9 American Flow Control
2500 Series
65 18/04
10 Allen-Bradley
SLC 500
120 30/04
11 Phi Robotics
H-ELC-SEN-MAG-1
5 30/03
12 Schmalz
SCPi
9 13/03
13 resideo
Braukmann R295SA
8 02/03
14 Flowserve
Valtek Mark Two
16 11/03
15 HydroQuip
9700 Series
40 20/05
16 Siemens
SINAMICS G120P CU230P-2
52 01/02
17 Bailey
Infi 90 NIDO01
30 20/01
18 SSS Siedle
BMM 611-0
28 06/12
19 rako
RA-IBB
4 24/02
20 ABB
ACS850 series
28 16/04
Popular Right Now:
# Brand Model Document (PDF) Pages Size Check Date
1 HIKVISION
DS-2CC5197P-VP
6 08.05.
2 EGO
CH5500E
65 19.03.
3 ADJ
KAOS
18 28.02.
4 Casio
5130 (OC)
4 31.01.
5 GEA
D 10
96 11.02.
6 Lennox
ComfortSense 7000 series
8 06.01.
7 Toro
23518
118 28.05.
8 Blodgett
KLS-G SERIES
12 01.04.
9 Clockaudio
SM 80 Series
2 01.04.
10 Grindmaster
B-DAP
1 0.17 Mb 24.03.
11 Cleanmaxx
PC-P003WH
48 02.02.
12 Interlogix
ES3002-4P-4T
8 24.05.
13 Panasonic
TX-P50UT50Y
48 11.12.
14 Sony
VGN-CR515E - VAIO CR Series
2 14.12.
15 Medel
SONNET
15 02.04.
16 Sven
KB-C3060
8 09.12.
17 Baby Lock
A-LINE Grace BL40
102 2.94 Mb 26.01.
18 Fujitsu
ScanParter 10C
32 27.01.
19 Herz
7708 Series
7 22.04.
20 Hozelock
PROMO 4005
32 16.04.
Operating Impressions, Questions and Answers: