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Catalogo para especificação de valvulas
Tipologia: Manuais, Projetos, Pesquisas
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HC-2 CONTROLAIR
® VALVE
Service Information
Description of Models
The HC-2 Type Controlair Valves are handle
operated 4-way, exhausted center, pressure
control valves.
The typical unit contains two directional control
3-way side valves and a pressure graduating
portion that is arranged to increase, decrease
or maintain air pressure to (2) separate delivery
lines. In neutral position both 3-way side valves
exhaust both delivery lines. A movement of 10
degrees either side of center position opens
the appropriate side valve and directs pressure
to the indicated outlet port. Continued move-
ment past 10 degrees up to full travel or 46
degrees either side of neutral continues to ac-
tuate the pressure-graduating portion to deliver
a graduated pressure according to the value of
the control spring.
Models
There are four models with similar valve func-
tions, but different handle operating character-
istics.
HC-2-X Controlair Valve -Handle is spring
returned to neutral position from all positions in
the handle travel. Some special models exist.
See notes on Identity schedule on page 7.
HC-2-LX Controlair Valve - Handle is spring
returned to neutral position from all positions
except at the maximum pressure setting on
both sides of center. The handle is held in both
extreme positions by a mechanical detent.
HC-2-FX Controlair Valve - Handle is
equipped with a friction brake that will hold the
handle in any position selected in the handle
travel.
HC-2-SX Controlair Valve - Handle holds in
only one maximum pressure position. The han-
dle is spring returned to neutral position from
all other positions in the handle travel. The
valve can be ordered to hold in either extreme
position.
Table of Contents Page
Description of Models 1
Warnings 2 Technical Data 2 Installation 2
Maintenance and Repair 2 Outline Dimensions 3 Descriptions of Operation 4
Maintenance and Repair 5 Graphical Symbol 6 Identity Schedule 7
Exploded View 8 Part List 9 Repair Kit List 10
Testing Function 11
Pressure Range 11 Leakage 11 Flow Capacity 11
Response 11 Mechanical Detents 11 Test Setup 11
Test Diagram 12
GENERAL MAINTENANCE AND REPAIR
RECOMMENDATIONS
Maintenance periods should be scheduled in accor-
dance 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 leak-
age test at least once a year. If these visual observa-
tions indicate valve repair is required, the valve must
be removed immediately and repaired.
A major overhaul is recommended at one million cy-
cles. However, where frequency of use is such that it
would require more than two years to obtain the one
million cycles, the valve must be overhauled at the two
year period.
When it is determined that the Controlair Valve re-
quires a major repair as a result of the one million cy-
cles, one year routine inspection or the two year ser-
vice period has elapsed, the device must be disassem-
bled, cleaned, inspected, parts replaced as required.
The valve then must be tested 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
removed without disturbing the pipe connections by
just removing the (3) screws that hold the pipe bracket
to the valve.
No special tools are required to maintain the Controlair
valves, with the exception of internal snap– ring pliers.
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 inspec-
tion and replacement of parts at a more appropriate
time and favorable location.
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 re-
pair 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 de-
vices, unless under trained supervision.
Compressed air and hydraulic systems con-
tain 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 pres-
sure 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 Maintenance Rec-
ommendations
Before installing the Controlair
Valve, all air
lines in the system should be cleaned to re-
move all dirt, moisture or contamination.
A strainer is furnished on the inlet port to pro-
tect the valve from large particles or foreign
matter in the supply line. To ensure long, trou-
ble-free service, a 10 micron or better filter
should be installed in the supply line to the
valve.
The HC-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 installation view for panel
opening dimension. Allow suitable clearance
for installing or removing of the (3) pipe bracket
screws which are 2 1/8” long.
Installation and General Maintenance Recommendations
Description of Operation
For HC-2 Controlair
®
Note in the diagrammatic view that supply pressure is connected to
port (2) and this supply pressure is directed only to the pressure-
graduating portion. The delivery from the pressure graduating portion
encounters plugged port (8) (a pressure gage can be connected at
this port) and continues to become the supply air to each of the side
valves. The delivery from the side valves is directed to outlet ports
(1) or (3).
With the handle in neutral position, both outlet ports are exhausted to
atmosphere through their respective side valve.
Movement of the handle through the first 10 degrees of travel from
neutral operates one of the 3 way side valves to connect the gradu-
ated pressure from the graduating portion to the appropriate outlet
port (1) or (3).
Movement of the handle beyond 10 degrees either side of center po-
sition starts the cam to push down on the pressure control plunger
closing the exhaust valve and opening the upper supply valve that
allows air to flow through the selected side valve to an outlet port. As
the pressure 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 diaphragm deflection is ob-
tained 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 move-
ment in turn is controlled by the cam contour and is proportional to
the handle travel.
The HC-2 Controlair Valve will automatically compensate for air pres-
sures changes. 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 the handle position, the
diaphragm in the control portion will deflect downward opening the
lower exhaust valve and exhausting air until the original setting is ob-
tained. If the pressure drops below that called for by the handle posi-
tion, 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 the Identity Sched-
ule on page 7.
Repair and Maintenance Instructions When it has been determined that the Controlair
Valve
requires repairs, the following general instructions are rec-
ommended.
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 #2. Be sure all pas-
sages 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 #55, use of an impact
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 repair kits is recom-
mended.
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 dia-
phragm 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 com-
pound. Be sure to clean these parts prior to installing in the
valve.
Installing the cam set screw Item #55: The cam set screw
must be fully seated into the drill point location on the cam-
shaft, items #62 or #63. When installing set screw Item #
use a thread locker like Loctite TL242.
When installing the handle Item #53, seat the handle into
the yoke, Item #52 before installing the nut, Item #51.
Do not over torque the cap nut, Item #60.
Adjustments Screw, Item #40 varies the graduated output pressure
setting. Screw Item #23 adjusts the opening of the side
valves and screw. Item #19 aligns the follower Item #
with the cam Item #61. The nut Item #50 adjusts the brake
tension on the HC-2-FX versions.
Side Valve Lever Adjustments
With air supplied to the valve, turn adjusting screw Item
#40 in until the control spring Item #30 is slightly com-
pressed. Remove the snap rings and screens Item #15, 16
& 17. Move the Controlair Valve handle Item #53 back and
forth, both sides of the neutral position, observing the action
of the levers Items #20 & #22. The side valves should be
fully open after the handle moves the first 10 degrees of
travel.
Move the control handle to a maximum pressure position.
With a 3/32” Allen wrench, back out adjusting screws Item
#23 of the operated lever Items #20 or #22 just far enough
to open the exhaust valve so that gage in the output line
starts to show a drop in pressure. From this point, turn the
adjusting screw in a full three (3) turns. This will open the
inlet valve of the side valve to its maximum capacity.
Move the handle to the other extreme position and repeat
these adjustments on the other side valve lever.
Graduated Output Pressure Adjustments Adjusting screw Item #40 varies the maximum pressure setting. Turning the adjusting screw in raises the maximum
pressure. Turning the screw out decreases the maximum pressure. The maximum control pressure adjustment should not exceed the maximum control pressure shown in the
Identity Schedule for part numbers. (Control springs are color-coded).
Changing the control spring Item #30 can change the maximum output pressure rating. With air supplied to the valve, move handle in either di-
rection from neutral to full travel position and hold. Adjust graduating valve screw Item #40 to obtain the maximum control pressure per Identity schedule. Move handle back to
neutral position and note delivery line is exhausted to zero. Move handle to full travel position in the opposite direction and the delivery pressure should be the same as the other
side. If the delivery pressure is higher or lower by 2 to 3 psi it can be corrected by adjusting the cam dog Item #18 with adjusting screw Item #19. Move the handle back to neutral
position and note delivery line is exhausted to zero.
Cam Dog Adjustment
The eccentric cam dog screw Item #19 aligns the cam follower Item #18 with the rise in the cam item #61. If the pressure setting is not within 2 to 3 psi from one full handle
travel position to the other, turning the eccentric screw Item #19 either clockwise or counter-clockwise can compensate
for the difference. This adjustment is accessible from the outside of the valve through the notch under the panel flange using a long flat bladed screwdriver.
The following procedure is recommended: move the valve handle to Full Travel in one direction (on detented models handle should be placed in detent position). Observe the
output gage and note the pressure. Move the handle to the opposite position, turn the eccentric cam follower screw Item #19 to half way between the pressure difference. Con-
tinue adjustment until delivery gages (ports 1 and 3) match within 2 to 3 psi of each other for related handle position.
Special Preload Setting This setting calls for a predetermined delivery pressure when the handle is moved 10° from neutral in either direc-
tion. Place handle 10° from neutral in either direction. Turn adjusting screw Item #40 in until the gage reads the desired
preload pressure. Move the handle to the maximum pres- sure position. The delivery gage should read, preload pres-
sure plus the range value of the control spring within ± 3 psi. Check handle setting in the opposite direction.
Force Brake Adjustment
The handle force of the HC-2-FX 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 travel.
This adjustment is normally made on the cam housing portion before assembling to the control portion.
Repair and Maintenance Instructions
HC-2 IDENTITY SCHEDULE
Model Complete Part^ Control Pressure^ Control Spring & Color^ Cam Portion^ Valve Portion^ Remarks
HC-2-X P –050975-00008^ 0 - 30^ P60295 Dark Blue^850253 P –055583-
HC-2-FX P –055781-00001^ 0 - 65^ P55442 Brown^ P65690^ P –055583-00001^ Note 8
HC-2-LX P –055582-00003^ 0 - 125^ 540577 Light blue^850430 P –055583-
HC-2-SX P –051206-00004^ 0 - 150 P55441 Red^ P68525^ P –055583-
EXPLODED VIEW
HC-2-X CONTROLAIR®
HC-2-LX CONTROLAIR®
HC-2-SX CONTROLAIR®
HC-2-FX CONTROLAIR®
60
60
63 59
58 57
58 56
65 64 62
47
48
49
50
54
53
52
51
67
66
38
61
55
44
46
45
41
37
36
25
30
31
32
5
68
69
35
34
35
29
39
42
4
1
2
3
7
15
16
17
22
24
21
23
18
19
20
28 27
40
33
Repair Kits for HC-2 Controlair
® Valves
Chrome plated HC-2 Controlair
® Valves
with chrome plated parts for item numbers listed
(See notes 4, 5, 9, 10, 11 and 15 --Page 7)
Item 38 Item 52 Item 53
Model Cam Housing Yoke Handle Shaft
Part Number Part Number Part Number
HC-2-X P –065689-00001 P –050851-00008 P –066852-00001 P –050979-
P –065689-00003 P –050851-00008 P –066852-00001 P –050979-
P –065123-00001 P –050851-00008 P –066852-00001 P –050979-
HC-2-FX P –065123-00002 P –050851-00008 P –066852-00001 P –050979-
P –065123-00003 P –050851-00008 P –066852-00001 P –050979-
HC-2-LX P –068520-00003 P –050851-00008 P –066852-00001 P –050979-
Complete
Part Number
Quantity Description per valve
P -055687-00000 1 Minor Graduating Valve Portion-Repair Kit
Note 1 includes items 25, 29, 34, 35, 36, 37, 39 & 42
P -057136-00000 1 Major Graduating Valve Portion-Repair Kit
Note 1 includes items 2, 3 & 18 and kit P
P -055474-00002 2 Minor Side Valve Portion-Repair Kit
includes item 7 cartridge with "O" Rings
P -057094-00001 2 Major Side Valve Portion-Repair Kit
includes snap rings, screen and kit P -055474-
P -064894-00002 (^1) Complete Repair Kit for Control Portion -
Notes 1,2,3 & 4 includes (1) kit P -055687-00000,
(2) kits P -057094-00001, items 2, 3, 16 & 17
P -064421-00001 1 Spring Latch Kit for LX and SX Models
Note 5 includes items 44, 45 & 46
850187-00000 (^1) Friction Brake Kit for FX Models
Note 5 includes items 47, 48, 49, 50 & 65
P -064421-00004 1 Cam Shaft Kit for FX Models
Note 5 includes items 51, 52, 53, 54 & 62
P -064421-00005 (^1) Cam Shaft Kit for All Models
Note 5 includes items 51, 52, 53, 54 & 63
P -064421-00009 (^1) Return Spring and Arbor Kit for X, LX & SX Models
Note 5 includes items 57, 58 & 59
Piece Number
P –066891-K0000 1 Pipe Bracket Portion Kit for all Models
includes items 1, 2, 3 & 4
NOTES:
a matched set. Kits that contain these items from the factory include matched sets.
parts are listed on pages 7, 8 and 9.
Testing and Test Set-Up
Testing
After any repair or adjustments, the HC-2 Contro-
lair Valve should be tested using the following proce-
dures and test arrangements.
Pressure control valves need to be tested for the
following:
The adjustments affecting these points were de-
scribed in the previous sections.
General instructions for accomplishing these tests
are listed below.
1. Function: The HC-2 Controlair valve is a 4 way
exhausted center valve capable of graduating
pressure in one or the other delivery lines. This
function must be checked using the test arrange-
ment to insure that only one volume is charged in
either direction of handle travel.
2. Pressure Range : The minimum and maximum
pressure range generated in the delivery lines (1)
and (3) is specified by the control spring in use.
See the graduated output pressure setting Ad-
justment Section. After the valve is adjusted,
confirm that the minimum and maximum pres-
sure ranges are generated in the delivery lines
(1) and (3) as per the Identity Schedule by mov-
ing the handle from neutral to first 10° then to the
full travel position on both sides of center.
3. Leakage: Set supply pressure to 20 psi above
maximum delivery pressure of the valve being
tested. Using a soap and water solution, coat the
valve at the pipe bracket and spring housing
parting lines. No leakage is permitted in any han-
dle position.
A. Port (1)
90 psi., set supply line pressure to 100 psi,
handle to full travel position and hold (detent
position on detented valves). Close valve in
supply line to port (2) and valve in delivery
line (1) to isolate graduating valve. Observe
delivery pressure gage in line (1). A pressure
drop of no more than 2 psi in 30 seconds is
permitted.
and above, set supply line pressure to 100
psi. Move valve handle to deliver 95 psi to
delivery line (1) and hold in that position.
Close valve in supply line to port (2) and
valve in port (1) delivery line to isolate the
graduating valve. Observe the delivery gage
in line (1). A pressure drop of no more than 2
psi in 30 seconds is permitted.
B. Port (3)
less in opposite direction of the handle
travel.
more in opposite direction of the handle
travel.
4. Flow Capacity: Set supply line pressure to 100
psi regardless of the control spring rating. Move
the handle from neutral position in either direc-
tion to full travel position. The delivery volume (1)
or (3) should start to fill within the time limits
shown in Table 1.
Move the handle quickly from full travel position
back to neutral position. This should exhaust vol-
ume (1) or (3) within the time limits shown on
table 1. Note valve with less than 0 to 35 psi or
less rated springs require an additional volume
as shown in test arrangement diagram.
5. Response
A. Port (1) Move valve handle to the full travel
position and hold. Fully open the valve at test
volume (1) so that that the air exhausts
through the choke plugs. Observe the deliv-
ery pressure gage at volume (1). A pressure
drop of no more than 3 psi permitted.
B. Port (3) Repeat test 5A for opposite direction
of handle travel.
6. Mechanical Detent (HC-2-LX or SX Models only):
Move handle to extreme detent position. Connect
a spring scale just under the knob Item #54. The
force required to pull the handle out of detent
position should be at least 12-lbs. Check detent
hold in both extreme handle positions.
Valve Range
Fill Psi Maximum Time-Sec
Exhaust Psi
Max. Time
Test Vol. 0 to psi
0 to 15 psi 2 sec^
15 to 5 psi 2 sec.^
cu.in.
0 to psi
0 to 15 psi 2 sec^
15 to 5 psi 2 sec.^
cu.in.
0 to psi
0 to 15 psi 2 sec^
15 to 5 psi 2 sec.^
cu.in.
0 to psi
0 to 15 psi 2 sec^
15 to 5 psi 2 sec.^
cu.in.
0 to 35 psi
0 to 15 psi 2 sec^
15 to 5 psi 2 sec.^
cu.in.
0 to 65 psi
0 to 50 psi 2 sec.^
50 to 10 psi 2 sec.^
cu. In.
0 to 100 psi
0 to 50 psi 2 sec.^
50 to 10 psi 2 sec.^
cu. In.
0 to 125 psi
0 to 50 psi 2 sec.^
50 to 10 psi 2 sec.^
cu. In.
0 to 150 psi
0 to 50 psi 2 sec.^
50 to 10 psi 2 sec.^
cu. In.
0 to 65 psi
0 to 15 psi 2 sec.^
50 to 10 psi 2 sec.^
cu. In.
35 to 85 psi
35 to 70 psi 2 sec.^
70 to 40 psi 2 sec.^
cu. In.
Flow Capacity Tests- Ports 1 & 3 Test Ranges & Times