SM-800.6516 H4 Controlair
SM-800.6516 H4 Controlair
Service Information
DESCRIPTION OF MODELS
SM-800.6516
Installation and General Maintenance Recommendations
Installation General Maintenance
Before installing the Controlair® Valve, all air lines in Maintenance periods should be scheduled in
the system should be blown clean to remove any accordance with frequency of use and working
moisture, dirt, or harmful contamination. Strainers are environment of the Controlair Valve. All valves must
furnished in the Inlet and Outlet ports to protect the be visually inspected for wear and given an “in
valve from large particles of foreign matter in the line. system” operating performance and leakage test at
To further ensure long, trouble-free service, a 10 least once a year. If these visual observations
Micron or better filter should be installed in the supply indicate valve repair is required, the valve must be
line to the valve. removed, repaired and tested.
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OUTLINE DIMENSIONS
Page 3
DESCRIPTION OF OPERATION
VALVE
FUNCTION
Exhaust Outlet
Inlet
Description of Operation
Page 4
IDENTITY SCHEDULE
New H-4 Old H-4 Delivery New Valve Old Valve New Control Old Control Remarks
Complete Complete Pressure Portion Portion Spring Spring
Part Part Part Part Part Part Number &
Number Number Number Number Number Color Code
R431002818 P -050967 0-65 psi R431002874 P -051133 R431003732 P -055442-00000 Clockwise knob rotation
-00001 -00001 Brown increases pressure
R431002819 P -050967 0-100 psi R431002875 P -051133 R431000043 -526749-0000 Clockwise knob rotation
-00002 -00002 Yellow increases pressure
R431002820 P -050967 0-125 psi R431002876 P -051133 R431000099 -540577-0000 Clockwise knob rotation
-00003 -00003 Lt. Blue increases pressure
P -050967 0-150 psi R431002877 P -051133 R431003731 P -055441-00000 Clockwise knob rotation
R431002821 -00004 -00004 Red Increases pressure
P -050967 0-20 psi OBSOLETE R431005473 P -060293-00000 Clockwise knob rotation
OBSOLETE -00006 White Increases pressure
P -050967 0 -30 psi R431002878 P -051133 R431005475 P -060295-00000 Clockwise knob rotation
R431002822 -00008 -00008 Dk. Blue Increases pressure
P -050967 0-175 psi R431002879 P -051133 R431003311 P -054159-0000 Clockwise knob rotation
OBSOLETE -00015 -00015 Silver increases pressure
P -050967 0-55 psi P -051133 R431006501 P -064822-0000 Clockwise knob rotation
OBSOLETE -00016 -00016 Plain increases pressure
P -052742 0-30 psi P -057182 R431005475 P -060295-0000 Clockwise knob rotation
-00008 -00008 Dk. Blue increases pressure
P -051173 0-65 psi R431002874 P -051133 R431003732 P -055442-00000 Counterclockwise knob
R431002885 -00001 -00001 Brown pressure
rotation increases
P -051173 0-100 psi R431002875 P -051133 R431000043 -526749-00000 Counterclockwise knob
R431002886 -00002 -00002 Yellow pressure
increases pressure
P -051173 0-125 psi R431002876 P -051133 R431000099 -540577-00000 Counterclockwise knob
R431002037 -00003 -00003 Lt. Blue pressure
increases presssure
* Control portion less pipe bracket with operator portion and mounting screws. (See pages 6 & 7 for item numbers and parts
description).
**Same as R431002822 (P -050967-00008) except diaphragm unit complete is R431003715 (P -055409-00002); items 10,
13, 14 and 18 are part numbers R431000486 (P -005102-00000), R431003711 (P -055406-00000), R431001923 (P -
049623-00113), and R431000489 (P -005103-00000) respectively (low temperature operation to -65°F or -54°C).
Page 5
EXPLODED VIEW
Note:
20
21 1. See page 5 & 7 for part
number
2. See page 8 for repair kits 33C
3. Matched/lapped set of item
16 13 & 8 are in kit, P/N 33A
19 R431003895
(R431003895), page 8 33B
7
6 25
7
27
14
29
13 (Note 3)
33B
14 28
15 32
26
8 (Note 3)
10
14
24
23
12
30
31
5
31
2 4
Valve Control Portion Complete
(See Identity Schedule, Page 5)
Page 6
PARTS LIST
Ref. Qty Description New Part Number Old Part Number
1 1 Adjusting screw R431006770 P -066209-00000
2 1 Spring housing with nut R431006822 P -066488-00002
3 4 Nuts, 5/16” – 18 R431002419 P -049901-00020
4 1 Spring set R431000036 -526347-00000
5 1 Control Spring (See identity schedule, Pg. 4) (See identity schedule, Pg. 4)
6 1 Body with 2 studs R431000045 -526874-00000
7 2 5/16” – 18 X 1 3/8” Cap screws R431000160 -850557-00000
1 Diaphragm Unit incl. 8, 9, 10, 11, 12 * SEE KITS * SEE KITS
8 1 Exhaust valve seat * SEE KITS * SEE KITS
9 1 11/16” O.D. “O” ring * SEE KITS * SEE KITS
10 1 Diaphragm * SEE KITS * SEE KITS
11 1 Diaphragm follower * SEE KITS * SEE KITS
12 1 5/16” – 18 Hex nut * SEE KITS * SEE KITS
13 1 Inlet and exhaust valve * SEE KITS * SEE KITS
14 2 ¾” O.D. “O” ring * SEE KITS * SEE KITS
15 1 Exhaust valve spring * SEE KITS * SEE KITS
16 1 Boot, dirt protector * SEE KITS * SEE KITS
17 2 Strainers * SEE KITS * SEE KITS
18 2 Gasket * SEE KITS * SEE KITS
19 1 Pin, pivot R431001563 P -048189-00000
20 2 Retaining ring, ¼ R431001844 P -049528-00001
21 1 Cam dog R431003014 P -052835-00000
22 1 ¼” – 20 X ¾” Screw R431002085 P -049728-00011
23 1 Spring seat, washer R431002466 P -049904-00053
24 1 Spring * SEE KITS * SEE KITS
25 1 Shaft R431003713 -055407-00000
26 1 Cam (clockwise) * SEE KITS * SEE KITS
26a 1 Cam (counterclockwise) R431000095 -539406-00000
27 2 1/8” X ½” Key R431002108 P -049767-00002
28 1 Brake * SEE KITS * SEE KITS
29 1 Adjustable stop * SEE KITS * SEE KITS
30 1 ¼” – 20 X ½” Screw R431001873 P49592-0004
31 2 3/8” – 16 X 1 ¾” Cap screws R431000161 -850563-00000
32 1 Pipe bracket complete R431004173 P -057557-00000
33 1 Knob assembly incl. 33a, 33b, 33c, * SEE KITS * SEE KITS
33a 1 Knob, adjustment * SEE KITS * SEE KITS
33b 2 Set screw, ¼ - 20 X ½ * SEE KITS * SEE KITS
33c 1 Position plate * SEE KITS * SEE KITS
Page 7
REPAIR KITS
Quantity
New Part Old Part Num-
Per Description
Number ber
Valve
Minor Graduating Valve Portion – repair kit (includes
R431003895 P -055687-K0000* 1
items 8,9,10,11,12,13, 14) see note
Notes:
1. *The inlet and exhaust valve unit item 13 and exhaust valve seat item 8 are 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 recommended for
repair of valve portion only.
5. On severely worn or damaged components, additional parts my be required especially in
the mechanical operating portions of the valve. Select as required from parts list on pages
6 and 7.
* For counterclockwise, order this kit plus cam part no. R431000095
Page 8
Repair and Maintenance Instructions
Repair and Maintenance Instructions 4 Controlair Valves. This is the adjusting screw item
When it has been determined that the Controlair® #1, that varies the output pressure.
Valve requires repairs, the following general
instructions are recommended. Graduated Output Pressure Adjustments
Adjusting screw Item #1 varies the maximum
Disassembly, Cleaning and Lubrication pressure setting. Turning the adjusting screw “in”
Completely disassemble the Controlair valve. Wash raises the maximum pressure. Turning the screw
all metal parts in a non-flammable solvent. Rinse “out” decreases the maximum pressure. The
each part thoroughly and blow dry with low maximum control pressure adjustment should not
pressure air. exceed the maximum control pressure shown in the
Identity Schedule for that part number. (Control
Inspect and clean the inlet filter Item #17 and both Springs are color coded).
gaskets Item #18. Be sure all passages in the body
and pipe bracket and sensing port orifice in top of The maximum output pressure rating can be
the diaphragm chamber are clean and unrestricted. changed by changing the control spring Item #5.
Examine all parts carefully. Replace all rubber parts With air supplied to the valve, move handle from
and all worn or damaged parts. The use of repair start to full travel position. Adjust graduating valve
kits is recommended. screw Item #1 to obtain the maximum control
pressure per Identity schedule. Move handle back
Reassemble to neutral position and note delivery line is
Refer to exploded Parts and Assembly Views. exhausted to zero.
Valves should always be reassembled using new
rubber parts. Special Preload Setting
This setting calls for a predetermined delivery
Lubricate all metal to metal wear surfaces with pressure.
Lubriplate 107 Grease. Lubricate all the rubber
parts, except the diaphragm with Dow Corning
No. 55 Pneumatic Grease.
Adjustments
There is one adjustment that can be made to the H-
Page 9
Testing and Test Set-Up (See Test Arrangement Diagram)
Page 10
Test Arrangement Diagram
Notes:
1. Taskmaster Timing Volumes, part number R434002699 (TM-058887-00225), 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 (1 meter) 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 a gage as practical be used on the delivery lines. A 6” gage is
recommended.
TEST VALVE
TO SUPPLY PORT
PRESSURE
GAGE
DELIVERY
PRESSURE GAGE
IN
TO DELIVERY PORT
AVENTICS
P/N (PD-020031-00191)
RECOMMENDED
AVENTICS P/N
R432016357
(PR-007816-00019)
Page 11
NOTICE TO PRODUCT USERS
1. WARNING: FLUID MEDIA from a system before performing any service work. Failure to do so can
AVENTICS pneumatic devices are designed and tested for use with result in serious personal injury.
filtered, clean, dry, chemical free air at pressures and temperatures within MOUNTING! Devices should be mounted and positioned in such a
the specified limits of the device. For use with media other than air or for manner that they cannot be accidentally operated.
human life support systems, AVENTICS must be consulted. Hydraulic 4. WARNING: APPLICATION AND USE OF PRODUCTS
cylinders are designed for operation with filtered, clean, petroleum based The possibility does exist for any device or accessory to fail to operate
hydraulic fluid; operation using fire-resistant or other special types of fluids properly through misuse, wear or malfunction. The user must consider
may require special packing and seals. Consult the factory. these possibilities and should provide appropriate safe guards in the
2. WARNING: MATERIAL COMPATIBILITY application or system design to prevent personal injury or property
Damage to product seals or other parts caused by the use of damage in the event of a malfunction.
noncompatible lubricants, oil additives or synthetic lubricants in the air 5. WARNING: CONVERSION, MAINTENANCE AND REPAIR
system compressor or line lubrication devices voids AVENTICS warranty When a device is disassembled for conversion to a different configuration,
and can result in product failure or other malfunction. See lubrication maintenance or repair, the device must be tested for leakage and proper
recommendations below. operation after being reassembled and prior to installation.
AIR LINE LUBRICANTS! In service higher than 18 cycles per minute or MAINTENANCE AND REPAIR! Maintenance periods should be
with continuous flow of air through the device, an air line lubricator is scheduled in accordance with frequency of use and working conditions. All
recommended.* (Do not use line lubrication with vacuum products.) AVENTICS products should provide a minimum of 1,000,000 cycles of
However, the lubricator must be maintained since the oil will wash out the maintenance free service when used and lubricated as recommended.
grease, and lack of lubrication will greatly shorten the life expectancy. The However, these products should be visually inspected for defects and
oils used in the lubricator must be compatible with the elastomers in the given an "in system" operating performance and leakage test once a year.
device. The elastomers are normally BUNA-N, NEOPRENE, VITON, Where devices require a major repair as a result of the one million cycles,
SILICONE and HYTREL. AVENTICS recommends the use of only one year, or routine inspection, the device must be disassembled,
petroleum based oils without synthetic additives, and with an aniline point cleaned, inspected, parts replaced as required, rebuilt and tested for
between 180° F and 210° F. leakage and proper operation prior to installation. See individual catalogs
COMPRESSOR LUBRICANTS! All compressors (with the exception of for specific cycle life estimates.
special "oil free" units) pass oil mist or vapor from the internal crankcase 6. PRODUCT CHANGES
lubricating system through to the compressed air. Since even small Product changes including specifications, features, designs and
amounts of non-compatible lubricants can cause severe seal deterioration availability are subject to change at any time without notice. For critical
(which could result in component and system failure) special care should dimensions or specifications, contact factory.
be taken in selecting compatible compressor lubricants. *Many AVENTICS pneumatic valves and cylinders can operate with or
3. WARNING: INSTALLATION AND MOUNTING without air line lubrication; see individual sales catalogs for details.
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
--Refer to the appropriate service catalog for parts and service information.
Page 12
AVENTICS Corporation
1953 Mercer Road
Lexington, KY 40511
www.aventics.com/us
info.us@aventics.com
AVENTICS Incorporated
3426 Mainway Drive
Burlington, Ontario CANADA L7M 1A8
www.aventics.com/ca
info.ca@aventics.com