Sun Hydraulics Technical Tips

Pressure Relief and Regulating Valves

APPLICATIONS
Pressure Limiting and Regulating Relief Direct acting pressure limiting relief valves are fast acting
Cartridges and should be used to:

Sun pressure limiting and regulating relief cartridges are Protect fixed displacement pumps and directional control
normally closed pressure control elements designed to maintain valves when pump output flow in intermittently blocked.
a constant pressure differential between port 1 (inlet) and port 2 Limit pressure overshoot associated with pressure compen-
(outlet) when oil flows through the valve. Sun Hydraulics relief sated pumps.
valves are all fully adjustable over a wide range of operating Protect hydraulic actuators (both cylinders and motors) from
pressures up to and including 5000 psi (350 bar) (6000 psi [420 shock pressures associated with starting and stopping high
bar] intermittent). (Air piloted versions have lower pressure inertia loads.
ranges). Prior to shipping, all Sun relief valves are factory Pilot operated [two stage] pressure regulating relief valves
pressure set with a flow of 4 gpm (16 L/min). have lower pressure override characteristics than direct oper-
NOTE: All Sun two port relief cartridges (except reliefs used to ated valves, although they are not as fast acting. They incorpo-
control pilot flow) are functionally interchangeable (i.e. same flow rate a mechanism to protect the orifice leading to the second
path and same cavities for a given frame size.) stage, from oil borne contamination. They should be used to:
Maintain a constant pressure by modulating continuous,
variable flow over a wide adjustment range.

With blocked center directional With equal or unequal displacement

valves and variable displacement actuators consider:
pumps, or open center directional 1) Pilot operated valves for accurate
valves and fixed displacement pressure regulation
pumps where fast response, low 2) Direct acting valves for fast
leakage and dirt tolerance are re- response, dirt tolerance and low
quired for shock pressure relief, leakage
consider direct acting valves. 3) Kick-down valves to eliminate heat
generation. (Do not use in load
holding applications.)

With blocked center directional However, with unequal displacement

valves and fixed displacement actuators or motors having drain
pumps where accurate pressure ports, be careful to use relief valve
regulation of continuous flow is circuits that avoid cavitation and/or
required, consider pilot operated supercharging.
valves.
This drawing is not a real
circuit and is intended for
description only.

DESIGN CONCEPTS AND FEATURES Utilizes a seated design which makes the valve suitable for
use in load holding applications.
Two Port Direct Acting Differential Area Pressure Fast opening and closing (2 ms typical response time).
Limiting Relief Cartridges RD*A Insensitivity to varying oil temperature and oil-borne
contamination.
The performance parameters optimized in Suns unique RD*A
differential area relief valves are: Reliable cold oil closing and exceptional hot oil stability (no
oscillation).
Relatively flat pressure rise (especially at high end of spring
range.) Rugged, robust, construction withstands high pressure
shocks or back pressure.
High flow capacity (25 to 200 gpm [100 to 800 L/min])
relative to physical size (comparable to piloted operated Not suitable where frequent pressure adjustment is re-
valves). quired, as they are difficult to adjust under pressure.
Low hysteresis (reseats at 90% of valve setting) and very
NOTE: See General Relief Valve Notes 1, 2, and 4 on page 5.
low leakage (10 drops/min at reseat).

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Two Port Pilot Operated Pressure Regulating direct acting differential area relief valves. They offer less
Relief Cartridges - RP*C sensitivity to contaminants, have lower shut off leakage, and
are more stable.
Suns RP*C balanced piston, two stage, pressure regulating NOTE: See General Relief Valve Note 1 on page 5.
cartridge valves that are optimized to maintain a constant
pressure variable flow. Performance parameters include:
Two Port Pilot Operated Kick-Down Relief
Low hysteresis (+/-1%) and low spool leakage (leakage is Cartridges RQ*B
frame size dependant and varies fro 2-5 in.3/min. per 1000
psi [32-82 cc/min per 70 bar], from port 1 to port 2 or port 2 Suns RQ*B balanced piston kick-down relief cartridges act like
to port 1.) a circuit breaker in an electrical system; they will self-vent and
Exceptional stability. shift completely open approximately 25 ms after the pressure
Very flat pressure override curve resulting in little pressure setting is attained. All flow needs to stop in order to reset the
change over a wide variation in flow. valve; they are intended to be used either on the actuator side of
a directional valve or after the pump in systems where it is
Easy to adjust under pressure.
practical to shut off the pump. Performance parameters of Suns
Typical response time of 10 ms.
kickdown relief valves include:
Can be sensitive to oil-borne contamination.
Accurate trigger point (valve setting).
NOTE: See General Relief Valve Notes 1, 2 and 5 on page 5.
At nominal full flows, pressure drop is very low, reducing
heat generation. (Approximately 50 psi [3,5 bar] for RQEB
Two Port Pilot Operated Pressure Regulating at 10 gpm [40 L/min].)
Relief Cartridges RP*S Low spool leakage in closed mode (before reaching trigger
point) from port 1 to port 2 (leakage is frame size
Suns RP*S balanced poppet, two stage, pressure regulating dependant and varies from 2-5 in.3/min per 1000 psi [32-82
cartridges have similar features to the RP*C series except a cc/min per 70 bar], from port 1 to port 2 or port 2 to port 1.)
poppet replaces the spool in the main stage. The modified Once opened, the valve can only be reset by stopping all
performance parameters include: flow through the valve. Reversing the directional valve or
shutting off the pump will reset the valve.
Slightly higher hysteresis (+/- 2%). Do not use in load holding applications.
Pressure override curve greater than RP*C balanced piston
valve, but lower than RD*A direct acting relief. NOTE: See General Relief Valve Note 1 on page 4.
Seated poppet design achieves very low leakage (10 drops/
min at reseat); valve is suitable for use in load holding Two Port Air Controlled Pilot Operated Pressure
applications. Regulating Relief Cartridges - RP*D
Exceptional stability [no oscillation].
Poppet design almost eliminates cavitation erosion that can Suns RP*D balanced piston relief valves use compressed air
occur in manifolds adjacent to the valve discharge holes. over a diaphragm instead of an adjustable spring to provide
remote control of the valve pressure setting. Performance
NOTE: See General Relief Valve Notes 1, 2, and 4 on page 5. parameters/features include:

Hydraulic pressure setting is directly proportional to air

Two Port Pilot Operated Rapid Response pressure setting (pilot ratio is 20:1).
Maximum operating pressure equals 2000 psi (140 bar).
Pressure Limiting Relief Cartridges RP*E
Maximum air pressure should not exceed 150 psi (10,5
Suns RP*E fast acting two stage balanced piston relief bar).
cartridges are used to protect hydraulic components from Most other performance characteristics similar to RP*C
pressure shock damage. Performance parameters include: relief valves.
May be useful as an explosion proof valve where remote
Fast opening and closing (obtained by reducing internal pressure control is required.
damping and overlapping.) Pressure settings are insensitive to back pressure at port 2
Typical response time of 2 ms. up to 1000 psi (70 bar) maximum.
Response time is improved compared to a standard RP*C
relief, but stability is reduced; this valve is unsuitable for use Two Port Pilot Operated Soft Start Relief Valves
in continuous duty applications. RP*T
Low hysteresis and low spool leakage (leakage is frame Suns unique soft start balanced poppet, two stage, relief valves
size dependant and varies from 2-5 in.3/min. per 1000 psi ramp pressure up from a threshold pressure to the maximum
(32-82 cc/min per 70 bar), from port 1 to port 2 or port 2 to set pressure over a fixed time period, which is slow enough to
port 1.) eliminate virtually all pressure overshoot in addition to providing
For most rapid response applications, use Suns RD*A a repeatable pressure rise ramp. (See Figure 1) This feature

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makes these valves very useful in applications where smooth

acceleration is needed, especially where high inertia loads are Fast opening and closing (2 ms).
involved. Performance parameters include: Low hysteresis.
Low leakage (when closed) at reseat (5 drops/min.)
Valve will limit pressure rise rates to below 10,000 psi (700 Requires little effort to adjust under pressure, and are
bar) per second. available with hand knobs and panel mount options for
The threshold pressure (valve starts to open) is generally frequent-adjust applications.
2400-2700 psi (168-189 bar) below maximum set pressure Flow capacities: RBAC, and RBAD: .25 gpm (1 L/min),
(pressure where valve is fully open after ramping). RBAA: 0.5 gpm (2 L/min), RBAE and RBAR: 2.5 gpm
If maintained operating pressure falls somewhere between (10 L/min).
the threshold pressure and the maximum set pressure, the Dual pilot relief cartridge, RBAD, contains a shuttle valve to
main stage will not open, but there will be a continuous pilot allow sensing pressure from two sources with no cross
flow of 10-25 in3/min (0,16-0,41 L/min). This feature talk.
essentially keeps the valve setting at approximately 100 psi
Because flow capacity of the RBAA, RBAC, and RBAD pilot
(7 bar) above the load pressure. (An analogy would be the
valves is limited, these valves should only be used as
system pressure in a load sense circuit, with the standby or
remote control elements for valves or pump/motor controls
pump differential pressure adding to the system pressure up
which have compatible control pilot flows.
to the pressure limiter setting.)
Any pressure at port 2 (outlet) is directly additive to the
In the pressure range between threshold and maximum
pressure setting for direct acting cartridges.
setting, if the pressure rises faster than the valve setting,
For the air piloted RBAR, back pressure at port 2 has no
the valve will open to limit pressure rise rate.
effect on the valve setting.
Ramp times are typically between 300-500 ms., depending
on frame size.
Because of potential pilot flow leakage when operating Two and Three Port Pilot and Direct Operated
between the threshold pressure and the set maximum Sequence Cartridges RS*C, SC*A, SC*B, SX*A,
pressure, this valve is NOT suitable for load holding. and SX*B. (Also see Tech Tips for Sequence
Poppet design almost eliminates cavitation erosion that can Valves)
occur in manifolds adjacent to the valve discharge holes.

NOTE: See General Relief Valve Note 1 on page 5. Sequence relief valves provide a separate drain (port 3 or vent
to atmosphere) for the adjustment spring chamber.

Venting port 3 to tank or atmosphere makes the relief

valve settings insensitive to back pressure at port 2 (the
outlet).
With the atmospheric vent option, in addition to possible
external leakage, there is the risk of contaminant intrusion,
depending on the operating environment, which can result
in internal corrosion and valve malfunction.
Direct operated versions (SC*A, SC*B, SX*A and SX*B)
have very low leakage and can be used in load holding
applications.
Pilot operated versions (RS*C) may be vented or blocked.
Blocking the pilot flow at port 3 [with a two-way valve, for
instance], will cause the valve to remain closed even at its
set point. If port 3 is then vented, the valve will operate
normally, opening at its set point.

Three Port Pilot Operated Vented Relief

Cartridges RV*A and RV*S
Figure 1. Suns RV*A balanced piston, and RV*S balanced poppet, two
stage, vented, pressure regulating cartridges provide an extra
remote pilot port (port 3) between the main piston and pilot.
Two Port Pilot Relief Cartridges, Direct Acting General performance characteristics are the same as RP*C
and Air Piloted RBAA, RBAC, RBAD, RBAE, balanced piston and RP*S balanced poppet two port valves
and (air piloted) RBAR described above. Other performance parameters include:
Suns pilot relief cartridges are comprised of the direct acting Port 3 control pilot flow varies between 7 and 20 in.3/min
pilot stages of Suns pilot operated relief valves and are used to (0,11-0,33 L/min), depending on frame size. To control the
remotely control the pressure setting of other pilot operated valve, the use of appropriately matched pilot valves in the
valves (relief, sequence, and reducing). Performance port 3 circuit is required (Sun RBAA, RBAC, RBAD are
parameters include: recommended.)

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Venting or blocking the pilot flow from port 3, such as Three Port Pilot Operated Bypass Compensator
with a 2-way valve (See Figure 2), will affect the main flow (with Relief) Cartridges RV*B
from port 1 to port 2, causing the valve to either Suns RV*B balanced piston, two stage, relief cartridges use the
vent (open) or block (close at the main relief setting), main section of the valve as a bypass compensator for an
respectively. With spring ranges of 3000 psi (210 bar) and external fixed/variable orifice (such as a needle valve).
below, and atmospheric pressure at port 3, pressure at port
1 will be 40-75 psi (2,5-5 bar) at half the valves rated flow. Port 3 is connected to the outlet, or load side, of the orifice,
and port 1 is connected to the inlet side (See Figure 3).
NOTE: See General Relief Valve note 3 on Page 5.
The valve bypasses flow to tank (port 2) at work load
Three Port Pilot Operated Soft Start Vented pressure plus the compensator pressure drop. The resulting
Relief Cartridges RV*T function is a pressure compensated bypass flow control.
If outlet or work pressure rises to the maximum pressure
Suns RV*T balanced poppet, two stage, vented, soft-start setting, the valve then acts as a system relief valve.
pressure regulating cartridges provide a remote pilot port (port 3) Pressure at port 2 (bypass) is directly additive to the
between the main piston and pilot. General performance maximum pressure setting sensed at port 3 (sense). Also, if
characteristics, including the extended ramp time with almost no pressure at port 2 exceeds work pressure (at port 3) plus
overshoot, are the same as RP*T two port valves described bypass compensator pressure differential, pressure
prior. Other performance parameters include: compensation of orifice will cease.
Venting or blocking the pilot flow from port 3, such as
with a 2-way valve (See Figure 2), will affect the main flow Sun RV*B bypass compensator with
from port 1 to port 2, causing the valve to either relief function
vent (open) or block (close with a ramp to the main relief
setting), respectively. With spring ranges of 3000 psi (210
bar) and below, and atmospheric pressure at port 3,
pressure at port 1 will be 125-200 psi (9-14 bar) at half the
valves rated flow.
When blocking the vent port, the valve will ramp from a
lower threshold pressure, less than 200 psi (14 bar), and
have a ramp time of 500-700 ms.
Port 3 control pilot flow varies between 10 and 20 in.3/min
(0,16-0,33 L/min), depending on frame size.
This valve, working in conjunction with a Sun soft-shift
solenoid valve as the vent (port 3) control valve (See Figure
2), can provide an effective shock free load and unload in
hydraulic systems.
Figure 3. This drawing is not a real circuit and
RV*A/S Vented Relief (or RV*T Soft Relief) is intended for description only.

Four Port Pilot Operated Vented Relief

Cartridges RV*D
Suns RV*D balanced piston, two stage, vented, pressure
regulating cartridges provide a drain port (port 4) in addition to
the remote pilot port (port 3). General performance
characteristics are identical to RV*A three port valves previously
described. Other performance parameters include:
With drain port (port 4) connected to tank, the valve is
insensitive to any back pressure on port 2.
Can be used as a dual pressure sequence valve by
Figure 2. Pilot operated vented relief valves can be used to connecting the vent port (port 3) to a remote, selectable, pilot
start and stop hydraulic motors by using a two-way valve con- source.
nected to the vent port (port 3). (By using a pilot operated Any pressure at the drain port (port 4), is directly additive to
vented soft relief valve, an actuator, such as a motor connected pressure setting at the inlet (port 1).
to a conveyor drive or fan, can be softly ramped up to its oper-
ating speed with little or no shock.) This drawing is not a real NOTE: See General Relief Valve note 3 on page 5.
circuit and is intended for description only.

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General Relief Valve Notes:

1) Any pressure at port 2 (outlet) is directly additive to the pressure setting at port 1 (inlet).
2) If absolute system pressure must be regulated when variable back pressure is present at port 2, consider using either Suns RS*C,
SC*A, SC*B, SX*A, or SX*B 2 and 3-port sequence valves, (The SC*A and SC*B valves incorporate a reverse flow check) or
Suns RV*D 4-port ventable relief valve with an external drain.
3) The main relief pressure setting of vented relief valves must always be higher than that of the remote pilot relief valve.
4) In lower pressure circuits, pressure drop through the cartridge, manifold, and plumbing must be considered

Which Relief Valve should I choose?

In order to help with deciding which type of relief is the right choice for a typical application, the table below represents a short review
of the features and benefits of the most popular relief designs described previously. (Key advantages for each type are shown in
bold.)

Pilot Operated Relief Valves

Direct Acting Relief Valves
Differential Area Type Sliding Spool Type Balanced Poppet Type

Fast response (2 ms) Medium response (10 ms) Medium response (7 ms)
Low hysteresis (8-10%) Lowest hysteresis (1%) Low hysteresis (2-3%)

Dirt tolerant Can be contaminant sensitive Dirt tolerant

Low over/under shoot Potential for higher over/under shoot Potential for higher over/under shoot

Moderate pressure override Low pressure override Slightly higher pressure override

Low leakage (10 drops/min) Some internal leakage (2-5 in.3/min.) Low leakage (10 drops/min)

Difficult to adjust under pressure Easy to adjust under pressure Easy to adjust under pressure

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Relief Valve Overview

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