H-4 Controlair Valve: Description of Models
H-4 Controlair Valve: Description of Models
H-4 Controlair Valve: Description of Models
DESCRIPTION OF MODELS
SM-800.6516
Installation and General Maintenance Recommendations
Installation General Maintenance
Before installing the Controlair® Valve, all air Maintenance periods should be scheduled in
lines in the system should be blown clean to accordance with frequency of use and working
remove any moisture, dirt, or harmful environment of the Controlair Valve. All valves must
contamination. Strainers are furnished in the Inlet be visually inspected for wear and given an “in
and Outlet ports to protect the valve from large system” operating performance and leakage test at
particles of foreign matter in the line. To further least once a year. If these visual observations
ensure long, trouble-free service, a 10 Micron or indicate valve repair is required, the valve must be
better filter (see catalog SC-500) should be removed, repaired and tested.
installed in the supply line to the valve.
A major overhaul is recommended at one million
cycles. However, where frequency of use is such that
The H-4 type Controlair is designed for either side or it would require more than two years to obtain one
panel mounting, and may be mounted in any position million cycles, the valve must be overhauled at the
convenient for operation. Refer to installation view, two-year period.
page 3, for panel thickness and opening dimensions.
Allow suitable clearance for removal of the pipe When it is determined that the Controlair Valve
bracket screws which are 1 ¾” long. requires a major repair as a result of the one million
cycles, one year routing 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
Technical Data REPAIR AND MAINTENANCE INSTRUCTION, page
9, and TEST PROCEDURES, page 10.
Maximum Operating Pressure ... 200 psi (13.8 Bar)
Admissible Medium ................... Air, clean and dry One complete Controlair Valve should be kept in
Operating Temperature ............. -40° F to +160° F stock for each four valves in service. During the
Hysteresis.................................. 1 ½ PSI maintenance period, replace the complete valve with
Control Pressure Range ............ (Ref. Identity Chart, Pg 5) the “stand-by” unit. This will reduce production time
Pressure Change....................... ½ PSI Increment loss and afford inspection and replacement of worn
Mounting.................................... Flange Plate parts at a more appropriate or opportune time and
Port Size .................................... ¼ - 18 NPTF favorable location.
Materials
Controlair Valve
Housing and Body.................. Die Cast Aluminum Notice that the operating portion of a valve can be
Knob ...................................... Plastic removed without disturbing the pipe connections.
Stop and Cam Dog ................ Sintered Steel Remove the valve from the pipe bracket by loosening
Internal Parts.......................... Brass, Rubber (Buna-N), (2) screws and lift the unit free.
Steel
Weight ....................................... 5.5 lbs approximately No special tools are required to maintain the
Controlair Valve.
Page 2
OUTLINE DIMENSIONS
Page 3
DESCRIPTION OF OPERATION
VALVE
FUNCTION
Exhaust Outlet
Inlet
Description of Operation
The H-4 Controlair is factory set to provide normal 240 DIAGRAMMATIC VIEW
degree rotation of the control knob. However, the 240-
degree rotation can be reduced by changing the
relationship of the stop with the cam brake.
Page 4
IDENTITY SCHEDULE
* Control portion less pipe bracket with operator portion and mounting screws. (See pages 6 & 7 for item numbers and parts
description).
**Same as P50967-0008 except diaphragm unit complete is P55409-0002; items 10, 13, 14 and 18 are part numbers
P5102, P55406, P49623-0113, and P5103 respectively (low temperature operation to –65° degrees F).
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 33A
19
13 & 8 are in kit, P/N
P55687, 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
Page 7
REPAIR KITS
Quantity Per
Piece Number Description
Valve
Minor Graduating Valve Portion – repair kit (includes
P55687* 1
items 8,9,10,11,12,13, 14) see note
Major Graduating Valve Portion – repair kit (includes
P59028 1
items 15,16,17,18 and kit P55687)
P64421 1 Knob Kit (includes items 33a, 33b,33c)
Operator Kit for clockwise*
P64421-0007 1
(includes items 24,26,28,29 and kit P64421)
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. 539406.
Page 8
Repair and Maintenance Instructions
Lubricate all metal to metal wear surfaces with Special Preload Setting
Lubriplate 107 Grease. Lubricate all the rubber This setting calls for a predetermined delivery
parts, except the diaphragm with Dow Corning pressure.
No. 55 Pneumatic Grease.
Page 9
Testing and Test Set-Up (See Test Arrangement Diagram)
Page 10
TEST ARRANGEMENT DIAGRAM
Notes:
1. Taskmaster Timing Volumes, part number P58887-225, 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 a gage as practical be used on the delivery lines. A 6” gage is
recommended.
Page 11
NOTICE TO PRODUCT USERS
1. WARNING: FLUID MEDIA devices without proper training in the technique of working on pneumatic
Bosch Rexroth pneumatic devices are designed and tested for use with or hydraulic systems and devices, unless under trained supervision.
filtered, clean, dry, chemical free air at pressures and temperatures within Compressed air and hydraulic systems contain high levels of stored
the specified limits of the device. For use with media other than air or for energy. Do not attempt to connect, disconnect or repair these products
human life support systems, Bosch Rexroth must be consulted. Hydraulic when a system is under pressure. Always exhaust or drain the pressure
cylinders are designed for operation with filtered, clean, petroleum based from a system before performing any service work. Failure to do so can
hydraulic fluid; operation using fire-resistant or other special types of fluids result in serious personal injury.
may require special packing and seals. Consult the factory. MOUNTING! Devices should be mounted and positioned in such a
2. WARNING: MATERIAL COMPATIBILITY manner that they cannot be accidentally operated.
Damage to product seals or other parts caused by the use of 4. WARNING: APPLICATION AND USE OF PRODUCTS
noncompatible lubricants, oil additives or synthetic lubricants in the air The possibility does exist for any device or accessory to fail to operate
system compressor or line lubrication devices voids Bosch Rexroth's properly through misuse, wear or malfunction. The user must consider
warranty and can result in product failure or other malfunction. See these possibilities and should provide appropriate safe guards in the
lubrication recommendations below. application or system design to prevent personal injury or property
AIR LINE LUBRICANTS! In service higher than 18 cycles per minute or damage in the event of a malfunction.
with continuous flow of air through the device, an air line lubricator is 5. WARNING: CONVERSION, MAINTENANCE AND REPAIR
recommended.* (Do not use line lubrication with vacuum products.) When a device is disassembled for conversion to a different configuration,
However, the lubricator must be maintained since the oil will wash out the maintenance or repair, the device must be tested for leakage and proper
grease, and lack of lubrication will greatly shorten the life expectancy. The operation after being reassembled and prior to installation.
oils used in the lubricator must be compatible with the elastomers in the MAINTENANCE AND REPAIR! Maintenance periods should be
device. The elastomers are normally BUNA-N, NEOPRENE, VITON, scheduled in accordance with frequency of use and working conditions. All
SILICONE and HYTREL. Bosch Rexroth recommends the use of only Bosch Rexroth products should provide a minimum of 1,000,000 cycles of
petroleum based oils without synthetic additives, and with an aniline point maintenance free service when used and lubricated as recommended.
between 180° F and 210° F. However, these products should be visually inspected for defects and
COMPRESSOR LUBRICANTS! All compressors (with the exception of given an "in system" operating performance and leakage test once a year.
special "oil free" units) pass oil mist or vapor from the internal crankcase Where devices require a major repair as a result of the one million cycles,
lubricating system through to the compressed air. Since even small one year, or routine inspection, the device must be disassembled,
amounts of non-compatible lubricants can cause severe seal deterioration cleaned, inspected, parts replaced as required, rebuilt and tested for
(which could result in component and system failure) special care should leakage and proper operation prior to installation. See individual catalogs
be taken in selecting compatible compressor lubricants. It is for specific cycle life estimates.
recommended that users review the National Fluid Power Association 6. PRODUCT CHANGES
"Recommended Guide Lines For Use Of Synthetic Lubricants In Product changes including specifications, features, designs and
Pneumatic Fluid Power Systems" (NFPA T1.9.2-1978). availability are subject to change at any time without notice. For critical
3. WARNING: INSTALLATION AND MOUNTING dimensions or specifications, contact factory.
The user of these devices must conform to all applicable electrical, *Many Bosch Rexroth pneumatic valves and cylinders can operate with or
mechanical, piping and other codes in the installation, operation or repair without air line lubrication; see individual sales catalogs for details.
of these devices.
INSTALLATION ! Do not attempt to install, operate or repair these
--Refer to the appropriate service catalog for parts and service information.
SM-800.6516
(Supercedes B4-65.16)
© 2005 Bosch Rexroth Corporation April 2005
Page 12