FLEXAIR PNEUMATIC CONTROL VALVES

Transcription

1 FLEXAIR PNEUMATIC CONTROL VALVES Service Information INTRODUCTION The FLEXAIR Valve is a highly versatile pressure control valve with many assembly combinations for a wide variety of control functions. There are three valve cavities in the body which may contain several types of valve assemblies or may be plugged. Two standard handle lengths, plus an adjustable handle, are available. Various handle guide inserts limit the handle motion to the desired areas of travel. The handle return characteristic may be one of three different types. Since its introduction, the Flexair Valve has undergone a number of design changes and modifications to improve performance and satisfy customers requests. The engineering performance and production quality of the current valve are the result of years of field service. This publication points out most of the design changes that affect interchangeability of parts and, thus, assist you in updating your valve. Major repair kits, which include necessary conversion kits if applicable, are listed in the Part Number Index on the last pages of this publication. When these kits are installed as recommended, the result should be a fully rebuilt, current Flexair Valve. Partial repair kits are listed by model designation under Repair & Conversion Kits. Technical Data Port sizes 1/4"-18 NPTF Working pressure per control valve spring rating Supply pressure max. 150 psi (10. bar) Temperature range -40 F to +160 F (-40 C to +71 C) Media Air, clean and dry Materials Housing and Body: Die cast aluminum Internal Parts: Rubber (Buna-N), aluminum, stainless steel Weight 6 lbs. (.7 kg) Table of Contents Page Technical Data 1 Operation Maintenance and Repair Disassembly Levers Model Designation Code 4 Assembly View 5 Assembly (Exploded) 6 Parts List 7 Body Assemblies 8-9 Graduating Vlvs-Seat Replacement 8 Graduating Spring Assemblies 10 Adjustment 11 Obsolete Assemblies 1 Design Changes Affecting Replacement 1 Accessories 1 Test Arrangement Diagram 14 Testing and Test Set-Up 15 Repair and Conversion Kits 16 Part Number Index 17 SM

2 Installation and General Maintenance Recommendations WARNING: INSTALLATION AND MOUNTING WARNING! 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. MOUNTING! Devices should be mounted and positioned in such a manner that they cannot be accidentally operated. OPERATION Pressure Graduating Valves The precise pressure control of the Flexair valve, and its ability to change outlet pressure in small increments is obtained through the use of a spring balanced piston. With the handle in the center position, the inlet valve is held closed by the inlet spring. The outlet port is connected to atmosphere through the hollow plunger in the inlet valve. When the handle is moved, the exhaust valve moves down to seal off the exhaust port. Further movement unseats the inlet valve to connect the inlet port to the outlet port and the underside of the piston. Air pressure builds up in the outlet line and underneath the piston. When the air pressure (working on the piston s area) overcomes a spring on top of the piston, the inlet valve seats. Further movement of the handle to increase pressure depresses the valve assembly, and again opens the supply valve. Pressure is increased in the outlet line and below the piston until another balanced condition occurs at the higher pressure. Movement of the handle to decrease pressure decreases the force on the valve assembly, and allows the air pressure and return spring to raise the piston and unseat the exhaust valve. Pressure is therefore vented from the outlet line until it is reduced to the value called for by the handle position. Should leakage or a temperature variation occur that would change the outlet line pressure called for by the handle position, this deviation in pressure opens either the inlet valve or exhaust valve to restore the correct pressure. Way Valves With the handle in the center position the inlet valve is held closed by the inlet spring. The outlet port is connected to atmosphere through the hollow plunger. When the handle is moved, the exhaust valve moves down to seal off the exhaust port and unseat the inlet valve. The inlet pressure then pressurizes the outlet port to full pressure. Movement of the handle back to center position allows the inlet spring to close off the inlet port and open the delivery port to exhaust. Maintenance Major repair kits, which include necessary conversion kits, are listed in the Part Number Index (page 17). For partial repair kits by model designation, see Repair & Conversion Kits on page 16. Graduating Spring (inner) Piston Return Spring Exhaust Valve Seat Delivery Port Supply Port Exhaust Port Handle Return Spring (outer) Piston Supply Valve Seat Plunger Return Spring NOTE: Every 500 hours of operation, clean and lubricate the following portions of the valve (it is not necessary to remove the valve from its mounting): slots inside the latch cover (9); slots, center hole, underside and groove on the detent latch (10B); edges of the handle guide insert and the four detent lugs on the cover (14). Lubricate with Sun Oil Company C , Sunaplex 780, Texaco Marfax-0 or equivalent grease. Every 1000 hours of operation, using the above lubricant, additionally clean and lubricate the following (it is not necessary to remove the valve from its mounting): contact ends of the set screws (7); handle shafts (9); contact surface (top) of the full pressure adjusting caps (); and the inside of the handle shaft bearing (4). Refer to the Assembly View on page 5 for other lubrication points. Page

3 Disassembly Periodically remove the valve from its mounting and disassemble for cleaning, inspection and complete lubrication. Refer to the applicable exploded view for order of disassembly. When the valve units are removed from cavities 1 and make sure they are reinstalled in the same cavities from which they were removed to prevent possible c h a n g e s i n t h e o p e r a t i n g characteristics of the valve. Up to 1970, in some valves, there were from one to three shims located on top of the graduated spring assembly (4). The number of shims required was stamped on the underside of the spring housing () adjacent to the applicable cavity. However, it was found that these shims were not n e c e s s a r y f o r t h e p r o p e r performance of the valve, and they may be discarded. The loss of space can be compensated by adjusting the set screws (7) so that there is a to 0.00 (0.0 to 0.08 mm) clearance between the screw and cap (). Torque set screw jam nuts to inch-lbs. See pages 5 & 6. NOTE: The graduating spring assembly (4) is set at the factory and should not be disassembled (see pages 8 & 10). Cleaning 1. Clean all metal parts with a nonflammable solvent.. Wash all rubber parts with soap and water.. Rinse parts thoroughly and blow dry with a low pressure. 4. Inspect all parts and replace those which are worn or damaged. Reassembly Refer to the applicable exploded a n d a s s e m b l y v i e w s a n d reassemble the valve. No special tools are required. As the assembly proceeds, follow the previously noted lubrication recommendations. 1. Lubricate all metal-to-metal contact surfaces with same lubricant as noted under Maintenance note for 500 and 1000 hours (page ).. Lubricate all rubber parts with Dow Corning Number 55 Pneumatic Grease.. A f t e r r e a s s e m b l y i s complete, test for correct operation and evidence of leakage. NOTE: When reinstalling the graduating valve assembly (4) in cavities 1 and, make sure that the flat sides of the spring washers face toward cavity (see illustration on page 8). If improperly installed, these washers will interfere with the valve operation in cavity before tightening the spring housing () to the body (65), be sure these washers are entirely seated in the recess provided in the body. Levers (Ref. 0 of Parts List Operating Assemblies. ) The yoke on the handle lever varies in dimensions between centers (Dimension A) to obtain an essentially common handle force for both long and short handles. Normally, the close-yoke lever (0A) is used with the short handle (6A), and the wide-yoke lever (0B) requires the long handle (6B) or adjustable handle (6E). Even lighter handle forces can be obtained by combining the close-yoke lever with the long handle. The lever and handle combinations for special handle and variations from standard are noted in the Part Number Index. Choice of graduating springs for valve cavities 1 and is directly related to the width of the lever yoke (see Graduating Spring Assemblies page 10 and 11). A YOKE SPACING Dim. "A" Close 1-5/8" Wide 1-7/8" Ref. No. 0A 0B Description New Part No. Lever, Handle R (close yoke) Lever, Handle R (wide yoke) Old Part No. Quantities when first digit is: 1 S P * P * *See the Part Number Index Page

4 MODEL DESIGNATION CODE DESIGNATION CODE EXAMPLE 1 A -A D -0 VALVE CAVITIES HANDLE RETURN SIDE VALVE D-Spring return with detents F-Friction (short handle only) 1 & S-Spring return, no detents 0-Cavity plugged 1- way valve -Graduating HANDLE GUIDE INSERTS HANDLE (see diagrams) LENGTH 1-Long Handle -Short Handle -Adjustable Handle A-One operating valve, other cavity plugged B-Two operating valves Inserts are staked in place and require replacement of the complete cover when changing the function of the valve. A 1 B C D E G COVER WITH INSERTS J K L M N P R U Part No. According to 4th digit: HANDLE GUIDE INSERTS INSERT VALVE CAVITY ACTUATED NEW D & S OLD D & S NEW F OLD F A 1, separately R P R41000 P B, sep or simult R P R P C only R41001 P R41001 P D 1,, sep; 1, or, simult R P R P E 1, sep or simult; after R P P G 1,, sep R41001 P R4100 P J 1,, sep; 1, simult R P P K 1, sep; after R P R4100 P L, sep - P P M sep; after R P P * N 1, sep or simult R P P P sep; 1 partial; 1 full after R P * - - R (no longer used) N/A N/A U (no longer used) N/A N/A * No detent lugs on cover. Page 4

5 ASSEMBLY VIEW Torque set screw jam nuts to inch-lbs. Contact surfaces of valve cavity details that require lubrication when valve is periodically disassembled for cleaning, inspection and lubrication. See page, Reassembly Note 1. Page 5

6 EXPLODED VIEW Handle Assemblies (See Levers for handle and lever relationshippage.) (Refer to Parts List) HANDLE ASSEMBLIES WHEN 1ST DIGIT IS 1 S OPERATING ASSEMBLIES WHEN 4TH DIGIT IS D S F D S 7 F A 10A 10B 10B 10C 14 For Handle Guide Insert, see page 4. See page (Levers) A - 11B 8 9A 4 See Obsolete Assemblies C A 8 9B A B Page 6

7 HANDLE ASSEMBLIES PARTS LIST REF. DESCRIPTION 1st DIGIT 1 S NEW PART NO. OLD PART NO. 1A* KNOB, STANDARD See Kit See Kit 1B KNOB, FLUTED R P * EXTENSION, HANDLE See Kit See Kit * LOCKNUT See Kit See Kit 4 RING, RETAINING R P A PIN, 1/8 x 5/8" R P B* PIN, 1/8 x 9/16" See Kit See Kit 6A HANDLE,SHORT-1" (05mm) R P B HANDLE,LONG-0-7/8" (50mm) R P C HANDLE,SPECIAL-16" (406mm) R P D HANDLE,SPECIAL-18" (457mm) R P E* HANDLE, ADJUSTABLE See Kit See Kit *These parts are available in kit form, order Kit Part Number R (P ). OPERATING ASSEMBLIES REF. DESCRIPTION 4th DIGIT: D S F NEW PART NO. OLD PART NO. 7 COVER, LATCH SPRING R P SPRING, DETENT LATCH R P A COVER, LATCH SPRING R P B COVER, LATCH SPRING (black vinyl paint) Obsolete Obsolete 10A SPACER, COVER R P B* LATCH, DETENT See Kit See Kit 10C RETAINER, LATCH COVER R P A* PIN, 1/8 x.610" See Kit See Kit 11B PIN, 1/8 x 1/ R P SCREW R P WASHER R P COVER (with handle guide insert) See Covers pg. 4 See "Covers" pg NUT, HEX R P SPRING, FRICTION BRAKE R41001 P SCREW, HEX HEAD R P SCREW R P SPACER, BRAKE R P BODY, BRAKE (with grease fitting) R41001 P PIN, /16 x 1-1/8" ROLL R P COLLAR R P * PIN, 1/8 x 1-/4" ROLL See Kit See Kit 4* BEARING, HANDLE SHAFT See Kit See Kit 5* NUT, HEX (Torque jam nut to inch-lbs) See Kit See Kit 6 SEAT, SPRING (only when 5th digit is ) R P * SCREW, SET See Kit See Kit 8* PIN, /1 x 1" ROLL See Kit See Kit 9A SHAFT, HANDLE R P B SHAFT, HANDLE R P LEVER, HANDLE See Levers pg. See "Levers" pg. 1* GASKET See Kit See Kit A HOUSING, SPRING R P B HOUSING, SPRING (only when nd digit is P) R P C HOUSING, SPRING R P * Recommended spare parts to be retained in stock at all times. These parts are available in kit form (see pages 17-9 for part numbers). One each required for each cavity that has a valve unit. Eliminated on newer models due to redesign of Latch Cover, ref. no. 9. Page 7

8 REF. NO. BODY ASSEMBLIES NOTE: See the "Part Number Index" for exact assembly. When only one graduating valve is required and cavity is plugged, normal assembly is with the graduating valve in cavity. Push or pull operation can be obtained by proper mounting of the Flexair Valve. QTY REF. NEW PART DESCRIPTION I II III OLD PART NO. NO. NO. CAVITIES 1 & WHEN RD DIGIT IS A One Graduating Valve One Plugged Cavity PLUGGED CAVITY DESCRIPTION QTY B Two Graduating Valve GRADUATING VALVE CAVITIES 1 & GRADUATING VALVE NEW P/N * 4 CAP, Full pressure adjusting ASSEMBLY, Graduating spring - 1 See Kit See Kit - 1 4A* O-RING - 1 See Kit See Kit 4B SEAT, Exhaust valve (not shown) - 1 R P C CLIP - 1 R P * SPRING, Piston return - 1 See Kit See Kit 6 SPACER, Filter 1 4 R P RING, Retaining 1 1 R P PLUG R P * Seat, Supply valve - 1 See Kit See Kit 40* O-RING 1 1 See Kit See Kit 41 PLUNGER, Valve - 1 R P * O-RING 1 1 See Kit See Kit 4* SPRING, Plunger return - 1 See Kit See Kit 44 WASHER - 1 R P * O-RING - 1 See Kit See Kit I Plugged cavity II Graduating Valve III Two Graduating * Recommended spare parts to be retained in stock at all times. These parts are available in kit form (see "Repair & Conversion Kits page 16). See "Graduating Spring Assemblies" page 10. OLD P/N Cavity 1 6 SCREW R P WASHER, LOCK R P BODY 1 R P Cavity Cavity Graduating Valves Cavities 1 & SUPPLY VALVE SEAT REPLACEMENT Before removing or installing the retaining ring (7), force the plunger (41) down until the plunger is exposed below the bottom of the valve body (65). Page 8

9 BODY ASSEMBLIES Cavity CAVITY WHEN 5TH DIGIT IS 0 1 Fastens on Spring Housing () REF. NO. DESCRIPTION 0 1 NEW P/N OLD P/N 46 SEAL, DUST R P SPRING, HANDLE 47* RETURN EXTENSION, A* ( WAY) EXTENSION, 48B* 1.65 (LESS FULL PRESSURE) EXTENSION, 1.64 (W/ 48C* FULL PRESSURE) See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 49 RING, RETAINING R41009 P A NUT, RETAINING R P B NUT, RETAINING R P SPRING, HANDLE 51A* RETURN SPRING, CONTROL ( B* W/FP) SPRING, CONTROL ( C* W/FP, 0-65 LESS FP) SPRING, CONTROL 51D* (0-100 LESS FP) See Kit See Kit See Kit See Kit R P R P INLET VALVE R P WASHER R P PLUG R P RING, RETAINING R P O-RING R P * Recommended spare parts to be retained in stock at all times. These parts are available in kit form (see "Repair & Conversion Kits") page 16. Page 9

10 GRADUATING SPRING ASSEMBLIES GRADUATING SPRING ASSEMBLIES (Ref. 4 of Parts List Cavities 1 & Body Assemblies ) All graduating spring assemblies for cavities 1 and are made from four basic assemblies, each colorcoded for easy recognition and reference. Pressure ranges and part numbers change only because of the lever used, adjustment for full pressure, or the addition of shims for preload. The pressure range and full pressure aspect of the graduating spring assemblies installed in each Flexair Valve are listed in the Part Number Index. On standard valves the suffix of the complete part number also indicates the maximum pressure for springs furnished in cavities 1 and. The lever used (see Levers page ) is directly related to the length of the handle, which is indicated by the first digit of the model designation. Exceptions to the normal handle and lever combinations are noted in the index. Example: A Flexair Valve in service has the following information on its nameplate: Pt. No. P , Model Designation 1A-BS-0 The Part Number Index lists P as a standard valve with a spring assembly in both cavities 1 and, and without the full pressure feature. The suffix of the part number on the valve nameplate shows the maximum pressure of the springs installed in cavities 1 and to be 55 psi (.8 bar) and 75 psi (5.1 bar), respectively. Both on the nameplate and in the Index, the first digit of the model designation indicates the valve uses a long handle and, consequently, a wide-yoke lever. STANDARD SPRING ASSEMBLIES DESCRIPTION SHORT HANDLE [Close-Yoke Lever] (Ref. 0A) LONG HANDLE [Wide- Yoke Lever] (Ref. 0B) WITH FULL PRESSURE LESS FULL PRESSURE COLOR RANGE RANGE CODE NEW P/N OLD P/N NEW P/N OLD P/N (psi) (psi) Red R41008 P Blue 0-40 R P R P Green 0-50 R P R P Yellow 0-70 R P R P Orange 0-95 R P R41008 P Blue 0-45 R P R P Green 0-60 R41009 P R41000 P Yellow 0-80 R P R P Orange R P R P PRELOAD SPRING ASSEMBLIES DESCRIPTION SHORT HANDLE [Close-Yoke Lever] (Ref. 0A) LONG HANDLE [Wide-Yoke Lever] (Ref. 0B) COLOR CODE WITH FULL PRESSURE LESS FULL PRESSURE RANGE RANGE NEW P/N OLD P/N (psi) (psi) NEW P/N OLD P/N Blue P Blue P P Blue R P Green 7-55 R P P Green 4-74 R P R P Yellow 5-75 R P R P Yellow P Orange R P Orange 5-10 R P Blue R P Blue 8-5 R41009 P P Green P Yellow 5-85 R P Yellow R P Page 10

11 B A FULL PRESSURE ADJUSTING SCREW ADJUSTMENT SPRING GUIDE EXHAUST VALVE SEAT TYPICAL GRADUATING SPRING ASSEMBLY SPRING WASHER Do not attempt to adjust the graduating spring assembly. The required operating pressure range is set at the factory and locked in position. Dimension A is.40 (61.5mm) for current graduating spring assemblies with a round exhaust valve seat, and.400 (61mm) for earlier assemblies with a flat seat (see Graduating Spring Assemblies for conversion of flat to round seats). If inspection shows a deviation from Dimension A the complete graduating spring assembly should be replaced. Full pressure engagement is normally set at 17 of handle travel from center position. At the normal setting, Dimension B is.755 (70mm) when a close-yoke handle lever (0B) is used. If adjustment is necessary, hold the spring guide stationary with a ½ wrench and use a 5/ Allen wrench to adjust the full pressure adjusting screw. Turn the adjusting screw clockwise to cause a decrease of Dimension B and the full pressure feature to engage at a later point in the travel path of the handle. Turning the adjusting screw counterclockwise will cause an increase in Dimension B and an earlier engagement of the full pressure feature. The full pressure may be completely nullified by turning the screw in until slightly below the spring guide. To prevent altering the pressure range of the graduating spring assembly, the spring guide must be held stationary during these adjustments. Refer to the applicable exploded views in other sections of this publication. As the set screw (7) and cap () wear, the resulting free handle travel may prevent a valve unit from being actuated when the handle is at the normal three degrees from center. To remove lost handle motion, place the handle perfectly vertical in the center of the handle guide insert and adjust the screw (7) until there is to 0.00 (0.0 to 0.08 mm) clearance between the screw and cap. Torque set screw jam nuts to inch-lbs. The detenting force of the handle (6) may be varied as desired, but excessive force should be avoided to reduce wear on detent lugs and detent latch (10B). Force is changed by turning the latch spring cover (7) clockwise to increase the force and counterclockwise to decrease force. The adjustable handle (6E) can be varied in length and locked in place by means of a handle extension () and locknut (). Holding the handle extension firmly, turn the locknut clockwise until the extension moves freely up and down the handle. Holding the extension at the desired position, turn the locknut counterclockwise until the extension is securely in place. The holding force of the friction brake can be adjusted by tightening or loosening the screw (17) as desired. Since the delivery line pressure called for by any handle position is a function of the graduating spring rate, leakage or temperature variations that occur in the delivery line are automatically compensated for within the valve assembly. Page 11

12 OBSOLETE ASSEMBLIES AND DESIGN CHANGES OBSOLETE ASSEMBLIES The detent latch was originally designed crossslotted to accommodate a lever with pin. By rotating the latch 90 the handle detent feature could be nullified. Obsolete Obsolete 11B 9B Obsolete 9C Subsequently, the handle lever was redesigned with a key slot instead of a pin hole. Concurrently, the detent latch was redesigned with a T slot for use with either a pin (new size) on the old lever or key on the new lever. The keyed lever also required rotating the latch 90 to nullify the detent feature. Since the T slotted latch could not be rotated on the pinned lever, a retainer (9C) was substituted when a replacement latch was required for non-detented handle operation using the pinned lever. Later still, levers were furnished with both a key slot and a pin hole. On the current design, the T slotted detent latch and the retainer have been retained, but the key slot in the lever has been omitted in favor of the pin and hole. Keys are not recommended as a service part, and their replacement with the current lever and pin is urged. DESIGN CHANGES AFFECTING REPLACEMENT Clip Rounded Seat CURRENT ASSEMBLY Rivet Flat Seat OBSOLETE ASSEMBLY GRADUATING SPRING ASSEMBLIES The current graduating spring assemblies listed on the facing page include a rounded exhaust valve seat. This rounded seat is used with the current valve plunger, Part No. R (Old Part No. P ) (see Ref. 41 of Parts List Body Assemblies ). IMPORTANT: These two assemblies are interchangeable, but the exhaust valve seat is compatible only with its associated plunger because important tolerances are involved. If replacement of the complete graduating spring assembly is required, make sure the current valve plunger in used. If only repair of an assembly with a flat seat is necessary, convert as follows, using the Conversion Kit in the table below. SPRING VALVE SEAT CONVERSION KIT, Complete: R (P ) REF. NO. DESCRIPTION 4B SEAT, Exhaust valve (not shown) 4C CLIP 41 PLUNGER, Valve Page 1

13 ACCESSORIES Panel Mounting Kit, Complete: New P/N R (Old P/N P ) REF. NO. QTY DESCRIPTION 1 1 BAND 4 RETAINER, Grip nut 4 SCREW, Hex nut 4 4 WASHER, Lock 5 BRACKET, Panel mounting A B Early model Flexair Valves were made with a cast iron body, and mounting dimensions were different from current models; however, the current valve can be used as a direct replacement for an early model by using the kits below. Complete Mounting Adapter Kit (R ) adapts the mounting holes on the current valve to the bolt pattern of the cast iron model. Kit R more closely approximates the handle position of the cast iron model. Kit Part No. R (common bolt pattern) 1 Kit Part No. R (common bolt pattern and handle height) Mounting Adapter Kits: New P/N R (Old P/N P ) & New P/N R (Old P/N P ) REF. NO. QTY DESCRIPTION 1 4 SCREW A 1 PLATE, Mounting adapter (for R ) B 1 PLATE, Mounting adapter (for R ) Exhaust Adapter Kit, Complete: New P/N R (Old P/N P ) 5 REF. NO. 1 QTY DESCRIPTION 4 SCREW, Self-tapping ADAPTER, Exhaust 1 Adjustable Handle Kit, Complete: New P/N R (Old P/N P ) 1 4 REF. NO. QTY DESCRIPTION 1 1 HANDLE 1 HANDLE ASSEMBLY 1 LOCKNUT 4 1 PIN, Spirol Page 1

14 TEST ARRANGEMENT DIAGRAM NOTES: 1. AVENTICS TASKMASTER timing volume, New Part Number R (Old P/N TM ), can be used for the volumes indicated. Three () set ups required (cavity 1,, ).. The supply air lines to the valve and delivery lines must be full size as shown. Line length must not exceed ft. (1 meter) between the supply valve and IN port, and between the OUT port and delivery test volumes. 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.. It is recommended that as large of a gauge as practical be used on the delivery lines. A 6 (15mm) test gauge is recommended. 4. Close supply lines when all testing has been completed and remove test valve. TEST VALVE NOTE: ALL () DELIVERY PORTS TO HAVE SAME SET-UP. CHOKE PLUG.0 New P/N R Old P/N PD Clean, dry chemical-free air supply 150 psi maximum (or 0 psi above maximum delivery pressure of any valve to be tested). New P/N R Old P/N (PR ) Page 14

15 TESTING AND TEST SETUP After any repair or adjustment, the Flexair Valve should be tested using procedures and test arrangements described in this section. Pressure control valves of this nature should be tested for the following: 1. Function. Pressure range. Leakage 4. Response 5. Mechanical detent 6. Spring return models 7. Friction models The adjustments affecting these points have been described in the previous section. General instructions for accomplishing the above tests follow. 1. Function: The Flexair Valves are spring returned, way pressure graduating valves. A handle actuates the valve to increase, decrease or maintain graduated air pressure to the delivery line. This function should be checked using test arrangement shown.. Pressure range Cavities 1, & : Supply pressure at IN port will be delivered as graduated pressure to OUT port delivery line depending on range of control spring being used and handle position. In handle release position the OUT line is at zero pressure setting. Moving the handle actuates the graduating control portion to deliver graduated pressure to the OUT line. See Adjustment (page 11) to adjust the valve. After valve is adjusted, check that minimum and maximum pressure ranges are generated in delivery line per valve part number.. Leakage: Set supply pressure to 0 psi (1.4 bar) above maximum 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 handle position. a. On all valves with spring ranges less than 100 psi (6.9 bar), set supply line pressure to 100 psi (6.9 bar). Move handle to full travel position and hold. 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 gauge. A pressure drop of no more than psi (0. bar) in 0 seconds is0permitted. b. On all valves with spring ranges 100 psi (6.9 bar) and above, set supply line pressure to 100 psi (6.9 bar). Move handle to deliver 95 psi (6.5 bar) 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 gauge. A pressure drop of no more than psi (0. bar) in 0 seconds is permitted. 4. Response: Move handle to full travel position. Fully open the valve at delivery volume so that air exhausts through the choke plug. Observe the delivery line pressure gauge. A pressure drop of no more than psi (0. bar) is permitted. Release handle. 5. Mechanical detent: ( D Models only) Connect a spring scale just under the knob. Move handle from neutral position to Position #1. A minimum of 4 to 6 lbs. (1.8 to.7 kg) should be required to pull handle until 0 psi (.0 bar) output is indicated. Adjust detent knob to proper load. Repeat by moving handle toward Position #. 6. Spring return models: Must return to center position from all positions when released. 7. Friction models: Must remain in any position that the handle is in. Page 15

16 REPAIR AND CONVERSION KITS Major repair kits, which include applicable kits, are listed by the part number of each valve in the Part Number Index. When these kits are installed as recommended, the result is a fully rebuilt and current Flexair Valve. When partial repairs are desired, the basic repair kits that follow should provide adequate selection. All major kits for Flexair Valves are made up from these six basic kits. The major kits listed in the index are identified here by valve model designation and show the basic kits they include. WHEN DIGITS ARE D A or 0 F A S 0 D B or 0 A A B B or F or F S F - B S 0 D 1 - or 1 S - or D 1 - or 1 - or MAJOR REPAIR KIT QTY PART NO. DESCRIPTION R MAJOR REPAIR KIT (P ) 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Detent 1 REPAIR KIT, Cavities 1 & R MAJOR REPAIR KIT (P ) 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Cavities 1 & R MAJOR REPAIR KIT (P ) 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Detent REPAIR KIT, Cavities 1 & R MAJOR REPAIR KIT (P ) 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Cavities 1 & Use kit R (P ) when cavity is -way Use kit R (P ) when cavity graduated 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Detent 1 REPAIR KIT, Cavities 1 & 1 REPAIR KIT, Cavity Use kit R (P ) when cavity is -way Use kit R (P ) when cavity graduated 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Cavities 1 & 1 REPAIR KIT, Cavity Use kit R (P ) when cavity is -way Use kit R (P ) when cavity graduated 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Detent REPAIR KIT, Cavities 1 & 1 REPAIR KIT, Cavity Use kit R (P ) when cavity is -way Use kit R (P when cavity graduated 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Cavities 1 & 1 REPAIR KIT, Cavity MAJOR REPAIR KITS WHEN DIGITS ARE: A D or F A S B D F 1 - or 1 -or 1 - or 1 B S - or MAJOR REPAIR KIT PART NO. QTY BASIC KITS DESCRIPTION NEW P/N OLD P/N Repair Kit, Common Parts R41001 P Repair Kit, Detent R41000 P Repair Kit, Cavities 1 & R P Repair Kit, Handle R P Repair Kit, Major Cavity, Graduated Repair Kit, Major Cavity, -Way Repair Kit, Minor Cavity, Graduated Repair Kit, Minor Cavity, -Way R41004 R4100 R4100 R DESCRIPTION Use kit R (P ) when cavity is -way Use kit R (P ) when cavity graduated 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Detent 1 REPAIR KIT, Cavities 1 & 1 REPAIR KIT, Cavity Use kit R ( -0P ) when cavity is -way Use kit R (P ) when cavity graduated 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Cavities 1 & 1 REPAIR KIT, Cavity Use kit R (P ) when cavity is -way Use kit R (P ) when cavity graduated 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Detent REPAIR KIT, Cavities 1 & 1 REPAIR KIT, Cavity Use kit R (P ) when cavity is -way Use kit R (P ) when cavity graduated 1 REPAIR KIT, Common Parts 1 REPAIR KIT, Cavities 1 & 1 REPAIR KIT, Cavity P P P P These repair kits renew the elastomer seals and some common wear parts of the component. On damaged or severely worn valves, additional parts may be required. Page 16

17 PART NUMBER INDEX These repair kits renew the elastomer seals and some common wear parts of the component. On damaged or severely worn valves, additional parts may be required. Complete part numbers of most Flexair Valves in service are listed numerically in the following index. For part numbers not listed, consult the factory. Major repair kits, which include necessary conversion kits, if applicable, are listed beside the complete part number of each valve. When these kits are installed as recommended, the result is a fully rebuilt, current Flexair Valve. If partial repairs are desired, see Repair and Conversion Kits page 16 for selection. PART NUMBER CODE NOTE: Obsolete part numbers are noted Obs. for service parts only cannot be purchased. The construction of each valve is indicated by the model designation (see Model Designation Code ). Additional information on each valve is indicated by the suffix of the complete ptn as follows: SUFFIX: 0000 Standard valve with a current valve unit cavity, if filled. The pressure range on a standard valve may range from zero to any maximum delivery pressure with the design limitations of the valve. On the nameplate of a standard valve, the 4-digit suffix (replacing the 4 zeroes) of the complete part number indicates the maximum delivery pressure in psi of the graduated valve units in cavities 1 &. The 1 st and nd digits apply to cavity 1, and the rd and 4 th to cavity. When the digits are: Actual maximum pressure 10-1 Multiply times 10 for actual maximum pressure 1 Maximum pressure is 15 psi. (9. bar) 1 digit or none Non-standard valve with obsolete details in cavity, if filled (a few exceptions appear, but the major repair kits listed are appropriate). Pressure ranges listed in the Index are fixed and not stamped on the valve nameplate. 000 & 4 th digit Non-standard valve with a current valve unit in cavity. Pressure ranges listed are fixed and not stamped on the valve nameplate. Valve Repair Kit Remarks OLD P/N NEW P/N OLD P/N NEW P/N OLD P/N NEW P/N P R P R P R P R P R P R P R P R P R P R P R P R P R P R P P R P R P R P P R P P R P R P R P R P R p OBSOLETE P OBSOLETE P R P R P R P OBSOLETE P R P R P R P P R P R P R P R P R P R P R P P R P R P R P R P R Page 17

18 Val ve Repair Kit Remarks OLD P/N NEW P/N OLD P/N NEW P/N OLD P/N NEW P/N P R P R P OBSOLETE P R P R P R P R41000 P R P OBSOLETE P R41000 P R P R41000 P OBSOLETE P R P P R P R P R P P R P P R P OBSOLETE P R P P R P R P R P R P R P R P R P R P OBSOLETE P R P P R P P R P R P R P R P R P P R P R41009 P R P P R P R P R P OBSOLETE P R P R P R P P R P R P R P R P R P OBSOLETE P R P P P R P P R P R P R P P R P R P R P R P R P R P R P R P R P OBSOLETE P R P P OBSOLETE P OBSOLETE P R P R P R P P R P P R P R P R P R P R P R P R P R P R P R P R P R P R P R P R Page 18

19 Val ve Repair Kit Remarks OLD P/N NEW P/N OLD P/N NEW P/N OLD P/N NEW P/N P P R P P R P R41004 P R P R P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P R P R P P R P P R P R P R P R P R P P R P P R P P R P P R P P R P P R P P R P P R P P R P P R P P R P R P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P R P R P R P R P R P R P P R P P R P R P R P P R P P R P P R P P R P P R P P R P R P R P R P P R P OBSOLETE P R P R P R P P R P R P R P OBSOLETE P R P OBSOLETE P R P P R P P R Page 19

20 Val ve Repair Kit Remarks OLD P/N NEW P/N OLD P/N NEW P/N OLD P/N NEW P/N P P R P R P R P R P R P P R P R P R P R P R P R P R P R P R P R P R P OBSOLETE P R P R P R P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P P OBSOLETE P R P R P R P OBSOLETE P R P R P R P R P R P R P R P R P R P R P R P OBSOLETE P R P P R P P R P P R P R P R P P R P P R P R P R P R P R P P R P P R P R P R P R P R P P OBSOLETE P R P OBSOLETE P R P R P OBSOLETE P R P R P R P R P R P R P R P R P R P R P R P R P P R P R P R P OBSOLETE P R P OBSOLETE P R P R P R P R P R P R P R P R P P R P R P R P R P R Page 0

21 Valve Repair Kit Remarks OLD P/N NEW P/N OLD P/N NEW P/N OLD P/N NEW P/N P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P R P OBSOLETE P R P R P R P R P OBSOLETE P R P OBSOLETE P R P R P R P P R P P R P R P R P OBSOLETE P R P P R P P R P P R P P R P OBSOLETE P R P OBSOLETE P R P R P R P P R P P R P P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P P P R P R41001 P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P P OBSOLETE P R P P P R P OBSOLETE P R P R P R P R P OBSOLETE P R P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R Page 1

22 Valve Repair Kit Remarks OLD P/N NEW P/N OLD P/N NEW P/N OLD P/N NEW P/N P R P R P R P R P P R P R P OBSOLETE P R P P R P R P R P R P R P R P R P R P R P R P P R P R P R P R P R P R P R P R P R P P R P R P R P R P R P OBSOLETE P R DELETE P OBSOLETE P R P R P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R DELETE P OBSOLETE P R DELETE P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R DELETE P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R DELETE P OBSOLETE P R P R P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R DELETE P OBSOLETE P R P OBSOLETE P R P R41009 P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R P OBSOLETE P R Page