TYPE S RELAY VALVE (Volume booster) Service Manual The Type "S" Relay Valve is a pilot operated, 3-way, pneumatic pressure control valve with open exhaust. This large capacity valve receives pressure signals from a remote control valve and repeats this pressure with a greater rate of flow to the component being controlled. It serves in a pneumatic circuit to speed response time between sending and receiving stations that are separated by long pipe runs or branch circuits. Where the controlled component is not in a readily accessible location, remote piloting provides a solution. INCREASING PRESSURE Applying pressure to the pilot port moves the diaphragm assembly down to seat the exhaust valve, unseat the inlet valve plunger, and compress the inlet valve spring. Air pressure from a local source at the IN port flows to the OUT port. A controlled flow of air is also directed to the underside of the diaphragm. Air flow continues until the pressure at the OUT port equals the pressure at the pilot port. 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 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. DECREASING PRESSURE Reducing pressure in the pilot port unbalances the pressure across the diaphragm. The diaphragm assembly and exhaust valve move away from the seated inlet valve, opening the OUT port to exhaust through the hollow inlet valve plunger. Air continues to exhaust until the air pressure at the OUT port under the diaphragm balances the air pressure to the pilot port on the top of the diaphragm. MOUNTING! Devices should be mounted and positioned in such a manner that they cannot be accidentally operated. OPERATION SM-400.8007 C L O S E D C E N T E R POSITION When the outlet pressure (pressure below the diaphragm) is equal to the pilot pressure (pressure above the diaphragm), the balance of pressure allows the inlet valve spring to move the valve assembly up. This seats the inlet valve and exhaust valve, sealing the IN and OUT ports.
MAINTENANCE A complete "S" Relay Valve should be maintained in stock for each four valves in service. The maintenance periods determined by use and working conditions should be scheduled to permit complete valve replacement; thus loss of production time will be kept to a minimum and more time will be afforded to clean, carefully inspect and replace worn parts of the relay. Each "S" Relay should be supported by those parts recommended - see the parts list. Completely disassemble the Relay Valve on a well lighted work bench. Clean all metal parts with a non flammable solvent and wash all rubber parts with soap and water. Rinse thoroughly and blow dry with a low pressure air jet. Lay all parts on a clean, preferably white, surface. Arrange them in the order of the exploded view. Examine each part carefully for wear or cracks. Replace those parts that will not give good service until the next inspection period. Reassemble the "S" Relay using the exploded and assembly views as reference. No special tools are required. As the assembly proceeds, lubricate all metal to metal surfaces with No.107 Lubriplate and all rubber parts with Cosmolube or their equivalents. ADJUSTMENTS No internal adjustments are required. INSTALLATION The "S" Relay Valve can be installed directly in the line at any location. Satisfactory operation and service life can be expected in a temperature range of -20 F to + 160 F (-29 C to 71 C). Clean out the air supply line before connecting it to the "IN" port of the "S" Relay. Harmful deposits in in the air line can impair the efficiency and service life of the valve. It is recommended that a good line filter be installed in the air line upstream of the "S" Relay. Internal lubrication of the moving parts can be accomplished by a line lubricator being installed between the line filter and the "S" Relay. The oil mist will also keep the operating equipment downstream of the valve in good condition. TYPE S RELAY VALVE Exploded View Page 2
TYPE S RELAY VALVE Repair Parts List Ref. No. Description of Part 3-S 4-S 6-S 8-S 1 Body, Plugged (includes Ref. 18) R431003663 P -055160- R431003561 P -055086-00003 R431003664 P -055161- R431003561 P -055086-00003 R431003665 P -055162- R431003666 P -055163- R431003612 R431003612 P -055113-2* Ring, O See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 3 Washer R431002158 P -049804-00017 R431002158 P -049804-00017 R431002165 P -049804-00039 R431002165 P -049804-00039 4* Spring, Supply Valve See Kit See Kit See Kit See Kit See Kit See Kit X See Kit 5* Ring, O See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 6* Plunger, Valve See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 7* Ring, O See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 8* Seat, Supply Valve See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 9* Ring, O See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 10* Baffle, Complete See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 11 Follower, Diaphragm R431003669 P -055166- R431003669 P -055166- R431001024 P -030153- R431001024 P -030153-12* Diaphragm See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 13 Retainer, Diaphragm R431003667 P -055164-14* Nut, Hex R431001932 P -049633-00001 R431003667 P -055164- R431001932 P -049633-00001 R431003671 P -055168- R431001933 P -049633- R431003671 P -055168- R431001933 P -049633-15 Ring, O See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit 16 Cover R431003670 P -055167- R431003670 P -055167-0000 R431003674 P -055171- R431003674 P -055171-17 Screw, (req d) R431002250 P -049835-00022 R431002250 P -049835-00022 R431002253 P -049835-00027 R431002253 P -049835-00027 18 Plug, 1/8 Pipe (2 req d) 19 Mounting Bracket R431004138 P -057410- R431004138 P -057410- R431004139 P -057411- R431004139 P -057411-20 Screw, (2 req d) R431002254 P -049835-00028 R431002254 P -049835-00028 R431002252 P -049835-00026 R431002252 P -049835-00026 * Recommended spare parts to be retained in stock at all times. These parts may be ordered in kit form by ordering Repair Kit P/N R431004153 for 3-S and 4-S models ( P-057429-) or P/N R431004155 for 6-S and 8-S models ( P -057431-). Page 3
ORDERING REFERENCE Pipe Size Model Piece Drawing Weight Designation Number 3/8-18 Dryseal NPTF 3-S R431003663 P -055160-2Ib.. 6 oz. (1.1 kg) BP55160 1/2-14 Dryseal NPTF 4-S R431003664 P -055161-2Ib.. 4 oz. (1.0 kg) BP55160 3/4-14 Dryseal NPTF 6-S R431003665 P -055162-2lb.. 10 oz. (1.2 kg) BP55162 1-11 Dryseal NPTF 8-S R431003666 P -055163-2Ib.. 7 oz. (1.1 kg) BP55162 SPECIFICATIONS Maximum Inlet Pressure Maximum Pilot Pressure Temperature Exposure Ratio-Pilot to Delivery Pressure 1:1 Hysteresis 250 psi (17.2 bar) 250 psi (17.2 bar) -20 F to +160 F (-29 C to 71 C) Less than 5 psi (0.3 bar) Material Die cast aluminum (3/4 & 1 size) or zinc (3/8-1/2 ) Body. Nylon reinforced HYCAR diaphragm, anodized aluminum or plated parts. Type S Relay Valve Dimension Schedule R431003663 R431003664 R431003665 R431003666 P -055160- P -055161- P -055162- P -055163- A B C D E F G H I J K 3 9/16 3 1/4 3 1/4 4 1/2 4 1/16 2 1/4 1 11/32 1 5/8 2 7/8 11/16 15/32 3 9/16 3 1/4 3 1/4 4 1/2 4 1/16 2 1/4 1 11/32 1 5/8 2 7/8 11/16 15/32 4 11/32 4 1/8 4 1/8 5 1/4 4 7/8 2 7/8 1 1/2 2 1/16 3 3/16 3/4 1 3/16 4 11/32 4 1/8 4 1/8 5 14 4 7/8 2 7/8 1 1/2 2 1/16 3 3/16 3/4 1 3/16 Page 4
NOTICE TO PRODUCT USERS 1. WARNING: FLUID MEDIA AVENTICS pneumatic devices are designed and tested for use with filtered, clean, dry, chemical free air at pressures and temperatures within the specified limits of the device. For use with media other than air or for human life support systems, AVENTICS must be consulted. Hydraulic cylinders are designed for operation with filtered, clean, petroleum based hydraulic fluid; operation using fire-resistant or other special types of fluids may require special packing and seals. Consult the factory. 2. WARNING: MATERIAL COMPATIBILITY Damage to product seals or other parts caused by the use of noncompatible lubricants, oil additives or synthetic lubricants in the air system compressor or line lubrication devices voids AVENTICS warranty and can result in product failure or other malfunction. See lubrication recommendations below. AIR LINE LUBRICANTS! In service higher than 18 cycles per minute or with continuous flow of air through the device, an air line lubricator is recommended.* (Do not use line lubrication with vacuum products.) However, the lubricator must be maintained since the oil will wash out the grease, and lack of lubrication will greatly shorten the life expectancy. The oils used in the lubricator must be compatible with the elastomers in the device. The elastomers are normally BUNA-N, NEOPRENE, VITON, SILICONE and HYTREL. AVENTICS recommends the use of only petroleum based oils without synthetic additives, and with an aniline point between 180 F and 210 F. COMPRESSOR LUBRICANTS! All compressors (with the exception of special "oil free" units) pass oil mist or vapor from the internal crankcase lubricating system through to the compressed air. Since even small amounts of non-compatible lubricants can cause severe seal deterioration (which could result in component and system failure) special care should be taken in selecting compatible compressor lubricants. 3. 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 repair of these devices. 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. 4. WARNING: APPLICATION AND USE OF PRODUCTS The possibility does exist for any device or accessory to fail to operate properly through misuse, wear or malfunction. The user must consider these possibilities and should provide appropriate safe guards in the application or system design to prevent personal injury or property damage in the event of a malfunction. 5. WARNING: CONVERSION, MAINTENANCE AND REPAIR When a device is disassembled for conversion to a different configuration, maintenance or repair, the device must be tested for leakage and proper operation after being reassembled and prior to installation. MAINTENANCE AND REPAIR! Maintenance periods should be scheduled in accordance with frequency of use and working conditions. All AVENTICS products should provide a minimum of 1,000,000 cycles of maintenance free service when used and lubricated as recommended. However, these products should be visually inspected for defects and given an "in system" operating performance and leakage test once a year. Where devices require a major repair as a result of the one million cycles, one year, or routine inspection, the device must be disassembled, cleaned, inspected, parts replaced as required, rebuilt and tested for leakage and proper operation prior to installation. See individual catalogs for specific cycle life estimates. 6. PRODUCT CHANGES Product changes including specifications, features, designs and availability are subject to change at any time without notice. For critical dimensions or specifications, contact factory. *Many AVENTICS pneumatic valves and cylinders can operate with or without air line lubrication; see individual sales catalogs for details. 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, LIMITATIONS OF WARRANTIES & REMEDIES AVENTICS warrants its products sold by it to be free from defects in material and workmanship to the following: For twelve months after shipment AVENTICS will repair or replace (F.O.B. our works), at its option, any equipment which under normal conditions of use and service proves to be defective in material or workmanship at no charge to the purchaser. No charge will be made for labor with respect to defects covered by this Warranty, provided that the work is done by AVENTICS or any of its authorized service facilities. However, this Warranty does not cover expenses incurred in the removal and reinstallation of any product, nor any downtime incurred, whether or not proved defective. All repairs and replacement parts provided under this Warranty policy will assume the identity, for warranty purposes, of the part replaced, and the warranty on such replacement parts will expire when the warranty on the original part would have expired. Claims must be submitted within thirty days of the failure or be subject to rejection. This Warranty is not transferable beyond the first using purchaser. Specifically, excluded from this Warranty are failures caused by misuse, neglect, abuse, improper operation or filtration, extreme temperatures, or unauthorized service or parts. This Warranty also excludes the use of lubricants, fluids or air line additives that are not compatible with seals or diaphragms used in the products. This Warranty sets out the purchaser's exclusive remedies with respect to products covered by it, whether for negligence or otherwise. Neither, AVENTICS nor any of its affiliates will be liable for consequential or incidental damages or other losses or expenses incurred by reason of the use or sale of such products. Our liability (except as to title) arising out of the sale, use or operation of any product or parts, whether on warranty, contract or negligence (including claims for consequential or incidental damage) shall not in any event exceed the cost of replacing the defective products and, upon expiration of the warranted period as herein provided, all such liability is terminated. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER FOR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE. No attempt to alter, amend or extend this Warranty shall be effective unless authorized in writing by an officer of AVENTICS Corporation. AVENTICS reserves the right to discontinue manufacture of any product, or change product materials, design or specifications without notice. Page 5
Al'BffltS CeqioRli T95J-ltten:er Raad Le ingtnn, l"iy: 405TT www.aventi cs.cam/ us infa.us@aventics.cam m AVENTICS AfflDICS mkl(mldedi J4 2-& Itta i nway. [Jri v.e BurUngtan, Ontario CANAD"A-L71tt TM www.av.entics.cam/ca infa.ca@a11entics.cam Slv1-4QQ.8QQ7/May 2QT4 Sub1ec:ttn c:hange. Printed in United States. AVENTICS Carparatian This dac:urnent. as well as the data. spec:ific:atians. and atherinfurmatian setfurth in it are the ED\Clusive property at AVEl"-JTICS. It may natb.e reproduced ar given ta third parties withaut its can sent