CERAM - AVENTICS€¦ · from internal pilot supply to external pilot supply. See conversion information. MAINTENANCE Ceram Valves may be serviced after shutting off and venting the

CERAM™ VALVE Service Information

Summary of Specifications For Ceram Valves TECHNICAL DATA: Port Sizes: 1/4” - 3/8” ISO Size I, 3/8”-1/2” ISO Size II 1/2” - 3/4” ISO Size III, 1” ISO Size IV Working Pressure: 0 to 150 psi (0 to 10.3 bar) (Intrinsically Safe versions: Maximum internal pilot valve pressure is 115 psi or 7.9 bar) Vacuum applications: to 24” Hg (sizes I & II) Consult factory (sizes III & IV) Pilot Pressure: SIZES I & II 29 psi minimum (2.0 bar), all 2 position valves 44 psi minimum (3.0 bar), all 3 position valves 150 psi maximum (10.3 bar) (Intrinsically Safe versions: Maximum external pilot pressure is 115 psi or 7.9 bar) SIZES III & IV 36 psi minimum, all 2 position valves 44 psi minimum, all 3 position valves 150 psi maximum (Intrinsically Safe versions: Maximum external pilot pressure is 115 psi) Flow: Valve Size I II III IV Cv 1.1 2.4 4.3 7.5 Nl/min 1100 2400 4300 7500 Temperature Range:

Solenoid Valves: +5°F to +150°F (-15°C to +66°C) (-10°F or -23°C operation possible with low temperature solenoid operators. Available for 2-position double solenoid and air spring return valves.) Air Pilot Valves: -10° F to +175° F (-23°C to +79°C)

Media: Air, either Lubricated or Nonlubricated Materials: Body - GS: Die Cast Anodized Aluminum GT: Die Cast Zinc Valve Elements - Ceramic Slide Plated (Al2O3) Combination Manual Override: Locking & Non-Locking sizes I & II Non-Locking sizes III & IV

Table of Contents Page Installation ......................................... 2 Operation........................................... 2 Adjustments ...................................... 2 Maintenance ...................................... 2 GT Series - Size 1 Repair Info .......... 3 Operator and Body Assembly ........... 4 Typical Repair Parts Needed ............ 4 Operator and Body Disassembly ...... 5 Part Identification List - Size I & II ..... 6 Exploded View - Size I & II ................ 7 Part Identification List - Size III & IV .. 8 Exploded View - Size III & IV ............ 9 Repair Kits & Parts - Size I & II ....... 10 Repair Kits & Parts - Size III & IV .... 11 Part Number Code Identification ..... 12 Piping Instructions ........................... 13 Internal to External Pilot Conversion, Size I & II ..................... 14 Pilot Conversion - Size III & IV ........ 18 Troubleshooting Guide .................... 19

ISO Valve Size Standard Voltages

(All coils are rated for continuous duty)

Power Consumption

Inrush Holding

I and II (III and IV Oct. ‘92

& later)

24, 120, 240 VAC (50/60 Hz) 6.4 VA 3.7 VA

12, 24, VDC 2.7 W 120, 240, VAC

(50/60 Hz) 15.6 VA 9.4 VA

12, 24, VDC 6.1 W

III and IV (Prior to Oct. ‘92)

ELECTRICAL DATA:

Voltage Tolerance: ± 10% All standard valves rated for NEMA 4. SM-300.10

Installation and General Maintenance Recommendations

Page 2

* ATTENTION *

DO NOT remove the static base. Special fixtures are required to reinstall plates to factory specifications. Roller bearings and ceramic plate stack are calibrated to obtain proper mechanical pre-loading. Therefore, field disassembly is not recommended for the plate/bearing assembly. The ceramic slide plates do not require maintenance under normal operating conditions and should not be removed from the valve. Consult the factory if plate maintenance becomes necessary. There are no seals for the static base / ceramic plate assembly contained in repair kits.

ADJUSTMENTS No adjustments are needed on the Ceram Valve. Solenoid valves may be converted from internal pilot supply to external pilot supply. See conversion information.

MAINTENANCE Ceram Valves may be serviced after shutting off and venting the main air supply. However, it is recommended the valve be removed from its mounting for servicing. Main air supply must be vented before removing valve from a manifold. If a solenoid operated valve fails to operate, pressing the manual override button on top of the operator should quickly indicate whether the trouble is electrical or mechanical. If the problem is electrical, the coil may be replaced by removing the retainer nut and replacing the coil. Ceram Valves are lubricated at the factory for long trouble-free service. An efficient air line lubricator will further extend the service life of the valve. When no additional lubrication is provided, the solenoid/air pilot piston assemblies should be disassembled every thirty million cycles for lubrication, cleaning and inspection.

INSTALLATION Before installing the Ceram Valve, all

air lines in the system should be blown clean to remove any moisture or loose material. To further insure long, trouble-free service, an efficient filter should be installed in the air line on the supply side of the valve. Ceram Valves are lubricated at the factory and should provide over thirty million cycles of trouble-free service with lubricated or non-lubricated air. WARNINGS - 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 systems and devices, unless under trained supervision.

Compressed air 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 the pressure from an air system before performing any service work. Failure to do so can result in serious personal injury.

Disconnect the electrical power supply before connecting or servicing a solenoid operated valve.

MOUNTING! Devices should be mounted

and positioned in such a manner that they cannot be accidentally operated.

Caution – If Using a Lubricator, Please Note the Following: 1. The lubricants used in a lubricator must

be compatible with Buna-N elastomers and must be petroleum based without synthetic additives. The aniline point for this lubricant must also be between 180 degrees and 210 degrees Fahrenheit (82 degrees and 99 degrees Celsius).

2. The lubricator must be continually maintained as the lubricant will wash out the factory lubrication resulting in a dependency which if not maintained will shorten the life of the valve.

3. Air compressors will pass small amounts of lubricant, which must also be compatible with Buna-N elastomers. It is recommended that customers review the National Fluid Power Association’s “Recommended Guidelines for the Use of Synthetic Lubricants in Pneumatic Fluid Power Systems” (NFPA/T1.9.2-1978). Ceram Valves can be installed in any convenient position; however, the preferred mounting for all models is horizontal. For mounting dimensions see Catalog SC-300. Prior to connecting the power supply, be sure the coil rating is compatible. Voltage characteristics for solenoid operators are indicated by the valve part number suffix. Solenoid voltage is indicated on the side of the coil except for certain special models.

OPERATION

The air pilot signal is controlled in solenoid operators by energizing the coil to open and close a 3-way valve in the operator. Although the solenoid coil may be energized for extended periods of time, it is better to design your electrical circuits so the coil is de-energized for the extended period and energized for the shorter period (especially for ambient temperatures between 120 degrees-150 degrees F).

General Note: Grease all new O-rings with grease tube provided in kit before installation. 1. Remove valve from base by loosening and removing the four mounting bolts (4). 2. (Solenoid Models only) Remove solenoid mounting screws (12) and solenoid(s) (13) from valve. 3. (Single operator, metal spring return models only) CAUTION: Spring under pressure. Carefully remove spring retainer (1) and return spring (14) by turning retainer (1) approximately 1/4 turn counter- clockwise allowing it to be removed from the valve body (11). Do not reuse retainer (1); use new one from kit. Locking tabs break off during removal. 4. Loosen and remove saddle cover to valve body retaining screws (9). 5. Carefully lift the saddle cover (2) from the valve body (11). 6. Repair kit R432009099 is for 2-position valves and contains three piston assemblies. There are two identical piston assemblies with black pistons that are used to repair double solenoid valves and single solenoid valves with a metal spring return operator. The piston assembly with the blue piston is used on the “12” end of single solenoid valves with air spring operators. See page 12 for explanation of valve and operator codes. Repair kit R432009100 is for 3-position valves and contains two identical piston assemblies. 7. Remove and replace five O-rings (8) in valve body (11) then set valve body aside, no further disassembly of valve body is necessary. No parts are contained in repair kit for the Ceramic Stack area (6); DO NOT DISASSEMBLE. Remove piston assembly(ies) (5) and o-ring(s) (7). Place new greased o-ring(s) (7) on tube(s) then push piston assembly(ies) over tube(s) and o- ring(s). 8. Place cover back on valve body and replace screws (9) and solenoid(s) (3) and o-rings (10) if

appropriate. 9. (Single operator, metal spring return models only) Carefully install return spring (14) and retainer (1) by fully depressing spring until retainer seals in valve body (11). Turn retainer (1) clockwise until locking labs snap into the body. 10. Note orientation of gasket (13) before removal. Remove and replace gasket (13). 11. Install and retest valve before placing back into service.

Size I Ceram™ Valve (GT Series) Repair Instructions

See page 3 for “GT” Series Size 1 repair information.

Operator and Body Disassembly

Follow the disassembly instructions listed below for the various operator assemblies.

Clean all metal parts in a nonflammable solvent and wash all elastomer and plastic parts with soap and water. Rinse all parts thoroughly with water and blow dry with a low-pressure air jet. Lubricate all seals with grease provided before reassembling. Check all internal ports and flow passages in the valve body and flow channel plate (if applicable) to make sure they are clear. Replace any elastomer parts that are damaged or worn. Repair parts and kits for operator portions are available as shown in the appropriate parts section. Note: Repair kits contain parts that will not be used. As with any product, Ceram™ valves are continually being improved and therefore minor engineering changes may occur. Please choose the appropriate matching seals by matching the style in the unit being serviced. NOTE: For parts location, refer to pages 6 & 7 for sizes I and II and refer to pages 8 & 9 for sizes III and IV. NOTE: Piston (reference 36) is for representative purposes only. It is shown as both a two position and a three-position assembly. Since disassembly of three-position assembly is not recommended, it is shown in this way to represent placement only. Remove Ceram Valve from subplate by loosening 4 valve-mounting screws (1). Remove subplate gasket (2) from bottom of valve.

1. SOLENOID OPERATORS (12 and 14 Operators; all sizes)

To remove Solenoid Operator, remove 2 mounting screws (3) being careful to find 2 O-ring Seals (16) under the solenoid body.

To disassemble solenoid operator, unscrew retainer nut (5), remove washer (6) (sizes III & IV only) and coil (7). Remove o-ring (8), remove 2 screws (9), remove armature retainer plate (10), armature (12), spring (13), plunger (14) and O-ring (11) from solenoid valve body (15). Be careful when removing the armature assembly from the solenoid valve body so that the spring-loaded plunger is retained.

Disassembly of items (8) through (14) should only be necessary if the solenoid pilot valve is leaking or sticking.

For reassembly, reverse procedure outlined above.

2. TWO POSITION SOLENOID OR AIR PILOT PISTON ASSEMBLIES

(12 and 14 Operators; all sizes) Remove 4 end cover screws (31), cover (32)

then gasket (33). For sizes III and IV, note the slot in the gasket (33) connecting the pilot passage. Carefully remove the cylinder insert (34) and position (36) as a unit. Then push the piston (36) from insert (34). Remove the U-cup or O-ring (35) from piston (36) and O-ring (37) from body.

3. AIR SPRING RETURN PISTON ASSEMBLY

(12 Operator only; all sizes) Remove items (31), (32) and (33) as

described above. Sizes I and II, carefully remove insert (34a)

and piston (39) as a unit. Then push out the piston (39) and remove O-ring (38) from insert (34a) and O-ring (37) from body.

Sizes III & IV, carefully remove insert (40) and piston (39) as a unit. Then push out the piston (39) and remove O-ring (38) from piston (39) and insert shim (41) from body.

4. METAL SPRING RETURN OPERATOR

(12 Operator only; all sizes) CAUTION: Return springs are assembled under load. Care should be taken when removing these operators to avoid personal injury.

Slowly remove 4 screws (31) while securely holding the end cover (32) in place. Remove the cover (32) slowly, then gasket (33). For valve sizes I and II, remove piston (36) and return spring (45) and from valve sizes III and IV, remove spring seat(s) (42) and return springs (43) and (44).

5. THREE POSITION SOLENOID OR AIR PILOT PISTON ASSEMBLIES

(12 and 14 Operators; all sizes) Caution: Centering springs are assembled under load. Care should be taken when removing these operators to avoid personal injury.

Slowly remove 4 screws (31) while securely holding the end cover (32) in place. Remove the cover (32) slowly, then gasket (33). When removing gasket (33) from valve sizes III and IV, note position of slot connecting the pilot passage. Carefully remove cylinder insert (34) and piston assembly (36) as a unit. Then push the piston assembly (36) from insert (34) and remove seal (35). It is not recommended that the piston assembly (36) be disassembled or the cage height will be altered. Should repair or adjustment be necessary, consult the factory.

6. BODY COVER

(All operators) Sizes I and II

Remove solenoid operator(s) (if applicable) by loosening the 2 operator mounting screws (3), being careful to retain the 2 O-rings (16). Remove cover screws(s) (19) and carefully lift off saddle cover (20). Remove the cover gasket (21) from the top of the valve body. Sizes III and IV

Remove solenoid operator(s) (if applicable) by loosening the 2 operator mounting screws (3) and/or blanking plate screws (17) and blanking plate(s) (18), being careful to retain the 2 O-ring (16). Remove cover screws (19) and carefully lift off saddle cover (20).

Slightly squeeze the cover (20) inward at the AVENTICS logo for easier removal. Remove the 2 multifunction gaskets (21) and the common pilot gasket (22). Remove flow channel plate (23), then remove 4 retainer plugs (24) and channel plate gasket (25) from the top of the valve.

NOTE: When reassembling the body cover, the function gasket(s) must be arranged according to valve type. Refer to page 18 for correct gasket arrangement.

7. QUICK RELEASE VALVE

(All operators) To repair the quick release valve, follow the

disassembly instructions for the body cover as shown above, the do the following:

Size I

Remove quick release valve cover (26), cover insert (26a) (solenoid models only), cover O-ring (27) and diaphragm (28). Then remove quick release valve seat (29) and O-ring (30). Note that on end 12 for the mechanical spring return there is no diaphragm (28) or insert (26a), and on 12 end of the air spring return there is no diaphragm (28) and seat (29) has no flow passage. NOTE: On air pilot operators, insert (26a) is not needed. Size II (prior to 4th quarter ’92)

Remove quick release valve cover (26), cover insert (26a) (solenoid models only), cover O-ring (27) and diaphragm (28). Note, on end 12 for the mechanical spring return there is no insert (26a) or diaphragm (28), and on end 12 for air spring there is no insert (26a) but there is a diaphragm (28).

Size II (4th quarter ’92 and later)

Remove quick release valve cover (26), cover insert (26a) (solenoid models only), cover O-ring (27) and diaphragm (28). Note, on end 12 for the mechanical spring return there is no insert (26a) or diaphragm (28), and on end 12 for air spring there is no diaphragm (28) and seat (29) has no flow passage.

NOTE: Insert (26a) is not shown but resembles a small sled. When placing into groove on QRV cover, the “sled runners” go down and the flat surface faces upward to support the saddle cover gasket. NOTE: On air pilot operators, insert (26a) is not needed. Size III and IV

Remove quick release valve cover (26), cover O-ring (27), diaphragm (28), seat insert (29) and insert O-ring (30). Note: On end 12 for mechanical spring return and for air spring return there is no diaphragm (28) and the cover (26) and insert (29) are different than those on the 14 end. For assembly, reverse procedure outlined above.

GS Series

OPERATOR AND BODY ASSEMBLY INSTRUCTIONS

On single solenoid and single air pilot valves with metal spring return or air spring return, install the solenoid or air pilot piston assembly into the 14 end first.

1. TWO POSITION SOLENOID AND AIR PILOT PISTON ASSEMBLIES

Place the lubricated piston seal (35) into the piston (36) seal groove. Place lubricated cylinder O-ring (37) into bottom of body cavity. Insert the piston (36) into cylinder tube (34), aligning the piston so that the nose is parallel to the tube wall. Slide the piston/cylinder assembly into the body cavity, then press on the piston (36) until it comes in contact with the dynamic plate carrier. Replace end cover gasket (33), insuring the slotted corner lines up with the pilot cavity in the body (size III and IV only). Place end cover (32) onto valve and secure with 4 screws (31).

2. AIR SPRING RETURN OPERATOR

Note the air spring operator is for the 12 end only. Size I and II

Assemble piston (39) into cylinder (34a) then slide O-ring (38) over piston into groove in bottom of cylinder (34a). Insert lubricated O-ring (37) into bottom of valve body cavity then insert piston/cylinder assembly into body cavity. Press in on piston (39) until it contacts dynamic plate carrier. Insert end cover gasket (33) into body groove and place end cover (32) onto body and secure with 4 screws (31).

Size III and IV

Place lubricated O-ring (38) into groove in piston (39) and insert piston assembly into cylinder (40). Place insert shim (41) into bottom of valve body cavity then insert piston/cylinder assembly into the body cavity. Replace end cover gasket (33), insuring the slotted corner lines up with the air pilot cavity in the valve body. Place end cover onto the body and secure with 4 screws (31).

3. METAL SPRING RETURN

OPERATOR Note the metal return spring operator is

for the 12 end only. Size I and II

Insert return spring (45) into body cavity onto end of dynamic plate carrier. Place spring return piston (36) over spring (45). Replace end cover gasket (33). Place end cover (32) against piston face and slowly

depress spring until cover (32) enters recess in body. Hold cover in place and secure with 4 screws (31).

Size III and IV

Place 1 spring seat (42) onto dynamic plate carrier. Set springs (43) and (44) on seat (42) and place second spring seat (42) (size III only) on springs. Replace end cover gasket (33), insuring the slotted corner lines up with the air pilot cavity in the valve body. Place end cover (32) on spring seat (42) (Size III only) and slowly depress springs until cover contacts body. Hold cover in place and secure with 4 screws (31).

4. THREE POSITION SOLENOID AND AIR PILOT PISTON ASSEMBLIES

Notes: For 3-position operation, 3 position operators are required on each end. 3-Position piston assemblies are built to a precise caged height and should not be disassembled. Should repair or adjustment become necessary, consult the factory.

Place lubricated piston seal (35) into groove in piston assembly (36) and insert piston assembly into cylinder (34). Place lubricated cylinder O-ring (37) into bottom of valve body cavity and insert piston and cylinder assembly, pressing on the piston head until contact is made with the plate carrier. Replace the end cover gasket (33) insuring the slotted corner lines up with the pilot cavity (size III and IV only). Place end cover (32) onto back of piston assembly (36) and press inward until the cover (32) comes in contact with the valve body. Hold cover in place and secure with 4 screws (31).

5. BODY COVER ASSEMBLY

Size I and II Place the cover gasket (21) on the valve

body as shown on pages 16 & 17 to correspond to your valve type. Slide the body cover (20) onto the valve and secure with the cover screws (19). Size III and IV

Place the flow channel plate gasket (25) onto the top of the valve body. Insert the 4 retaining plugs (24) then place the flow channel plate (23) onto the gasket. Place 2 multi-function gaskets (21) and 1 common pilot gasket (22) as shown on page 18 for your particular model. Place cover (20) onto body, squeezing slightly at the AVENTICS logo to insert the tabs into the body cavities provided. Secure the cover with screws (19).

Replace solenoid operator(s) and blanking plate(s) (18) (if applicable) to top

of valve using screws (3) for solenoid valve and screws (17) for blanking plate. Make sure O-rings (16) are in place on body before solenoid operator and/or blanking plate(s) are installed.

Typical Repair Parts Needed

Size I and II

Generally a rubber seal kit (ref. Page 10) and the appropriate saddle cover gasket (ref. Page 16 or 17) will be needed. See special notes on page 15 for size II valves. Size III and IV Generally only a rubber seal kit (ref. Page 11) is all that is normally required. Be sure to inspect your unit for other parts that may be worn and replace as necessary.

Note: After reassembly, test valve before placing back in service.

GS Series

Part Identification List

Page 6

VALVE TYPES

A - 2 position, single solenoid with metal spring return. B - 2 position, single solenoid with air spring return. C - 2 position, double solenoid.

D - 3 position, double solenoid (closed or exhaust open center). E - 2 position, single air pilot with metal spring return.

F - 2 position, single air pilot with air spring return. G - 2 position, double air pilot. H - 3 position, double air pilot (closed or exhaust open center).

SIZE I VALVE TYPE (GS SERIES*) A B C D E F G H ITEM DESCRIPTION QUANTITY 1 Screw, Mounting 4 4 4 4 4 4 4 4 2 Gasket, Subplate 1 1 1 1 1 1 1 1 3 Screw, Sol. Mtg. 2 2 4 4 0 0 0 0 5 Nut, Coil 1 1 2 2 0 0 0 0 7 Coil 1 1 2 2 0 0 0 0 8 O-Ring, Coil 1 1 2 2 0 0 0 0 9 Screw, Arm. Ret. 2 2 4 4 0 0 0 0 10 Plate, Armature 1 1 2 2 0 0 0 0 11 O-Ring, Armature 1 1 2 2 0 0 0 0 12 Armature 1 1 2 2 0 0 0 0 13 Spring, Plunger 1 1 2 2 0 0 0 0 14 Plunger 1 1 2 2 0 0 0 0 15 Body, Sol. Valve 1 1 2 2 0 0 0 0 16 O-Ring, Body 2 2 4 4 0 0 0 0 19 Screw, Saddle 3 3 1 1 5 5 5 5 20 Cover, Saddle 1 1 1 1 1 1 1 1 21 Gasket, Saddle 1 1 1 1 1 1 1 1 26 Cover, QRV 2 2 2 2 2 2 2 2 26a Insert 1 1 2 2 0 0 0 0 27 O-Ring, QRV Cover 2 2 2 2 2 2 2 2 28 Diaphragm, QRV 1 1 2 2 1 1 2 2 29 Seat, QRV 2 2 2 2 2 2 2 2 30 O-Ring, QRV Seat 2 2 2 2 2 2 2 2 31 Screw, End Cover 8 8 8 8 8 8 8 8 32 Cover, End 2 2 2 2 2 2 2 2 33 Gasket, End Cover 2 2 2 2 2 2 2 2 34 Cylinder, Piston 1 1 2 2 1 1 2 2 34a Cylinder, Air Spring 0 1 0 0 0 1 0 0 35 U-Cup, Piston 1 1 2 2 1 1 2 2 36 Piston 2 1 2 2 2 1 2 2 37 O-Ring, Cylinder 1 2 2 2 1 2 2 2 38 O-Ring, A.S. Piston 0 1 0 0 0 1 0 0 39 Piston, Air Spring 0 1 0 0 0 1 0 0 45 Spring, Return 1 0 0 0 1 0 0 0

SIZE II

VALVE TYPE A B C D E F G H ITEM DESCRIPTION QUANTITY 1 Screw, Mounting 4 4 4 4 4 4 4 4 2 Gasket, Subplate 1 1 1 1 1 1 1 1 3 Screw, Sol. Mtg. 2 2 4 4 0 0 0 0 5 Nut, Coil 1 1 2 2 0 0 0 0 7 Coil 1 1 2 2 0 0 0 0 8 O-Ring, Coil 1 1 2 2 0 0 0 0 9 Screw, Arm. Ret. 2 2 4 4 0 0 0 0 10 Plate, Armature 1 1 2 2 0 0 0 0 11 O-Ring, Armature 1 1 2 2 0 0 0 0 12 Armature 1 1 2 2 0 0 0 0 13 Spring, Plunger 1 1 2 2 0 0 0 0 14 Plunger 1 1 2 2 0 0 0 0 15 Body, Sol. Valve 1 1 2 2 0 0 0 0 16 O-Ring, Body 2 2 4 4 0 0 0 0 19 Screw, Saddle 4 4 2 2 6 6 6 6 20 Cover, Saddle 1 1 1 1 1 1 1 1 21 Gasket, Saddle 1 1 1 1 1 1 1 1 26 Cover, QRV 2 2 2 2 2 2 2 2 26a Insert 1 1 2 2 0 0 0 0 27 O-Ring, QRV Cover 2 2 2 2 2 2 2 2 28 Diaphragm, QRV 1 2 2 2 1 2 2 2

31 Screw, End Cover 8 8 8 8 8 8 8 8 32 Cover, End 2 2 2 2 2 2 2 2 33 Gasket, End Cover 2 2 2 2 2 2 2 2 34 Cylinder, Piston 1 1 2 2 1 1 2 2 34a Cylinder, Air Spring 0 1 0 0 0 1 0 0 35 U-Cup, Piston 1 1 2 2 1 1 2 2 36 Piston 2 1 2 2 2 1 2 2 37 O-Ring, Cylinder 1 2 2 2 1 2 2 2 38 O-Ring, A.S. Piston 0 1 0 0 0 1 0 0 39 Piston, Air Spring 0 1 0 0 0 1 0 0 45 Spring, Return 1 0 0 0 1 0 0 0

30 O-Ring, QRV Seat 2 2 2 2 2 2 2 2 29 Seat, QRV 2 2 2 2 2 2 2 2

NOTE: Some numbers have been omitted to pro-mote consistency between Sizes I-IV diagrams.

* For GT 1xxxx-xxxx Series Valves, see page 3.

GS Series Size I and II

*

* Not used after Mid 1992

A. 2 Position, single solenoid with metal spring return B. 2 Position, single solenoid with air spring return C. 2 Position, double solenoid

D. 3 Position, double solenoid (closed or exhaust open center) E. 2 Position, single air pilot with metal spring return

F. 2 Position, single air pilot with air spring return G. 2 Position, double air pilot H. 3 Position, double air pilot (closed or exhaust open center)

Part Identification List VALVE TYPES

SIZE III A B C D E F G H

Item Description Quantity

1 Screw, Mounting 4 4 4 4 4 4 4 4 2 Gasket, Subplate 1 1 1 1 1 1 1 1 3 Screw, Sol. Mtg. 2 2 4 4 0 0 0 0 4 Washer, #8 lock 2 2 4 4 0 0 0 0 5 Nut, Coil 1 1 2 2 0 0 0 0 6 Washer, Coil Nut 1 1 2 2 0 0 0 0 7 Coil 1 1 2 2 0 0 0 0 8 O-Ring, Coil 1 1 2 2 0 0 0 0 9 Screw, Arm. Ret. 2 2 4 4 0 0 0 0

10 Plate, Armature 1 1 2 2 0 0 0 0 11 O-Ring, Armature 1 1 2 2 0 0 0 0 12 Armature 1 1 2 2 0 0 0 0 13 Spring, Plunger 1 1 2 2 0 0 0 0 14 Plunger 1 1 2 2 0 0 0 0 15 Body, Sol. Valve 1 1 2 2 0 0 0 0 16 O-Ring, Sol.Mtg. 4 4 4 4 4 4 4 4 17 Screw, Blank Cvr. 2 2 0 0 4 4 4 4 18 Cover, Blanking 1 1 0 0 2 2 2 2 19 Screw, Saddle 2 2 2 2 2 2 2 2 20 Cover, Saddle 1 1 1 1 1 1 1 1 21 Gasket, MF. 2 2 2 2 2 2 2 2 22 Gasket, Com. Pil. 1 1 1 1 1 1 1 1 23 Plate, Flow Channel 1 1 1 1 1 1 1 1 24 Plug, Ret. F/QRV 4 4 4 4 4 4 4 4 25 Gasket, Channel Plt. 1 1 1 1 1 1 1 1 26 Cover, QRV 2 2 2 2 2 2 2 2 27 O-Ring, QRV Cover 2 2 2 2 2 2 2 2 28 Diaphragm, QRV 1 1 2 2 1 1 2 2 29 Seat, QRV 2 2 2 2 2 2 2 2 30 O-Ring, QRV Seat 2 2 2 2 2 2 2 2 31 Screw, End Cover 8 8 8 8 8 8 8 8 32 Cover, End 2 2 2 2 2 2 2 2 33 Gasket, End Cover 2 2 2 2 2 2 2 2 34 Cylinder, Piston 1 1 2 2 1 1 2 2 35 O-Ring Piston 1 1 2 2 1 1 2 2 36 Piston 1 1 2 2 1 1 2 2 37 O-Ring Cylinder 1 1 2 2 1 1 2 2 38 O-Ring, A.S. Piston 0 1 0 0 0 1 0 0 39 Piston, Air Spring 0 1 0 0 0 1 0 0 40 Cylinder, Air Spring 0 1 0 0 0 1 0 0 41 Shim, Insert 0 1 0 0 0 1 0 0 42 Seat, Ret. Spring 2 0 0 0 2 0 0 0 43 Spring, Outer Ret. 1 0 0 0 1 0 0 0 44 Spring, Inner Ret. 1 0 0 0 1 0 0 0

Valve Type SIZE IV A B C D E F G H

Item Description Quantity

1 Screw, Mounting 4 4 4 4 4 4 4 4 2 Gasket, Subplate 1 1 1 1 1 1 1 1 3 Screw, Sol. Mtg. 2 2 4 4 0 0 0 0 4 Washer, #8 lock 4 4 8 8 0 0 0 0 5 Nut, Coil 1 1 2 2 0 0 0 0 6 Washer, Coil Nut 1 1 2 2 0 0 0 0 7 Coil 1 1 2 2 0 0 0 0 8 O-Ring, Coil 1 1 2 2 0 0 0 0 9 Screw, Arm. Ret. 2 2 4 4 0 0 0 0

10 Plate, Armature 1 1 2 2 0 0 0 0 11 O-Ring, Armature 1 1 2 2 0 0 0 0 12 Armature 1 1 2 2 0 0 0 0 13 Spring, Plunger 1 1 2 2 0 0 0 0 14 Plunger 1 1 2 2 0 0 0 0 15 Body, Sol. Valve 1 1 2 2 0 0 0 0 16 O-Ring, Sol.Mtg. 4 4 4 4 4 4 4 4 17 Screw, Blank Cvr. 2 2 0 0 4 4 4 4 18 Cover, Blanking 1 1 0 0 2 2 2 2 19 Screw, Saddle 2 2 2 2 2 2 2 2 20 Cover, Saddle 1 1 1 1 1 1 1 1 21 Gasket, MF. 2 2 2 2 2 2 2 2 22 Gasket, Com. Pil. 1 1 1 1 1 1 1 1 23 Plate, Flow Channel 1 1 1 1 1 1 1 1 24 Plug, Ret. F/QRV 4 4 4 4 4 4 4 4 25 Gasket, Channel Plt. 1 1 1 1 1 1 1 1 26 Cover, QRV 2 2 2 2 2 2 2 2 27 O-Ring, QRV Cover 2 2 2 2 2 2 2 2 28 Diaphragm, QRV 1 1 2 2 1 1 2 2 29 Seat, QRV 2 2 2 2 2 2 2 2 30 O-Ring, QRV Seat 2 2 2 2 2 2 2 2 31 Screw, End Cover 8 8 8 8 8 8 8 8 32 Cover, End 2 2 2 2 2 2 2 2 33 Gasket, End Cover 2 2 2 2 2 2 2 2 34 Cylinder, Piston 1 1 2 2 1 1 2 2 35 O-Ring Piston 1 1 2 2 1 1 2 2 36 Piston 1 1 2 2 1 1 2 2 37 O-Ring Cylinder 1 1 2 2 1 1 2 2 38 O-Ring, A.S. Piston 0 1 0 0 0 1 0 0 39 Piston, Air Spring 0 1 0 0 0 1 0 0 40 Cylinder, Air Spring 0 1 0 0 0 1 0 0 41 Shim, Insert 0 1 0 0 0 1 0 0 42 Seat, Ret. Spring 1 0 0 0 1 0 0 0 43 Spring, Outer Ret. 1 0 0 0 1 0 0 0 44 Spring, Inner Ret. 1 0 0 0 1 0 0 0

Valve Type

NOTE: Some numbers have been omitted to promote consistency between Sizes I-IV diagrams.

Exploded View Size III & IV

Repair Kits Size I & II

Repair Kits & Parts-Size I Repair Kits & Parts-Size II (See page 3 for GT Series)

Rubber Seal Repair Kit Qty Ref No Rubber Seal Repair Kit Qty Ref No (GS Series) R432008630 (GS Series) R432008631 Solenoid O-Ring 4 16 Solenoid O-Ring 4 16 Packing O-Ring 2 37 Packing O-Ring 2 37 Piston Seal 2 35 Piston Seal 2 35 O-Ring for Air Spring Return 1 38 O-Ring for Air Spring Return 1 38 Gasket End Cover 2 33 Gasket End Cover 2 33 Subbase Gasket (new style) 1 2 Subbase Gasket (new style) 1 2 Grease (2 Grams) 1 — Grease (2 Grams) 2 — Subbase Gasket (old style) 1 2 Subbase Gasket (old style) 2 2

Complete Std. Solenoid-Sizes I-IV (III & IV: Oct. '92 and later) Complete Std. Solenoid - Sizes I-IV (III & IV: Oct. '92 and later) 120VAC R432015466 As Req. 5,7-15 120VAC R432015466 As Req. 5,7-15 240VAC R432015467 As Req. 5,7-15 240VAC R432015467 As Req. 5,7-15 12VDC R432015468 As Req. 5,7-15 12VDC R432015468 As Req. 5,7-15 24VDC R432015469 As Req. 24VDC R432015469 As Req. 24VAC R432015470 As Req. 24VAC R432015470 As Req. As Req. Std. Coil Only—Sizes I-IV (III & IV: Oct. '92 & later) 7 Std. Coil Only - Sizes I-IV (III & IV: Oct. '92 & later) 7 120VAC R432011985 As Req. 120VAC R432011985 As Req. 240VAC R432011986 As Req. 240VAC R432011986 As Req. 12VDC R432011988 As Req. 12VDC R432011988 As Req. 24VDC R432011989 As Req. 24VDC R432011989 As Req. 24VAC R432011990 As Req. 24VAC R432011990 As Req. Std. Operator Only R432008909 - Sizes I-IV (III & IV: Oct. '92 & later) Std. Operator Only P28197 - Sizes I-IV (III & IV: Oct. '92 & Later) As Req. 9-15 As Req. 9-15 Explosion Proof Operators Explosion Proof Operators 120VAC R432008525 As Req. 5,7-15 120VAC R432008525 As Req. 5,7-15 24VDC R432008526 As Req. 5,7-15 24VDC R432008526 As Req. 5,7-15 240VAC R432008527 As Req. 5,7-15 240VAC R432008527 As Req. 5,7-15 Coil Only 7 Coil Only 7 120VAC R432013760 As Req. 120VAC R432013760 As Req. 240VAC R432013761 As Req. 240VAC R432013761 As Req. Quick Release Valve Kit R432008632 Quick Release Valve Kit R432008632 Insert 2 26a Insert 2 26a Quick Release Valve Cover 4 26 Quick Release Valve Cover 4 26 Quick Release Valve Diaphragm 2 28 Quick Release Valve Diaphragm 2 28 O-Ring Cover 4 27 O-Ring Cover 4 27 Grease (2 Grams) 1 — Grease (2 Grams) 1 — Seat 3 29 Seat 3 29 O-Ring for Seat 2 30 O-Ring for Seat 2 30 Return Spring 8960499004 1 45 Return Spring 8965157404 1 45 Solenoid/Air Pilot Piston Kit R432008560 Solenoid/Air Pilot Piston Kit R432008561 Piston Seal 1 35 Piston Seal 1 35 Sleeve O-Ring 1 37 Sleeve O-Ring 1 37 Grease ( 2 Grams) 1 — Grease ( 2 Grams) 1 — Std. Solenoid Plunger Kit R432015687 Std. Solenoid Plunger Kit R432015687 Sizes I-IV (III & IV: Oct '92 and Later) 1 11-14 Sizes I-IV (III & IV: Oct '92 and Later 1 11-14 Solenoid Nut Kit (Old Style: Plastic) 8994702802 Solenoid Nut Kit (Old Style: Plastic) 8994702802 As Req. 5 As Req. 5 Solenoid Nut Kit (New Style: Metal) R432008975 Solenoid Nut Kit (New Style: Metal) R432008975 As Req. 5 As Req. 5 Mounting Bolt and Body Screw Kit R432008784 Solenoid Mtg. Screws 2 3 Solenoid Mtg. Screws 2 3 Body to Subbase Mtg. Bolts 4 1 Body to Subbase Mtg. Bolts 4 1 O-Rings Solenoid to Saddle Cover 2 16 O-Rings Solenoid to Saddle Cover 2 16 Saddle Cover Mtg. Screws 3 19 Saddle Cover Mtg. Screws 3 19 End Cover Screws 4 31 End Cover Screws 4 31

Mounting Bolt and Body Screw Kit R432008785

Page 10

Repair Kits Size III & IV

Repair Kits & Parts - Size III Repair Kits & Parts - Size IV

Rubber Seal Repair Kit R432015773 Qty Ref. No. Rubber Seal Repair Kit R432015774 Qty Ref. No. Piston O-Ring 2 35 Piston O-Ring 2 35 Packing O-Ring 2 37 Packing O-Ring 2 37 Common Pilot Gasket 1 22 Common Pilot Gasket 1 22 Multi-Function Gasket 2 21 Multi-Function Gasket 2 21 Subbase Gasket 1 2 Subbase Gasket 1 2 Flow Channel Gasket (new & old style) 1 25 Flow Channel Gasket (new & old style) 1 25 Quick Release Gasket (GA series only) — Quick Release Gasket (GA series only) — O-Ring for Spring Return Piston O-Ring for Spring Return Piston Plus contents of QRV Kit R432008681 1 38 Plus contents of QRV Kit R432008681 1 38 Complete Std Solenoid or Coil Only Complete Std Solenoid or Coil Only (Oct. '92 & later) Size I&II Listing (Oct. '92 & later) Size I&II Listing Coil Only Coil Only 7 120VAC R432015417 1 120VAC R432015417 1 240VAC R432015418 1 240VAC R432015418 1 12VDC R432030367 1 12VDC R432030367 1 24VDC R432015419 1 24VDC R432015419 1

As Req. 9-15 As Req. 9-15 Explosion Proof Operators Explosion Proof Operators 120VAC R432008525 As Req. 5 7-15 120VAC R432008525 As Req. 5, 7-15 24VDC R432008526 As Req. 5 7-15 24VDC R432008526 As Req. 5, 7-15 240VAC R432008527 As Req. 5 7-15 240VAC R432008527 As Req. 5, 7-15 Coil Only 7 Coil Only 7 120VAC R432013760 As Req. 120VAC R432013760 As Req. 240VAC R432013761 As Req. 240VAC R432013761 As Req. Quick Release Valve Kit R432008681 Quick Release Valve Kit R432008681 Quick Release Valve Insert 2 29 Quick Release Valve Insert 2 29 Quick Release Valve Cover 2 26 Quick Release Valve Cover 2 26 Quick Release Valve Cover O-Ring 2 27 Quick Release Valve Cover O-Ring 2 27 Quick Release Insert O-Ring 2 30 Quick Release Insert O-Ring 2 30 Quick Release Valve Diaphragm 2 28 Quick Release Valve Diaphragm 2 28 Return Spring Kit R432008887 Return Spring Kit R432008888 Seat 2 44 Seat 1 44 Spring 1 45 Spring 1 45 Spring 1 46 Spring 1 46 Solenoid/Air Pilot Piston Kit R432008658 Solenoid/Air Pilot Piston Kit R432008658 Piston 1 36 Piston 1 36 Piston O-Ring 1 35 Piston O-Ring 1 35 Piston Cylinder Insert 1 34 Piston Cylinder Insert 1 34 Packing O-Ring 1 37 Packing O-Ring 1 37 End Cover Gasket 1 33 End Cover Gasket 1 33 Dow Corning Grease (2 grams) 1 — Dow Corning Grease (2 grams) 1 — Std Solenoid Plunger Kit R432011919 Std Solenoid Plunger Kit R432011919 (Prior to Oct. '92) (Prior to Oct. '92) Armature Assembly 1 11-14 Armature Assembly 1 11-14 Solenoid Nut R432030337 Solenoid Nut R432030337 (Prior to Oct. '92 & Later) As Req 5 (Prior to Oct. '92 & Later) As Req 5 Solenoid Nut Kit R432008975 Solenoid Nut R432008975 (Prior to Oct. '92 & Later) As Req 5 (Prior to Oct. '92 & Later) As Req 5 Mounting Bolt & Body Screw Kit R432008799 Mounting Bolt & Body Screw Kit R432008800 Solenoid Mtg Screws 2 3 Solenoid Mtg Screws 2 3 Body to Subbase Mtg 4 1 Body to Subbase Mtg 4 1 O-Rings Solenoid to Saddle Cover 2 16 O-Rings Solenoid to Saddle Cover 2 16 Saddle Cover Mtg Screws 3 19 Saddle Cover Mtg Screws 3 19 End Cover Screws 4 31 End Cover Screws 4 31

Page 11

Part Number Code Identification

Page 12

GX - 0X 00 X X - OPERATORS

“14” END “12” END

G X X (SIZE) 00 X (DESCRIPTION) X (Solenoid Arrangement)

4-Way, 5-Ported CERAM Valve

S or T 1 ISO 1 1 3 Position Valves, Exhaust Open Ctr. Ext. Pilot 0 None

2 ISO 2 2 3 Position Valves, Closed Ctr. Ext. Pilot 1 Single Solenoid

S 3 ISO 3 3 3 Position Valves, Exhaust Open Ctr. Int. Pilot 2 Double Solenoid

4 ISO 4 4 3 Position Valves, Closed Ctr. Internal Pilot

5 2 Position Valves, Ext. Pilot

6 2 Position Valves, Int. Pilot

3rd and 4th digits are always zero

0

0

0

0

0

VALVE OPERATORS 03 2 or 3 Position ANSI 3 pin MiniConnection 120 VAC 50/60 Hz

04 2 or 3 Position ANSI 4 pin MiniConnection 24 VDC

05 2 or 3 Position ANSI 5 pin MiniConnection 120 VAC 50/60


07 2 or 3 Position ANSI 5 pin Mini.Dbl.Sol/Sgl.Conn.120 VAC 50/60 Hz

08 2 or 3 Position ANSI 5 pin Mini.Dbl.Sol/Sgl.Conn.24 VDC

09 2 or 3 Position ANSI 4 pin Micro.Dbl.Sol/Sgl.Conn.24 VDC


11 2 Position Low Temp Operator 120 VAC 50/60 Hz

13 2 Position Low Temp Operator 24 VDC

•

•

•

•

•

•

•

•

14 2 Position 240 VAC 50/60 Hz Low Temp

15 2 or 3 Position 12 VAC 50/60 Hz

16 2 or 3 Position 480 VAC 50/60 Hz or 253 VDC

17 2 or 3 Position 36 VDC



20 2 or 3 Position 24 VDC 2.1 W (For Contact Bridge)

24 2 Position 120 VAC 50/60 Hz

26 3 Position with Centering Springs 120 VAC 50/60 Hz



33 Air Pilot—2 Position Valves

35 Air Pilot with Centering Springs—3 Position Valves

36 2 Position 12 VDC

38 3 Position with Centering Springs 12 VDC

39 2 Position 24 VDC

40 Metal Spring Return

41 3 Position with Centering Springs 24 VDC

43 Explosion Proof 2 Position 120 VAC 50/60 Hz

46 Explosion Proof 2 Position 24 VDC

49 Explosion Proof 2 Position 240 VAC 50/60 Hz

†

51 † Air Spring Return

53 Explosion Proof 3 Pos. w/ Centering Springs 120 VAC 50/60 Hz

56 Explosion Proof 3 Pos. w/ Centering Springs 24 VDC

59 Explosion Proof 3 Pos. w/ Centering Springs 240 VAC 50/60 Hz



72 2 or 3 Position U.L. Approved 120 VAC 50/60 Hz

73 2 or 3 Position U.L. Approved 24 VDC

78 2 or 3 Position CSA Approved 120 VAC 50/60 Hz

79 2 or 3 Position CSA Approved 24 VDC

90 2 or 3 Position Factory Mutual Approved Intrinsically Safe 24 VDC

† Used on “12” end only. • ANSI Connection universally known as Brad Harrison®.

NOTE: The previous version of the GS series was the GA series. The GS valves are direct functional and dimensional replace-ments for the previous GA series. Size I valves are now GT series, and are also direct functional and dimensional replacements. Also, there are various special CERAM valves which have part numbers that begin with “P” (such as P –069431-00001). Effective April 2008, part numbers begin with “R” and are 10 digits. For online part number crossover: www.aventics.com/us

Piping Instructions

Normal Piping Procedure (Figure A)

All Sizes – Single Pressure Piping Instructions – I, II, III, & IV Use these connections if you have one supply pressure

only.

Special Piping Procedure (Size I & II Only)

(Figure B) Consult factory for Dual Pressure Applications for sizes III & IV. Dual Pressure Piping Instructions (Do not use unless you must use 2 different supply pressures). Read conditions in tab removal procedure for vacuum supply.

Caution: Air Supply should be removed before modification

Dual Pressure Valve Conversion Instructions

Size I & II CERAM™ Valves are de-signed for dual pressure applications. For this service, “replumb” the subbase by using ports “3” and “5” for the two different supply pressures, and port “1” for a common exhaust.

(Ports “2” and “4” are still the delivery ports). Port “3” will supply port “2”, and port “5” will supply port “4”. (see fig. B) After the subbase has been “replumbed”, remove the valve from the subbase and also re-move the bottom gasket.

Rotate the gasket so the internal pilot hole will be covered by the gasket as shown below in Figure C before reinstalling. Gasket, Tab A must be removed as de-scribed below.

Tab Removal Procedure: Tear off tab “A” (tab closest to the 14 side of the valve) to expose the small hole under-neath the tab. Be careful to only tear off Tab “A”. Exposing this small hole allows

the solenoid(s) to now be piloted internal-ly. Please note that the supply pressure in Port 5 must be at least 29 psi (for 2-position models) or 44 psi (for 3-position models). Port 3 does not require a mini-

mum supply pressure. Port 3 can also be used for a vacuum supply in this configu-ration.

SEE SPECIAL NOTE ON PAGE 15 FOR DETAILS ON SIZE II VALVES BUILT 4TH QUARTER 1992 AND LATER.

Internal to External Pilot Conversion, Size I & II GS Series I & II and GT Series Size I

Caution: Air Supply should be removed before modification

Externally Piloted Valves are available directly from the factory. See model explanation on page 6 as well as individual notes in SC-300 catalog under standard valve models for ordering instructions. The following procedure should be used to convert a solenoid valve from internal pilot to external pilot pressure operation. All valves come from the factory internally piloted. External pilot function is required if the supply pressure is below the minimum pilot pressure of 29 psi (2-position valves; 44 psi for 3-position models) or if the customer is using vacuum for supply pressure. Note: The only function that can be changed on the simplified multifunction valve (without ordering different valve covers and matching gaskets) is from internal to external pilot. 1. Remove solenoid(s) from valve with slotted head screwdriver 2. Remove the valve cover with a Phillips head screwdriver 3. Note the position of the valve cover gasket. The gasket is factory installed in the internal pilot configuration. See figure

A for single solenoid/metal spring return or double solenoid. Turn the gasket over so it is repositioned as shown in Figure B (for single solenoid/metal spring or double solenoid).

4. Put the valve cover back on the valve and re-tighten the screws. Note: Size I is shown in Figures A & B. Size II is slightly different and is shown in the encircled inset above figures A & B. Gasket orientation for all models of Size I & II valves can be found on pages 16 & 17.

5. Reinstall the solenoid(s).

6. The bottom subbase gasket is factory installed as shown in Figure C. This is the internal pilot configuration. Note that the internal pilot hole is open. Close this hole by flipping the gasket from end to end as shown in Figure D for external pilot.

7. Apply a minimum of 29 psi (2-position valves) or 44 psi (3-position valves) to Port 14. Port 14 will provide pilot pressure to all solenoids regardless of single or double configuration.

Note: Port 12 does not need to be plugged. Port 12 is used only on Double Air Pilot models.

SEE SPECIAL NOTE ON PAGE 15 FOR DETAILS ON SIZE II VALVES BUILT 4TH QUARTER 1992 AND LATER.

SPECIAL NOTE SIZE II VALVES

Valves built during the fourth quarter of 1992 will be mixed production of style on page 14 (with saddle cover gasket) and of next generation design (has no saddle cover gasket). Second generation Size II valves are easily identifiable from the bottom. Three screws hold the static base to the valve body and the static base gasket looks like Figure A (below). Figure B shows previous design gasket. If your valve has this gasket and no screws holding in the base, follow directions on page 14; otherwise proceed as follows.

Internal to External Pilot Conversion

Flip new generation gasket end to end to cover up internal pilot hole as in example at the bottom of page 14. Do not remove saddle cover; there is no gasket to flip. Instead, simply remove tab in “14” port to open the passage and plumb in appropriate supply pressure noted on page 14.

Dual Pressure Instructions: For dual pressure applications, flip gasket as shown in Figure C on page 13. then tear off tab in either port 3 or 5. Remove only one tab. Be sure that the port chosen has sufficient pressure to operate your valve model (reference tab removal procedure on bottom of page 13).

8973338014

“Consult Factory”

R432008159

8973339504



Internal to External Pilot Conversion, Size III & IV

Gasket Orientation Information for Repair or External Pilot Conversion

Caution: Air supply should be removed before modification Reorient the gaskets located underneath the saddle cover. Pneumatic symbols are stamped on the cover of the valve to indicate which function has been chosen. The black corner tab of each gasket is visible through a hole (in the cover) located by the symbol of the operator chosen. As you can see by the diagram below, each outside operator gasket can be rotated in one of four positions (details A, B, C, or D). Also shown is the common pilot gasket, which can be rotated in two positions (details E & F). This gasket should al-ways be in the “E” position except for double solenoid (external pilot) with a common pilot. Ports 12 or 14 must be used for the common pilot, but the other unused port must be blocked. For separate pilot pressures, continue to use position E.

Gasket Position Chart

Operator Combination Desired

12 End

Common Pilot Gasket 14 End

Single Solenoid (internal pilot)/metal spring return Single Solenoid (internal pilot)/air spring return (internal) Single Solenoid (internal pilot)/air spring return (external) Single Solenoid (external pilot)/metal spring return Single Solenoid (external pilot)/air spring return (internal) Single Solenoid (external pilot)/air spring return (external) Double Solenoid (internal pilot) 2 & 3 position *Double Solenoid (external pilot) 2 & 3 position Air Pilot/Metal Spring Air Pilot/Air Spring (internal) Air Pilot/Air Spring (external) Double Air Pilot 2 & 3 positions

C B D C B D A C C B D D

E E E E E E E F E E E E

B B B D D D B D C C C C

*Note: Position “F” for double solenoid external pilot supply only. All other valve models use position “E”.

Troubleshooting Guide

Problem Probable Cause Remedy 1. Valve fails to shift

A. Pilot pressure is low B. Internal pilot pressure port blocked by subbase

gasket (Size I & II only) C. Multifunction gaskets rotated incorrectly for type of

operation desired (Size III & IV only) D. Electrical power E. During bench testing, if delivery ports are open to

atmosphere, there is not enough “back pressure” to shift the valve

1. Check pilot pressure Minimum pilot pressures required are: 29 psi – size I & II, 2 position 36 psi – size III & IV, 2 position 44 psi, all sizes, 3 position 1. Remove valve from subbase or manifold; inspect to see that the internal supply hole in the bottom of the valve is not blocked. See page 14 for more detailed descriptions. 1. Consult diagrams and descriptions on page 18 for correct orientation. 1. Try shifting valve using manual override. If valve can be shifted in this manner, check electrical supply for proper voltage. 2. If valve cannot be shifted with manual override, remove solenoid coil, disassemble solenoid operator and inspect for binding of the solenoid plunger or blockage of inlet or exhaust passages in solenoid body. 1. Connect the valve to cylinder or put plugs or gauges in both delivery ports.

2. Valve sticks/shifts slowly

A. Pilot piston(s) not adequately lubricated B. Accessory item out of adjustment (sizes I-III) C. Valve to manifold/base attachment bolts are over-

torqued D. Leakage at quick release valve cover or ruptured

quick release valve diaphragm

1. Remove end cover(s) and re-lubricate piston seals and piston sleeves. 1. Check to see if sandwich flow controls, regulators, etc. are adjusted adequately to provide proper function. 1. Loosen bolts and re-torque to proper specifications: Size I 4ft-lb max Size II 6ft-lb max Size III 7ft-lb max Size IV 7ft-lb max 1. Replace quick release valve components.

3. Excessive leakage under valve cover

A. Leakage at quick release valve cover or ruptured

quick release valve diaphragm B. Piston sleeve installed backwards (Size I & II only)

1. Replace quick release valve components. 1. Revise piston so the large diameter end is against the end cover.

4. Excessive leakage from end cover

A. End cover seal has been pinched B. Piston sleeve installed backwards (Size I & II only)

1. Reposition end cover seal or replace 1. Reverse piston so the large diameter end is against the end cover

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 non-compatible lubricants, oil additives or synthetic lubricants in the air system compressor or line lubrication devices voids the 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. 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. 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.

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.

AVENTICS Corporation 1953 Mercer Road Lexington, KY 40511 www.aventics.com/us [email protected] AVENTICS Incorporated 3426 Mainway Drive Burlington, Ontario CANADA L7M 1A8 www.aventics.com/ca [email protected]

SM-300.10/May 2014 Subject to change. Printed in United States. AVENTICS Corporation. This document, as well as the data, specifications, and other information set forth in it, are the exclusive property of AVENTICS. It may not be reproduced or given to third parties without its consent.

Documents

CERAM - AVENTICS€¦ · from internal pilot supply to external pilot supply. See conversion information. MAINTENANCE Ceram Valves may be serviced after shutting off and venting the