Valve Selection Guidelines

CPE10 Valve INTRODUCTION:

When selecting a directional control valve there are 4 main criteria's to look at. The criteria's are the valve function, the type of actuation, the installation options (mounting, wiring, and network), and the required flow rate needed for the application

Valve Function:

The valve function refers to how the valves internal pathways are connected. There are four main valve functions for directional control valves. These valve functions are 2/2, 3/2, 5/2, and 5/3 way valves.

1.1

2/2

All 2-Way valves have a pressure supply port (1) and a working port (2). These valves come in two different variants either Normally Closed (NC) or Normally Open (NO). When a Normally Closed valve is in its initial state, port 1 and 2 are not connected to each other until the valve is actuated. When a Normally Open valve is in its initial state, port 1 and 2 are connected to each other until the valve is actuated. These valves are used when it is not necessary or desirable to exhaust downstream pressure when the valve is closed. These valves are commonly used in applications as blow off or to drive a vacuum nozzle. Most 2way valves have an actuator and a return spring.

1.2

3/2

All 3-Way valves have a supply port (1), working port (2), and an exhaust port (3) . They come in two different variants either Normally Open (NO) or Normally Closed (NC). These two variants are a little different then the same function in the 2/2 valves. When a Normally Closed valve is in its initial state, port 2 and 3 are connected to each other and port 1 is blocked until the valve is actuated. When the valve is actuated port 1 is connected to the port 2 and the port 3 is blocked. When a Normally Open valve is in its initial state, port 1 and 2 are connected to each other and port 3 is blocked until the valve is actuated. When the valve is actuated port 3 is connected to port 2 and port 3 is blocked. These valves are most commonly used when it is necessary to exhaust downstream pressure through the valve. For this purpose, port 3 is usually returned to atmosphere through a pipe port, or an orifice (vent) in the body of the valve. For example, this valve can be used to control single-acting actuators (cylinders, rotary actuators, grippers, etc,,), which must be exhausted to atmosphere in order to return to their un-actuated position. These valves will have an actuator and a mechanical spring or air spring to return the valve to its initial position. If Port 3 is plugged, the 3/2 valve will function identically to a 2/2 valve.

1.3

5/2

All 5/2 Way valves have a supply port (1), 2 working ports (2,4), and 2 exhaust ports (3,5). These valves are most commonly used to control the position of double-acting actuators. For this purpose, the working ports (2, 4) are connected to the actuator, and the exhaust ports (3, 5) are usually returned to atmosphere through pipe ports, or orifices (vents) in the body of the valve. A 5/2 valve always has one of the working ports (2,4) connected to the pressure supply port (1), and the other working port is always connected to an

Valve Selection Guidelines

exhaust port (3,5) which is connected to atmosphere, regardless of the position of the valve. 5/2 valves come in two different configurations single actuated or double actuated valves. Single actuated valves will either have a mechanical spring or an air spring to return the valve to its initial position. A double actuated valve uses two actuators to control the position of the valve. Often double actuated valves are referred to as "Memory" valves because the valve will not return to its initial position until one of the coils are actuated.

1.4

5/3

Like 5/2 way valves 5/3 valves have a supply port (1), 2 working ports (2,4), and 2 exhaust ports. The main difference is that the 5/3 has 3 possible positons.5/3 valves have an additional spring-centered neutral position, which the valve takes when both actuators are not engaged.. In the neutral position, both working ports (2,4) may be blocked (5/3G), pressurized (5/3B), or exhausted (5/3E) depending on the specific type of 5/3 valve. In the blocked version, none of the ports are connected to each other. In the pressurized version, the supply port is connected to both the working ports (2,4) and the exhaust ports are blocked. In the exhausted version, the working ports(2,4) are connected to the exhaust ports(3,5) and the supply port 1 is blocked.

2
2.1

ACTUATOR TYPES:
Solenoid Actuators

2.1.1 Direct-Acting Direct acting solenoid valves are shifted exclusively by the direct mechanical action of a solenoid coil . This means that either the plunger in the coil is used in the valve as poppet or the solenoid plunger is connected to the poppet or spool in the main part of the valve.. These types of valves usually have substantially larger solenoid coils than comparable valves of the Pilot Assist design (see below). The size of the solenoid grows dramatically with increased pressure and flow capacity ratings. This often results in large valves that generate substantial amounts of heat. As a result, some direct-acting solenoid valves are not rated for continuous duty. Direct-acting solenoid valves are used in applications where low-flow switching at high speeds is required. However, while it is true that direct-acting valves shift much faster than Pilot-Assist valves, direct-acting valves have much less flow capacity for an equivalently-sized solenoid. What matters in the end is how quickly can the necessary volume of air, at a given pressure, be delivered to the component or system downstream. For this reason, a slower pilot-assist valve (with a higher flow-rate) can move an actuator much more quickly than a fast direct-acting valve (with a lower flow rate) can. 2.1.2 Pilot-Assist Unlike Direct-Acting solenoid valves, Pilot Assist valves have no mechanical linkage between the solenoid plunger and the main spool of the valve. The shifting of the main spool is, instead, accomplished by air pressure acting on an integral piston or diaphragm. This arrangement can therefore be regarded as two valves in one. A very small Direct-Acting 3/2 solenoid valve controls the pilot air going to a much larger, air-actuated main valve. This is done, even in small valves, to obtain significant reduction in the solenoids size, energy consumption and heat generation. Since the air volume required to shift even a large air-piloted valve is small, a small solenoid-actuated pilot valve will suffice. Most solenoid-operated valves used in todays industrial applications are of the Pilot-Assist design. These units come in two basic configurations; Internal and External Pilot supplies. 2.1.2.1 Internally Piloted

The solenoid actuator of an internal pilot supply valve gets its air from the main working supply port (1). There is an internal connection that diverts a small amount of air from Port 1 up to the solenoid head. This means that there must be a minimum pressure (control pressure) present on Port 1 at all times in order for the valve to work properly. This requirement prevents these valves from being used with low pressures and vacuum, or being used in unconventional supply

Valve Selection Guidelines

pressure arrangement, such as using the working ports as the supply ports and using the supply port as a working port. This is sometimes done so that two different pressures can be selected 2.1.2.2 Externally Piloted External pilot supply valves have an extra connection port(s) for supplying air exclusively to the solenoid actuator (and return air-spring, where applicable). In this case, the supply port (1) is no longer required to have a minimum pressure present. This allows valves of this type to be used for controlling vacuum and low pressure circuits, creating separate pressure zones, and a host of other creative or unconventional applications. Regardless of application, however, there must always be present available supplies of pilot air at no less than the minimum specified (control) pressure.

2.2

Mechanical/Manual Actuation

Another method of valve actuation in which some sort a of lever or push button, or knob is used to change the position of the valve. Mechanically/Manually actuated valves are often used when a machine requires human intervention to run a machine or when an pneumatic output is needed to start another process in a machine.

2.3

Air Piloted Actuation

Air actuated valves are valves which require a pilot pressure so that the valve may be switched. These valves always have external pilot ports on them. They are often used in applications where solenoid valves are not permitted due to safety reasons. These valves get pilot pressure from external valves. They can either be actuated via a manual valve or a solenoid valve, which is connected to its pilot ports.

Installation Options:

How valves are to be installed in the system often drives the selection process. Valves may or may not be easily accessible, the environment may be hostile, or there may be special requirements for maintenance. There are 2 main installation options for valves stand-alone valves and manifold mounted valves.

3.1

Stand Alone

Stand-alone valves can be categorized in 3 different ways In-Line, Semi In-Line, and subbase mounted. Inline refers to a valves where all of the ports are part of the body of the valve. The working ports are usual on the one side of the valve and the exhaust ports and supply port are usually on the side parallel to the working ports. Semi-inline valve refers to valves, which are mounted on a subbase and have the working ports coming out the top of the valve and the other ports being part of the subbase. A subbase valve is a valve where all of the ports are part of the subbase and are not located on the valve external walls. In-line valves are often used for individual installations where the actuator performance can be improved by locating it physically close to the valve. In applications where there are a few widely scattered actuators, in-line installations are usually preferred over manifolds. Sub-base mounted offer the additional benefit of simplified maintenance and system repair, since the system plumbing to the sub-base need not be disturbed when replacing individual valves. Sub-base valves are especially attractive when rigid system piping is used.

3.2

Manifold

Manifold mounted valves are banks of valves that are mounted together and share exhaust channels and supply channels. There are two different types of manifolds, extruded and subbase manifolds. Extruded manifolds are manifolds created from long extrusions where holes are drilled in the manifold for attaching several valves. Subbase manifolds are manifolds which consist of several subbase connected together to create a manifold. Manifolds also come in two sub-divisions Semi-Inline and with the working ports as part of the manifold. One of the more interesting developments in solenoid valve manifold design is the integration of electrical and electronic devices into the manifold assembly. For example, valve manifolds that have plug-in solenoids can have all electrical connections going to a single multi-pin connector, thus simplifying installation. Other integration techniques include the incorporation of various common industrial PLC network transceivers. This technique allows large numbers of solenoids to connect to a

Valve Selection Guidelines

remote PLC using a small two-wire high-speed data cable, thereby drastically reducing the amount of installed system wiring that would otherwise be required. These so-called Fieldbus manifolds can even be fitted with powered electrical receptacles for connecting proximity sensors and low-powered electrical output devices.

FLOW CAPACITY

Once the type of valve is selected, the next most important selection criterion is the valves flow capacity. Flow, which is measured as Volume Coefficient (Cv) or in Liters per Minute of flow, is an indication of the amount of resistance a valve presents to a pneumatic circuit. All devices that conduct air will resist flow to some degree, which causes the pressure drop across the device to increase as the flow increases. The less resistance, the smaller the pressure drop. It must be noted that any device, fitting, or run of tubing can effect the flow rate in a system. In highly time-critical applications, a few extra inches of tubing, or the wrong fitting can mean the difference between a circuit that works and one that does not. For this reason, valve flow ratings alone cannot predict the flow rate through a system branch. In the past, the common practice used in selecting a valve was to match the port size of an actuator and the valve. This is no longer a suggested way of sizing a valve to an actuator. Advancement in technology has allowed smaller valves to have increased flow. Smaller valves tend to have several advantages over larger valves. In general, the advantages of smaller valves are quicker switching time, lower leakage, less expensive and generally lower power consumption since smaller solenoids are generally used. With these advantages, smaller valves will initially save money and then save money due to decreased leakage in a system and decreased power use. In order to select a valve the flow required to move the actuator in the time required by the application. This flow required can be found by using the following equation. US UNITS Q= (Volume x Compression Factor)/(Time x 28.8) SI UNITS Q=(Volume x Compression Factor)/Time Q Volume Time Flow Rate in ft3/min or liter/sec in3 sec

Compression Factor (P1 + Pa)/Pa P1 Pa Inlet Pressure in psi or bar Atmospheric Pressure 14.7psi or 1bar

After the flow is calculated the Cv required can be calculated using the following equations. US UNITS
Cv ( T. G ) Q . . 22.48 P P 2 P a

SI UNITS

Valve Selection Guidelines

Cv ( T. G ) Q . 114.5 P . P 2 P a

T G P P2 Pa EXAMPLE:

Temperature in Rankine or Kelvin Specific Gravity (G=1 for air) Pressure drop across the valve in psi or bar Outlet Pressure in psi or bar Atmosphere Pressure 14.7psi or 1bar

A double acting cylinder with a 25mm bore and 100mm stroke is extended with a pressure of 6 bar. The rod of the cylinder has a 10mm diameter. The cylinder is required to extend in 0.25 seconds and return in 0.2 seconds. What Cv is required to extend cylinder and retract the cylinder? Step 1 : Calculate the areas and volumes
A extend 25 . 2 2

A extend = 490.874 2 2 A retract = 412.334

A retract

25 . 2

10 . 2

V extend

A extend . 100

4 V extend = 4.909 . 10 4 V retract = 4.123 . 10

V retract

A retract . 100

Step 2 : Calculate the Compression Factor

CF 6 1 1

CF = 7

Step 3 : Calculate the flow rate

Q extend V extend . CF ( 0.25 ) V retract . CF ( 0.2 ) Q extend 1.374

Q retract

Q retract

1.443

Step 4 : Calculate the Cv

Cv extend Q extend . 114.5 ( 293. 1 ) ( 0.25 . ( 5.75 1 ) Cv extend = 0.158

Valve Selection Guidelines

Q retract ( 293. 1 ) . ( 0.25 . ( 5.75 1 ) 114.5 Cv retract = 0.166

Cv retract

For the above example, a Cv of 0.158 for the extend and a Cv of 0.166 retract is required to meet the time parameter. Since a valve with the specific flow for both the extend and the retract most likely does not exist, a valve with a larger Cv should be selected. A valve with a Cv of 0.200 should accomplish our parameters. With the larger flowing valve we are also taking into account fittings and tubing lengths, which can effect our time values. If the valve selected causes the cylinder to extend and retract to fast, flow controls can be added to the cylinder to reduce the flow rate going into the cylinder.