VALVE INSTALLATION & SERVICE MANUAL
Contents
1. Base Gasket cccsseseeeesseeeeeeeeeeees D Damaged Seals cccccccccsseeeeceesseeccesseeeceeeeseeeeeaeeeeeseaees B Damaged SP OOlheicisecscsiscs everest ssesceynsediactcdenadsiavedeevttslanccamenens F Cylinder L AKS ccccccseseeeeceeeeeeesseeeeeceeeeeeeeseaeeeeesanseeeeas H Inadequate Air Supply cccccccsseeeeecesseeeeeeeeeeeeseeneeeeenaes I Water or Oil Contamination ccececeeeeeeeceeeeeeeeneeeeeseaees R Solenoid Fails to Actuate Valve But Manual Override Loose Pilot Cover or Faulty SOI nOiId ccccseeeeeeeeeeeees G Does Actuate Valve Inadequate Voltage at SOICNOI cccceeseeeeeeeeeseeeeeenees J Solenoid Fails to Actuate Valve and Manual Override Damaged Seals ccccccccssseeeccenseeeceeeseeceeeeseeeenneenssseseess B Also Fails to Actuate Valve Varnish Deposits in Valve ccccceceecseseeeeeeeeeseeeeeseseeesaees C Inadequate Pilot Pressure cccsssseceesseeeeseeeeeeeeeeseeeeess L Water or Oil Contamination ccccceeeeeeeeceeeeeeeeeeeeeesaaees R Air Flow is Normal Only in Actuated Position Broken Return Spring cccccccsssceeccseeseeeeeeeeeeeeeeeeeesaeeeess E Solenoid Buzzes Damaged Solenoid ccccseccccceseeeeeceeeeeeeeeeeeeeeaaeeesesaeeess G Inadequate Voltage at SOIGNOI cccccsseeeeeeeeeeeeeeneees J Varnish in Direct Operated Spool ValVe ccccseeeeeeeeees C Solenoid Burns Out Varnish in Direc2. and reinstall the plug in the internal pilot supply INTERNAL passage E M 3 Replace pilot section PASSAGE 4 Attach 1 8 pilot supply line to external plot supply port X 1 5 External pilot supply pressure must be at least equal to the main supply pressure INTERNAL PILOT SUPPLY pe ANSI SIZE 4 10 20 BASE MOUNTED VALVES See Figure 13 PIPE 1 Remove valve from base fi PEUL 2 Remove pipe plug from underside of valve body ro EXTERNAL 3 Install pipe plug in internal pilot supply passage A P 4 Attach 1 8 pilot supply line to external pilot supply port X in base PORT X 5 Replace valve on base 6 For poppet valves external pilot supply pressure must be at least equal to the Figure 13 main supply pressure ISO SIZES 1 2 amp 3 and ANSI SIZES 1 5 amp 2 5 Base mounted valves CA See Figures 14 and 15 1 Remove plug from port 14 port 12 on ANSI 1 5 amp 2 5 coo 2 Pipe 1 8 supply line to port 14 3 Pressure in external supply line should be greater than inlet If for any reason the external supply is lost or drops below inlet pressure the valve will switch back to internal pilot supply oni Figure 14 Figure 15 www rosscontrols com 7 ROSS ROSS CONTROLS Troy MI U S A Telephone 1 248 764 1800 Fax 1 248 764 1850 In the United States
3. body assembly must be replaced If there is no damage to poppet or seat s inspect other parts of valve for damage If there is no other damage clean thoroughly lubricate lightly and reassemble FAULTY SEALS The materials of which seals are made can be attacked by substances such as chlorinated hydrocarbons trichloroethylene for example and some lubricating oils This can produce swelling or shrinking of the seals and result in erratic valve action or blowing to exhaust Swollen seals may cause poppet valves to stick in a partially open position so that the valve blows to exhaust See Figure 1 and 2 Swollen seals on a spool valve see Figure 3 can result in sluggish or erratic valve action or even failure of the spool to move at all RESILIENT SEALS AN aa ear oS es se a Figure 3 Resilient Seal Aluminum Spool Valve Body for Base Mounting Badly nicked or torn seals can produce blowing to exhaust in valves by allowing air to pass from one port area to another Small leaks in piston poppet seals can affect the timing accuracy of sequence adaptors on inline valves or even render the valve inoperable Before disassembling the valve to inspect the seals turn off the electrical power to the valve shut off the air supply and exhaust the air in the system Follow appropriate lock out tag out procedures Inspect the seals and replace any that are defective Lubricate the seals lightly and reassemble the valve To insure long s
4. can allow pilot or signal pressure to leak by the piston and cause erratic valve response Operating problems are apt to be most noticeable on valves with timed sequence adaptors A leaking piston seal can bleed off the pressurizing air and seriously affect the timing function FLUCTUATING AIR PRESSURE If a valve with a timed sequence adaptor suffers from erratic timing the cause can be a fluctuating supply pressure Consistent timing requires a consistent supply pressure If the supply pressure varies considerably install a pressure regulator set at the system s lowest expected pressure and reset the timed sequencer to provide the desired time delay FLOW CONTROL VALVES ADJUSTING Flow control valves are most often used to control the flow of air as it is exhausting from a cylinder The flow control valve s flow pattern is indicated on the valve body by an arrow and also by a fluid power diagram Check to be sure the installation is correct If itis check for foreign material in the valve which could prevent the poppet from seating properly See Figure 10 POPPET Figure 10 Flow Control Valve 6 2012 ROSS CONTROLS All Rights Reserved REPAIR PROCEDURES WATER OR OIL CONTAMINATION Accumulations of water or oil have an especially bad effect on devices with small MOISTURE OR OIL orifices such as timed sequence adaptors Accumulation in such a device can change the effective size of the time orifice or even bl
5. outlet port or blowing to exhaust The problem can be further aggravated by the spool s cutting the resilient seals and increasing the leakage A damaged spool cannot be repaired but must be replaced DAMAGED SOLENOID OPERATION Verify that the supply voltage is correct Refer to ncorrect Voltage at Solenoid Repair Procedure J With the electrical supply to the solenoid shut off check for the following See Figure 5 or 6 Loose pilot cover A loose pilot cover can give the symptoms of a defective solenoid because it prevents full travel of the pilot valve However the valve can operate properly if manual actuation is used This is because the gap is closed by the pressure of manual actuation Tighten the cover and check for normal operation Improperly installed solenoid If a solenoid is cocked out of line during assembly perhaps when a replacement solenoid was installed the pilot poppet may be held off its seat so that the valve will not function Check solenoid for burnout See below If solenoid passes this check reassemble carefully to eliminate misalignment Burned out solenoid Check the coil for electrical continuity with an ohmmeter and replace the solenoid if the coil is open In spool valves with direct solenoid control varnish deposits may prevent spool motion This will prevent full motion of the solenoid plunger and can cause solenoid burnout Solenoids operated in too high an ambient temperature are also subjec
6. than 10 during actuation of the valve the air supply may be inadequate Inspect the system for undersized supply lines sharp bends in the piping restrictive fittings a clogged filter element or a defective pressure regulator Remember too that the air volume supplied can be insufficient if more pneumatic devices are connected to a circuit than the compressor is designed to serve l NCORRECT VOLTAGE AT SOLENOID ROSS solenoids are rated for continuous duty at 85 to 110 of the voltage shown on the solenoid coil Multi rated solenoids e g 110 120 volts are rated for continuous duty at 85 to 110 of the maximum voltage shown on the solenoid coil A supply voltage that does not fall within this range can result in failure of the valve to shift or lead to solenoid burnout Before checking the electrical supply shut off and exhaust the air supply to the valve Attach a voltmeter to the electrical supply to the solenoid Actuate the solenoid and read the voltage during actuation If the voltage falls below the allowable operating range the electrical supply is inadequate even though the supply voltage might be correct without the electrical load A voltage that exceeds the allowable operating range can result in solenoid burnout or can cause impact damage resulting in a loss of air gap See Repair Procedure G PILOT SECTION DIRTY OR DAMAGED INSERT Turn off electrical power to valve Shut off the air supply and exhaust air in the s
7. Safety Department 1 248 764 1816 Customer Service 1 800 GET ROSS 438 7677 Technical Service 1 888 TEK ROSS 835 7677 GLOBAL Reach with a LOCAL fouch ROSS EUROPA GmbH Langen Germany Telephone 49 6103 7597 0 Fax 49 6103 74694 Email info rosseuropa com www rosseuropa com ROSS ASIA K K Kanagawa Japan www rosscontrols com Telephone 81 427 78 7251 Fax 81 427 78 7256 ROSS UK Ltd WWW rossasia co jp Birmingham United Kingdom Telephone 44 121 559 4900 Fax 44 121 559 5309 Email sales rossuk co uk ROSS CONTROLS CHINA Ltd Shanghai China Telephone 86 21 6915 7951 Fax 86 21 6915 7960 www rosscontrolschina com ROSS SOUTH AMERICA Ltda Sao Paulo Brazil CEP 09725 020 Telephone 55 11 4335 2200 Fax 55 11 4335 3888 Email vendas ross sulamerica com br ROSS CONTROLS INDIA Pvt Ltd Chennai India Telephone 91 44 2624 9040 Fax 91 44 2625 8730 Email rossindia airtelmail in Your local ROSS distributor is DIMAFLUID s a s Saint Ouen France Telephone 33 01 4945 6565 Fax 33 01 4945 6530 Email dimafluid dimafluid com www dimafluid com Warranty All products sold by ROSS CONTROLS are warranted for a one year period with the exception of all Filters Regulators and Lubricators FRLSs which are warranted for a period of seven years from the date of purchase to be free of defects in material and workmanship ROSS obligation under
8. Service Manual 32 aS IOULNOI SSOH VALVE INSTALLATION amp SERVICE MANUAL aS IOH LNO SSOH TABLE OF CONTENTS Page ADDITIONAL AVAILABLE SERVICE INFORMATION 2 INSTALLATION NOTES 0 c scccseeseeseeseesseseeeeesieeeesneeteeneeneateeten 2 CUNT 7 0 ere en eee ere eee eee 2 TROUBLESHOOTING 0 sseesceseeeeseeseeseeseesneeeeseeeeeteeteeneeneeneeneans 3 REPAIR PROCEDURES 0 scscsesesesesteseentestenesnenennenneaee 4 7 CONVERSION TO EXTERNAL PILOT SUPPLY 0 eeecee 7 WARRANTY ecstatic asec 8 The installation maintenance and troubleshooting information in this Service Manual is intended primarily for use with ROSS single element poppet and spool valves Similar information on double valves for press controls is covered in separate service manuals available from ROSS This Service Manual should be a useful guide to solving the problems most likely to be encountered in apneumatic system Other valuable guides are the Plate Drawings Installation Instruction Sheets gt a included with the product Instruction Sheets included in Service Kits A Plate Drawing is a ROSS information sheet giving the numbers of repair parts for particular valve models The Installation Instruction Sheet offers standard and technical specification information An Instruction Sheet details the valve installation and service processes Most parts are made available in the form o
9. VELY Excess oil can accumulate in low points of the system and restrict the flow of air It can also form pools which will produce a dashpot effect and slow valve action A visible oil fog exhausting from the valve is a sure sign of excessive lubrication Properly lubricated parts should have only a thin film on them For most applications an oil flow rate in the lubricator of one drop per minute is adequate UNDERSIZED OR PLUGGED SILENCER An undersized silencer or one that is partially plugged restricts the exhaust flow The resulting back pressure can cause erratic motion of poppet valve elements and or cylinders Remove silencer to see if valve performance is improved Clean silencer and verify that it is of adequate size Do not reinstall an undersized silencer Install cleaned or larger size silencer and check valve performance again CAUTION Restricting the exhaust port of a poppet valve can cause the valve to malfunction Silencers must be resistant to clogging and have a flow capacity greater than the exhaust capacity of the valve ROSS Muffl Air silencers of the proper pipe size fulfill these requirements ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type wrong size or inadequately maintained silencer installed with a ROSS valve DAMAGED PISTON SEAL Piston seals may be either O rings or the lip seal type If worn or damaged the seal
10. eal life be sure to use only compatible lubricant in the pneumatic system For a list of such lubricants see page 2 VARNISH DEPOSITS IN VALVE See Figures 1 3 or 4 Varnish deposits can cause a valve to act sluggishly or even prevent movement of the valve element altogether especially after a period of inactivity A spool valve frozen in position by varnish can cause a direct acting solenoid to buzz and eventually lead to solenoid burnout Varnish results from the action of oxygen on the lubricating oil and can be aggravated by excess heat Varnish can also come from overheated compressor oil carried over into the air lines Properly lubricated valves do not usually suffer from varnish deposits To remove varnish use a water soluble detergent or solvent such as kerosene Do not scrape varnish off Also avoid chlorinated solvents trichloroethylene for example and abrasive materials The former can damage seals and poppets and abrasives can do permanent damage to metal parts After cleaning lightly lubricate moving valve parts and reassemble See compatible lubricants chart on page 2 VARNISH DEPOSITS deciles ANN eee See N9 eg oh es on T Figure 4 Precision Finished Stainless Steel Spool Valve Body for Base Mounting DAMAGED GASKETS A broken or scored web on a valve to base gasket can produce air leakage between ports This can result in unwanted p
11. eeeeeeeesaeeeesaeseesaneeens R Damaged Gasket cccccssssecccssseeeceeeseeceseeseeeeeeeeeesseseess D Flow Control Valve Does Not Respond to Adjustment Excessive LUDIICAtION cccccssececeseeeceseeeseeeeeseueeeseneessees M Incorrect Installation or Dirt in Valve ccceccceeeseeeeeeeeeees Q ROSS www rosscontrols com 3 REPAIR PROCEDURES MAIN INLET POPPET NOT SEALING Foreign particles may be holding the poppet off its seat Taking appropriate safety precautions cycle the valve several times to see if the flow of air through the valve will flush the particles out If not it will be necessary to disassemble the valve See figure 1 or 2 PISTON EXHAUST POPPET RESILIENT FACE VALVE lt SEATS INLET RETURN POPPET SPRING GUIDED STEM Figure 1 Typical Inline Poppet Valve Body VALVE SEATS ANS ar Figure 2 Poppet Valve Body for Base Mounting Follow appropriate lock out tag out procedures Turn off the electrical power to the valve Shut off the air supply and exhaust the air in the system Disassemble the valve body assembly Inspect the inlet poppet for evidence of dirt particles or damage to the poppet Clean or replace poppet as required If the poppet is swollen or has deteriorated improper lubricants or solvents may be the cause Use only compatible lubricants see page 2 Also check the poppet seat s for dirt and damage If there is damage to a seat the entire valve
12. er minute is adequate Note that the valve does not itself require air line lubrication See below for information about lubricants that are compatible with the materials used in the valve and are suitable for use in compressed air systems Compatible Lubricants Although most ROSS valves do not require air line lubrication they may be used with lubricated air being supplied to other mechanisms Some oils contain additives that can harm seals or other valve components and so cause the valve to malfunction The best oils to use are those specifically compounded for air line service These are generally petroleum base oils with oxidation inhibitors an aniline point between 180 F 82 C and 220 F 104 C and an ISO 32 or lighter viscosity See chart on next page Cleaning the Valve If the air supplied to the valve has not been well filtered the interior of the valve may accumulate dirt and varnish which can affect the valve s performance Although ROSS poppet COMPATIBLE LUBRICANTS Brand Name American Industrial Oil 32 Amoco Spindle Oil C Amolite 32 Pacemaker 32 Spinesstic 22 Teresstic 32 Velocite 10 Air Lube 10H NR Turbo T32 Sunvis 11 Sunvis 722 Regal R amp O 32 Union Turbine Oil valves are very tolerant of dirty air the valve may sometimes need cleaning To clean the valve use any good commercial solvent or kerosene Do not use a chlorinated solvent or abrasive materials The former damages seals and abras
13. f service kits which contain all the parts normally required for specific service operations A Valve Body Service Kit for a poppet valve for example includes the seals poppets springs and gaskets required to service the valve body assembly Consider it i i m P j wi a ROSS CONTROLS ROSS CONTROLS ROSS CONTROLS ROSS CONTROLS ADDITIONAL SERVICE INFORMATION AVAILABLE For copies of technical publications or other product data visit ROSS website at www rosscontrols com call ROSS or your local ROSS Distributor INSTALLATION ss a TA a NID ie Ry Ky J at a e b S i za T P ww a J gt a nF ae s re 1S ee iE j lt elun Pneumatic equipment should be installed only by persons trained and experienced in the installation of such equipment Air lines Before installing a valve in an existing system the air lines must be blown clean of all contaminants which may be in the system Itis recommended that a 5 micron air filter be installed in the inlet line close to the valve Valve Inlet DO NOT RESTRICT AIR SUPPLY Any restriction of the air supply lines for example sharp bends or clogged filter element will reduce the speed with which the outlet volume is pressurized and can also cause the valve to malfunction Valve Outlet s For faster pressurizing and exhausting of the outlet volume locate the valve as close as possible to the mechanis
14. h in fact lies elsewhere We suggest therefore that potential malfunctions in all system components be considered when trouble occurs Leaky cylinder packings poor electrical contacts dirty filters and air line leaks or restrictions are just a few of the things to be considered when troubleshooting a pneumatic system Consideration of these possibilities can sometimes save an unnecessary valve disassembly job Caution Before disassembling a valve or other pneumatic component or removing it from its installation shut off and exhaust the entire pneumatic circuit and verify that any electrical supply is turned off Follow appropriate lock out tag out procedures When the valve fails to operate properly check for the Symptoms listed below in the first column For each Symptom several Possible Causes are listed in the second column For each Possible Cause there is a Repair Procedure identified by a letter in the last column These Repair Procedures are detailed in the following pages SYMPTOMS POSSIBLE CAUSES REPAIR PROCEDURES Valve Blows to Exhaust When Not Actuated Inlet Poppet Not Sealing cccsseeeccessseeeeeseeeeeeeeeeeeesaaees A Damaged Seals cceccceccseseeeeeeeseeeceeeeeeeseaeeeeeesaneeeesaaeees B Damaged Valve to Base Gasket cccsssseeecsseeeeeseeees D Cylinder L aKS cccccssseeecceeeseececeeeceeceeseeesceesseeeneeseeeeees H Valve Blows to Exhaust When Actuated Damaged Valve to
15. ives can do permanent damage to metal parts Reassemble the valve with a gasket and seal kit available from ROSS Lubricate all sliding surfaces with the grease provided in the gasket and seal kit Electrical Contacts In the electrical circuits associated with the valve solenoids keep all switches or relay contacts in good condition to avoid solenoid malfunctions Replace Worn Components In most cases it is not necessary to remove the valve from its installation for servicing However turn off the electrical power to the valve shut off the air supply and exhaust the air in the system before beginning any disassembly operation Follow appropriate lock out tag out procedures 2 2012 ROSS CONTROLS All Rights Reserved TROUBLESHOOTING Troubleshooting is the process of looking at a valve s symptoms e g blowing to exhaust or buzzing solenoid and then relating these symptoms to their most likely causes By carefully analyzing the problem the experienced troubleshooter can quickly isolate the trouble and take appropriate corrective steps To assist in the troubleshooting process the Troubleshooting Chart on page 5 lists most of the common symptoms which valves exhibit and their probable causes Before disassembling a valve to investigate a system malfunction check other possible causes of the malfunction Because malfunctions in other components can affect valve action the valve is sometimes blamed for a problem whic
16. m being operated Also any restriction in the outlet lines for example sharp bends or undersized lines will reduce both pressurizing and exhausting speeds Valve Exhaust s DO NOT RESTRICT EXHAUST OF POPPET VALVES as this can cause the valve to malfunction To reduce exhaust noise use a silencer such as the ROSS Muffl Air Electrical Conduit Port It is important that the electrical supply be of the correct voltage and Hertz ROSS solenoids are rated for continuous duty at 85 to 110 of the voltage shown on the solenoid coil Multi rated solenoids e g 110 120 volts are rated for continuous duty at 85 to 110 of the maximum voltage shown A supply voltage that does not fall within this range can lead to faulty valve action or solenoid burnout If electrical power is supplied by a separate transformer it must be capable of handling the inrush current of the solenoids without significant voltage drop Operating Pressures and Temperatures Maximum and minimum operating pressures and temperatures are specified for each type of valve Staying within these limits contributes to longer valve life and proper operation If you must exceed these limits consult ROSS for advice on such service Pilot Pressure For proper operation pilot pressure must not fall below the minimum specified for the valve For poppet valves pilot pressure must be at least equal to the main supply pressure If a solenoid piloted valve must operate at a pres
17. ock it completely See Figure 11 The device must be disassembled cleaned lightly lubricated and reassembled It may be necessary to install a filter in the supply line to prevent recurrence of the problem Accumulations of water or oil can also occur at low points in pilot supply lines This can PILOT LINE result in pressure fluctuations that produce erratic timing The best cure is to eliminate low ADAPTOR points Water and oil can also accumulate at low points in a valve and hinder movement of the valve element perhaps completely preventing its motion See Figure 1 This is especially true of a valve operating in a subfreezing environment where accumulated VALVE BODY water can turn to ice It is important in such applications to ensure that the supply air ASSEMBLY is dry and that the air line filter is drained frequently If there is evidence of excess oil accumulation see Repair Procedure M Figure 11 Sequence Adaptor CONVERSION TO EXTERNAL PILOT SUPPLY PILOT l j EXHAUST When a valve is converted to external pilot supply consult ROSS for the converted valve s PORT model number This will allow records and drawings to be changed and prevent errors when iT ordering future replacements 8 fF EXTERNAL pea PILOT y mm SUPPLY pay FONT INLINE POPPET VALVES See Figure 12 C 1 Remove pilot section and adaptor plate from valve body PLATE i l l 2 Remove pipe plug from external pilot supply port
18. ressurizing of an outlet port or blowing to exhaust A leaking gasket on an inline valve can also produce operating problems but is apt to be most noticeable on valves with timed sequence adaptors If the gasket between adaptor and valve body leaks it can bleed off the air which is slowly pressurizing the piston so that the timing can be seriously affected Damage to a gasket is most likely to occur during assembly Rarely does a gasket become defective during normal operation Do not attempt to make do with a damaged gasket It will give trouble sooner or later Replace it BROKEN RETURN SPRING A broken return spring on a spool valve see Figure 4 can cause the spool to remain in an actuated position or to be only partially returned In the latter case several abnormal flow patterns may result depending on the valve configuration If a spool valve has a normal flow pattern only in an actuated position a broken return spring is the most likely cause of the trouble A broken return spring on an inline poppet valve is less likely to prevent closing of the inlet poppet but should be considered as a possible cause of the valve s blowing to exhaust when not actuated especially in a low pressure application 4 2012 ROSS CONTROLS All Rights Reserved REPAIR PROCEDURES DAMAGED SPOOL If a spool is badly scored or nicked it can allow air to pass from one port area to another This can result in unwanted pressurizing of an
19. sure lower than the minimum specified pilot pressure an external pilot supply of adequate pressure must be used Some ROSS valves automatically accept an external pilot supply while others must be converted to such use as explained on page 7 Vacuum or Non Air Service Many ROSS valves can be used for vacuum service or with fluids other than air Such applications require an external pilot supply For more information consult ROSS for Bulletin 440 ROSS Valves for Vacuum Service Pipe Installation To install pipe in valve ports engage pipe one turn apply pipe thread sealant tape not recommended and tighten pipe This procedure will prevent sealant from entering and contaminating the valve MAINTENANCE Pneumatic equipment should be maintained only by persons trained and experienced in the maintenance of such equipment Supply Clean Air Foreign material lodging in valves is a major cause of improper operation The use of a 5 micron rated air filter located close to the valve is strongly recommended The filter bowl should be drained regularly and if its location makes draining difficult the filter should be equipped with an automatic drain Check Lubricator Supply Rate A lubricator should put a fine oil mist into the air line in direct proportion to the rate of air flow Excessive lubrication can cause puddling in the valve and lead to malfunctions For most applications an oil flow rate in the lubricator of one drop p
20. t Operated Spool ValVe ccccsseeeeeeeees C Incorrect Voltage at SOIGNOIC ccccsseeeeesesseeeeeseeeeeeenees J Pilot Section Blows to Exhaust Loose Pilot COVE pe sicecesrecetacocsaesdexeapeacedacennacnssnssionsteauptacesnet G Pilot Poppet Not Sealing c cccccccseseeeenseeeeeeseeeeeeeaaeeees K Poppet Chatters Inadequate Air Supply cccccccsseeeeeceeeeeeeeeeseeeeeeseeeesanees I Inadequate Pilot or Signal Pressure cccceeseseeeeeeeees L Damaged Silencer ccccescecccceseeeeceeeeeecseeeseeeeeaneesessaseess N Valve Action is Sluggish Damaged Seals on Spool Valve cccssseeeeeeeeeeeeeeeeeeees B Varnish in Spool Valve ccccccccccseseeceseeeeeeseeeeeeeeeeeeesaaees C Inadequate Air Supply ccccccsseeeeceeeeeeeeeeeeeeeeeaeeeeeesaeees I Inadequate Pilot or Signal Pressure ccceeeeeeeeeeeeeeees L Inadequate Lubrication cccseeceeeeeeeeeeeeeeeeeeseeeeeseaeeenes M Damaged Silencer ccccseeceecceseeeeceesseecceeseeeceneeeeesseaess N Water or Oil Contamination ccccccsseeeeeceeeeeeeeseeeeeeeeees R Sequence Valve Gives Erratic Timing Damaged Piston S al cccccscececeeeeeceeeeeceeeeeseeseeseeeeesaes O Excessive LUDIICAtION cccceeececeeeeeceeeeeeeeeeeseeeeeeeeeeesaes M Fluctuating Air Pressure cc ccceceeceeseeeeneneeeeeeansereneaaers P Accumulated WaAtel cccceceeeceeseeeeseee
21. t to burnout However the most common cause of solenoid burnout is improper supply voltage See Incorrect Voltage at Solenoid Repair Procedure J f the Solenoid coil is not burned out examine the solenoid for the following three conditions PILOT INSERT PILOT POPPET Figure 6 Pilot Section for ANSI valves size 2 5 20 with Plug in Bases PILOT INSERT PILOT POPPET Figure 5 Pilot Section for Inline Valves Dirt under the T plunger See Figure 7 Before removing T plunger mark it and the frame so that they can be reassembled with the same orientation Remove T plunger Clean T plunger and frame Before reassembling inspect shading coil and air gap as explained below Broken shading coil See Figure 7 Copper shading coils reduce the solenoid s tendency to buzz when operated on alternating current If a coil is broken the solenoid must be replaced Wear that causes a loss of air gap There must be a small gap between the solenoid plunger and field frame when the solenoid is energized See air gap Figure 7 If significant wear is apparent under T plunger the air gap can be lost and the solenoid must be replaced T PLUNGER POSSIBLE DIRT WEAR AREAS SHADING COIL AIR GAP FIEL FRAME Figure 7 Typical Pilot Solenoid CYLINDER LEAKS See figure 8 Four way valves sometimes blow to exhaust because of leaking packings in the work cylinder connected to the
22. this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective This warranty becomes void in the event that product has been subject to misuse misapplication improper maintenance modification or tampering THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND OR HEALTH LAWS OR REGULATIONS IN NO EVENT IS ROSS LIABLE TO PURCHASER USER THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS MAY EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN Printed in the U S A Rev 04 12 2012 ROSS CONTROLS All Rights Reserved Form SM018 ROSS CONTROLS ROSS CONTROLS ROSS CONTROLS ROSS CONTROLS
23. valve Before looking for faults in the valve check the cylinder for leaks In the following steps take appropriate safety precautions because both the valve and the cylinder will be actuated 1 Disconnect the air line to the end of the cylinder which is not under pressure If air comes out of the open cylinder port the cylinder packings are leaking and must be repaired If there is no leakage reconnect the air line 2 Reverse the position of the valve and disconnect the other air line to the cylinder Again check for air coming out of the cylinder port If there is air coming out the cylinder packings must be repaired 3 If there is no leakage at the cylinder reconnect the air line and proceed with troubleshooting the valve itself VALVE TO CHECK BREAK AT THESE POINTS ROD END CYLINDER Figure 8 Cylinder Operated by Four Way Valve www rosscontrols com 5 REPAIR PROCEDURES l INADEQUATE AIR SUPPLY An inadequate air supply volume causes an excessive pressure drop during valve actuation Pilot air pressure may be great enough to begin movement of the valve element but the pressure drop resulting from the filling of the outlet volume depletes the pilot air supply This may result in chattering or oscillating of the main valve or may simply keep the main valve partially actuated so that it blows to exhaust Check the pressure drop shown on the gauge at the pressure regulator If the pressure falls more
24. ystem Follow appropriate lock out tag out procedures Disassemble the pilot section For pilots shown in Figure 5 or 6 remove pilot insert Check action of insert by pressing lightly on the spring protruding from the top Throughout its travel about 1 32 inch it should move easily without jerking or grabbing If not the insert must be replaced Inspect the poppet and seats for foreign particles or damage If the poppet or upper seat is damaged the pilot insert must be replaced If the lower seat is damaged the entire pilot housing must be replaced Before installing a new insert blow out the pilot air passages to remove any loose dirt particles Reassemble For ISO valves and size 1 5 ANSI valves see Figure 9 Disassemble pilot to remove the plunger Inspect seals on both ends of the plunger as well as the seats against which they seal Anything damaged should be remedied only by replacing the entire pilot assembly Figure 9 Pilot Section of Valves for Size 1 5 and ISO Bases L INADEQUATE PILOT OR SIGNAL PRESSURE Pilot or signal pressure below the minimum requirement can produce chattering valve oscillation or sluggish valve action Check your valve specifications for minimum pilot or signal pressure requirements LUBRICATION Some valves require lubrication to operate properly Check the system lubricator to see that it is working as it should Also check list of compatible lubricants on page 2 DO NOT LUBRICATE EXCESSI
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