By Jim

Popovich

An introduction to

Slip-In Cartridge

Valves

Part

On e

ydraulics involve the use of

fluid under pressure to control the velocity, direction of
movement, and force of various kinds of mechanical and
electro-mechanical devices,
such as hold-down clamps,
presses, grippers, injection
molders, and conveyors. The
efficiency with which these devices operate is directly
affected by the efficiency of the hydraulic systems
that power them. These hydraulic systems consist of
components such as pumps, reservoirs, filters, valves,
actuators, and fluid conductors such as tubing, hose,
or pipe. The movement of the fluid through a hydraulic system is directly controlled by directional control
valves, flow control valves, and pressure control valves,
which act independently or in conjunction with one
another to regulate the flow of fluid. Conventional
hydraulic systems are typically constructed with the
individual elements plumbed together by means of
the pipe, tube, or host (Fig. 1). Identifying flow paths
and isolating individual components for the purpose
of diagnosing faults is not overly challenging to the
trained troubleshooter, as the flow paths are readily
inferred by the experienced fluid power technician.

42

January/February 2011

The conventional means of hydraulic control where

the individual circuit components are inter-connected
by pipe, hose, and tubing has an alternative in modular
systems. While conventional valve systems in hydraulic circuits have served industry well over a number of
years, the search for better and more efficient methods
of construction resulted in the development of modular control systems. Hydraulic circuits employing conventional valves are economical in limited production
low-flow circuits, but modular control systems offer
economy, reduction in system envelope size, grouping
of control functions, fewer connections that result in
lower assembly labor cost, and a reduction in external
leakage points, etc. The quest for better control systems
has resulted in the modular building-block approach
to implementing hydraulic controls. Modular control
systems are available in three forms, which use manifold blocks to reduce labor content in building hydraulic circuits: stack valves, screw-in (threaded) cartridge
valves, and slip-in cartridge valves.
Stack valves (also known as sandwich valves) are
adaptations of conventional valve interfacing, which
allows for the vertical or horizontal stacking components (Fig. 2). The manifold blocks for sandwich
valves are typically standard, off-the-shelf building
blocks with which circuits may be constructed. Sand-

wich valve circuits can be more compact and have

a simpler design at lower cost than circuits utilizing
conventional valves due to the fact that most of the
valve-to-valve plumbing is accomplished through
passageways bored in the valve blocks.
With the pump flow and tank connections supplied
to the subplate manifold block, external plumbing is
often only required to the pump, reservoir, and the actuators themselvesvia the A and B ports. These stackable
valves present a challenge when used to build complex
circuits and are somewhat limited in their application.
Typically one stack is employed per actuator, with up to
eight stacks per standard manifold. Screw-in cartridge
valves are often used as the valve element in DO-3 and
DO-5 (NG 6 and NG 10) sandwich blocks.
Screw-in and slip-in cartridge valves typically
employ custom-designed and custom-manufactured
manifold blocks that are limited to a particular application or function. With these custom-manufactured
manifold blocks, circuits can be more compact than
those put together with conventional hydraulic valves
due to the fact that most of the valve-to-valve plumbing is replaced by passageways machined in the blocks.
Aluminum blocks are typically employed at operating
pressures up to 3000 psi (200 bar) and malleable steel
manifolds where pressures exceed 3000 psi.

www.fluidpowerjournal.com | www.ifps.org

The valves are relatively inexpensive due to their

modular design. In small-volume production runs,
when built in low quantities, the design and manufacture of the custom manifold blocks becomes a
major portion of the overall system cost. As the
production volume increases, the cost of production of the block itself decreases. For complex
machine controls, several manifold block modules
can be combined.
Screw-in cartridge valve blocks (Fig. 3) are primarily applied where flow requirements are less than 70
gpm (265 lpm). The screw-in cartridge valves, as the
name implies, screws into standardized threaded cavities bored out in a manifold block.
This article will focus on slip-in cartridge valves
(SICV), which is a technology that has its origins
in Europe in the 1970s. As a result of its origin, the
valves and manifolds typically follow ISO and DIN
ratings and standards.
Slip-in cartridge valves offer significant improvement over conventional hydraulic components:
Higher efficiency
Modularity in component design
Compact circuits
Minimal internal leakage
Easier component replacement
High flow capability
Rapid valve response
Low valve pressure drop
Low sensitivity to contamination
Greater reliability

The Major Components of a SICV Circuit

The Manifold Block: This block houses the cartridge valves, provides connecting passageways from
valve to valve, passages to pilot control valves, pump
flow and reservoir return lines, and passages leading
to the pilot control valves.
Cartridges: These form the mainstage of a valve
hydraulically controlled poppets with two working
ports and one pilot port. The elements of the cartridge consist of a poppet, a sleeve (bushing), and a
bias spring.
Pilot Valves: The function of the pilot valve is to
control the slip-in cartridge valves, which essentially
form the mainstage portion of the valve. Pilot-directional valves are typically DO-3 or DO-5 interface
conventional valves or may be screw-in cartridge
valves. The slip-in cartridge, then, becomes a mainstage of a valve whose operation and function is determined by the pilot valve.
Covers: The primary function of the cover is to
enclose the poppet, spring, and sleeve in the manifold
cavity. It is also used to provide control of the poppet,
either through orificed plugs contained in the cover or
by providing connections to pilot-control valves. The
orificed plugs, as shown in Fig. 4, are typically remov-

About the Author:

Jim Popovich, CFPAI, CFPPS, CFPHS, was
a senior training instructor for a hydraulic
manufacturer for 10 years, conducting formal
and custom training classes for engineering,
sales, maintenance, and distributor personnel.
He currently teaches automation technology
classes at Washtenaw Community College in
Ann Arbor, Mich.

A slip-in cartridge valve mainstage is a two-port

poppet valve inserted into a cavity in a manifold. A
typical valve consists of a sleeve, poppet, and spring
inserted into a manifold cavity. The poppet moves
within the sleeve to control flow through the valve.
The insert parts are held in the manifold by a cover
plate that contains pilot flow passageways to control
the poppet. O-rings and backup rings seal the cover
and insert sleeve at the manifold bore.

able in the standard cover with the use of a hex key

wrench and are sized to obtain the desired opening and
closing speed of the poppet. The goal is typically to
maximize the response of the cartridge while minimizing system shock due to the rapid opening or closing of
the poppet. In many cases, the cover acts as a connecting block between the pilot valves and the mainstage.
Fig. 5 illustrates a directional valve interface cover onto
which a pilot directional valve is bolted.
The size of the cartridge refers to the diameter of
the port opening at port A of the poppet (Fig. 6),
typically sized in millimeters, with the standard sizes
being NG16, 25, 32, 40, 50, 63, 100, 125, and 160.
The flow ratings for the size 16-mm to 160-mm ranges from 32 gpm to 4000 gpm (120 lpm to 15,100
lpm) at a valve pressure drop of 3.5 bar (50 psi).
Additional economy in circuit design can be achieved
by matching the individual cartridge elements to the
flow requirements determined by its location within
a hydraulic circuit.
A slip-in cartridge valve graphical symbol depicts
the areas of the poppet that are active at each port.
Pressure applied to either of the main ports exerts a
force on the poppet to move it off its seat, allowing
flow through the valve. If pressure is applied to the AP
area, a force is created to close the valve.
Common area ratios used in slip-in cartridge valves
are 1:1 and 1:2. The area ratio corresponds with the
ratio of the A port area to the AP area (A:AP). (Note:
This article will use this approach to designating area
ratios, although some manufacturers use AP:A or
even B:A.) Some organizations and manufacturers
designate the AP area as F.
Part Two of this article will look at how the construction of SICV systems and poppets contribute to a
reduction in internal and external leakage. It will also
examine different poppet area ratios as applied in pressure control and directional control applications.

January/February 2011

43