3/30/2014 BOOK 2, CHAPTER 5: Counterbalance Valve Circuits | Other Technologies content from Hydraulics & Pneumatics

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HOME > TECHNOLOGIES > OTHER TECHNOLOGIES > BOOK 2, CHAPTER 5: COUNTERBALANCE VALVE CIRCUITS
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BOOK 2, CHAPTER 5: Counterbalance Valve Circuits
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For more on counterbalance valves, read this section What is in this article?:
on pressure control valves.
BOOK 2, CHAPTER 5: Counterbalance Valve
Circuits

Externally piloted counterbalance valve

Machine thrusts with different

counterbalance valve pilot options

Counterbalance valves
Hot Topics
Some actuators with running-away (or overrunning) loads will let the load free fall when Automate With Air Fluid Power Handbook
the directional valve that controls the actuator shifts to lower the load. Cylinders with & Directory Digital
Edition
large platens and tooling or hydraulic motors on winch drives are two examples of such
actuators. When the directional valve shifts, an overrunning load forces the actuator to View All

move faster than pump flow can fill it. Oil at high velocity leaves one end while the Advertisement
opposite side starves for fluid. A vacuum void forms in the inlet side of the actuator that
must be filled before applying force. Any running-away or overrunning load needs some
method to retard its movement.

A meter-out flow control is one way to control a running-away load at a constant speed.
Unless pump flow never changes, setting flow precisely on this type control is critical.
Setting the flow control for minimum pump flow will waste energy when pump flow is
high. Setting the flow control for maximum pump flow lets the cylinder run ahead when
pump flow is low. Incorporating a pressure control valve called a counterbalance is a
better way to control running-away loads. A counterbalance keeps an actuator from
running away even with variable flow rates.

Fig. 5-1: Internally piloted

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Figure 5­1 shows the symbol for an internally piloted counterbalance valve. Use an Posted 1 week ago
internally piloted counterbalance to hold a load back when the actuator does not need in The Hitch Post

full power at the end of stroke. This type of counterbalance valve retards flow
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3/30/2014 BOOK 2, CHAPTER 5: Counterbalance Valve Circuits | Other Technologies content from Hydraulics & Pneumatics
continuously, so it resists flow even after work contact stops the actuator. Note that it is EXPOSURE
by Michael Ference
necessary to adjust an internally piloted counterbalance valve every time the load
Posted 1 year ago
changes. The following circuits show these characteristics and how to design around
in Publisher's Blog
them.

Fig. 5-2: Externally piloted Advertisement Advertisement

counterbalance valve

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Figure 5­2 shows the symbol for an externally piloted counterbalance valve. This valve’s
pilot supply is from a source other than the controlled load. An externally piloted
counterbalance does not waste energy at the end of stroke and does not require
adjustment for changing loads. However, an externally piloted counterbalance valve does
waste a little more energy when moving the load to the work.

Fig. 5-3: Internally/externally

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Figure 5-3 shows the symbol for an internally/externally piloted counterbalance valve. and classic technical
This valve has the best of both systems. As the load extends, internal pilot supply gives training books available.
smooth control with little energy loss. After work contact, as system pressure builds, the Click below to browse the
external pilot fully opens the counterbalance to relieve all backpressure in the cylinder. bookshelves today!

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Counterbalance valves are manufactured in both spool and poppet designs. Spool designs
leak at a rate of 3 to 5 in.3/min, thus allowing actuator creep. Poppet designs leak at only
3 to 5 drops/min, minimizing cylinder creep. (Because hydraulic motors bypass
internally, a counterbalance only works with a moving load. The designer should apply a
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braking method to hold a hydraulic motor at rest.)

Internally piloted counterbalance valve

Figure 5-4 pictures a circuit with a running-away load. This circuit demonstrates the TwitterFacebook RSS
operation of an internally piloted counterbalance valve. The cylinder in Figure 5-4 has a
static pressure of 566 psi in the rod end due to the 15,000-lb load on the 26.51- in.2 area.
(15,000 / 26.51 = 566 psi). An open-center directional valve unloads the pump and keeps
backpressure off the counterbalance valve outlet and pilot port. The cylinder holds in any
position if the counterbalance valve is set correctly and does not leak. Set the
counterbalance approximately 100 to 150 psi higher than the load-induced pressure.

Fig. 5-4: Internally piloted

counterbalance valve at rest with pump
running

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3/30/2014 BOOK 2, CHAPTER 5: Counterbalance Valve Circuits | Other Technologies content from Hydraulics & Pneumatics

Normal procedure for setting a counterbalance valve is to turn the adjusting screw to its
highest pressure before raising the cylinder. After starting the pump, energize the
directional valve and carefully raise the load a short distance. With the load suspended,
deenergize the directional valve. A working counterbalance will hold the load suspended
and gauge PG3 will show the load-induced pressure. Now start lowering the
counterbalance pressure setting slowly. When the cylinder begins to creep downward,
increase the pressure until creeping stops. Then continue turning the adjusting control in
the same direction another to turn. After setting the counterbalance this way, power the
cylinder down and notice the pressure reading on gauge PG3. Pressure should be
approximately 700 to 750 psi. Any time the cylinder loading changes, repeat the above
process. Resetting the counterbalance valve keeps the cylinder from running away and
reduces energy loss with a lighter load.

Fig. 5-5: Internally piloted counterbalance

valve with cylinder extending

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3/30/2014 BOOK 2, CHAPTER 5: Counterbalance Valve Circuits | Other Technologies content from Hydraulics & Pneumatics

When the directional valve shifts to extend the cylinder in Figure 5­5, oil from the pump
flows into the cap end of the cylinder and pressure starts to build. When pressure in the
cap end of the cylinder reaches about 75 psi, the cylinder should start to stroke. (This is
because it builds an extra 140 psi in the rod end, adding to the load’s 566 psi.) At this
point the cylinder starts to extend and continues to move as long as the pump supplies oil
at 75 psi or higher to the cylinder cap end. If pump flow changes, cylinder speed changes
also.

Fig. 5-6: Internally piloted counterbalance

valve with cylinder retracting

While the cylinder is retracting, Figure 5­6, pump flow bypasses the counterbalance
valve through the integral bypass check. The counterbalance valve offsets the potential
energy of the weight on the rod end of a cylinder. The 15,000-lb force in this figure
cannot do useful work when using an internally piloted counterbalance valve. (See
Figures 5­13 through 5­15 for energy loss and heat generation for different types of
counterbalance circuits.)

Externally piloted counterbalance valve »

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3/30/2014 BOOK 2, CHAPTER 5: Counterbalance Valve Circuits | Other Technologies content from Hydraulics & Pneumatics

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