Академический Документы
Профессиональный Документы
Культура Документы
V O LU M E 1 8 , N O. 1
The LNG
Challenge
PLUS:
䡲 Extreme Valves
䡲 The Butterfly Valve Evolves
䡲 Do We Need Valve
Qualification Programs?
䡲 The Ins and Outs of
Solenoid Pilot Valves
䡲 OEM Vs. Non-OEM Parts
SOLENOID PILOT VALVES FOR
VALVE ACTUATION
KNOWING THE INS AND OUTS OF PILOT
T
he term “pilot valve” is used in
reference to a three- or four-way
solenoid valve that pilots or controls
VALVES WILL HELP USERS SELECT THE
the flow of media, such as air or CORRECT PILOT VALVE CONSTRUCTION FOR
water, into an actuator, which in turn
controls the movement of a valve con-
AN APPLICATION.
nected to the actuator. In other
BY BILL REESON
words, the pilot valve drives or con-
trols the main process or control valve
in a process control system. Design Challenges
To meet specific customer needs, Over the past decade, one of the biggest challenges of solenoid design has been min-
pilot valves are available in a multi- imizing power consumption. This is especially true for pilot valves. The increased
tude of variations. Electrically, they use of distributed controls systems and bus protocols has meant the average sole-
vary by voltage, power consump- noid power consumption in DC voltage has dropped from a level of 10 watts to 1.5
tion, and method of protection. watts. The less power consumed, the smaller and less expensive a power supply
Most solenoids can be designed for need be. Bus protocols are demanding more stringent power levels than ever. The
use in almost any voltage, whether less power consumed over a bus network, the more nodes or slave devices are possi-
it’s AC or DC. The trend in the mar- ble over that network. If the protocol is powering the solenoid directly off the bus,
ket is toward DC because of power restrictions are limited from 0.5 watts to as low as 1.4 milliamps, depending
increased use of distributed control on the type of network. As soon as the power consumption drops to
systems and bus protocols. The only the milliamp range, the technology shifts from a typical
drawback in using DC is that most electromagnetic circuit solenoid to a piezo or
solenoid valves in DC valves cannot constant bleed device. Powering the pilot valve
operate at the same pressure as directly off the bus via a position indicator gives
their AC equivalents. However, the user less wiring since only one cable is con-
some manufacturers now have tech- nected from node to node, eliminating the need
nology that permits the same pres- to run a separate cable to each device from a
sure rating whether the valve is AC PLC. This one cable transmits data and power.
or DC. In fact, solenoid coil tech- To use a pilot valve that cannot be powered off of
nology has improved so much that a the bus would require an external power supply
customer can purchase one valve from the bus and in many cases a different node
and operate it over a given voltage device that will allow use of an external power sup-
range such as 100 to 240 at 50 to ply. Pilot valves that can be used as individual
60Hz in AC or DC. nodes or slave devices over certain net-
work protocols are also available. How-
ever, they are not as common because most
pilot valves used over networks are standard pilot
valves that serve as an output device from a posi-
tion indicator. Piezo-operated pilot valve for
Depending on the environment, many methods of use as a Foundation fieldbus
protection are used. A large part of the process control or Profibus PA output device
market requires explosion-proof equipment. To meet
that requirement, the pilot can be designed using intrinsic safety in such a manner
that the solenoid cannot cause a spark or generate sufficient heat to create an ignition
source. Another protection method is to contain possible sparks or explosions within
an enclosure that will not allow flame to propagate to the outside atmosphere. These
products either have the explosion-proof enclosure or use electronics that are encapsu-
lated with some type of potting compound. Third-party approval for these protections
can be achieved, depending on where the customer is located.
Valve with a voltage ranging coil
C2 | Valve M A G A Z I N E
Pilot Valve Functions 2 and 4, or A and B; and a com-
Pilot valve function has typically been mon exhaust port for both of the
either three- or four-way. Today there working ports, designated 3 or E.
are many functions based on these two A 5/2 valve is a four-way valve
basic descriptions, and it is not uncom- that has five ports designated as fol-
mon to see descriptions such as 3/2 lows: Port 1 is the air inlet or pressure
NC, 3/2 NO, 3/2 U, 3/3, 4/2, 5/2, and port, ports 2 and 4 are the cylinder or
5/3. While these designations may look working ports, and ports 3 and 5 are
confusing, they are actually quite sim- the exhausts. Port 3 is the exhaust for
ple. For a three-way pilot valve, for port 2 and port 5 is the exhaust for NAMUR mount valve
example, the expression 3/2 NC means: port 4. Each cylinder port has its own
䡲 The number 3 signifies three exhaust so you can add flow controllers integrated into a position indicator or
ports on the valve. to the exhaust ports to control the integrated as part of the actuator itself.
䡲 The number 2 designates that the opening or closing speed of the actua- The overwhelming majority of pilot
valve has two positions. The two tor that the pilot valve controls. valves sold each year are piped. How-
positions are energized or de- ever, the other configurations are rap-
energized. Single or Dual Solenoids idly growing in use.
䡲 NC stands for normally closed, All the constructions described above Perhaps the fastest growing configu-
which means that in the de-ener- are available with a single solenoid or ration is the NAMUR standard mount-
gized position, the process con- dual solenoids. The single-solenoid ver- ing, which started in Europe more than
nection to the actuator is closed. sions normally have a spring return so two decades ago. This standard allows
the valve automatically returns to its the customer to save on piping costs
The first port is normally marked as normal state during power loss. The because the pilot valve can be attached
P (pressure) or 1. This is the air supply dual-solenoid versions remain in the to the actuator without the need for
to the valve. The second port is C last position when power is lost. piping. The only pipe needed is for air
(cylinder) or 2. This is the working port With the dual-solenoid versions, supply to the valve. As actuator manu-
connected to the piston side of a there are constructions designated as facturers accepted this standard, so too
spring-return actuator. The third port is 3/3 and 5/3. Again, the second number have pilot valve companies. The two
designated 3 or E (exhaust). The designates number of positions. The sizes for the NAMUR mounting for
exhaust port is where the air from the positions are the following: de-ener- pilot valves are 1/4-inch and 1/2-inch
actuator is released when the pilot gized or center position; solenoid A standards. The 1/2-inch is not as com-
valve changes state from energized to energized; and solenoid B energized. In mon right now, but actuators and pilot
de-energized. this dual-solenoid construction, the valves in this size are available, as are
Sometimes there is another port on center position is the only position that the more common 1/4-inch NAMUR
a 3/2 pilot valve. This most likely will is different. Typically, this center posi- standard for control valve applications.
be designated as R, which stands for tion is called “center open,” where all The difference between this standard
re-breather—the port connected to the of the cylinder ports to exhaust are and the normal 1/4-inch standard is a
spring side of a spring-return actuator. open, or “center closed,” where all of port included for external pilot air.
As the air being exhausted travels out the ports are closed. The center posi-
of the piston side of the actuator, the tion can be made to accommodate Pilot Valve Islands
re-breather port channels it into the almost any function—depending on The pharmaceutical industry uses pilot
spring side. This keeps outside air from customer needs—that the pilot valve valve islands (or manifolds), where the
being ingested into the spring side of design will allow. The majority of pilot primary function is the actuation of
the actuator, giving that actuator some valves for this function are spool valves sanitary valves. Since the ingress pro-
environmental protection from any- used for keeping the actuator from tection and approvals of these types of
thing in the atmosphere that may cor- moving from its position during power valves are limited, pilot valve islands
rode internal parts. loss. are mounted inside an enclosure. All
Four-way pilot valves typically are the electronics reside in the enclosure,
used for double-acting actuators. A Mounting Configurations and tubing runs from the enclosure to
pilot valve designated 4/2 is a four-way Pilot valves also are available in many each point of actuation. A benefit of
valve with four ports. It consists of an mounting configurations. The most these islands is that the pilot valves
air supply, designated 1 or P; two cylin- common are piped, NAMUR-mounted, usually are in one location, with one
der or working ports, designated ports pilot valve islands, and pilot valves point of electrical connection as well as
W i n t e r 2 0 0 6 | C3
S O L E N O I D P I L O T V A L V E S F O R V A L V E A C T U A T I O N
C4 | Valve M A G A Z I N E