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TECHNOLOGIES > HYDRAULIC VALVES

Understanding Counterbalance Valves

Learn how they work and how they di erentiate from pilot-operated check valves.
Hank Ayers
MAY 29, 2018

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Counterbalance valves are used with cylinders to safely hold suspended loads and deal with over-
running loads. This valve can also be used with hydraulic motors and is then commonly called a
brake valve. Both counterbalance valves and pilot-operated check valves can be used to lock fluid
in a cylinder to prevent drifting. However, a pilot-operated check valve cannot control an over-
running load. Whenever uncontrolled movement can occur from an overrunning load, a
counterbalance valve should be used.

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With no pressure in the line leading to the cylinder’s cap-end port, the counterbalance valve
prevents the load from dropping. The check valve lets fluid flow into rod-end port to raise the
load.

Here’s What Happens

Referring to Fig. 1, when no pressure is applied to the cap end of a cylinder, the counterbalance
valve maintains fluid pressure in the rod-end volume. The two pilot lines shown act on different
surface areas inside the counterbalance valve. The ratio of these areas is usually 3:1 or 4:1. We’ll
assume the 3:1 ratio. The line connected between the counterbalance valve and cylinder’s rod-

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end port acts on a small piston area (1 in.2) inside the valve. To overcome a spring force of 1,800
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lb, the pressure would have to build to 1,800 psi.

Because the load in our example exerts a force producing only 1,500 psi, the valve remains
closed. To lower the load, the cap-end volume of the cylinder must be pressurized. The external
pilot line will then be pressurized to open the counterbalance valve. This is because the external
pilot line acts on a surface area three times (3 in.2) that which the internal pilot pressure acts on.

Actually, 1,500 lb of force is already being exerted by the load on the spring. Therefore, the
external pilot pressure only has to develop 300 lb of additional force to open the valve. Pressure
only has to build to 100 psi on the 3 in.2 surface to develop the necessary 300 lb. of force (Fig. 2).

The pressure and the weight of the load will cause the valve to open, allowing the load to lower.
The load dropping too fast would cause a pressure drop in the external pilot line. The
counterbalance valve’s spool would then partially close, preventing an uncontrolled drop of the
load.

Pressurizing the line leading to the cylinder’s cap-end port also applies pilot pressure to the
counterbalance valve. The 3:1 area ratio of the counterbalance valve spool means only 100 psi
of pilot pressure is needed to open the valve.

Setup and Troubleshooting

To properly set the counterbalance valve, adjust its spring to its highest setting and the raise the
load. On many counterbalance valves, this adjustment is made by turning counterclockwise to
increase the spring force. Next, very slowly turn the adjustment in the opposite direction.
Caution: For safety, make absolutely sure nothing of value (especially yourself) is underneath
the load. Once the load starts to drift down very slowly, turn the adjustment back in the opposite
(original) direction until the drifting stops. Turn the adjustment a quarter of a turn in the same
direction and then tighten the lock nut.

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When a counterbalance valve fails, it usually sticks in the open condition. This results in the load
slowly drifting downward. When this occurs, service people often assume the drifting because is
caused by cylinder’s piston seals leaking. As a result, they change out or repair the cylinder,
which does not solve the problem. It’s usually quicker, easier, and less expensive to check the
counterbalance valve.

Contamination can cause the internal check valve or spool to stick open. Before removing the
valve, exercise caution and lower the load to the ground. Equally important, be certain that
pressure in the hydraulic lines has been bled down to 0 psig. After positively confirming this,
remove the valve and inspect for broken springs, trash, etc. Don’t forget to inspect the internal
check valve.

This discussion was excerpted from a blog by Hank Ayers, a hydraulics consultant and
instructor with GPM Hydraulic Consulting Inc., Monroe, Ga. Click here to view his blog.

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TECHNOLOGIES > HYDRAULIC VALVES

Troubleshooting Challenge: Pressure Poses Problem

Try your luck with this month's reader challenge.
Robert Sheaf
MAY 01, 2020

A company that makes concrete blocks has a carousel with 10 horizontal two-piece molds that
are clamped together, one at a time, by a 3-in. bore, 15-in. stroke hydraulic cylinder. Concrete is
then poured into the top gate to fill each mold. The clamp cylinder and mold are then moved to
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the next position on the carousel by a hydraulic motor. The circuit provided shows the transfer
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motor and only one of the 10 clamp cylinders.

No more than two mold clamp cylinders move at a time. One opens while the other closes. Once
the mold that’s opening trips a position sensor, the motor turns the carousel. After a dwell time
needed for the concrete to harden, that mold is opened and a block removed. The cycle then
repeats unless someone trips a safety-light curtain.

A problem occurred when a freshly filled mold would open slightly, allowing concrete to leak
from the bottom gap of the partially open mold. This happened when the carousel first started to
rotate resulted in a rejected block because of the void created.

Any idea why the clamp cylinders didn’t always do their job?

Find the Solution

Think you know the answer to this month’s problem? Submit your solution via e-mail. Bob and
his company have been involved in troubleshooting, training, and consulting internationally for
30 years. All correct answers submitted by Nov. 16, 2019 will be entered into a random
drawing for a $50 gift card. The winner will be notified, and his or her name will be printed in a
future issue. Only one gift card will be awarded to any participant within a calendar year.

Solution to Last Month’s Challenge:

Press Mold Moving When it Shouldn’t

The bottom mold that occasionally moved as if it was losing clamping force only happened when
a large pneumatic cylinder nearby was shifted and the propeller press started to open at the
same time. The large cylinder caused the system supply pressure to drop when both were
moving. Technicians installed a large-volume chamber in the supply line close to the press, and
it solved the problem.

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