EMERGING

TECHNOLOGIES
TECHNOLOGIES

BOOK 2, CHAPTER 8:
Directional Control Valves
Sept. 23, 2008
Table of Contents
Bud Trinkel

Directional Control Valves

Directional control valves perform only three

functions:

stop fluid flow

allow fluid flow, and

change direction of fluid flow.

These three functions usually operate in

combination.

The simplest directional control valve is the 2-way

valve. A 2-way valve stops flow or allows flow. A

water faucet is a good example of a 2-way valve. A

water faucet allows flow or stops flow by manual

control.

A single-acting cylinder needs supply to and

exhaust from its port to operate. This requires a 3-

way valve. A 3-way valve allows fluid flow to an

actuator in one position and exhausts the fluid

from it in the other position. Some 3-way valves

have a third position that blocks flow at all ports.

A double-acting actuator requires a 4-way valve. A

4-way valve pressurizes and exhausts two ports

interdependently. A 3-position, 4-way valve stops

an actuator or allows it to float. The 4-way function

is a common type of directional control valve for

both air and hydraulic circuits. A 3-position, 4-way

valve is more common in hydraulic circuits.

The 5-way valve is found most frequently in air

circuits. A 5-way valve performs the same function

as a 4-way valve. The only difference is an extra

tank or exhaust port. (Some suppliers call their 5-

way valves, “5-ported 4-ways.") All spool valves are

five ported, but hydraulic valves have internally

connected exhaust ports going to a common outlet.

Because oil must return to tank, it is convenient to

connect the dual tank ports to a single return port.

For air valves, atmosphere is the tank, so exhaust

piping is usually unimportant. Using two exhaust

ports makes the valve smaller and less expensive.

As will be explained later, dual exhausts used for

speed-control mufflers or as dual-pressure inlets

make this configuration versatile.

Following are schematic symbols for commonly

used directional control valves.

2-way directional control valves

A 2-way directional valve has two ports normally

called inlet and outlet. When the inlet is blocked in

the at-rest condition, as shown in Figure 8-1, it is

referred to as "normally closed" (NC). The at-rest

box or the normal condition is the one with the

flow lines going to and from it.

The boxes or enclosures represent the valve’s

positions. In Figure 8-1, the active box shows

blocked ports, or a closed condition, while the

upper box shows a flow path. When an operator

shifts the valve, it is the same as sliding the upper

box down to take the place of the lower box. In the

shifted condition there is flow from inlet to outlet.

Releasing the palm button in Figure 8-1 allows the

valve spring to return to the normal stop flow

condition. A 2-way valve makes a blow-off device

or runs a fluid motor in one direction. By itself, a 2-

way valve cannot cycle even a single acting

cylinder.

Figure 8-2 shows a "normally open" (NO) 2-way

directional valve. Energizing the solenoid on this

valve stops fluid flow.

Valve operators come in different types. Figure 8-3

shows a solenoid pilot operator using solenoid-

controlled pressure from the inlet port to move the

working directional spool. Figure 8-4 shows a cam-

operated valve. A moving machine member usually

operates this type valve.

3-way directional control valves

A 3-way valve has three working ports. These ports

are: inlet, outlet, and exhaust (or tank). A 3-way

valve not only supplies fluid to an actuator, but

allows fluid to return from it as well. Figures 8-5

through 8-10 show schematic symbols for 3-way

directional control valves.

Figure 8-9.

Solenoid pilot-

operated 3-way

selector valve.

Figure 8-6 depicts an all-ports-blocked, 3-way, 3-

position valve. A valve of this type connected to a

single-acting, weight- or spring-returned cylinder

could extend, retract, or stop at any place in the

stroke.

Some 3-way valves select fluid flow paths as in

Figure 8-9. Use a spool-type valve for this

operation. Another flow condition is the diverter

valve shown in Figure 8-10. A diverter valve sends

fluid to either of two paths.

Figure 8-10.

Palm-button-

operated 3-way

diverter valve.

4-way directional control valves

Figures 8-11 to 8-15 show different configurations

available in 4-way directional control valves. They

range from the simple, two-position, single, direct

solenoid, spring-return valve shown in Figure 8-11,

to the more complex three-position, double

solenoid, pilot-operated, spring-centered, external-

pilot supply, external drain valve shown in Figure

8-15.

ADVERTISEMENT

Figure 8-11. 4-way,

2-position direct

solenoid-operated

spring return.

Lines to the boxes show flow to and from the valve,

while lines with arrows in the boxes show direction

of flow. The number of boxes tells how many

positions the valve has.

Figure 8-12 shows a single solenoid, spring-

centered valve. This valve has a third position but

there is no operator for it. Use this spring-centered,

single solenoid valve in control circuits for special

functions. In the past, to get this configuration, you

only had to wire one solenoid of a double-solenoid,

three-position valve.

Figure 8-12. 4-way,

2-position direct

solenoid-operated

spring centered.

Figure 8-13 shows another unusual 4-way

configuration. This valve shifts from an actuator

moving flow path to center condition for certain

special circuits.

5-way directional control valves

Figures 8-16 through 8-20 show symbols of some

5-way air valves. Most spool-type air valves come

in a 5-way configuration. Because air usually

exhausts to atmosphere, the extra exhaust port is

no problem.

Figure 8-13. 4-

way, 2-position

direct solenoid-

operated spring

return.

Many valves use the two exhaust ports for speed

control mufflers. Mufflers not only make the

exhaust quieter, but throttle the exhaust, which in

turn controls cylinder speed in a meter-out circuit.

Another example later in this section shows dual

exhaust ports piped with different pressures to save

air. Also use dual inlet piping to make an air

cylinder operate quickly and smoothly. (See

Figures 8-48 through 8-55.)

Figure 8-14. 4-way,

2-position solenoid,

pilot operated detented, line-mounted.

Most air cylinders stroke from one extreme to the

other. A two position, single solenoid, spring return

valve is sufficient for this operation. About 90% of

air circuits use this type of valve. To stop an air

cylinder in mid-stroke, use the 3-position valve

shown inFigures 8-19 through 8-21.

Figure 8-17.Line-

mounted, solenoid

pilot-operated, 2-position,spring

returned 5-way valve.

It is difficult — if not impossible — to accurately

stop an air cylinder any place other than at end of

the stroke. When the cylinder moves slowly, a

repeatable mid stroke position of plus or minus an

inch might be possible. The problem is, if the load

on the cylinder changes or there is any slight leak

in the piping or seals, it will not hold position once

it stops.

ADVERTISEMENT

Figure 8-18. Line-

mounted, hand

lever-operated, 2-position, spring-

returned 5-way valve.

Three-position valves come in several styles,

including: cylinder ports open as seen in Figure 8-

19; all ports blocked as seen in Figure 8-20; and

pressure to cylinder ports as seen in Figure 8-21.

Using 2-way valves

Figures 8-22, 8-23, and 8-24 show some uses for 2-

way directional control valves.

Figure 8-19. 5-way,

3 position, spring-

centered solenoid, pilot-operated,

cylinder ports open-center condition,

line mounted.

One use is the blow-off function shown in Figure

8-22. A 2-way valve in Figure 8-23 operates a

one-direction motor with an open exhaust in the

motor housing. The circuit in Figure 8-24 works

well for electrically unloading a pump for easy start

up and/or reduced heat generation

Figure 8-20. 5-

way, 3 position,

spring-centered solenoid, pilot-

operated, all ports blocked center

condition, line mounted.

Figure 8-25 shows a weight-returned, single-

acting cylinder powered by a 2-way in theat rest

condition. At first sight it looks as if this circuit

might work. Shifting the 2-way valve, or

extending, sends fluid to the cylinder cap end and

it extends. The problem comes when the 2-way

returns to normal at the end of cycle. Instead of

the cylinder retracting after the solenoid de-

energizes, it stays in the extended position. The

cylinder would only return if the valve, cylinder

seals, or pipe connections leak.

Figure 8-21. 5-

way, 3 position,

spring-centered pressure to

cylinder ports, exhausts blocked

center condition, solenoid-pilot

operated, line mounted.

shows a circuit that operates a single-acting

cylinder with 2-way valves. One (NO) and one (NC)

2-way directional valve piped to the cap end

cylinder port allows fluid to enter and exhaust from

it. Actuating both operators simultaneously

extends the cylinder. According to valve size and

inlet air flow, the cylinder might not extend if just

energizing the (NC) valve. If the cylinder extends

with only one valve actuated, it would be slow and

waste a lot of air.

Figure 8-22. Blow-

off.

Figure 8-23. Running a one-direction

fluid motor.

Figure 8-24.

Unloading a pump.

Figure 8-25. Using

one 2-way valve to

operate a single-acting cylinder.

Figure 8-26.

Operating a

single-acting

cylinder with

two 2-way valves.

Figure 8-27 shows four 2-way valves piped to

operate a double-acting cylinder. A pair of 2-way

valves at each cylinder port gives a power stroke in

both directions. Energize and de-energize all four

valves simultaneously to cycle the cylinder and

keep from wasting fluid.

ADVERTISEMENT

Four 2-way valves may seem to be a complex and

expensive way to operate a cylinder. However, in

the past few years, poppet type slip-in cartridge

valves have been operating large bore hydraulic

cylinders this way. See chapter four on Cartridge

Valves for the advantages of these valves in high

flow circuits.

Figure 8-27.

Operating a

single-acting

cylinder with

four 2-way

valves.

Using 3-way valves

Figure 8-28 shows a 3-way valve, used to select Pr.

1 or Pr. 2. Use a spool type directional control valve

in this type of circuit. Spool valves normally take

pressure at any port without malfunction. Poppet

design valves normally take pressure at the inlet

port only.

Since the example selector valve is solenoid pilot-

operated, it is important to determine which port

has the higher pressure. Most solenoid pilot-

operated valves take air from the normal inlet port

to operate the pilot section. If both inlet pressures

are too low to operate the valve, plumb an external

pilot supply from the main air system.

When it is necessary to lock out one of two circuits

while the other one operates, the hookup in Figure

8-29 works well.

While circuit one has fluid going to it, working on

circuit two is no problem. Use a spool type valve

here also. Poppet valves usually only take pressure

at one port.

Figure 8-28.

Pressure selector.

The most common limit

valve is a miniature 3-way like the one shown in

Figure 8-30. This particular example is (NC).

Contact with a machine member opens it. Except

for bleeder type control circuits, a limit valve

requires at least a 3-way function.

Once this normally closed valve shifts, it passes a

signal on to continue the cycle. In normal

condition, fluid in the control circuit exhausts

through the exhaust port.

Figure 8-29. Fluid

diverter.

Figure 8-31 shows a

single-acting cylinder

with a 3-way valve powering it. Energizing the

solenoid, or extending, allows flow to move to the

cylinder port and it extends. Deenergizing the

solenoid or retracting, lets the valve shift to home

position, and the cylinder retracts from outside

forces.

The exhaust port on a 3-way valve lets fluid in the

cylinder escape to atmosphere.

Figure 8-30. NC

limit valve.

Figure 8-31. Operating a single-acting

cylinder with one 3-way valve.

To operate a double-acting cylinder with 3-way

valves, use the hookup shown in Figure 8-32. With

a 3-way directional valve at both ports, both extend

and retract strokes of a double-acting cylinder have

force.

Some manufacturers use dual 3-way valves to

conserve air. Piping between the valve and cylinder

ports wastes air. Every time a cylinder cycles, the

lines to both ports fill and exhaust. The longer the

valve-to-cylinder lines are, the greater the air

waste. Mounting air valves directly to the cylinder

ports minimizes air waste. The higher cycle rate

results in greater savings.

Figure 8-32.

Operating a double-

acting cylinder with

two 3-way valves.

Lowering pressure at the

rod end port is another way to save air with dual 3-

way valves mounted directly to the cylinder port.

As discussed before, reducing air pressure at the

cylinder uses less compressor horsepower. Usually,

force required to return a cylinder is minimal, so

lower pressure at the rod port saves energy.

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