F3 Series Valves - Manifold Installation
V-413DP
Assembly Procedures for Manifolds
Manifolds may be assembled to one another either before or after
assembling valves to manifolds. If inlet or exhaust common galleries
are to be isolated from neighboring manifolds, follow instructions
given in the Manifold Isolation Procedures section before
proceeding with this section. If air pilot valves are part of the
manifold assembly, be sure to isolate their pilot signals so that
they do not supply undesirable pressure to other valves in the
manifold assembly.
1. Line up manifolds (Items #3, 7, 9) in order of assembly while
viewing cylinder ports #2 and #4. Place the right end plate
(Item #1) at the right end of the bank. See Figure 2.
2. Each manifold should be accompanied with three tie rods. Screw
together all the tie rods into three sets of equal length — each
set will number the same as the number of manifolds to be
stacked.
3. Thread each set of tie rods into the right end plate then place
the end so that the tie rods are pointing up away from the
assembly surface.
4. Apply a light coating of grease to molded gasket (Item #2) and
place it in groove of right end plate (Item #1).
5. Assemble first manifold in sequence to right end plate allowing
the three tie rod sets to pass through the manifold holes.
6. In like manner, install another greased gasket and place the
second manifold in sequence over the first. Assemble remaining
manifolds by repeating steps 4 and 5.
7. Assemble the last gasket to the last manifold, then mount the
left end plate (Item #10) with three socket head cap screws
with flat & lock washers (Items #11). Start the screws into the
last tie rods but do not tighten the screws at this stage.
! CAUTION: If the socket head cap screws do not engage
the last tie rod, it is because the stack of uncompressed
gaskets causes the manifolds and gaskets to be longer
than the tie rod sets. It will be necessary to lengthen the
tie rod sets by backing away each tie rod from its adjacent
tie rod about one or two turns. This stack up length
problem is likely to occur at 6 or 7 manifold bases and
worsens with each additional manifold.
8. Place the entire assembly on a flat surface — Square up each
manifold (by lightly tapping on the manifold) and each of the
end plates with the flat surface. Then tighten each screw in an
alternating tightening pattern so that each screw tightens nearly
equally. Final torque should be 4.5 to 5.1 Nm (40 to 45 in. lb.)
9. If valves (Item #15) or top blanking plate (Item #18) were not
attached to their respective manifolds, mount them per Valve
Mounting Procedures or Station Blanking Plate Procedures.
10. Apply pressure and check for leaks and proper function. If any
leaks are present, do not operate the valves - repeat the
assembly process until satisfactory performance has been
obtained.
Manifold Isolation Procedures
Inlet & exhaust galleries, and pilot supply/signal galleries may be
isolated from those in adjacent manifolds through the use of isolation
plugs. Note: air piloted valves, whether single or double, will need
to be isolated at 14 and/or 12 galleries to prevent improper air
pressure signals reaching adjacent valves. Figure 1 schematically
indicates where to place plugs (shown as “X” marks) for typical air
piloted valves. Figure 2 pictorially indicates assembly locations of
main gallery plugs (Item #8), which are assembled on the left side
of the base. The pilot gallery plugs (Item #5), are assembled on the
right side of the base.
The following describes how to install these plugs:
1. Determine which gallery is to be isolated between two manifolds.
2. As displayed in Figure 2, use the large plugs (Item #8) from the
service kits to isolate manifolds from the main gallery(s). The
middle plug is used to isolate port #1 (inlet air supply), the left
plug is used to isolate port #5 and the right plug is used to
isolate port #3.
3. Apply a light coating of grease to isolation plug and insert it
into counterbore.
4. Apply a light coating of grease to gasket (Item #2) and assemble
in manifold groove.
5. Assemble plugged manifold into manifold bank in its
proper position.
6. Apply main pressure and check for leaks. If any are present,
do not operate the valve - repeat the reassembly process until
satisfactory.
Port Connections
(Below is a brief summary of typical port connections. See Technical
Data section of the F3 catalog for more details.)
1. Connect an inlet air supply to manifold inlet gallery by one of
the following methods:
a. All valves being supplied with a common pressure:
Connect air supply to port marked #1 on either end of
manifold package and plug port on other end marked #1 (or
connect air supply to both ends for applications requiring a
larger volume of air).
b. Two groups of valves - each requiring a different single
pressure supply:
Isolate valves into two groups using steps outlined in the
Manifold Isolation Procedures section. Connect
appropriate air supply to each end of manifold package at
port #1.
2. For dual pressure applications, connect air supply to ports #3
and #5.
3. Pipe exhaust at ports #3 and #5 for single air supply. For dual
pressure applications, connect to port #1. If mufflers are being
used, connect mufflers to the same ports.
increase pressure levels include supply air at both end plates (Items
#1 & 10), at intermediate inlets and sequencing the valve operation
to maximize time between different valve shifts.
! WARNING: Air exhausting from one valve into the exhaust
gallery of the manifold assembly may momentarily pressurize
other valve circuits open to the same gallery. Design the circuit
such that there is no hazard or consequence of damage from
this action.
Valve Mounting Procedures
If valve and manifold are purchased separately, use the following
procedure to mount valve to manifold:
1. Using a clean, lint free cloth, clean top surface of manifold and
bottom surface of valve body of dirt and dust.
2. Check to insure that gasket (not shown) is properly seated in
gasket track on sandwich block.
3. Place valve assembly (Item #15) on top of manifold (Items #3,
7, 9). On electrically operated valves, line up plug with socket
in manifold and gently press down on valve to seat plug properly.
4. Then line up the mounting holes and insert valve mounting
screws (Item #16). Tighten using a 3 mm hex wrench; torque
from 2.5 to 2.9 N•m (22 to 26 in-lbs) using progressive steps
with a criss-cross pattern.
5. Apply main pressure and check for leaks. If any are present,
do not operate the valve - repeat the reassembly process until
satisfactory.
