Counterbalance valves

The fourth and last normally closed pressure control valve found in hydraulic circuits is the
counterbalance valve. Cylinders with external forces such as weight from a platen, machine
members, or tooling acting against them will overrun when cycled if oil flowing out of them is
not restricted. A meter-out flow control circuit is one way to control overrunning loads but it has
one main drawback. A flow controls speed is fixed except for manual adjustment or when using an
infinitely variable proportional type. Because flow is fixed, the actuator will continue at the same
speed even when working flow to it increases or decreases. Thus, control is minimal and there
could be high energy waste. (Figure 13-8 shows a meter-out flow control circuit for running
away loads.)
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A counterbalance valve keeps an actuator from running away regardless of flow changes because
it responds to pressure signals, not flow. A counterbalance valve is almost the same as a sequence
valve except it normally does not have an external drain connection. The cutaways and symbols
in Figure 14-6 depict the physical makeup of three different counterbalance valves and how they
are represented on a schematic drawing.
The two cutaways and symbols on the left are spool designs with internal and external pilots. The
valve on the right is a poppet design that is both Internally and externally piloted. Each valve type
has advantages in different circuit arrangements that will be discussed later. A counterbalance
valve usually has a bypass check valve for reverse flow because its most common use is in
controlling actuators with running away or overrunning loads.
An internal pilot-operated
counterbalance valve shifts to
allow excess fluid to flow to the
outlet when pressure at the inlet
increases to the pressure set by
the pressure adjustment. Pressure
at the inlet never drops below set
pressure when there is flow at the
outlet. Flow from the inlet to the
outlet is just enough so that
backpressure on the actuator
never drops below set pressure.
This means the actuator moves
only as fast as it is supplied and
stops when Inlet flow ceases.

Figure 14-6. Three types of counterbalance valves

Pressure adjustment on the Internal-piloted counterbalance valve is usually made by first screwing
the pressure adjustment all the way in. To assure that the valve is capable of high enough pressure,
start the pump and raise the load a small amount. Then center the directional valve which
connects the cylinder rod-end port to tank to see if it holds. If the load holds, next raise the load
in increments checking for load stop every few inches. With the load suspended, start reducing
set pressure on the counterbalance valve slowly until the load creeps forward. When the load starts
drifting down slowly, increase pressure until movement stops, then turn the pressure adjustment
another quarter to half turn higher. This method of adjusting usually wastes less energy while it
always stops and holds the load.
The main disadvantage of an internal pilot-operated counterbalance valve is that backpressure is
constant and it holds back even when the actuator needs maximum force. Another disadvantage is
that to maintain optimum performance, an Internal-piloted counterbalance valve must be
readjusted every time the load changes. The valves main advantage is that it produces smooth
cylinder action while advancing to the work.
An external pilot-operated counterbalance valve shifts to allow excess fluid flow to the outlet when
pressure at the opposite cylinder port reaches the pressure set by the pressure adjustment. Pressure
at the inlet never drops below load-induced pressure plus pressure set on the pressure adjustment
when there is flow at the outlet. Flow from inlet to outlet is just enough that the actuator moves
only as fast as it is supplied and stops when flow to the actuator ceases.
Pressure adjustment on the external pilot-operated counterbalance valve can be made on a test
stand by setting the pressure adjustment at 100 to 200 psi. If pressure must be set on the machine,
set the pressure adjustment higher than 200 psi and lift the load a small distance to make sure it
stops and holds. If it holds, continue to raise the load high enough to have some time for the next
step. Now, power the load down and observe pump pressure. Pump pressure while lowering the
load should not exceed 200 psi. Continue this action until pump pressure is between 100 and 200
psi while the load is lowering. This method of adjusting usually wastes less energy while always
stopping and holding the load.
The main disadvantage to an external pilot-operated counterbalance valve is that it may cause
lunging or even stop cylinder action while advancing to the work. The main advantage is that
backpressure is only present when the actuator is advancing to the work. At work contact, pressure
at the actuator inlet increases and forces the counterbalance valve wide open, thus eliminating all
backpressure. Another advantage is that an external pilot-operated counterbalance valve does not
need to be readjusted when the load changes.
Internal and external pilot-operated counterbalance valves shift when pressure at the internal pilot
area reaches the pressure set on the pressure adjustment and allows excess flow to go to the outlet.
Pressure at the Inlet never drops below set pressure when there is flow at the outlet. Flow from the
inlet to the outlet is just enough that backpressure on the actuator never drops below set pressure.
This means the actuator moves only as fast as it is supplied and stops when Inlet flow ceases.
Pressure adjustment on an internal and external pilot-operated counterbalance valve is usually
made by first screwing the pressure adjustment all the way in. To assure that the valve is capable

of high enough pressure, start the pump and raise the load a small amount. Then center the
directional valve that has the cylinder rod-end port connected to tank to see if it holds. If the
load holds, then raise the load in increments checking for load stop every few inches. With the
load suspended, start reducing set pressure slowly until the load creeps forward. When the load
starts drifting down slowly, increase pressure until movement stops, then turn the pressure
adjustment another quarter to half turn higher. This method of adjusting usually wastes less
energy while always stopping and holding the load.
An internal and external pilot-operated counterbalance valve lowers loads smoothly and opens
fully when pressure at the actuator inlet increases upon contact with the work. The valve does need
to be readjusted when loads change, but this is a small price to pay for good control.
Figure 14-7 depicts a vertically oriented cylinder with rod facing down and a load trying to extend
it. To keep the cylinder from running away, the counterbalance valve must resist the load-induced
pressure from the weight. The load-induced pressure can be calculated and the counterbalance
valve could be preset at 100 to 150 psi higher on a test stand, but pressure adjustment is usually
done at the machine (as mentioned earlier).
Notice that the directional control valve has
ports A and B connected to tank in the center condition.
There is no chance of extra pressure buildup in the pilot line
while the circuit is at rest. If ports A or B were blocked,
pressure could build and pilot the counterbalance valve
open, allowing the cylinder to drift.

Figure 14-7. Internally pilot-operated

counterbalance valve circuit

Energizing solenoid A1 sends pump flow to the cylinder

cap end. As pressure builds there, pressure also increases
in the rod end. When pressure at the cylinder rod end
reaches 100 to 150 psi above the load-induced pressure,
the cylinder starts to extend as fast as the pump fills the
cap end. When flow increases, cylinder speed increases
and when flow decreases, cylinder speed decreases.

As stated in the counterbalance valve explanation, backpressure at the cylinder rod end is present
during the entire extend stroke. As a result, at work contact cylinder force is reduced by
counterbalance pressure times the cylinders rod-end area. The total weight of the platen and
tooling on a press plus the amount of added pressure at the counterbalance valve cannot be used to
do work. Energy is expended to raise the weight but it is not recouped during the work cycle.
Energizing solenoid B1 sends fluid around the counterbalance valve through the bypass check
valve and on to the cylinder rod end to retract it.
The circuit in Figure 14-8 shows the same cylinder with an
external pilot-operated counterbalance valve. An externally
piloted valve can be set at approximately 100 to 200 psi
regardless of load-induced pressure in the cylinder. This is
especially convenient in applications where loads constantly
change. It is also the best use of energy because the
counterbalance valve opens fully when the cylinder meets

resistance so the weight is able to do some work. Because

backpressure on the cylinder rod end is zero, more force is
available.

Energizing solenoid A1 sends fluid to the cylinders cap

end to start it extending. As pressure builds in the
cylinder cap end, it pressurizes the external pilot and
opens the counterbalance valve The valve only opens
enough to let fluid out when the cap end is at pilot
pressure. If pilot pressure is set too low, the
counterbalance valve may quickly open too far
allowing the cylinder to run away and pilot pressure to
Figure 14-8. Externally pilot-operated
counterbalance valve circuit
drop. At this point, the counterbalance valve shuts
abruptly and the cylinder stops. Almost immediately,
pressure again builds at the cylinder cap end, the counterbalance valve reopens, and the same
scenario repeats until the cylinder meets resistance. A meter-in flow control in the external pilot
line can help, but is very difficult to set. Energizing solenoid B1 sends fluid around the
counterbalance valve through the bypass check valve and on to the cylinder rod end to retract it.
The internal and external pilot-operated counterbalance valve in Figure 14-9incorporates the best
features of both valves. The internal pilot provides a smooth advance stroke at low force, while the
external pilot opens the valve fully to eliminate backpressure from the cylinder rod end when it
contacts the workpiece. (Like the internally piloted valve. this version must be reset at each load
change to maintain its efficiency and keep energy losses low.)
The symbols in these example circuits show a direct-acting
pressure control valve. Several suppliers offer a pilotoperated version that is more stable and has less pressure
differential between cracking and full flow operation.

The circuits shown here work equally well with

hydraulic motors, except that a counterbalance valve
will not stop and hold a running away load on a motor
without creep. All hydraulic motors have internal
leakage that increases as the motor wears. The
counterbalance valve may not have any bypass but fluid
will slip by the motor parts no matter what its design.

Figure 14-9. Internally and externally pilotoperated counterbalance valve circuit

There are no counterbalance valves for air circuits. Air

circuits depend on meter-out flow controls to keep an actuator from running away. Usually an air
circuit uses a 2-position valve that keeps pressure on the retract side at rest so it stays in place at
end of stroke. When a load must be stopped in mid-stroke, a 3-position valve with cylinder ports
blocked in center is the common method of trying to do this. There also is available a pilot-operated
check valve for air service that gives some control for stopping and holding a pneumatic cylinder in
mid-stroke.