TYPE “S” RELAY VALVE

(Volume booster)
Service Manual
The Type "S" Relay Valve is a pilot INCREASING PRESSURE Applying pressure to the pilot port
operated, 3-way, pneumatic moves the diaphragm assembly down to seat the exhaust
pressure control valve with open valve, unseat the inlet valve plunger, and compress the
exhaust. This large capacity valve inlet valve spring. Air pressure from a local source at the IN
receives pressure signals from a port flows to the OUT port. A controlled flow of air is also
remote control valve and repeats directed to the underside of the diaphragm. Air flow
this pressure with a greater rate of continues until the pressure at the OUT port equals the
flow to the component being pressure at the pilot port.
controlled. It serves in a pneumatic
circuit to speed response time
between sending and receiving
stations that are separated by long
pipe runs or branch circuits. Where
the controlled component is not in a readily accessible
location, remote piloting provides a solution.

WARNING: INSTALLATION AND

MOUNTING
The user of these devices must conform to all applicable
electrical, mechanical, piping and other codes in the
installation, operation or repair of these devices.

INSTALLATION! Do not attempt to install, operate or repair
these devices without proper training in the technique of
working on pneumatic or hydraulic systems and devices,
unless under trained supervision.
Compressed air and hydraulic systems contain high levels
of stored energy. Do not attempt to connect, disconnect or
repair these products when a system is under pressure.
Always exhaust or drain the pressure from a system before
performing any service work. Failure to do so can result in
serious personal injury.
DECREASING PRESSURE Reducing pressure in the pilot port
unbalances the pressure across the diaphragm. The
diaphragm assembly and exhaust valve move away from
the seated inlet valve, opening the OUT port to exhaust
through the hollow inlet valve plunger.
Air continues to exhaust until the air pressure at the OUT
port under the diaphragm balances the air pressure to the
pilot port on the top of the diaphragm.

MOUNTING! Devices should be mounted and positioned in

such a manner that they cannot be accidentally operated.

OPERATION
CLOSED CENTER
POSITION When the outlet
pressure (pressure below
the diaphragm) is equal to
the pilot pr es s ur e
(pressure above the
diaphragm), the balance
of pressure allows the
inlet valve spring to move
the valve assembly up.
This seats the inlet valve
and exhaust valve,
sealing the IN and OUT
ports.

SM-400.8007
MAINTENANCE

A complete "S" Relay Valve should be maintained

in stock for each four valves in service. The
maintenance periods determined by use and
working conditions should be scheduled to permit
complete valve replacement; thus loss of
production time will be kept to a minimum and
more time will be afforded to clean, carefully
inspect and replace worn parts of the relay.

Each "S" Relay should be supported by those

parts recommended - see the parts list.

Completely disassemble the Relay Valve on a well

lighted work bench. Clean all metal parts with a
non-flammable solvent and wash all rubber parts
with soap and water. Rinse thoroughly and blow
dry with a low pressure air jet. Lay all parts on a
clean, preferably white, surface. Arrange them in
the order of the exploded view. Examine each part
carefully for wear or cracks. Replace those parts
that will not give good service until the next
inspection period.

Reassemble the "S" Relay using the exploded and

assembly views as reference. No special tools are
required. As the assembly proceeds, lubricate all
metal to metal surfaces with No.107 Lubriplate and
all rubber parts with Cosmolube or their
equivalents.

ADJUSTMENTS
No internal adjustments are required.

INSTALLATION

The "S" Relay Valve can be installed directly in the

line at any location. Satisfactory operation and
service life can be expected in a temperature
range of -20°F to + 160°F (-29°C to 71°C).

Clean out the air supply line before connecting it to

the "IN" port of the "S" Relay. Harmful deposits in
in the air line can impair the efficiency and service
life of the valve.

It is recommended that a good line filter be

installed in the air line upstream of the "S" Relay.

Internal lubrication of the moving parts can be

accomplished by a line lubricator being installed TYPE “S” RELAY VALVE
between the line filter and the "S" Relay. The oil Exploded View
mist will also keep the operating equipment
downstream of the valve in good condition.

Page 2
 TYPE “S” RELAY VALVE
Repair Parts List

Ref. Description of Part 3-S 4-S 6-S 8-S

No.
R431003663 P -055160- R431003664 P -055161- R431003665 P -055162- R431003666 P -055163-
00000 00000 00000 00000
New P/N Old P/N New P/N Old P/N New P/N Old P/N New P/N Old P/N
1 Body, Plugged R431003561 P -055086- R431003561 P -055086- R431003612 R431003612 P -055113-
(includes Ref. 18) 00003 00003 00002
2* Ring, “O” See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit

3 Washer R431002158 P -049804- R431002158 P -049804- R431002165 P -049804- R431002165 P -049804-

00017 00017 00039 00039
4* Spring, Supply Valve See Kit See Kit See Kit See Kit See Kit See Kit X See Kit

5* Ring, “O” See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit

6* Plunger, Valve See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit

7* Ring, “O” See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit

8* Seat, Supply Valve See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit

9* Ring, “O” See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit

10* Baffle, Complete See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit

11 Follower, Diaphragm R431003669 P -055166- R431003669 P -055166- R431001024 P -030153- R431001024 P -030153-
00002 00002 00000 00000
12* Diaphragm See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit

13 Retainer, Diaphragm R431003667 P -055164- R431003667 P -055164- R431003671 P -055168- R431003671 P -055168-
00000 00000 00000 00000
14* Nut, Hex R431001932 P -049633- R431001932 P -049633- R431001933 P -049633- R431001933 P -049633-
00001 00001 00002 00002
15 Ring, “O” See Kit See Kit See Kit See Kit See Kit See Kit See Kit See Kit

16 Cover R431003670 P -055167- R431003670 P -055167- R431003674 P -055171- R431003674 P -055171-

00000 0000 00000 00000
17 Screw, (req’d) R431002250 P -049835- R431002250 P -049835- R431002253 P -049835- R431002253 P -049835-
00022 00022 00027 00027
18 Plug, 1/8” Pipe R431002133 P -049787- R431002133 P -049787- R431002133 P -049787- R431002133 P -049787-
(2 req’d) 00000 00000 00000 00000
19 Mounting Bracket R431004138 P -057410- R431004138 P -057410- R431004139 P -057411- R431004139 P -057411-
00000 00000 00000 00000
20 Screw, (2 req’d) R431002254 P -049835- R431002254 P -049835- R431002252 P -049835- R431002252 P -049835-
00028 00028 00026 00026

* Recommended spare parts to be retained in stock at all times.

These parts may be ordered in kit form by ordering Repair Kit P/N R431004153 for 3-S and 4-S models (Old P/N P-057429-00000)
or P/N R431004155 for 6-S and 8-S models (Old P/N P -057431-00000).

Page 3
 ORDERING REFERENCE

Model Piece Drawing

Pipe Size Weight
Designation New P/N Old P/N Number

3/8-18 Dryseal NPTF 3-S R431003663 P -055160-00000 2Ib .. 6 oz. (1.1 kg) BP55160

1/2-14 Dryseal NPTF 4-S R431003664 P -055161-00000 2Ib .. 4 oz. (1.0 kg) BP55160

3/4 -14 Dryseal NPTF 6-S R431003665 P -055162-00000 2lb .. 10 oz. (1.2 kg) BP55162

1-11 Dryseal NPTF 8-S R431003666 P -055163-00000 2Ib .. 7 oz. (1.1 kg) BP55162

SPECIFICATIONS

Maximum Inlet Pressure 250 psi (17.2 bar)

Maximum Pilot Pressure 250 psi (17.2 bar)
Temperature Exposure -20°F to +160°F (-29°C to 71°C)
Ratio-Pilot to Delivery Pressure 1:1
Hysteresis Less than 5 psi (0.3 bar)
Material Die cast aluminum (3/4” & 1” size) or zinc (3/8”-1/2”)
Body. Nylon reinforced HYCAR diaphragm, ano-
dized aluminum or plated parts.

Type “S” Relay Valve Dimension Schedule

New P/N Old P/N A B C D E F G H I J K

R431003663 P -055160-00000 9/16 1/4 1/4 1/2 1/16 1/4 11/32 5/8 7/8
3 3 3 4 4 2 1 1 2 11/16 15/32
R431003664 P -055161-00000 3 9/16 3 1/4 3 1/4 4 1/2 4 1/16 2 1/4 1 11/32 1 5/8 2 7/8 11/16 15/32
R431003665 P -055162-00000 4 11/32 4 1/8 4 1/8 5 1/4 4 7/8 2 7/8 1 1/2 2 1/16 3 3/16 3/4 1 3/16

R431003666 P -055163-00000 4 11/32 4 1/8 4 1/8 5 14 4 7/8 2 7/8 1 1/2 2 1/16 3 3/16 3/4 1 3/16

Page 4
 NOTICE TO PRODUCT USERS
1. WARNING: FLUID MEDIA
AVENTICS pneumatic devices are designed and tested for use
with filtered, clean, dry, chemical free air at pressures and
temperatures within the specified limits of the device. For use
with media other than air or for human life support systems,
AVENTICS must be consulted. Hydraulic cylinders are designed
for operation with filtered, clean, petroleum based hydraulic fluid;
operation using fire-resistant or other special types of fluids may
require special packing and seals. Consult the factory.
2. WARNING: MATERIAL COMPATIBILITY
Damage to product seals or other parts caused by the use of
noncompatible lubricants, oil additives or synthetic lubricants in
the air system compressor or line lubrication devices voids
AVENTICS warranty and can result in product failure or other
malfunction. See lubrication recommendations below.
AIR LINE LUBRICANTS! In service higher than 18 cycles per
minute or with continuous flow of air through the device, an air
line lubricator is recommended.* (Do not use line lubrication with
vacuum products.) However, the lubricator must be maintained
since the oil will wash out the grease, and lack of lubrication will
greatly shorten the life expectancy. The oils used in the
lubricator must be compatible with the elastomers in the device.
The elastomers are normally BUNA-N, NEOPRENE, VITON,
SILICONE and HYTREL. AVENTICS recommends the use of
only petroleum based oils without synthetic additives, and with
an aniline point between 180° F and 210° F.
COMPRESSOR LUBRICANTS! All compressors (with the
exception of special "oil free" units) pass oil mist or vapor from
the internal crankcase lubricating system through to the
compressed air. Since even small amounts of non-compatible
lubricants can cause severe seal deterioration (which could
result in component and system failure) special care should be
taken in selecting compatible compressor lubricants.
3. WARNING: INSTALLATION AND MOUNTING
The user of these devices must conform to all applicable
electrical, mechanical, piping and other codes in the installation,
operation or repair of these devices.
disconnect or repair these products when a system is under
pressure. Always exhaust or drain the pressure from a system
before performing any service work. Failure to do so can result
in serious personal injury.
MOUNTING! Devices should be mounted and positioned in such
a manner that they cannot be accidentally operated.
4. WARNING: APPLICATION AND USE OF PRODUCTS
The possibility does exist for any device or accessory to fail to
operate properly through misuse, wear or malfunction. The user
must consider these possibilities and should provide appropriate
safe guards in the application or system design to prevent
personal injury or property damage in the event of a malfunction.
5. WARNING: CONVERSION, MAINTENANCE AND REPAIR
When a device is disassembled for conversion to a different
configuration, maintenance or repair, the device must be tested
for leakage and proper operation after being reassembled and
prior to installation.
MAINTENANCE AND REPAIR! Maintenance periods should be
scheduled in accordance with frequency of use and working
conditions. All AVENTICS products should provide a minimum of
1,000,000 cycles of maintenance free service when used and
lubricated as recommended. However, these products should be
visually inspected for defects and given an "in system" operating
performance and leakage test once a year. Where devices
require a major repair as a result of the one million cycles, one
year, or routine inspection, the device must be disassembled,
cleaned, inspected, parts replaced as required, rebuilt and
tested for leakage and proper operation prior to installation. See
individual catalogs for specific cycle life estimates.
6. PRODUCT CHANGES
Product changes including specifications, features, designs and
availability are subject to change at any time without notice. For
critical dimensions or specifications, contact factory.
*Many AVENTICS pneumatic valves and cylinders can operate
with or without air line lubrication; see individual sales catalogs
for details.

INSTALLATION ! Do not attempt to install, operate or repair

these devices without proper training in the technique of working
on pneumatic or hydraulic systems and devices, unless under
trained supervision. Compressed air and hydraulic systems
contain high levels of stored energy. Do not attempt to connect,

LIMITATIONS OF WARRANTIES & REMEDIES

AVENTICS warrants its products sold by it to be free from defects in material and workmanship to the following:
For twelve months after shipment AVENTICS will repair or replace (F.O.B. our works), at its option, any equipment which under
normal conditions of use and service proves to be defective in material or workmanship at no charge to the purchaser. No charge will
be made for labor with respect to defects covered by this Warranty, provided that the work is done by AVENTICS or any of its
authorized service facilities. However, this Warranty does not cover expenses incurred in the removal and reinstallation of any
product, nor any downtime incurred, whether or not proved defective.
All repairs and replacement parts provided under this Warranty policy will assume the identity, for warranty purposes, of the part
replaced, and the warranty on such replacement parts will expire when the warranty on the original part would have expired. Claims
must be submitted within thirty days of the failure or be subject to rejection.
This Warranty is not transferable beyond the first using purchaser. Specifically, excluded from this Warranty are failures caused by
misuse, neglect, abuse, improper operation or filtration, extreme temperatures, or unauthorized service or parts. This Warranty also
excludes the use of lubricants, fluids or air line additives that are not compatible with seals or diaphragms used in the products. This
Warranty sets out the purchaser's exclusive remedies with respect to products covered by it, whether for negligence or otherwise.
Neither, AVENTICS nor any of its affiliates will be liable for consequential or incidental damages or other losses or expenses incurred
by reason of the use or sale of such products. Our liability (except as to title) arising out of the sale, use or operation of any product or
parts, whether on warranty, contract or negligence (including claims for consequential or incidental damage) shall not in any event
exceed the cost of replacing the defective products and, upon expiration of the warranted period as herein provided, all such liability is
terminated. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER FOR
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE. No attempt to alter, amend or extend this
Warranty shall be effective unless authorized in writing by an officer of AVENTICS Corporation.
AVENTICS reserves the right to discontinue manufacture of any product, or change product materials, design or specifications without
notice.

Page 5
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infa.us@aventics.cam

AfflDICS mKl(Mldedi
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infa.ca@a11entics.cam

Slv1-4QQ.8QQ7/May 2QT4 Sub1ec:ttn c:hange. Printed in United States. AVENTICS Carparatian

This dac:urnent. as well as the data. spec:ific:atians. and atherinfurmatian setfurth in it are the ED\Clusive
property at AVEl"-JTICS. It may natb.e reproduced ar given ta third parties withaut its cansent