To: Nancy Myers

From: Joey Persyn

Date: April 18, 2022
Subject: Instructions report

FIND THE SETTING AND SET A SYSTEM RELIEF VALVE

Every hydraulic system needs a system relief valve. This is necessary to protect pumps, actuators, supply
lines and other components in the system, more importantly this will protect you and your staff. It is
necessary to understand Fluid power equations, flows, and pressure, to accurately set a system relief
valve. Follow these steps to set a system relief:

TOOLS AND MATERIAL NEEDED:

• Writing utensil
• Paper
• Calculator

Information from customer:

Directional
• Design PSI-2000
control valve
• Extend force-50000 lbs.
(DCV) operates
the actuator using • Retract force-5000 lbs.
the handle. • Stroke (distance)-20”

The information supplied is for

System relief example purposes only.
valve

The following is only a guide. Information may vary. Its always

NOTICE best to consult a fluid power specialist when preforming the
following instructions.
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1. Acquire this information from the customer:
• Design pressure (DPSI), a pressure the customer can support.
• The force of the work to be done.
• The distance said force will need to travel.

2. Get the theoretical area of the cylinder bore, extend force divided by DPSI. For example:
50000÷2000=25
3. Find the theoretical bore size of the cylinder, square root the theoretical area and divide by
.7854. For example:
√𝟐𝟓 ÷. 𝟕𝟖𝟓𝟒=5.64
4. Select the cylinder, round theoretical bore up to next size, refer to your supplier’s cylinder chart.
For this example, we have selected this bore diameter size:
Bore-6”
5. Select a rod size, refer to your supplier’s cylinder sizing chart. For this example, we have selected
this rod size:
Rod-2”
6. Find the blind end area (BEA), BEA² X .7854. For example:
6² X .7854 = 28.27
7. Find the rod end area (REA), (BEA² - REA²) X.7854. For example:
(6² - 2²) X .7854 = 25.13
8. Find the BEA volume, this will be the stroke X the BEA. For example:
20” X 28.27 = 565.4
9. Find the REA volume, this will be the stroke x the REA. Example:
20” X 25.13 = 502.6
10. Find the Extend Load Pressure (ELPSI), take the extend force and divide it by the extend area.
For Example:
50000 ÷ 28.27 = 1768
11. Find the Retract Load Pressure (RLPSI), take the retract force and divide by the retract area. For
example: 5000 ÷ 25.13 = 198
12. Find the highest load pressure (LPSI). For this Example:
1768 or 198 = 1768
13. Find the actual relief valve setting, take the highest LPSI and times it by the standard safety
factor of 15%. For example:
1768 X 1.15 = 2033
14. Find the gauge setting, you will need to round up to the nearest 50. Example:
2033 will round up to 2050 (this is easy to find on a pressure gauge)
15. Back the adjustment on the system relief valve all the way out.

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 KEEP BODY CLEAR OF MOVING EQUIPMENT. ALWAYS
WARNING CONSULT A TRAINED OPERATOR PRIOR TO STARTING THE
MACHINE. MAY CAUSE SEVERE INJURY.

16. Start the system. (Flow will return to tank at minimal pressure).
17. Bottom the cylinder out, extended or retracted. Leave Directional control valve (DCV) shifted
until Step 19 Is complete.
18. Adjust the System relief valve, while watching the pressure gauge. This can be done by turning
the knob.
19. When gauge reads 2050 PSI, you are finished.

System relief valves are essential for operating a safe and effective hydraulic system. Every
hydraulic system needs to have a system relief valve, this valve needs to be set accurately to
supply proper protection for you and your system.