Application Notes
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comatrol hydraulic cartridge valves

Relief valves are used as pressure limiting devices to protect hydraulic systems and components. They are available in direct-acting poppet, differential area poppet, bidirectional poppet, and pilot-operated spool types.

relief-valves-group

OPERATION

relief-valves-direct-act-poppetDirect-acting poppet
The direct-acting poppet blocks flow from 1 to 2 until sufficient pressure is present at 1 to force the spring-opposed poppet from it’s seat. This pressure is commonly known as the crack pressure.  The valve will remain open until the pressure drops to a level allowing the spring to close the valve. This pressure is known as the re-seat pressure and is typically 70-80% of the crack pressure. The difference between crack and re-seat pressure is commonly referred to as hysteresis.

Differential-area poppet
The differential area poppet operates in the same manner except flow is blocked from 2 to 1 until sufficient pressure is present at 2 to force the spring-opposed poppet from it’s seat.

Advantages of direct-acting poppet and differential area poppet relief valves are:

  • Fast response
  • Contamination tolerant
  • Low leakage
  • Low cost
     

Because of these features some common applications for direct-acting and differential area poppet relief valves are:

  • Main system relief valve if flow is relatively constant, or as a safety relief valve for “spike clipping” to protect components from overpressure
  • Work port cross-over relief to protect a cylinder or motor from overpressure
relief-valves-system-relief-valve relief-valves-work-ports-cross-relief

 

relief-valves-bidirectional-poppet-reliefBi-directional poppet
The bi-directional poppet is a dual cross-over relief in a single cartridge.  When pressure at 1 exceeds the nominal setting, the lower poppet acts as a direct-acting relief valve and opens flow from 1 to 2. When pressure at 2 exceeds the nominal setting, the upper poppet acts as a differential area relief valve and opens flow from 2 to 1 .

Note that the valve is designed so that the crack pressure is the same in either direction

A common application for a bi-directional relief valve is as a work port cross-over relief where one bi-directional valve can replace two direct-acting valves.

 

relief-valves-pilot-operated-spool-reliefPilot operated spool
The pilot operated spool blocks flow from 1 to 2 until sufficient pressure is present at 1 to force the pilot poppet off it’s seat. This creates a pressure differential across the spool that  causes the spool to shift and open flow from 1 to 2.

Advantages of pilot-operated relief valves are:

  • Smooth, stable response
  • High flow and high pressure capability
  • Precise pressure control with varying flow rates. Low pressure rise
  • Low hysteresis
     

A common application for pilot-operated relief valves is as a main system relief where high pressure or flow capability and/or extremely precise pressure control is required.

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