1. Slip-in Cartridge Valves
FTH002
Field Training Module
Value of module is $400 plus instructor’s expenses when conducted live.
For credit, please take the FTH002 Slip-in Cartridge Valves quiz located in the “Blended Learning Quizzes” folder on the MI Power of 3 training site.

2. Orifice Cover Pilot Passage Spring Sleeve Poppet Cavity in Manifold
Slip-in cartridges get their name from the fact that they are slipped into standard cavities that have been machined into a manifold. Here we have a cut-away view of a manifold which shows one of several cavities that we possibly may have. Let’s slip a valve into this cavity.
The basic components of a cartridge valve are the sleeve, …the poppet … and the spring . Once these components are inserted into the manifold, then a cover is bolted on to hold everything in.
We call this a standard cover because it basically only has one passageway in it. This passage way is for pilot pressure. And in the passage way you’ll find an orifice. .
The orifice is there to keep the pilot pressure from going into or out off the spring chamber too rapidly. This keeps the poppet from opening and closing so quickly and causing shock in the system.
You can think of a single slip-n cartridge valve as being a check valve, in that it’s either open or closed. But, they are more than just check valves.
Next, we’ll take about how all of these components work together to perform various hydraulic functions.

3. Pilot Pressure B Port A Port
Everything that we have assembled so far makes up a two-position, two-way valve. Two position…because it will be either open or closed. Here we see it in the closed position, which means the poppet is on its seat. ..and there is no flow from A to B or B to A
We have two things holding the poppet closed: the spring… and the pilot pressure . As long as the spring force added to the pilot pressure is greater than the pressures on the A and B ports, the valve remains closed.
A typical spring has gives 40 pounds of closing force. So let’s say that in our example here, there is 1,000 PSI pilot pressure and that the pilot area is 2 square inches. If we add the forces trying to close the poppet, we’ll have 1,000 PSI x 2 square inches …. Or 2000 pounds. Now add the 40 pound spring and you’ll have 2040 pounds.
Okay, let’s also say that there is zero pressure B port and 2000 PSI on the A port. Since this is a 1:2 ratio poppet, there is 1 square inch of area at A. So we have 2000 PSI x 1 square inch, which give us 2000 pounds of force trying to open the valve. Well now, 2040 pounds of force holding it closed and 2000 pounds trying to open it, so it stays closed.
A Port

4. A Port
B Port
Here we see the valve in the open position, because the poppet is off of its seat, which allows flow from A to B or B to A.
The valve opens because we have now removed the pilot pressure and the pressure on A or B is high enough to overcome the spring force.

5. + =
Pilot
1:2 Ratio B
Okay, I know you are wondering why I keep saying that pressure on the B port can open the valve. To understand this, let’s take a look at the three areas in question. If you take a look at the poppet from the top, you’ll see the pilot area. …Now look at the bottom of the poppet. The flat surface is exposed to the A port ….and the angled surface is exposed to the B port.
Now, this particular poppet has a 1:2 ratio of the areas. This means that the pilot area is 2 times the area of “A” and also 2 times the area of “ B”. So if you add A and B together, they will equal the pilot area. A

6. Pilot Pressure X Port B Port A Port x P
Okay, now back to the cover. You remember the standard cover which only contains a pilot passage with an orifice. We call this the “X” port and pilot pressure is applied to it from some source through manifold.
As you may imagine, there has to be a valve somewhere that controls the pilot pressure. That valve would most likely be mounted on the manifold in close proximity to the cover.
When the solenoid is energized as shown here there would be pilot pressure applied to close the poppet. And when the solenoid is de-energized, the pilot pressure would go away and the poppet could open.
A Port

7. Solenoid P T A B D03 Pattern
Interface Cover
D03 Pattern
Cavity in Manifold X Y
So, if you’re going to use a solenoid valve to supply the pilot pressure to the pilot passage, why not just have a cover that is equipped with a pad on which you can mount the valve.
These are called “interface covers” … and come with a industry standard “D03” mounting patterns.
Now, let’s check this out. If the solenoid is energized, you’ll have “X” going into the “P” port, out the “A” port, and into the spring chamber, thus closing the poppet.

8. P T A B D03 Pattern Interface Cover Y X Cavity in Manifold T P A B
And with the solenoid de-energized, you’ll have the spring chamber connected the “A” port, which routes the oil to the tank port of the solenoid valve; from there it goes into the “Y” passage. “Y” is the pilot drain passage and will be connected through the manifold to the reservoir.

9. Relief Valve Pilot Stage Relief Valve Cover 1:1 Poppet Tank Pressure
Another cover that is popular with us cartridge valve fans, allows us to turn a slip-in cartridge into a relief valve. As you see, this cover has a relief pilot-stage sitting right on top.
Also, notice that the slip-in poppet has a different shape at the bottom. This is a 1:1 poppet, which means that the pilot area is equal to the A area, and that there is no B area.
This set up functions just like a conventional balanced piston, piloted operated relief valve.
Tank
Pressure

10. Flow Control Flow Control Cover Metering Notches
And for those applications where you need flow control, here is a flow control cover that is used with a slip-in that is equipped with metering notches.
This valve is adjusted by turning the knob, which moves the stem up or down to limit how far the poppet can open. But, unlike a regular flow control, this one can be remotely closed by applying pilot pressure. When the pilot pressure is removed the valve will open back up to where the stem is set.
Metering Notches

11. Sizes & Schematic Symbols 1:2 Ratio With Metering Notches
16 mm – 100 mm
53 to 1850 GPM
The slip-in valve inserts come in sizes from 16 millimeters in diameter, that will handle about 53 gallons per minute, up to 100 millimeters in diameter, that will handle an amazing 1850 gallons per minute. This is one of the major attractions of the slip-in cartridges … extremely high flows.
Now reading from left to right, we see the schematic symbols… starting with the 1:1 ratio ..followed by the 1:1.1 ratio …and the 1:2 ratio … and finally the 1:2 ratio with metering notches.
Okay, are you ready for some applications? We have several, just a mouse-click away. Mouse-click - is that a verb?
1:2 Ratio With Metering Notches
1:1 Ratio
1:1.1 Ratio
1:2 Ratio

12. Check Valve
You remember the notched poppet and flow control cover used for flow control, right. Okay, what if you want to meter the oil in one direction and have free flow in the other?
Then you can use a cartridge valve as a check valve. It will be installed in the manifold and connect as you see here. So, you’ll have metered flow through the throttle and free flow through the check valve. If flow tries to go through the check valve in the opposite direction to the red arrow, the pressure will enter the pilot passage and close the poppet.
Cartridge valves make great check valves.

13. Directional Control
Okay, here is a question for you; “how many slip-in cartridge valves will it take to make a 4-way directional control? Four is correct.
Let’s label these cartridges as one , two , three and four.
Now, which valves will be open and which will be closed to extend the cylinder? That would be 2 open to allow oil into the blind end of the cylinder, and 4 open to allow oil from the rod end to go back to tank . And of course, one and three will remain closed.
Cartridge valves make great directional control valves. 1 2 3 4

14. Retracting the Cylinder
What’s it going to take to retract the cylinder with these four slip-ins?
You’ve got it, three and one open and two and four closed.
Here is an example of when you may see different size cartridges in the same manifold. Let’s say this is a 2:1 ratio cylinder, meaning that the blind area is twice that of the rod area, and we are pushing 100 GPM into the rod area. How many gallons per minute will be coming out of the blind area? Right – 200 GPM. So valve one needs to be bigger than the others. 1 2 3 4

15. Open Center
Okay, I’m digging this. What if all four are open? Well, it would be the same as an open center valve in the center position, meaning all ports will be open to tank.

16. Closed Center
And with all four valves closed, what would we have? Yep, closed center. That’s P, T, A and B all blocked.

17. Float Center
Are we having fun yet? What if two and three are closed and one and four are open? Right again – a float center You know, with P blocked and A and B going back to tank.
All of these examples show us that another major advantage of slip-ins is their versatility. See, once the four valves are mounted into a manifold and each has a solenoid valve controlling its respective pilot pressure, various operations can be obtained by just changing the sequence of energizing the solenoids. This is like making a software change, instead of a hardware change. 1 2 3 4

18. Regeneration
And last, but not least. What if one and four are closed and two and three are open? Well, you’ll have what is know as a regenerative center. When in this condition, the flow from the pump enters the blind end of the cylinder… which causes the cylinder to extend … and if the cylinder is extending, oil is coming out of the rod end... and the only place it can go is into the blind end with the pump flow. This is called regeneration and it makes the cylinder go really fast.
Listen, come to Birmingham for a hands-on class, and we’ll let you hook up this circuit and prove it to yourself. 3 4 1 2

19. Automotive Bumper Plant Injection Molding Machine
Perhaps it would be fitting to end this program with a photo of an actual slip-in cartridge valve application. You’re looking at a cartridge valve manifold on an injection molding machine in an automotive bumper plant.

20. Slip-in Cartridge Valves
FTH002
Motion employees may receive credit for this class by taking the quiz in the “Blended Learning Quizzes" folder of the MI Power of 3 site.