A-Series Internal Pilot with Flange Connections

Models

AAPF: Cast Iron

ACPF: Cast Steel

ASSPF: Stainless Steel

API 520 & 614 Approved
Chatter-free operation
Mount in any position
Suitable for continuous duty

Size Range: 2.5″, 3″ & 4″
Pressures: 50 – 500 psi
Flow Rate: 150 – 600 gpm

DOWNLOAD THE A‐SERIES SECTION PDF

Installation, Maintenance & Operation Assembly Number Identification Dimensions & Parts Performance Data

INSTALLATION, MAINTENANCE & OPERATION

Installation

Fulflo valves can be mounted in any position. A tee may be inserted in the pump discharge line to mount the valve. The pipe lines carrying the heavy valves must be well supported and overhung weights avoided. The correct size of valve must be used, preferably equal to the size of the pipe line to which they are connected. Flanged valves (AADF and ACDF) are bolted to the companion flange which may be threaded or welded to the pipe. The outlet of the valve should be piped to the supply tank, unless specific applications call for alternate piping of return lines. Care must be taken to have the discharge well below the oil level in the tank to prevent air entrainment and erratic operation.

Setting Valves

Valve may be set with a hydraulic hand pump for cracking pressure. If a test stand is available, valve should be connected to the discharge header with the pump bypass open, and the bypass gradually closed until the desired pressure registers on the gauge. For Internal Pilot Operated valves, adjust valve adjusting screw until approximately 5-7 GPM is flowing through the valve, at that point the main piston will open and then the valve will be considered at the set point, then lock adjusting screw. If a valve is required to bypass a given amount of fluid at a given pressure, a test stand having a flow meter in the pump discharge line must be available. With a valve adjusting for cracking pressure as above, continue closing bypass until the required flow registers on the flow meter and observe pressure. Readjust pressure, if necessary, to obtain desired pressure at desired flow.

Maintenance & Operation

Fulflo valves provide reliable “chatter-free” operation when the system is free of abrasives and foreign matter. Continuous filtration of the liquid used is strongly recommended.

TYPICAL DISASSEMBLY OF STANDARD TYPE VALVE

To dismantle the valve for inspection or cleaning:

Remove cap “A” and gasket “D”
Remove nut “C”
Remove adjusting screw “B”
Remove cap screws “E”
Remove bonnet “F”
Remove gasket “G”
Remove pilot spring “J”
Unscrew and withdraw cylinder “M” (do not unscrew cylinder retainer “L” until this step is complete)
Unscrew and remove cylinder retainer “L” (after removing cylinder “M”)*
Unscrew and remove piston retainer “K”
Remove retaining ring “H”
Remove pilot piston “N”
Remove balance spring “O”
Remove piston “P”
Remove retaining bushing “S” if necessary

*CAUTION: Hold in vise–balance spring “O” is under heavy compression

Inspect bores of both piston retainer “K” and cylinder “M”. Inspect pistons “N” and “P” for wear or scoring. Replace broken or damaged parts. Clean all parts thoroughly and re-assemble as follows:

Reverse process of disassembly from operation 15 to 6 above
Thread adjusting screw “B” into bonnet “F”, while re-assembling bonnet “F” to body “R”
Then proceed with steps 5, 4, 2 & 1, above, in reverse order.

ASSEMBLY NUMBER IDENTIFICATION CHART

Symbol Number	Designation	Code	Description
1	Series	A
2	Material	A C SS	Cast Iron Cast Steel Stainless Steel
3	Type	D P	Direct Acting Internal Pilot Operated
4 & 5	Size	09 10 11	2¹/2” 3” 4”
6	Connection	None F	Screw Type (2¹/2″ and 3” only) Flange
7, 8, 9	ASA Flange Rating	150# 300# 600#
10	Flange Style Only	A B C D	Raised Face, Staggered Bolt Centers Smooth Face, Staggered Bolt Centers Raised Face, Bolts on Valve Centerline Smooth Face, Bolts on Valve Centerline
11	O-Ring Material	R RV RS RT RA EPR RN	Buna O-Ring Cap Seal (Standard) Viton O-Ring Cap Seal Silicone O-Ring Cap Seal Teflon O-Ring Cap Seal Aflas O-Ring Cap Seal Ethylene Propylene Neoprene
12	Piston Material	/HS /SS /3SS	Hardened Steel 416 Stainless Steel 303 Stainless Steel (For Stainless valves only)
13	Spring (+/-1-5 PSI ON ALL SPRING RANGES)	A0980D & A1190D A1080D & A1190D A1181D & A1190D	Pressure Range = 50 – 500 psi Pressure Range = 50 – 500 psi Pressure Range = 50 – 500 psi
14	Setting		Desired Set Pressure

Example

ACP09F300AR
A	C	P	09	F	300	A	R
Series	Steel	Pilot Operated	2^1/2“	Flanged	Rating	Raised Face	Buna

How to Order

Specify:

Valve Model Number (1-10)
O-Ring Identification Number (11)
Piston Material (12)
Spring Part Number (13)
Spring Pressure Range or Desired Pressure Setting (14)

DIMENSIONS & PARTS

Dimensions in Inches

Valve Size	Flange Rating	AA	BB
2^1/2″	150# & 300#	15^7/8	5^3/4
2^1/2″	600#	16^1/4	6^1/8
3″	150# & 300#	16^1/8	6^1/4
3″	600#	16^1/2	6^5/8
4″	150# & 300#	18^3/16	7^15/16
4″	600#	18^3/8	8^1/8

Note: Refer to Engineering Section for Flange & Drilling Dimensions

Cutaway Drawing

Parts List

			Valve Size
Symbol	Name	Model	2^1/2”	3”	4”
A	Cap	AAP, ACP ASSP	A1101CR A1101SSR	A1101CR A1101SSR	A1101CR A1101SSR
B	Adjusting Screw	AAP, ACP ASSP	A1102C A1102SS	A1102C A1102SS	A1102C A1102SS
C	Lock Nut	AAP, ACP ASSP	505-S 505-SS	505-S 505-SS	505-S 505-SS
D	O-Ring⁺	All Models	604-*	604-*	604-*
E	Cap Screw	All Models	3/8×1 SHCS	3/8×1 SHCS	3/8×1 SHCS
F	Bonnet Cast Iron Steel Stainless Steel	– AAP ACP ASSP	– A0919A A0919C A0919SS	– A1019A A1019C A1019SS	– A1119A A1119C A1119SS
G	Gasket⁺	AAP, ACP ASSP	A0903E A0903RT	A1003E A1003RT	A1103E A1103RT
H	Retainer Ring⁺	All Models	A1120D	A1120D	A1120D
I	Pilot Spring⁺	All Models	A1190D	A1190D	A1190D
J	Piston Retainer⁺	AAP, ACP ASSP	A1118C A1118SS	A1118C A1118SS	A1118C A1118SS
K	Cylinder Retainer	AAP, ACP ASSP	A0912C A0912SS	A1012C A1012SS	A1112C A1112SS
L	Cylinder⁺	AAP, ACP ASSP	A0928C A0928SS	A1028C A1028SS	A1128C A1128SS
M	Piston⁺ Hardened Steel 416 Stainless Steel 303 Stainless Steel	0 AAP, ACP AAP, ACP ASSP (only)	0 A1115C A1115D A1115SS	0 A1115C A1115D A1115SS	0 A1115C A1115D A1115SS
N	Balance Spring⁺	All Models	A0980D	A1080D	A1181D
O	Piston⁺ Hardened Steel 416 Stainless Steel 303 Stainless Steel	– AAP, ACP AAP, ACP ASSP (Only)	0 A0936C A0936D A0936SS	0 A1036C A1036D A1036SS	0 A1136C A1136D A1136SS
P	Body	AAP ACP ASSP	A0900F A0900CF A0900SSF	A1000AF A1000CF A1000SSF	A1100AF A1100CF A1100SSF
R	Retaining Bushing	AAP, ACP ASSP	A0911C A0911SS	A1011C A1011SS	A1111C A1111SS

+ Recommended spare parts

* See Assembly Number Identification Chart, Symbol Number 13

PERFORMANCE DATA

All valve tests 110˚F. to 120˚F. Oil Viscosity 150 SSU at 100˚F

(Charts good from 30 to 500 SSU)

Overpressure: The pressure increase or accumulation above the set pressure when the valve is discharging flow.

A-Series Internal Pilot with Flange Connections

Models