Asco 126 Serie Manual De Instrucciones

INSTALLATION AND MAINTENANCE INSTRUCTIONS
Solenoid operators, fl ameproof enclosure, type MB, for safety applications, for series 126 sole-
noid valves, Very Low Demand version, according to IEC standard 61508 ("SIL" approval)
DESCRIPTION OF THE CERTIFICATION
Versions concerned by this certifi cation:
Series 126, Very Low Demand version, brass or stainless steel
body.
The use of any other product is prohibited and does not con-
stitute a part of this approval.
If the valves are used in operating conditions outside of the SIL
qualifi cation, the max. ambient temperature is limited to +60°C.
IEC standard 61508 describes a set of general requirements for each
phase in the life cycle of a safety system. The reliability analysis preformed
by the TÜV has demonstrated that these solenoid valves may be used in
a Safety Management System (SMS) up to and including level SIL 2 with
an HFT = 0 and up to and including level SIL 3 with an HFT = 1, where the
required HFT level is established following pathway 2H in accordance with
standard CEI 61508-2 :2010. A summary of the test results and reliability
data is provided on pages 34 and 35 of this document. For installation, main-
tenance, testing and set-up of the valves, it is advisable to consult the safety
manual (V9629) available at the internet site "www.asco.com". Depending
on the SIL level, they lay down the necessary measures relating to the
authority, qualifi cation and independence of the responsible person-
nel. All indications and provisions contained in the general installation
and maintenance instructions form the basis of the above-mentioned
documents. To ensure the reliability, all additional provisions mentioned
hereinafter must also be adhered to.
- Connect pipes for the required functions in accordance with this
documentation and the port markings on the product.
- Make sure no foreign matter enters the circuit to prevent blocking
the valve function. Restrict the use of sealing tape or sealing mat-
ter to a minimum.
- These valves are intended for use with clean and dry air or inert gas
only. Recommended minimum fi ltration: 50 microns. The fl uid con-
densation point at atmospheric pressure must be at least -20°C (36°F)
below the minimum temperature to which the fl uid shall be subjected.
When using lubricated air, the lubricant must be compatible with
the elastomers used. Instrument air in compliance with ANSI/ISA
standard S7.3 (1975) exceeds the necessary requirements and is,
therefore, an acceptable fl uid for these valves.
- Protect the exhaust port with the stainless steel exhaust protector
supplied with each product (see fi g. 4). The protective fi lter for the
exhaust must be protected against contact with water. When used,
as advised, in a pipe connection, the valves must be protected with
an appropriate fi lter. Connect this protector to port 3 (3/2 NC), see
fi g. 4. The reliability of the valve cannot be guaranteed if an exhaust
protection other than that supplied is used. ASCO Numatics accepts
no responsibility for the use of any exhaust protection other than
the exhaust protector supplied with the product. In this case, please
contact ASCO Numatics or one of its authorised representatives.
- Max. allowable temperature range according to the version used:
-40°C to +65°C
- Max. operating pressure range: 0 to 10 bar
GENERAL
These Installation and Maintenance Instructions are intended for
solenoid operator type MB with fl ameproof enclosure which are
fi tted to series 126 solenoid valves.
Malfunctions, damage or injury may occur if these instructions are
not followed.
This component is not a safety accessory, it is intended only for the
compliant use either as an individual component or incorporated
in apparatus, machinery and installations. All assembly, operation,
use, and maintenance must be performed by qualifi ed, authorised
personnel. Personnel working with the components must be familiar
with the applicable safety regulations and requirements relating to
the components, apparatus, machinery and electrical installations
(for valves, solenoid valves, electronic control equipment, air service
equipment). In case of problems, please contact ASCO Numatics
or one of its authorised representatives.
DESCRIPTION
Essential Health and Safety Requirements: Solenoid operators
types Solenoid operators types MB are designed in accordance
with Annex II of the European Directive 2014/34/EU. EU type ex-
amination certifi cates LCIE 03 ATEX 6059 X and IECEx 09.0001X
are in compliance with the European standards EN-IEC 60079-0,
EN-IEC 60079-1, EN-IEC 60079-31 and EN 13463-1.
Classifi cation: Ex db IIC T6 - T5 Gb
Ex tb IIIC T 85°C - T 100°C Db IP65
See the EU type-examination certifi cate at:www.asco.com
Do not open while energised. Waiting period before opening:
35 min.
Solenoid valve type MB with fl ameproof enclosure is available in
the following versions:
Series 126:
The valve's body is made of brass or AISI 316 L stainless steel.
Seals are made of VMQ and are suitable for a wide range of ap-
plications mainly at low temperature.
Series 126 solenoid valves with fl ameproof operators can be used
as follows:
- Standard version (with or without impulse manual operator) in
the following functions:
2/2 NC 2/2 NO 3/2 NC 3/2 NO mixer
2 2 2 2 2
3 1 3 1 3 1 3 1 3 1
2
3
2
3
- Version with manual reset in the following functions:
(requires a manual reset operator with coil energised to function,
reset on loss of power).
2/2 NC 2/2 NO 3/2 NC 3/2 NO
2 2
2 2
3 1
3 1 3 1 3 1
See nameplate for allowable differential pressure.
PUTTING INTO OPERATION
Max. speed: 10 cycles max. per year.
Special conditions for safe use:
ASCO components are intended to be used only within the technical
characteristics specifi ed on the nameplate. Solenoid operators type
MB are designed to be installed in potentially explosive atmospheres
caused by gas (groups IIA, IIB and IIC), vapours or mists of group II
(EPL Gb) and dusts of group III (EPL Db).
The surface temperature classifi cation is T6-T5/T85°C-T100°C and
depends on the power rating and ambient temperature stated on
the nameplate.
• Standard version with or without impulse manual operator:
TEMPERATURE CLASSIFICATION
Operator type MB AC (~) Operator type MB DC (=)
max. ambient temp. °C 1) max. ambient temp. °C
Pn Pn
surface temperature surface temperature
T6 T5 T6
(watt) (watt)
85°C 100°C 85°C
Insulation class H (180°C) 100% E.D. Insulation class H (180°C) 100% E.D.
19 50 65 15 50
22
• Version with manual reset:
TEMPERATURE CLASSIFICATION
Operator type MB AC (~) Operator type MB DC (=)
1)
max. ambient temp. °C max. ambient temp. °C
Pn Pn
surface temperature surface temperature
T6 T5 T6
(watt) (watt)
85°C 100°C 85°C
Insulation class H (180°C) 100% E.D. Insulation class H (180°C) 100% E.D.
18 50 65 12,5 50
The voltage indicated on the coil may only vary within a ±10% range
of the nominal voltage. A.C.: Rectifi ed coil construction.
Check the wattage compatibility with the selected product.
1) Minimum ambient temperature: -40°C (solenoid valves with
VMQ seals).
Depending on the ambient temperature/power rating, a heat resistant
cable suitable for the temperature indicated on the coil must be used.
Cable temperature:
Max.
max. power
min. min.
ambient ambient
cable T cable T
AC DC
T
°C °C watt watt °C
70 25 26 28 90
80 25 / 34 100
70 40 18 19 90
80 40 26 28
90 40 / 39
70 60 7 7
80 60 14 15
ASSEMBLY
Before installation, depressurise the piping system and clean
internally.
1. Series 126 solenoid valves may only be mounted vertically with
the solenoid operator upwards (all versions) (fi g.1 / fi g.2).
2. Use the 3 dia 6.6 mounting holes for assembly.
3. After having removed the plastic protective plugs, connect the
ports (nos. 1, 2 and 3).
Important notes:
- The pipe size must match the port size given in the valve's speci-
fi cation leafl et. Reducing the connections may cause improper
operation or malfunction.
- For the protection of the equipment, install a strainer or fi lter suitable
for the service involved in the inlet side as close to the product as
possible.
- If tape, paste, spray or a similar lubricant is used when tightening,
avoid particles entering the system.
- Use proper tools and locate wrenches as close as possible to the
connection point. To avoid damage to the equipment, DO NOT
selector
OVERTIGHTEN pipe connections.
2 - Pipe connections should not apply any force, torque or strain to
the product. Do not use valve or solenoid as a lever.
3 1
2
2
GB
3
1
1
2
3 1
1
ELECTRICAL CONNECTION
All wiring must comply with local and national standards and regula-
tions related to equipment for use in explosive atmospheres. The
housing is provided with a threaded hole (3/4 NPT) for cable/sleeve
mixer selector
entry. External wires and cables must be inserted through a suitable
2
2
and properly installed fl ameproof IECEx-ATEX cable gland.
3 1 To modify the orientation of the electrical connection of the
3 1
solenoid enclosure, STRICTLY proceed as follows:
1 - Loosen the set screw (1) and the knurled nut (2).
2 - Orient enclosure in desired position.
3 - Firmly tighten the knurled nut (2) and then the set screw (1) to the
specifi ed torque [a], fi g. 3.
To make the wiring connections to the coil terminals, remove the
cover from the solenoid operator (3) (twist to remove). Remove the
outer insulation from the cable and strip a few millimeters off the wires.
Insert the cable through the cable gland and connect the wires to the
terminals (8) of the coil (14), fi g. 5.
Leave enough slack in the wires between the cable entry and the coil
to avoid excessive strain on the wires. Assemble the cable gland and
tighten the elastomer compression seal so that it fi ts tightly around
the cable.
Reassemble the cover (3) and its seal (4) and tighten the 4 screws (5)
to the specifi ed torque [b]. The solenoid operator's housing is equipped
with an internal and external terminal for an earth wire (6) and (7).
A cable gland certifi ed to IECEx-ATEX with cable clamp can be supplied:
1)
- for non-armoured cable 8.5 to 16 mm dia.
- for armoured cable 8.5 to 16 mm ID / 12 to 21 mm OD.
Important notes:
T5
- Make sure to properly tighten the screw terminals (8), (6) and (7)
100°C
to the specifi ed torque [d].
- Depending on the voltage, electrical components must be ground-
ed according to local standards and regulations.
65
- Perform a functional test.
- 65
- The voltage indicated on the coil may only vary within a ± 10%
range of the nominal voltage for AC and DC operation.
- For the manual reset version: activate the manual operator when
the coil is energised. Reset on loss of power.
1)
The power supply must be within the range specifi ed on the nameplate.
Failure to stay within the electrical range of the coil rating will result in
damage to or premature failure of the coil. This will also invalidate its
T5
approval for use in explosive atmospheres caused by gases or dusts.
100°C
WARNING: Unauthorised personnel is not permitted to remove the
cover from the solenoid operator.
Take care not to damage the mating and sealing surfaces when
65
disassembling or reassembling the cover of the solenoid operator.
The spigot of the solenoid cover and the bore in the solenoid housing
constitute the tightly toleranced fl amepath of the fl ameproof solenoid.
When removing or re-assembling the solenoid cover, utmost care
should be taken to avoid any damage to either the spigot or the bore.
The fl ameproof joints are not intended to be repaired. Do not paint
theses surfaces. However, corrosion inhibiting grease, such as petro-
latum or soap-thickened mineral oils, may be applied to joint surfaces
before assembly. The grease, if applied, shall be of a type that does not
harden because of ageing, does not contain an evaporating solvent
Max.
max. power
and does not cause corrosion of the joint surfaces.
Wrong assembly will invalidate the approval.
AC DC
T
°C watt watt
Most solenoid valves are equipped with coils for continuous duty service.
60 22 24
To prevent personal or property damage, do not touch the solenoid
60 25 35
operator which can become hot under normal operation conditions.
65 14 15
If the solenoid valve is easily accessible, the installer must provide
protection against accidental contact.
SOUND EMISSION The emission of sound depends on the applica-
tion, medium and type of equipment used. The exact determination
of the sound level can only be made by the user having the valve
installed in his system.
Strictly follow all "Important Notes" given in the Chapter "PUTTING
INTO OPERATION" when disassembly and reassembling the valve.
The installer is required to proceed in accordance with European
Directive 1999/92/EC and associated standards.
Prior to any maintenance work or putting into operation, power off,
depressurise and vent the valve to prevent the risk of personal
injury or property damage.
DO NOT OPEN THE Ex d HOUSING WHILE ENERGISED.
Observe the waiting time indicated on the nameplate and in
these Installation and Maintenance Instructions prior to open-
ing the housing.
If problems arise during maintenance or in case of doubt, please
contact ASCO Numatics or one of its authorised representatives.
To avoid personal injury or property damage, check that the valve
operates correctly before putting it back into operation. Also check
for possible internal or external leaks (seats/discs) using a non-
explosive and non-infl ammable fl uid.
Coil disassembly and reassembly:
This operation must be carried out by suitably qualifi ed personnel.
Observe the waiting time indicated on the nameplate.
523716-001
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Solenoid operators, fl ameproof enclosure, type MB, for safety applications, for series 126 sole-
noid valves, Very Low Demand version, according to IEC standard 61508 ("SIL" approval)
• Remove the 4 screws (5) on the cover (3).
• Twist to remove the cover (do not use metal tools as they may
damage the mating surface or the seal (4)).
• Disconnect all connections (coil, earthing) (8) and (6 or 7).
• Loosen the set screw (1) and the knurled nut (2).
• Twist the solenoid enclosure from the core tube and remove it
from the top; take care not to lose the washer (9) and the O-ring
(10), fi g. 3.
• Remove the coil and magnetic circuit unit from the cover opening,
fi g. 8.
• Remove the elastic washer (11) (fi g. 9) and disassemble the mag-
netic circuit: the 2 laminated circuits (12) and the circuit plate (13)
fi g. 6.
• Grease the core tube (15) with the grease supplied in the capsule.
• Identify the coil to be replaced. See e.g. code "2521" on the coil
(complete coil code = 43002521), fi g. 12 and 15.
• Check that the code of the spare coil corresponds to that of the old coil
to be replaced. Make a note of the manufacturing date (e.g. "37/02")
indicated on the new coil in order to assure its traceability, fi g 11.
• Reassemble the unit by inserting the coil (14) into the plate (13).
• Mount the two laminated circuits (12) on either side of the circuit
plate (13), fi g. 6.
CAUTION: The rivet heads seat into the threads of the coil, make
sure the laminated circuits fi t closely on the coil (fi g 14).
• Place the elastic washer (11) on the upper laminated circuit and insert
the unit through the opening in the cover into the enclosure, fi g. 8.
• Make sure that the unit is positioned in such a way that the align-
ment hole on the circuit plate mates with the corresponding boss
on the enclosure with supply terminals at the front (fi g. 14) and
check that the unit is blocked against rotation.
• Check through the hole at the top of the solenoid enclosure that
the coil, magnetic circuit and elastic washer are correctly aligned
and that there is no risk of damage when installing them on the
core tube, fi g. 13.
• Reassemble the enclosure, fi rmly tighten the knurled nut (2) and
then the set screw (1) to the specifi ed torque [a].
• Reconnect all the connections.
• Reassemble the cover and tighten the 4 screws (5) to the specifi ed
torque [b].
CAUTION • Perform a functional test. For the manual reset version: activate
the manual operator when the coil is energised.
Caution: When replacing a coil, mark the nameplate accordingly
in order to ensure the traceability of the product (obligatory).
Replacement of screw no. 5: only use screws with 700 N/mm2
minimum tensile strength.
Wrong assembly will invalidate the approval.
In case of replacement of parts by the user, the traceability of
the fi nal product cannot be guaranteed by ASCO and must be
ensured by the user.
Manual operator disassembly and reassembly: (standard version)
• Unscrew the manual operator and make sure to correctly remove
the spring (16) and the washer (17) and clean the thread, fi g. 7.
• In case a manual operator is mounted, unscrew the sintered insert
(18) and clean the thread, fi g. 7.
• Apply a light coat of loctite 241 to the thread and screw in the
manual operator.
• Operate the valve at least once every 6 years to ensure proper
FUNCTION opening and closing. Its max. service life is 24 years.
• Ensure the solenoid housing is clean to allow proper dissipation of
the heat generated by the coil especially when used in continuous
duty.
• DO NOT OBSTRUCT (with paint for example) the sintered insert
at the bottom (18) fi g. 7.
• Preventive maintenance after 12 years of operation:
- Inspect all internal and external parts of the fl ameproof enclosure
type MB for evidence of defects or deterioration, remove any
grease or dust accumulation etc.
- Replaced the coil (14) fi g. 6.
MAINTENANCE - Check that the exhaust protector (19) fi g.4 is not clogged, and
in case replace it.
- Test the valve for proper operation.
• Make sure that no foreign matter enters the system.
If the exhaust is not connected, fi t the port with an exhaust protector
(the exhaust protector is supplied with the product).
• Incorrect outlet pressure: check the pressure on the supply side
of the valve.
• The valve does not function:
- Make sure that supply voltage matches nameplate rating.
- Check the electrical connections on the coil (qualifi ed personnel only).
• Cycling losses, unusual noise, leaks:
- Check the pneumatic connections for tightness.
- Check to make sure that no foreign matter interferes with the
valve operation.
- Proceed with valve maintenance as necessary (contact us).
To avoid personal injury or property damage, check that the valve
operates correctly before putting it back into operation. Also check
for possible internal or external leaks (seats/discs) using a non-
explosive and non-infl ammable fl uid.
3
2
2
GB
3
1
3 1
2 2
3 1
3 1
PREVENTIVE MAINTENANCE
TROUBLESHOOTING
523716-001