Page 1 of 13 ML464 v6 Issued 01/02/2016

Friction Free Solenoid Valve Manual ML 464

Contents:

1. General Specification

2. Technical Specification and Dimensions

3. User Instructions and Installation

4. Solenoid Valve User Instruction

5. Recommended Spares List

6. NAMUR Adapter Description

7. Drawings

8. Certificates

Page 2 of 13 ML464 v6 Issued 01/02/2016

1. GENERAL SPECIFICATIONS

The FFV “Friction Free Valve” offers exceptionally low power operation with high reliability in all service applications. From either non stop cycling to low use applications, the FFV gives wear free and frictionless operation.

The Friction Free Valve provides freedom from sticking even over long “Intrinsically Safe” and other low power wire loops.

1.1 Key Performance

Fast and positive control of equipment assured by high flow capacity. Low power output controls can be used on large sites or long control loops

with the FFV’s extremely low power needs. No sticking. Eliminate one of the most common plant valve problems with

the FFV’s friction free operation. Up to 4 solenoids can be operated via one I.S. interface. Minimize piping and simplify site installation using direct NAMUR actuator

mounting options. All common valve functions available to match virtually all process and

control applications. Manual “latch on” and L.E.D. “energized” indicator options valuable for

process set-up and local plant control. Easier circuit “proving” and visual indication on “sequential” process control.

Certified to all major National and International standards. A product manufactured by a leader in hazardous area technology, expert

advice and application support is part of the service.

1.2 Certification

Europe

ATEX to EN 50020. II 1 GD EEx ia IIC T6 PTB to VDE 0171 Ex is (Zone 1 & 2) G4,G5. ATEX to EN 50021. II 3G EEx nA IIC T6 or T4.

North America

FM/USA Class I, Div 1, Groups A, B, C, D (depend on barriers used).

Page 3 of 13 ML464 v6 Issued 01/02/2016

1.3 The Valve part number.

EXAMPLE 1 2 3 4 5 6 7 8 9 0

V 2 4 5 0 2 1 L 0 0 BOX 1

V VALUE + STANDARD PORT BLOCK B VALUE + BRASS PORT BLOCK S VALUE + ST/ST PORT BLOCK M MODULE ONLY C VALVE + ALUMINUM MANIFOLD WITH STOP VALVES R VALVE + NAMUR ADAPTER PLATE + MOUNTING KIT H VALVE + STEEL MANIFOLD

BOX 2 PORT SIZE

0 NOT APPLICABLE 2 ¼” BSP (G1/4) 3 ¼” BSP EPOXY PAINTED (G ¼) 4 ¼” NPT EPOXY PAINTED 5 ¼” NPT/API 6 3/8” BSP (G3/8) 7 3/8” BSP EPOXY PAINTED (G3/8) 8 3/8” NPT EPOXY PAINTED 9 3/8” NPT

BOX 3 VALVE FUNCTION

0 NOT APPLICABLE 1 2 PORT 2 POSITION NORMALLY CLOSED 2 3 PORT 2 POSITION NORMALLY CLOSED 3 3 PORT 2 POSITION NORMALLY OPEN 4 4 PORT 2 POSITION 5 4 PORT 3 POSITION

BOX 4 OPERATOR

1 PILOT AIR 2 SOLENOID MANUAL RESET + MANUAL OPERATOR 3 SOLENOID MANUAL RESET 4 SOLENOID + MANUAL OPERATOR 5 SOLENOID + MOMENTARY OPERATOR 6 LOW ENERGY SOLENOID + MANUAL OPERATOR 7 LOW ENERGY SOLENOID + MOMENTARY OPERATOR 8 LOW ENERGY SOLENOID RESET + MANUAL OPERATOR 9 LOW ENERGY SOLENOID RESET + MOMENTARY OPERATOR

BOX 5 SECONDARY OPERATOR

0 SPRING RETURN 1 PILOT AIR 4 SOLENOID + MANUAL OPERATOR 5 SOLENOID + MOMENTARY OPERATOR 6 LOW ENERGY SOLENOID + MANUAL OPERATOR 7 LOW ENERGY SOLENOID + MOMENTARY OPERATOR

Standard Materials

Solenoid Cap: Maranyl housing with metal electrical parts. Valve Modules: Kematal with metal springs and nitrile seals (optional seal materials). Port Blocks: Aluminum alloy LM6 anodized. Optional materials: brass, stainless steel.

The intrinsically safe FFV’s operate with suitable barriers available from all major suppliers. Further technical information is available covering other aspects of the solenoid valve range including dimensional information, installation data, manifolding options, materials, electrical criteria etc.

The 10 digit part number defines the valve. Select from the blocks below or speak with your technical sales representative for further advice.

The 3 basic sections of FFVs are as follows:

The Electrical parts: Solenoid Operator Cap and Connector.

The Main Pneumatic parts: Valve Module Section.

The Pneumatic Connection Block: Port Block or Manifold.

BOX 6 SOLENOID VOLTAGE

NOT APPLICABLE 0 12-24V AC/DC 1 14-24V AC/DC 2 50V AC/DC 3 110V AC/DC 4 200-240V AC/DC 5

BOX 7 SOLENOID CONNECTOR

NOT APPLICABLE 0 PLUG-IN CONNECTOR (PGA. DIN43650) 1 FLYING LEAD (1 METRE LENGTH) 2 M20 FEMALE PLUG CONNECTOR 3 FLYING LEAD (2 METRE LENGTH) 4 FLYING LEAD (4 METRE LENGTH) 5 PLUG-IN CONNECTOR 6 (1/2” NPT CONDUIT ENTRY)

BOX 8 APPROVAL REFERENCE

NOT APPLICABLE O BASEEFA (GB), I.S. (SFA3012) A ATEX CAT3 ZONE 2 Ex nA C PTB (D) I.S. (SUPERSEDED BY “L”) E ATEX CAT I, I.S. (EN 50 020) L

FM (USA), I.S. (J & K) J

BOX 9 MODULE

STANDARD SEALS AND STANDARD PILOT SUPPLY 0 STANDARD SEALS AND STANDARD PILOT SUPPLY 2 LOW TEMPERATURE SEALS AND STANDARD PILOT SUPPLY 3 LOW TEMPERATURE SEALS AND STANDARD PILOT SUPPLY 4 VITON SEALS AND STANDARD PILOT SUPPLY 5 VITON SEALS AND STANDARD PILOT SUPPLY 6

BOX 10 MANIFOLD VALVES

NOT APPLICABLE 0 SUPPLY COMMON EXHAUST COMMON XCOMMON SUPPLY ONLY Y

COMMON EXHAUST ONLY Z

Page 4 of 13 ML464 v6 Issued 01/02/2016

2. TECHNICAL SPECIFICATION PNEUMATIC VALVES (Friction Free)

2.1 Outline Performance Data

Range of Pneumatic Functions:

2 port 2 position normally closed. 3 port 2 position normally closed. 3 port 2 position normally open. 4 port 2 position. 4 port 3 position. Double 3 port 2 position in one valve module.

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Manual Reset

Option for when operator reset after valve “trip” is required. May be located on the valve or remotely piped.

Manifolds

Options for materials and function, common exhaust and supply options plus integrated individual stop valve options. Port Blocks:

NAMUR adapter plates for direct mounting to valve actuators are a standard option.

Operating Speed (typical):

70mS (3 port 2 position) 110mS (4 port 2 position).

Environment Suitability:

-10°C to +65°C (+14°F to +150°F) -20°C to +65°C (-4°F to +150°F) Low temperature seals. Flow Capacity:

With 4 bar (58 psi) inlet pressure and unrestricted outlet: 821 litres/min (29 scfm). With 6 bar (87 psi) inlet and unrestricted outlet: 1175 litres/min (41.5 scfm). Please consult Expo Technology for more details flow data. Expected life: Better than 100 million cycles under standard conditions.

Page 6 of 13 ML464 v6 Issued 01/02/2016

Air Quality:

Filtration to better than 50 micron particle size and dew point below expected ambient temperature. Lubricated air is not required but is not detrimental. Pressure Limits:

3/2 n/c & 2/2 n/c, 2-7 bar (30-100 psi). 4/2 and 3/2 n/o, 4-7 bar. 4/3, 2-7 bar (30 100 psi). Separate pilot supply and other low pressure valves are available. Outside this range consult Expo Technology for options. 3. USER INSTRUCTION AND INSTALLATION

The solenoid operated FFV consists of three components: the solenoid cap, the module which determines the pneumatic operation of the valve, and the port block which is plugged or drilled to suit the valve’s pneumatic function. Between the module and the port block are the gasket and filter which must be orientated as shown in the accompanying tables. The type number of the valve given on the solenoid cap label defines all three components. Identification of the module is given on a label on its top plate under the solenoid cap. If the valve is dismantled for any reason, care must be taken, on re-assembly, that all three components are correct for type and position to preserve the integrity of the valve type number and correct operation. (See the following table).

Nominal Voltage (AC/DC) 12-24 **18-24 50 110 220/240

Operating Voltage Range 10.8-26.4 13-26.4 45-55 99-121 *198-264

Nominal Current (mA) 8-16 9.5-16 11 11 10

Power Consumption (W) 0.1-0.4 0.15-0.4 0.6 1.3 2.4

Total Resistance (Ω) 1.5k 1.5k 4.5k 9.6k 26.0k

Rating Continuous

The built in bridge rectifier, as well as permitting AC or DC operation, effectively eliminates back e.m.f. spikes when the valve de-energises. *216 V for type N approved valves. ** Low energy type

Solenoid Cap (Shown with Plug Connector)

Module

Port Block

Page 7 of 13 ML464 v6 Issued 01/02/2016

3.1 Installation Ensure that the valve is mounted with sufficient clearance to allow the module and cap, if fitted, to be removed for maintenance purposes. The port block and connections need not be disturbed after installation. FFVs can be used with dry, wet or lubricated air provided that there is no contamination from pipework or compressor intake. Standard 50 micron moisture removing filters adjacent to the valves are normally adequate for reliable operation. If the air supply is likely to contain a mixture of oil or moisture and solids (e.g. dust, or burnt lubricants from a compressor) sub-micron oil removing filters for conditioning air to instrument quality are recommended for solenoid operated valves. These valves are fitted with their own base filter gasket to protect the solenoid cap, but this should not be used as a substitute for supplying instrument quality air to the valve. The valve will operate in any position. However, if a solenoid operated version is to be mounted in the open, it should preferably be mounted vertically, or otherwise be protected to avoid the ingress of water into the cap or ports. Before making connection to the valve a) Deburr metal and nylon pipes b) purge the system thoroughly with clean, dry air to remove any swarf and

dirt. c) Check, for solenoid operated valves, that the supply voltage, AC or DC, is

correct for the solenoid rating and type, and d) Leave plastic plugs in position in unused valve ports until commissioning. Port blocks are tapped to ¼” BSP parallel, or N.P.T tapered threads. Parallel fittings should be sealed with nylon and copper washers. Tapered fittings should preferably be sealed with a liquid sealant. P.T.F.E. tape is not recommended. Electrical connections to solenoid operated valves are shown in the diagrams. If the plug connector is removed, care should be taken on replacing it to tighten the retaining screw sufficiently to make the connection watertight, but not to overtighten it. Please note: Certain solvents can cause damage to the standard valve if present in the air supply or the environment. Alternative versions of the valve are available for such applications.

Page 8 of 13 ML464 v6 Issued 01/02/2016

Commissioning If valves are mounted on a manifold with common supply, remove the metal plug from the air supply port of the valve furthest from the air inlet. Turn on the air supply for several seconds to purge the manifold before replacing the plug. Remove all plastic plugs, but leave any metal plugs in position. Solenoid valves can be tested manually, if required, by means of the manual operator holes in the solenoid cap. The pressure required to operate the valve is only a few grams and ONLY A LIGHT PRESSURE MUST BE APPLIED, otherwise permanent damage to the solenoid cap may occur. If a solenoid cap is removed during commissioning, care should be taken not to overtighten the two fixing screws since this can distort the cap, causing malfunctioning.

Solenoid operators have a characteristic ‘hiss’ which is caused by a small quantity of bleed air, the flow of which can be felt at the base of the solenoid cap. Both the hiss and small bleed are normal and the cap should under no circumstances be tighten to try to remove them. If the air supply is contaminated, the pilot tube in solenoid operated valves may become restricted.If this occurs the valve will be sluggish or not operated at all. This cab be cleared by removing the cap, squrting a trichlorethylane based solvent down the small hole nearest to the relay with the relay held operated by hand, leaving for 10-15 seconds, and the applying a jet of clean air to the same hole. Warning Hazardous area (e.g. Intrinsically Safe) Installations can be dangerous unless the valves are installed in accordance with Expo Technologies’ approvals, and with the appropriate codes of practice for installation. If in any doubt as to the provisions of these documents please contact Expo. Appropriate precautions should be taken with electrical connections to the valves. Under certain circumstances, compressed air can be dangerous and cause injury. The installation of these valves must be carried out under the supervision of an experienced engineer.

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CIRCUIT SCHALTBILD CIRCUITS CONNECTIONS ANSCHLÜSSE CONNECTIONS Plug connector Geratestecker Connecteur enfichable

Single solenoid

Einfach Magnet-Spule Simple solenoide

E2 on schematic E3 am Symbol E1 au schema

Double solenoid

Doppel Magnet-Spule Double solenoide

To operator for output port 4 Nach Spule für Abluft Weg 4 Vers le relais sortie 4

Flying lead Kabel-Zuleitung

cable

To operator for output port 2

nach Spule für Abluft Weg 2 Vers le relais sortie 2

Item Valve-Schematic Identifying Type Number Digits

Module Identification

Base Gesket type & Position on Port Block

Port Block details

Pos. Ventil Symbol Kennzahlen der Typen-No.

Funktion und Modul-Kennung

Dichtung Zwischen Modul U Wegeblock

Kennung am Wegeblock

Poste Schema Numéro d’Identification Identification du Module Type d’éspaceur de la Base et sa Position

Details de la base

STANDARD SOLENOID VALVES / STANDARD MAGNETSTEURERVENTILE / VANNES SOLENOIDES STANDARD

1

--140---0- --150---0-

3/2

Port 3 plugged Weg 3 verschlossen 3 bouchée

2

--240---0- --250---0-

3/2

Standard

3

--340---0- --350---0-

4/2

Port 12 drilled Weg 12 gebohrt 12 percée

4

--440---0- --450---0-

4/2

Port 12 drilled Weg 12 gebohrt 12 percée

5

--544---0- --555---0-

4/3

Standard

6

--644---0- --655---0-

2 x 3/2

Solenoid Valves with separate pilot air supply (Version 1, 2, 3 or 4 only) Magnetsteuerventile mit seperater Zuluft zur Magnetarmatur (Nur für pos. 1, 2, 3, 4) Vannes Solenoides avec alimentation separée du pilote (Postes 1, 2, 3 ou 4 seulement)

7

--------2-

----/SP

As for 1, 2, 3 or 4 Wie 1, 2, 3, 4 Comme 1, 2, 3, 4

Note A

Solenoid Valves with reset facility (Versions 1, 2, 3, or 4 only) Magnetsteuerventile mit zusätzlicher Reset-Funktion (Nur für pos. 1, 2, 3, 4) Vannes Solenoides avec rearmement manuel (Postes 1, 2, 3, ou 4 seulement)

8

---6----0- ---8----0-

----/RRO ----/RR

As for 1, 2, 3 or 4 above Wie 1, 2, 3, 4 Comm 1, 2, 3, 4

Note A Note B

9

---7----2- ---9----0-

----/MRO ----/MR

Module position on port block 3-port valves – single groove on module against port 3. 4-port valves – double groove on module against port 4. NOTE A port 14 drilled: also port 12 for 4 port 2 valves NOTE B as for A; central airway plugged, and drilled from port 14 KEY: 1 supply, 2 output, 3 exhaust, 4 output, 12 pilot (non-solenoid) 14 pilot, NC normally closed

Modul position auf Wegeblock 3-Wege-Ventile: Einfach-Nut im Modul zeight auf Weg 3. 4-Wege-Ventile: Doppel-Nut im Modul zeight auf Weg 4. NOTE A Weg14 gebohrt; auch Weg 12 pos 3, 4 NOTE B A, und zentraler Zuluftung mit Weg 14 verbunden und verschlossen ERKLARUNG: Din Weg 1 (P) Zuluft, 2 (A) Abluft, 3 (R) Entlüftung, 4 (B) Abluft, 12 (X) Pilot-Anschlüsse, 14 (Y) Steuer-Anschlusse, NC Normal geschlossen

Position des Module 3 voie: simple rainure au-dessus du 3. 4 voie: double rainure au-dessus du 4. NOTE A 14 percée: 12 pércee aussi doubles à voie. NOTE B comme A: canal central en communication avec la sortie 14 puis obture NOTES: 1 alimentation 2 utilisation 3 echappement 4 sortie 12 entrée pilote (sans solenoide) 14 entrée pilote NC normalement close

Page 10 of 13 ML464 v6 Issued 01/02/2016

4. USER INSTRUCTIONS SOLENOID VALVE HOUSING TYPE L

4.1 ATEX Approval Data Manufacturer:

Expo-Telektron Safety Systems Ltd Unit 2 The Summit, Hanworth Road, Sunbury on Thames, TW16 5DB, UK.

Hazardous Area Marking Code:

EEx ia IIC T6 0518 II 1 GD Note: 0518 = Notified Body number Certificate Number:

ISSeP 03 ATEX 031X

Note: 031 = Certificate Number Type Identification and rating data: Solenoid Type: Type Number Voltage: 12 – 24 V ac/dc Maximum Supply Pressure: 7 bar Batch Number: 17-02 4.2 Application Suitability The Expo Solenoid valve is suitable for use with compressed air and other non toxic and non corrosive gasses. In the case of gasses other than compressed air, consideration should be given to the possible risk of asphyxiation should there be a build up of the gas. The valves are designed to be used in any non-mining hazardous area. When used in a Zone 0 area, please refer to the additional instructions under the heading “Precautions for use in Zone 0 areas”

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4.3 Material of Construction The following is a list of materials used in the construction of the housing.

Stainless Steel Brass Copper Nylon Silicone Rubber Nitrile Rubber

The operating ambient temperature that the valve may be used in is –20 to +40ºC.

Ensure that these materials are compatible with any substances present in the environment where the valve will be installed.

This valve is designed for use under normal industrial conditions of ambient temperature, humidity and vibration. Please consult Expo-Telektron before installing this equipment in conditions that may cause stresses beyond normal industrial conditions. 4.4 Electrical Installation The valve shall be installed in accordance with relevant standards such as EN60079-14 and local regulations.

The solenoid valve must be connected to an intrinsically safe circuit.

This intrinsically safe circuit may be provided by either Zener Barriers or Galvanic Isolators.

Where Zener barriers are used, the earth terminal of the barrier must be connected to the equi-potential bonding system for the installation and the equi-potential bonding system must exist over the entire area of installation of the solenoid valve and its wiring.

When Galvanic Isolators are used, no special earthing requirements are needed.

The output parameters of the barrier or isolator must be compatible with the input parameters of the solenoid valve:

Ui = Value to be agreed Ii= Value to be agreed Ci = 0 Li = 0

The solenoid valve is not polarity sensitive.

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4.5 Precautions for Use in Zone 0: The solenoid valve has a plastic/nylon housing which may present an electrostatic hazard under certain circumstances. The valve should not be installed in a Zone 0 area where there is a possibility that a dangerous electrostatic charge may build up on the solenoid housing. 5. NAMUR ADAPTER DESCRIPTION EXPO solenoid valves may be mounted directly onto NAMUR type actuators in accordance with NAMUR standard. The mounting types can accommodate 3 port 2 position valve function for spring return actuators, or 4 port 2 position and 4 port 3 position function for double acting actuators. For spring return actuators, air recirculation into the spring chamber is a built in function. 5.1 Adapter Plate An adapter plate is mounted onto the actuator. This enables a standard valve to be mounted using its base connection facilities and provides the most economical mounting to NAMUR actuators. Mounting is as shown below. All the components labelled in the diagram are supplied with the valve.

The interface plate is black anodised aluminium for use with standard block or, by special order, in stainless steel for use with stainless steel port block. Parallel G ¼” threads or tapered ¼” NPT are available for air connection. To specify use, R in first position. e.g. R227021L00

2 x M5 X 20 CHEESE HEAD SCREWS

2 x ‘O’ SEAL REF. OS 8

NORMAL VALVE OUTLETS PLUGGED

2 x ‘O’ SEAL 16 x 2mm

INTERFACE PLATE

SOLENOID VALVE WITH DRILLED BASE

4 x M5 x 30 PAN HEAD SCREWS

VALVE OUTLET PORT 1

Page 13 of 13 ML464 v6 Issued 01/02/2016

6. DRAWINGS The following drawings are attached: Intrinsically safe solenoid housing SD7424 sheet 1 and sheet 4 only 7. CERTIFICATES The following certificates are attached: Manufacturer’s Declaration of Conformity ETSS 03ATEX 1009 Intrinsically Safe Solenoid Housing ISSeP03ATEX 031X FM Approval Document 0R6A0.AX

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Expo Technologies Ltd., Tel + 44 (0) 20 8398 8011 Unit 2, The Summit, Fax + 44 (0) 20 8398 8014 Hanworth Road, E-mail: sales@expoworldwide.com Sunbury-On-Thames, TW16 5DB Expo Technologies Inc., Tel: +1 888-NFPA-496 9140 Ravenna Road Unit #3, Tel: +1 (440) 247 5314 Twinsburg Fax: +1 (330) 487 0611 OH 44087 E-mail: sales.na@expoworldwide.com USA

www.expoworldwide.com