Asco 8401 Series User manual

Page 5 of 8 (Section 2 of 2)
50-60 Hanover Road, Florham Park, ew Jersey 07932
ASCO Valves
eMCMXCVII All Rights Reserved. Printed in U.S.A.
Installation & Maintenance Instructions SERIES
2 POSITION, 3-WA AND 4-WA FUNCTION 8401
ADAPTER BASE MOUNTED SOLENOID PILOTED VALVES
FOR KE STONE, NAMUR AND GH-BETTIS AIR ACTUATORS - 1/4I NPT Form No.V6844R2 - Sec. 2
(Section 2 of 2)
NOTICE: See Installation and Maintenance Instructions, Form No.V6844 - Section of 2 for detailed instructions.
Continued from Form No. V6844 - Section 1 of 2
Solenoid Temperature
Series 8401 valves are supplied with coils designed for conĆ
tinuous duty service. When the solenoid is energized for a
long period, the solenoid coil beco es hot and can be
touched with the hand for only an instant. This is a safe opĆ
erating te perature. Any excessive heating will be indiĆ
cated by the s oke and odor of burning coil insulation.
MAINTENANCE
WARNING: To prevent the possibility of
personal injury or property damage, turn off
electrical power, depressurize valve, and
vent fluid to a safe area before servicing the
valve.
NOTE: The entire solenoid valve ust be re oved fro the
actuator for inspecting, cleaning, and/or rebuilding. It is not
necessary to solenoid valve for coil or pilot valve replaceĆ
ent.
Cleaning
All solenoid valves should be cleaned periodically. The ti e
between cleaning will vary depending on the ediu and
service conditions. In general, if the voltage to the coil is corĆ
rect, sluggish valve operation, excessive noise, or leakage
will indicate that cleaning is required. In the extre e case,
faulty valve operation will occur and the valve ay fail to
shift. Clean strainer or filter when cleaning the valve.
Preventive Maintenance
SKeep the ediu flowing through the valve as free fro
dirt and foreign aterial as possible.
SWhile in service, the valve should be operated at least
once a onth to ensure proper operation.
Causes Of Improper Operation
SFaulty Control Circuits: Check the electrical syste s by
energizing the solenoid. A etallic click signifies that the
solenoid is operating. Absence of the click indicates loss
of power supply. Check for loose or blown fuses,
open-circuited or grounded coil, broken lead wires or
splice connections.
SBurned-Out Coil: Check for open-circuited coil.
Replace coil as necessary: see Coil Replacement check
supply voltage; it ust be the sa e as specified on
na eplate.
SLow Voltage: Check voltage across the coil leads. Voltage
ust be at least 85% of na eplating rating.
SIncorrect Pressure: Check valve pressure. Pressure to
valve ust be within range specified on na eplate.
SExcessive Leakage: Disasse ble valve, and install a
co plete ASCO Rebuild Kit and pilot valve.
Coil Replacement
1. Disconnect coil lead wires, then re ove retaining clip or
cap.
2. Slip coil off the plugnut/core tube sub-asse bly.
CAUTION: When retaining clip disengages, it
springs outward.
3. Install new coil and replace retaining clip or cap. Torque
retaining cap to 10 - 12 in-lbs [1,1 - 1,3 N ] with a
21/32I socket.
4. Make electrical hookup; see Wiring section.
Valve Disassembly
5. Disasse ble valve in an orderly fashion. Use exploded
views for identification and place ent of parts.
6. Disconnect coil leads or re ove coil fro solenoid pilot
valve. See Coil Replacement section.
7. Re ove entire valve with flow gasket fro actuator as
follows:
SNamur Actuator - Re ove two socket head cap
screws using a 4 hex key wrench.
SKeystone Actuator - Re ove four socket head cap
screws, one fro each corner using a 5/32I hex key
wrench.
SGH-Bettis Actuator - Re ove four hex head
achine screws, one fro each corner using 5/16I
wrench.
8. Re ove two pilot valve screws, bracket (if present), pilot
valve asse bly, and two pilot valve gaskets fro valve
body.
CAUTION: When removing base screws hold valve
body/adapter base assembly together to prevent
parts from disengaging prematurely.

50-60 Hanover Road, Florham Park, ew Jersey 07932
ASCO Valves
Page 6 of 8 (Section 2 of 2) Form o.V6844R2 - Sec. 2
9. Disasse ble valve body fro adapter base as follows:
SGH-Bettis Actuator - Re ove four base screws
(Phillips head) fro corner of valve body.
SNamur or Keystone Actuator - Turn the valve
upside-down and re ove two base screws, fro
offset center holes on either side of adapter base.
10. With base screws re oved carefully disasse ble adapter
base, base gasket, plate, upper gasket, slide, and slide
spring fro valve body.
11. Fro either end of the valve body, re ove end cap screw,
etering end caps and one end cap gasket fro the soleĆ
noid end of the valve body.
12. Re ove spool with large and s all u-cups fro valve
body by pushing inward fro s all dia eter end.
13. Re ove large and s all u-cups fro spool.
14. All parts are now accessible for replace ent or cleaning.
Valve Reassembly
IMPORTANT: Install all parts supplied in ASCO Rebuild
Kit. Do not mix parts from Rebuild Kit with old parts from
valve.
15. Lubricate all gaskets, u-cups, and the bore of valve body
(where spool seats) with Key Lube anufactured by Key
Industries Inc.
16. Install large and s all u-cups on spool. Be sure outh
or open end of u-cup faces inward, toward the center of
the spool.
17. Install spool (s all dia eter end first) into large bore of
valve body. Be sure flat cut (notch) on botto of spool
is facing valve body opening for the slide.
18. Install end cap gasket on solenoid side of valve body.
Then install end caps and end cap screws at each end of
valve body. Torque end cap screws evenly to 15 in-lbs
[1,7 N ].
19. Lubricate the lapped surface of the slide with a light, uniĆ
for coat of DOW CORNINGr 111 Co pound lubriĆ
cant or an equivalent high-grade silicone grease.
20. Carefully install slide spring and slide into notch in spool.
Be sure the lapped and lubricated side of the slide is facĆ
ing outward.
CAUTION: Do not force slide in place.
21. Install upper gasket and plate in valve body.
NOTE: Hold this asse bly together and push spool back
and forth. Spool should slide easily.
22. Position base gasket in adapter base.
23. Asse ble valve body to adapter base as follows:
SGH-Bettis Actuator - Install four base screws in
corner holes of valve body. Torque base screws in a
crisscross anner to 15 in-lbs [1,7 N ].
SNamur or Keystone Actuator - Turn valve
body/adapter base upside-down Then install two
base screws and torque evenly to 8 ± 2 in-lbs [0,9 ±
0,2 N ].
24. Replace pilot valve gaskets (2), pilot valve asse bly,
bracket (if present) and two ounting screws. Torque
pilot valve ounting screws evenly to 8 ± 2 in-lbs
[0,9 ± 0,2 N ].
25. Reinstall valve on actuator, see Mounting section. Then
ake electrical hookup to solenoid.
WARNING: To prevent the possibility of
personal injury or property damage, check
valve for proper operation before returning to
service. Also perform internal seat and
external leakage tests with a nonhazardous,
noncombustible fluid.
26. Restore electrical power supply and pressure to solenoid
valve.
ORDERING INFORMATION
FOR ASCO REBUILD KITS AND COILS
Parts arked with an asterisk (*) in the exploded view are
supplied in Rebuild Kits. When Ordering Rebuild Kits for
ASCO valves, order the Rebuild Kit nu ber sta ped on the
valve na eplate. When Ordering Coils for ASCO valves,
order the nu ber sta ped on your coil. If the nu ber of the
kit or the coil is not visible, order by indicating the nu ber
of kits required, and the Catalog Nu ber and Serial
Nu ber of the valve(s) for which they are intended.
Figure 8. Alternate pilot valve construction.
cover gasket coil
cover
spring
washer
pilot valve
body assembly
lift pin
core assembly
core spring
plugnut/core tube
sub-assembly
pilot valve
gasket (2)
(see ote)
indicates parts supplied
in ASCO Rebuild Kit
manual operator
retaining cap
Partial View
ote:
Tabs on spring washer to face outward.
pilot valve screw (2)
bracket
(not present on
all constructions)
(see torque
(see instructions)
chart)

50-60 Hanover Road, Florham Park, ew Jersey 07932
ASCO Valves
Page 7 of 8 (Section 2 of 2)
Form o.V6844R2 - Sec. 2
Torque Chart
Part Name (Phillips Head Screws) Torque Value In-lbs Torque Value Nm
Pilot Valve Screws 8 ± 2 0,9 ± 0,2
End Cap Screws
15
17
Base Screws 15 1,7
Retaining cap 10 - 12 1,1 - 1,3
indicates parts supplied
in ASCO Rebuild Kit
pilot valve assembly
mounting screw (4)
pilot valve gasket (2)
alignment pin
base
pilot valve screw (2)
flow gasket
adapter base
manual operator
(see instructions)
valve body
large u-cup
small u-cup
slide spring
slide
plate
upper gasket
base gasket
screw (4)
spool
end cap gasket
(mouth or open end
to face spool)
(mouth or open end
to face spool)
CAUTION
HANDLE WITH CARE
DO NOT DROP
end cap
end cap
screw (4)
3
5/2 3/2
Partial view of
adapter base
Slots in adapter base
for tab on flow gasket.
Location of tab determines
valve function. See
Positioning of Flow Gasket
for 3-way or 4-way
Function" section.
(5/16 wrench)
I
Figure 9. Series 8401 valves for GH-Bettis Actuators.
Two Port 4 gaskets
supplied with
Solenoid Valve.
Use with Model os.
RPB 5000 and RPB 11000.
Use with Model os.
RPB 250, RPB 450,
RPB 1000 and RPB 2250.
Raised surface of gasket
seats in adapter base

50-60 Hanover Road, Florham Park, ew Jersey 07932
ASCO Valves
Page 8 of 8 (Section 2 of 2) Form o.V6844R2 - Sec. 2
Torque Chart
Part Name (Phillips Head Screws) Torque Value In-lbs Torque Value Nm
Pilot Valve Screws
8±2
09±02
Base Screws 8 ± 2 0,9 ± 0,2
End Cap Screws 15 1,7
Retaining cap 10 - 12 1,1 - 1,3
Figure 10. Series 8401 valves for amur or Keystone Actuators.
cover gasket
retaining clip
coil
cover screw
cover
spring
washer
pilot valve body
lift pin
core assembly
core
plugnut/core tube
sub-assembly
(see ote 1)
indicates parts supplied
in ASCO Rebuild Kit
mounting screw (4)
For Keystone Actuator
base screws (2)
flow gasket
(see ote 2)
gasket
port 4
pilot valve screw (2)
alignment pin
adapter base
slide spring
slide
plate
upper gasket
base gasket
manual operator
large u-cup
small u-cup
spool
end cap gasket
(mouth or open end
to face spool)
(mouth or open end
to face spool) end cap screw(4)
end cap
1
CAUTION
HANDLE WITH CARE
DO NOT DROP
(see instructions)
assembly
Slots in adapter base
for tab on flow gasket
Location of tab determins
valve function. See
Positioning of Flow Gasket
for 3-way or 4-way
Function" section.
Partial view of
adapter base
ote:
1.Tabs on spring washer
to face outward.
(5/32 hex wrench)
I
bracket
pilot valve
gasket (2)
mounting screw (2)
For Namur Actuator
(4mm hex key wrench)
spring
(not present on
all constructions)