Asco 641 Series User manual

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 1
These operating instructions are delivered with each product.
Malfunctions, damage or injury may occur if these instructions are not
followed.
Description
Series 641 Air Filter Regulators are designed for use in potentially explosive
atmospheres caused by gases, vapors, mists and/or dusts as per ATEX Directive
2014/34/EU and standards EN ISO 80079-36. UKSI Regulation 2016 : 1107 (as
amended by UKSI 2019:696)- Annex 3A, Part 1 after ATEX directive and BS
EN ISO 80079-36 (2016)
Classification (Zone 1 and 21): II 2 G Ex h IIC T5 Gb, II 2 D Ex h IIIC T5 Db
The Classification temperature depends on the ambient temperature. These
regulators are made of external metal parts & internal with plastic/metal parts.
Startup and maintenance are to be performed as detailed below.
General
This component is not a safety accessory. It is intended only for the compliant
use either as an individual component or incorporated in an apparatus,
machinery and installations. Filter Regulators are designed to be operated in
accordance with the limits specified in the nameplate or as specified in this
document. All applicable directives, legislations, orders and standards, as
amended from time to time, as well as state-of-the-art practices and procedures
must be observed for intended scope of application of the product. Where
applicable take all appropriate measure to ensure the requirements are met. This
device complies with the essential safety requirements of the EU PED
2014/68/EU. Declaration of conformity is available on request.
All assembly, operation, use and maintenance must be performed by
qualified, authorized personnel. Personnel working with the components must
be familiar with the applicable safety and regulations relating to the components,
apparatus and machinery installations. In case of problems, please contact
ASCO or one of its authorized representatives in your region.
General Operating Specifications
Fluid: Instrument air
Ambient Temperature: For manual drain: the temperature range should be within
-40C to + 90C (-40F to +194F); For Auto drain: the range should be within
0°C to + 90°C (32°F to +194°F).
Inlet Pressure: Do not exceed the maximum operating pressure 20 bar(290psi)
for manual drain FR, 11bar(160psi) for auto drain FR.
Installation
Check the preliminary storageconditions required for thecomponent. Theymust
be in accordance with the product’s specifications.
Carefully remove the Filter Regulator from the packaging.
Power off and depressurize the apparatus, machinery or installation designed to
receive the FR.
Install the FR near where the air is to be used.
Install ASCO pressure gauge comes accessory on the gauge port. & Do Not
modify the device.
Make sure that the fluid is compatible with the materials it contacts.
Operator or user must ensure that the gas group corresponds to the product’s
classification.
Check Nameplate for correct catalog number, pressure, temperature and service.
Never apply incompatible fluids or exceed pressure rating of the regulator.
The installer must install the air filter regulator at the user’s location in
accordance with the requirements specified in Directive 99/92/EC.
POSITIONING
Piping
Connect piping to valve according to markings on FR body. Apply pipe
compound sparingly to male pipe threads only. If applied to FR threads, the
compound may enter the FR and cause functional difficulty. Avoid pipe strain
by properly supporting and aligning piping. When tightening the pipe, do not
use the FR as a lever. Locate wrenches applied to piping as close as possible to
connection point.
Direct Frontal mounting or mounting with brackets possible.
Maintenance
NOTE: Ensure theair supply is completely stopped. It is notnecessary to remove
the FR from the pipeline for repairs.
Cleaning
All FRs should be cleaned periodically. The time between cleanings will
vary depending on the medium and service conditions. The most common part
that requires cleaning is the filter element.
Use running water for regular cleaning or a mild detergent for cleaning the
filter element. Do not use diluted acids, strong detergents or corrosive chemicals.
For auto drain version clean the filter ring periodically.
Causes of Improper Operation
Incorrect pressure: Check upstream pressure. Pressure to FR must be within
range specified on nameplate.
Excessive Leakage: Disassemble FR and clean all parts. If parts are worn or
damaged, install a complete ASCO Spare Parts kit.
Manual drain operation:
Hold the knurling face of drain with fingers & rotate it to the anti-clockwise
direction looking from top to unscrew the manual drain to purge out the water
that accumulated in the bowl. After draining out, screw the manual drain back
to its original position & ensure proper working of AFR.
Earthing:
Earthing can be given in any one of front/back side M5 mounting hole in body,
Earthing symbol shown on body for Reference
The earth is connected to the unit or to the combination of conditioning units by
the downstream and upstream use of metal pipes connected to the earth. If the
pipes are non-conductive, earth connection should be performed by the assembly
and/or fixing devices adapted to the ATEX products.
Automatic draining:
Auto drain provides hassle free draining of equipment which purge out the water
accumulated in the bowl automatically. Flexible tube (Barb connection)/ hard
piping (Adapter1/8” NPT-optional) can be used for collecting the condensate. It
also provides manual drain feature integrated with automatic drain. Anti-
clockwise to drain & clockwise to close drain when looking from top view.
For optimum life and performance, the FR should be mounted
vertically upright (Max. Inclination 5°).

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 2
FR DISASSEMBLY
1. Disassemble FR in an orderly fashion using exploded views for
identification and placement of parts. Refer to figure 1.
2. Remove bowl by unscrewing it from body and the bowl seal
3. Unscrew the filter assembly by hand itself
4. Carefully unscrew the bowl baffle in filter assembly and remove filter
element for cleaning
5. For normal maintenance(cleaning) it is not necessary to remove the
poppet assembly. However, if poppet assembly removal is required,
just pull it out of the body.
6. Remove the manual drain/auto drain from the bowl
7. Unscrew bonnet from the body to remove bonnet, top spring and
diaphragm assembly
8. All parts are now accessible to clean or replacement. If parts are worn
or damaged, install a complete ASCO Spare Parts Kit
- Service Notice -
When installing a new ASCO spare parts kit, the parts supplied are shown in
Figure. A. The parts supplied are new and a direct replacement for the
present parts provided all news parts are installed.
CAUTION: To ensure proper valve operation, install all parts supplied in
ASCO Spare Parts Kit. Do not mix old and new parts.
FR REASSEMBLY
1. Lubricate all gaskets with CERAN LT lubricant or an equivalent low
temperature silicone fluid.
2. Add a layer of NEVERSEEZ –160S on all screw threads
3. If removed, install poppet assembly in body. Apply a small amount of
NEVERSEEZ –160S to filter sub assembly threads. Hand tight the
assembly as far as possible. No special tool is required to provide
torque
4. Install diaphragm assembly, springs, spring disc and bonnet on top.
Screw tight bonnet on top of the body.
5. Replace manual drain/auto drain on bowl and reassemble the unit by
screwing bowl on bottom side of the body.
6. Install FR in vertical position.
Use Metal Pipes only for IN and OUT connection. For Non-
Metallic / Non –conductive pipes that requires EARTHING OR
GROUNDING can be given in any one of the front side/back side M5
mounting hole shown as
1

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 3
EXPLODED VIEW
BOLT
LOCK NUT
BONNET
DISC
SPRING
RING
DIAPHRAGM
ASSEMBLY
BODY ASSEMBLY
O-RING, BOWL
POPPET ASSEMBLY
POPPET SPRING
FILTER ASSEMBLY
MANUAL DRAIN
ASSEMBLY
BOWL
E-CLIP
DIAPHRAGM
SUPPORT PLATE
DIAPHRAGM
PLATE UNDER
DIAPRAGM
O-RING
DUMMY PLUG
BODY
PITOT TUBE
O-RING, STEM
STEM
POPPET ASSEMBLY
LIP SEAL
HEAD BAFFLE
FILTER ELEMENT
RETAINER
FILTER
LOWER ELEMENT
RETAINER
LOWER BAFFLE
FIG. 1

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 4
TECHNICAL DETAILS
641
TEMP, STANDARD, NBR (°C)
-40 TO +90
TEMP, FKM (°C)
-20 TO +80
TEMP, LOW TEMP (°C)
-52 TO +90
TEMP, AUTO DRAIN (°C)
+0 TO +90
TEMPERATURE CLASSIFICATION
FIG. 2: FR SECTIONAL VIEW
FIG. 3
FIG. 4: LABEL

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 5
GAUGES
MOUNTING
FIG. 5: ASSEMBLE VIEW
FIG. 6: DISASSEMBLED VIEW
FIG. 7: WIHOUT GAUGE
FIG. 8: WITH SS GAUGE
FIG. 9: WITH NON –SS GAUGE

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 6
TAMPER PROOF
1
ASSEMBLY (FIG 11)
FINAL ASSEMBLY (FIG 10)
1
2
2
1
DIS ASSEMBLY (FIG 12)
FIG. 13: PARTIAL SECTION
VIEW
FIG 14
LOCKING PROVISION

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 7
REGULAR
T –HANDLE TYPE
T- HANDLE
CLOCKWISE TO SET PRESSURE
(FROM TOP VIEW)
FIG. 15
FIG. 16

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 8
DISASSEMBLY
ASSEMBLY
CLOCKWISE
ANTI - CLOCKWISE
ANTI - CLOCKWISE
CLOCKWISE
To disassembly (From top view):
•Turn in clockwise direction to loosen the bowl from the
body
•Turn in anticlockwise direction to remove bonnet from
the body
To assembly (From top view):
•Tighten the bowl in anticlockwise direction to assembly it
with body
•Turn in clockwise direction to assembly bonnet with the
body
FIG. 17
FIG. 18

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 9
METAL MANUAL
DRAIN
(Brass/stainless
steel)
•TEMPERATURE: -40°C ... +90°C
•Min. INLET PESSURE (P1 Min.): 0 Bar
•Max. INLET PRESSURE (P1 Max.): 20 Bar
Automatic Drain
NC
•TEMPERATURE: +0°C ... +90°C
•Min. INLET PESSURE (P1 Min.): 2.5 Bar
•Max. INLET PRESSURE (P1 Max.): 11
Bar
PE
Filtration
5 µm
25 µm
40 µm
Colour
White
Yellow
Green
Bronze
Filtration
5 µm
25 µm
40 µm
Stainless Steel
Filtration
5 µm
25 µm
40 µm
STANDARD
WITH ADAPTOR
FILTER

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 10
641 SERIES
ATEX
USABLE IN ATEX ZONES
FIG. A

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 11
1
2
3
5
4
BOLT (1), BONNET (2), BODY
(3), BOWL (4), AND DRAIN (5)
ALL ARE METAL
EARTHING
Earthing can be given in any
one of front/back side M5
mounting hole in body
FIG. B

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
641
ALUMINIUM FILTER REGULATOR
SIZE: 1/4”, 3/8” & 1/2”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551461-001
Plot No P45, 8th Avenue, Mahindra world city REV: AB
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 12
This product category does not fall within the scope of the ATEX 2014/34 / EU directive: the risk analysis according to the EN ISO 80079-36
standard has shown that no potential source of ignition specific to the products are effective. These products can be used in specific explosion
zones 1 and 21 in compliance with our installation instructions:
* List of affected components
•Mounting components
•Assembly and connection components
•Mechanical accessories
•Filter
These conditioning units of compressed air and their accessories are capable for use in explosive atmospheres in the form of gas, steam,
mists and dust.
SPECIAL CONDITIONS FOR SAFE USAGE:
Risk from electrostatic charges
Prevent electrostatic charging of external insulating surfaces by using the appropriate installation and cleaning measures. To clean external
insulating surfaces, use a damp cloth.
Connect the conditioning units to the earth.
When combined with other conditioning units, ensure that all metallic and conductive parts are always interconnected and linked to the earth to
avoid significant electrostatic charges being created.
The earth is connected to the unit or to the combination of conditioning units by the downstream and upstream use of metal pipes connected to the
earth. If the pipes are non-conductive, earth connection should be performed by the assembly and/or fixing devices adapted to the ATEX products.
Installation, commissioning and servicing and maintenance
These operations may only be carried out by authorised personnel and in accordance with the usage instructions.
Only carry out maintenance in zones where there is no explosive atmosphere.
If during maintenance it is established that wearing and spare parts need exchanging, contact an ASCO Numatics or AVENTICS reseller.
Any modification of the product with parts not supplied by the manufacturer will invalidate the certification.
Filter equipped with a metallic bowl: (see fig. B)
When replacing a filter element saturated by the filter, proceed as described below:
• Remove the Bowl (4) from the body (3)
• Remove the filter element and replace with a new one
• Assemble the bowl (4)