Asco 643 Series User manual

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
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 643 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
+1°C to + 80°C (34°F to +176°F).
Inlet Pressure: Do not exceed the maximum operating pressure 20 bar(290psi)
for manual drain FR, 17bar(247psi) for auto drain FR.
Installation
Check the preliminary storageconditions required forthe component. Theymust
be in accordance to 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 not necessary 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:
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. 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
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
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 from the body (as shown in fig. 17) and the remove
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. Remove the bonnet from the body by unscrewing the M6 fasteners
and remove top spring and diaphragm assembly.
8. All parts are nowaccessible toclean orreplacement. Ifparts 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.
Secure the bonnet on top of the body by tightening the M6 fasteners
5. Replace manual drain/auto drain on bowl and assemble bowl on
bottom side of the body (as shown in fig. 18)
6. Install FR in vertical position.

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 3
(*) –Apply GREASE: BEM41-132 or equivalent
EXPLODED VIEW
BONNET
SPRING
BOLT(*)
LOCK NUT
DIAPHRAGM
ASSEMBLY
SIDE COVER
BODY
LIP SEAL,
BOWL (*)
POPPET
ASSEMBLY
POPPET
SPRING
FILTER
ASSEMBLY
BOWL(*)
GAUGE PORT
SCREW,
BONNET
DRAIN
ASSEMBLY (*)
DIAPHRAGM
SUPPORT
PLATE
DIAPHRAGM
PLATE UNDER
DIAPRAGM
O-RING(*)
O-RING(*)
STEM(*)
POPPET
ASSEMBLY(*)
LIP SEAL(*)
O-RING(*)
HEAD BAFFLE
FILTER
ELEMENT
RETAINER(*)
FILTER
LOWER
ELEMENT
RETAINER
LOWER
BAFFLE
FIG. 1: EXPLODED VIEW
6.8±0.3Nm (60±3 IN/LBS) 4x
SCREW
0.45±0.1Nm
(4±1 IN/LBS) 2x
GAUGE PORT
1.9±0,2 Nm
(17±2 IN/LBS)

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 4
TECHNICAL DETAILS
643
TEMP, STANDARD, NBR (°C)
-40 TO +90
TEMP, FKM (°C)
-20 TO +80
TEMP, LOW TEMP (°C)
NA
TEMP, AUTO DRAIN (°C)
+1 TO +80
FIG. 2: FR SECTIONAL VIEW
FIG. 4: LABEL

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 5
MOUNTING
GAUGES
FIG. 5: ASSEMBLED VIEW
FIG. 6: DISASSEMBLED VIEW
FIG. 7: WITHOUT GAUGE
FIG. 8: WITH SS GAUGE
FIG. 9: NON-SS GAUGE

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 6
TAMPER PROOF
ASSEMBLY (FIG 11)
DIS ASSEMBLY (FIG 12)
FIG. 13
FIG. 14: PARTIAL SECTIONAL VIEW
FINAL ASSEMBLY (FIG 10)
1
2
2
1
LOCKING PROVISION

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 7
CLOCKWISE TO SET PRESSURE
(FROM TOP VIEW)
REGULAR
T –HANDLE TYPE
T- HANDLE
FIG. 15
FIG. 16

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 8
DISASSEMBLY
ASSEMBLY
F
F
F
1
2
3
F
F
F
F
F
1
2
FIG. 17
FIG. 18
F –FRONT VIEW

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
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/NO
•TEMPERATURE: +1°C ... +80°C
•Min. INLET PESSURE (P1 Min.): 0.5 to 1.0 Bar
•Max. INLET PRESSURE (P1 Max.): 17 Bar
PE
Filtration
5 µm
25 µm
40 µm
Colour
White
Yellow
Green
ITEMS
N.m
Inch.pounds
J
1.1±0.2
10±2
K
0.45±0.1
4±1
10-32 UNF
G 1/8 (ISO 228/1)
J
K

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 10
643 SERIES
ATEX
USABLE IN ATEX ZONES
FIG. A

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 11
6
3
1
5
2
SCREW (1), BOWL (2), BODY (3),
BONNET (4), DRAIN (5), AND BOLT
(6) ALL ARE METAL PARTS
4
FIG. B

INSTALLATION AND MAINTENANCE INSTRUCTIONS
SERIES
643
ALUMINIUM FILTER REGULATOR
SIZE: 3/4” & 1”
ASCO NUMATICS INDIA Pvt Ltd., FORM NO: 551463-001
Plot No P45, 8th Avenue, Mahindra world city REV: AC
Chengalpattu, Kanchipuram ECN: 326819
Tamil nadu- 603002, India PAGE NO: 12
This category of products 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 product categories are named simple
mechanical products and do not include moving parts. 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:
• Loosen the screw (1)
• Remove the bowl (2) from the body (3)
• Remove the filter element and replace with a new one
• assemble the bowl (2)
• Tighten the screw (1) in the body (3) up to the contact of the bowl and screw one quarter to a half turn extra in order to ensure ground
continuity.