IMI NORGREN XSz8-XSz50 User manual

Operation and installation instructions
Safety valves XS
3/2- & 5/2-way safety valves
XSz8 - XSz50; XSz8V - XSz10V
electro-pneumatic & pneumatic actuated
G1/4, G1/2, G3/4, G1, G1 1/2 and 1/4-NPT,
1/2-NPT, 3/4-NPT, 1-NPT, 1 1/2-NPT
This manual contains proprietary information. No part of this publication
may be reproduced, transcribed or transmitted in any form without the
written consent of the publisher. Every eort has been made to ensure that
the information contained in this manual is accurate. All rights reserved.
Incorporating

1.1 Validity of documentation 03
1.2 Explanation of symbols 03
1.3 Risk categories (ANSI Z535.6) 03
1.4 Used symbols and signal words 03
1.5 Liability and warranty 04
1.6 Manufacturer‘s address 04
2
2.1 Intended use 05
2.2 Not intended use 05
2.3 General risks 05
2.5 Personal protective equipment 06
2.6 Log book 06
3.1 XSz8 - XSz50 / XSz8V - XSz10V 07
3.2 Materials 17
3.3 Requirements for operating media 17
3.4 Noise emissions 17
3.5 Design and function 18
5.1 Transport 22
5.2 Storage 22
6.1 Pneumatic connection 23
6.1 Elektrical connection 24
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
002

These instructions will enable you to safety install, set up and operate the XSz safety
valves. These instructions are an integral part of the product and must be accessible to
personnel. Personnel must carefully read through and understand these instructions befo-
re starting work of any kind on the valves.
Following all the safety and handling instructions contained in this manual is a fundamen-
tal requirement for safe working.
These instructions are valid for all 3/2- & 5/2 way valves of the range XSz. It is adressed to
all personnel with access to the area nearby the instalation and machines, especially:
User, operators, expert staff, instructed persons, mechanics, maintenance-/service-per-
sonnel, cleaning staff and mechanics.
In this documentation the following sym-
bols and signal words are used:
•numeration
´instruction
1.
2.
specified order of instructions
additional information
DAN-
GER
warning integrated in text
WAR-
NING
CAUTI-
ON
ADVICE
specific values respectively fixed attri-
butes
Example:
A tight pressure system contributes
energy savings, thus ressources and the
environment.
SIGNAL WORD
Consequences of non-observance
´Measurements to be taken to encoun-
ter the danger.
!
This warning indicates an immediate
hazardous situation with high risk, the
consequence of which could be fatal or
(severe) injuries if it is not prevented.
!WARNING
This warning indicates a possible hazar-
dous situation with medium risk, the
consequence of which could be fatal or
(severe) injuries if it is not prevented.
!
This warning indicates a hazardous
situation, the consequence of which could
be slight or moderate injuries if it is not
prevented.
This advice indicates a hazardous situa-
tion, the consequence of which could be
material damages if it is not prevented.
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
003

Modifications to the safety valves may
only be carried out by the manufacturer‘s
personnel.
If the safety valve requires repairs or ser-
vicing beyond the scope of the activities
described in these instructions, this work
may only be carried out by the manufac-
turer of the safety valve or by persons
who have been expressly authorised and
trained by the manufacturer.
Failure to observe the above will void the
warranty. The manufacturer accepts no
liability for damages incurred.
Norgren GmbH
Stuttgarter Str. 120
D-70736 Fellbach
Tel.: +49 (0)711 52 09-0
Fax: +49 (0)711 52 09-614
product.support@imi-precision.com
www.imi-precision.com/de
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
004

XSz series safety valves are used to control
hazardous movements in pneumatic safety
systems with category 4 control require-
ments per ISO 13849-1 with performance
level „e“. The valves are only intended to
use in large scale stationary industrial tools
or plants. The valve must not be used in
explosive zones/areas. The DGUV-certifi-
cate covers the press safety valve and the
press afety valve with fitted safety silencer,
manufatured by NORGREN
The use of the valve is in the following cases
:
•The valve is used outside the specified
operational values. The permitted
temperature- and pressure ranges are
exceeded.
•Damages on the valve have been
noticed, but the valve is still in operation.
•The valve has been structurally changed
without permission of the manufactu-
rer.
•The safety instructions in this documen-
tation have not been observed.
•The valve is used in explosive zones/
areas.
•A noise reduction measurement has not
been applied.
•The safety valve has been disassembled
or single parts separated/exchanged.
•The safety valve is used as a climbing
assist.
•XSz 5/2-way double valves are not sui-
table for the control of clutch and brake
on mechanical presses.
•Pneumatically actuated 3/2- and
5/2-way double valves are not suitable
for the control of clutch and brake on
mechanical presses.
!WARNING
Dirt can cause malfunction of the safety
silencer.
´Check for adequate air quality.
The following section lists residual risks which
may be present even if the safety valves are
used correctly.
!
When the power is switched
off or if there is a power cut
the loads supported by the safety valves
can drop and the system can lose pres-
sure. This can cause serious injuries..
´Provide additional mechanical saf-
ety devices that prevent hazardous
movements after the power is switched
off.
!
The safety valves can become
very hot during
operation. Skin contact with hot surfa-
ces causes severe burns.
´When working near hot surfaces,
always wear heat-resistant protective
clothes and protective gloves.
´Before you start any work, make sure
that all surfaces have cooled to ambient
temperature.
2
This section provides an overview of all major safety aspects for the protection of people
and for safe, fault-free operation. Further task-related safety notices appear in the sec-
tions on transportation, installation, checks before initial operation, and maintenance. The
safety instructions are related to the valve itself. In combination with other machine parts,
additional potential risks might occure which must be evaluated in a risk assessment of the
complete machine. The limitations of temperature, pressure ranges, must not be exceeded.
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
005

because of their spe-
cialist training, knowledge and experience,
and their knowledge of the relevant stan-
dards and regulations, qualifi ed electricians
are able to carry out work on electrical
installations and identify and avoid possible
risks by themselves.
Qualifi ed electricians are specially trained
for the area they work in, and they know
the relevant standards and regulations.
´While carrying out work of various kinds
on and with the safety valves, personnel
must wear personal protective equip-
ment which is referred to in the individual
sections in these instructions.
Protective clothes are heat-re-
sistant and closefitting clothes
with low tear strength, clo-
se-fitting sleeves and without
any parts sticking out.
Safety shoes protect the feet
from crushing, falling parts and
slipping on slippery surfaces.
Safety goggles protect the eyes
from
fl ying objects and splashing
liquid.
Protective gloves protect the
hands and forearms against
contact heat if they touch hot
surfaces..
Ear protection protects your
hearing from damage caused
by exposure to noise.
´To comply with legal requirements, a log
book must be kept of all activities invol-
ving the safety valves.
!WARNING
The noise level that occurs
can seriously damage your
hearing.
´Always wear ear protection when
working.
´Fit noise reduction measures, e.g. silen-
cers, during installation.
!WARNING
Compressed air can cause in-
juries if not handled correctly.
´Ensure systems are depressurised
before work begins.
´Have all work carried out by pneu-
matics specialists.
!WARNING
People who lack proper training cannot
assess the risks when handling the saf-
ety valves and they place others at risk
of serious injury or death.
´Have all work on the pneumatic
system carried out by pneumatics
specialists.
´Train the personnel widely in safety
related topics.
´Have all electrical installation work
carried out by qualified electricians.
are trained for the
specialist area they work in, and they know
the relevant standards and regulations.
Because of their special training and ex-
perience, pneumatics specialists can carry
out work on pneumatic, electropneumatic
and mechatronic systems and identify and
avoid risks by themselves.
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
006

Specification Value
Temperature range -10 ... +60°C (XSz8 ... XSz50)
-10 ... +55°C (XSz10 / XSz10V, pneumatic)
-10 ... +50°C (XSz10V)
+2 ... +50°C (XSz8V)
Installation position Preferably vertical, with the solenoid at the top. Pneumatic activated versions
with the valve spindle vertical.
Operation pressure 2 ... 8 bar (XSz20, XSz32, XSz50)
2 ... 10 bar (XSz10)
3 ... 10 bar (XSz8, XSz10V)
3,2 ...10 bar (XSz8V)
Gewicht 1,1 kg (XSz8)
2,2 / 1,9 kg (XSz10 with / without silencer)
6,0 / 3,6 kg (XSz20 with / without silencer)
11,2 / 10,3 kg (XSz32 with silencer with / without pressure balance)
8,9 / 8,0 kg (XSz32 without silencer with / without pressure balance)
16 / 15 kg (XSz50 without silencer with / without pressure balance)
1,5 kg (XSz8V)
2,8 kg (XSz10V)
2,1 / 3,0 kg (XSz10 / XSz10V, pneumatic)
Voltage solenoid type
3052, 0200, 0800
DC or AC voltage
Power consumption with
24 V DC & 230 V AC
Solenoid V DC V AC
0200 11 W 22/15 VA (Holding / Inrush)
0800 16 W 50/27 VA (Holding / Inrush)
3052 4,8 W 12/8,5 VA (Holding / Inrush)
Solenoid protection class IP 65
Elektrical connection Connector per DIN EN 175301-803
Form B (XSz8, XSz10, XSz8V, XSz10V)
Form A (XSz20, XSz32, XSz50)
1
3
D
2
2 (A)
D
4 (B)
1 (P)
3 (R)
5 (S)
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
0

1Flange surface for pressure switch or failure indicator unit
SØ T X
24 928 05 1/4 - 18 NPT 1/4 - 18 NPT 1/4 - 18 NPT 42 21 —21
24 928 06 G 1/4 G 1/4 G 1/4 42 21 —21
24 928 07 1/4 - 18 NPT 1/4 - 18 NPT 3/8 - 18 NPT 75 32 26,5 32
24 928 08 G 1/4 G 1/4 G 3/8 75 32 26,5 32
•XSz8 – 3/2-way valve with silencer Type: 249280X
~ 127
28,5
A
86
47,5
6
S
80
102
~ 69
ø 6,3
41
29,5
91
23
M5
52,5
R
P
12
28,5
23
1
X
øT
1
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
008

1Flange surface for pressure switch or failure indicator unit
24 928 50 AC / DC G 1/4
24 928 70 AC / DC 1/4 - 18 NPT
•XSz8V – 5/2 way valve with silencer Type: 24928xx
41
6
80
42
21
102
~ 69
86
91
15,5
ø 6, 3
31, 5
93, 5
34
88
28, 5
M5
23
135, 5
~180
28,5
20
P
1
SR
AB
1
5
32
4
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
009

1Flange surface for pressure switch or failure indicator unit
R
24 929 32 AC / DC G 1/2 G 1/2 blocked Silencer
24 929 33 AC / DC 1/2 – 14 NPT n. a. Silencer
24 929 30 AC / DC G 1/2 G 1/2 blocked G 3/4
24 929 31 AC / DC 1/2 – 14 NPT n. a. 3/4 – 14 NPT
•XSz10 – 3/2-way valve with silencer Type: 249293X
•XSz10 – 3/2-way valve without silencer Type: 249293X
22,5
M5
10
D
2
2
~73
29
21
1
P
63
128
116
17
37
R
26 53
~163
6,5
~167
1
2
3
1
A1
A
683
R
106
22,5
683
M5
10
D
R
63
128
116
17
37
1
26 53
~163
6,5
2
A
2
29
21
1
P
1
A1
3
2
R
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
010

1Flange surface for pressure switch or failure indicator unit
R
24 929 82 AC / DC G 1/2 G 1/2 blocked Silencer
24 929 83 AC / DC 1/2 – 14 NPT n. a. Silencer
24 929 80 AC / DC G 1/2 G 1/2 blocked G 3/4
24 929 81 AC / DC 1/2 – 14 NPT n. a. 3/4 – 14 NPT
•XSz10V – 5/2-way valve with silencer Type: 249298X
•XSz10V – 5/2-way valve without silencer Type: 249298X
22,5
M5
10
D
2
2
~73
29
51
1
P
4227
B
S
27,5
128
116
17
37
32
~69
R
5388
~225
6,5
~167
1
2
5
3
1
4
A1
A
683
R
22,5
M5
10
D
2
2
29
51
1
P
4227
B
S
27,5
128
116
17
R
5388
~225
6,5
106
1
2
5
3
1
4
A1
A
R
683
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
011

1Flange surface for pressure switch or failure indicator unit
2Plug connection for tube DA = 4 +0,05/ -0,10
-
R
44 204 03 pneumatic G 1/2 G 1/2 blo-
cked
Silencer
44 204 02 pneumatic G 1/2 G 1/2 blo-
cked
G 3/4
•XSz10 – 3/2-way valve with silencer Type: 4420403
•XSz10 – 3/2-way valve without silencer Type: 4420402
~115
~ 14 2
ø 6,5
5326
6
17
128
116
42
~ 167
22,5
P
M5
10
29
21
61,5
~ 73
21
2
Z
1
3 R
21
A
A1
3
R
~ 115
~ 142
Ņ 6, 5
5326
6
17
128
116
42
106
22,5
M5
10
29
21
61,5
2
2
Z
1
21
R
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
012

1Flange surface for pressure switch or failure indicator unit
2Plug connection for tube DA = 4 +0,05/ -0,10
-
R
44 204 53 pneumatic G 1/2 G 1/2 blo-
cked
Silencer
44 204 52 pneumatic G 1/2 G 1/2 blo-
cked
G 3/4
•XSz10V – 5/2-way valve with silencer Type: 4420453
•XSz10V – 5/2-way valve without silencer Type: 4420452
~115
~ 28 4
ø 6,5
~ 69
53
88
SW 32
6
17
116
128
27,5 27 42
~ 167
22,5
P
M5
10
6
29
51
61, 5
~ 73
21
2
5
4
Z
1
3 R
21
A
A1
B
S
22,5
M5
10
D
2
2
29
51
1
P
4227
B
S
27,5
128
116
17
R
5388
204
6,5
106
1
2
5
3
1
4
A
1
A
R
Z
2
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
013

1Flange surface for pressure switch or failure indicator unit
A-
R
24 930 32 AC / DC G 1/2 (G 3/4) G 3/4 G 1 Silencer
24 930 33 AC / DC 1/2 (3/4) – 14
NPT
3/4 – 14 NPT —Silencer
24 930 30 AC / DC G 1/2 (G 3/4) G 3/4 G 1 G 1
24 930 31 AC / DC 1/2 (3/4) – 14
NPT
3/4 – 14 NPT —1 – 11,5 NPT
•XSz20 – 3/2-way valve with silencer Type: 249303X
•XSz20 – 3/2-way valve without silencer Type: 249303X
~188
175
155
23
ø 9.2
~
~
263 133
61
51
37
153
8
115
135
M5
2¹
2
3
1
~224
100
A
4110
P
52 A ¹
66
1
ø 9.2
115
135
~ 188
61
51
37
M5
23
41
P
A
R
2
3
2¹
1
133
~ 153
A ¹
52
8
175
155
10 66
100
~ 224
1
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
014

1Flange surface for pressure switch or failure indicator unit
2Pressure balance
A 1 / A 2 R
24 931 05 AC / DC —G 1 G 1 / G1 1/2 Silencer
24 931 06 AC / DC yes G 1 G 1 / G1 1/2 Silencer
24 931 07 AC / DC —1 – 11,5 NPT —Silencer
24 931 18 AC / DC yes 1 – 11,5 NPT —Silencer
24 931 20 AC / DC —1 – 11,5 NPT —1 1/2 – 11,5 NPT
24 931 30 AC / DC —G 1 G 1 / G1 1/2 G 1 1/2
24 931 31 AC / DC yes G 1 G 1 / G1 1/2 G 1 1/2
•XSz32 – 3/2-way valve with silencer Type: 24931XX
•XSz32 – 3/2-way valve without silencer Type: 24931XX
11
26,5 98
~ 277,5
~ 315
A
194
174
116
A2
1
84
153
131
~ 191
~ 170
P
50,5
~ 316,5
~ 187
76,5
M5
38,5
11 22,5
42,5
56,5
1
22
1
2
D
3
A
2
1
2
11
26,5 98
~ 277,5
A
194
174
A
84
R
131
~ 191
~ 170
P
50,5
~ 207
~ 187
76,5
M5
38,5
11 22,5
42,5
56,5
1
22
2
D
3
1
~ 315
2
2
1
A
1
2
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
015

1Flange surface for pressure switch or failure indicator unit
2Flange surface for pressure balance
3Flange surface for pressure switch 18D
A/R
24 932 18 AC / DC yes 1 1/2 – 11,5 NPT 2 – 11,5 NPT
24 932 20 AC / DC —1 1/2 – 11,5 NPT 2 – 11,5 NPT
24 932 30 AC / DC —G 1 1/2 G 2
24 932 31 AC / DC yes G 1 1/2 G 2
•XSz50 – 3/2-way valve with silencer Type: 24932XX
R
A
P
A
R
~ 157,5
155
116
M10
13
65
138
159
104
60
217
112
127
260
41
G1 1/2112,5
40
G2
37
238
~ 470
110
M10
G 2
41
64
41
1
3
2
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
016

•Housing: aluminium
•Seals: PUR, NBR
•5 - 40 µm
•DVI value <8 (DIN ISO 1817)
•ISO viscosity class 32 - 46 (DIN 51519)
Valve
XSz 8 60.4 92
XSz 8V 60.4 90
XSz 10 6 3 93
XSz 10V 6 3 92
XSz 20 6 3 94
XSz 32 6 4 99
XSz 50 6 6 95
•Shell Tellus S2 MA 32
•ExxonMobil Febis K Series 32
•Filtered, oiled or oil-free compressed air
•According to ISO 85731-1:2010 [7:3:4]
7= Particle size < 40 µm
Particle concentration < 10 mg/
m³
3= Dew point under pressure < -20
°C
4= Oil concentration < 5 mg/m³
1 Gauge
2 Volume
3 Valve
4 Silencer
5 Noise level at measuring device
Class
Noise emissions depend on the installation site and the operating conditions. Con-
tact the manufacturer for ways of reducing noise, see .
30°
1000
P= 6 bar
12
3
4
5
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
0

The working connec-
tion
2 (A) is vented via
connection 3 (R).
Pressure connection 1
(P) is closed..
The solenoids in
the safety valve are
actuated simulta-
neously. Working
connection 2 (A) is
connected to the
pressure connection
1 (P).
The valve systems
monitor themselves
for correct operation
with every switching
procedure (dynamic
monitoring).
The solenoids are
actuated with a
time difference >
0.5 s.
The dynamic
monitoring system
detects the delayed
actuation and pre-
vents pressure build-
up at the working
connection 2 (A).
Y1 Y1
Y1
Y2 Y2 Y2
The safety valve is designed as a dual valve with piston valve. It comprises two mechanical-
ly separated pilot control systems and main valve systems. The pilot control systems are
depending on the ranges electromagnetic or pneumatic actuated respectively.
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
018

The working connec-
tion 2 (A) is vented
via connection 3 (R).
Pressure connection 1
(P) is closed. Connecti-
on 4 (B) is connected to
the pressure connection
1 (P).
The solenoids in the sa-
fety valve are actuated
simultaneously.
Working connection 2
(A) is connected to the
pressure connection 1
(P).
Connection 4 (B) is
vented via the vent
connection 5 (S).
The valve systems
monitor themselves
for correct operation
with every switching
procedure (dynamic
monitoring).
The solenoids are
actuated with a time
difference >0.5s.
The dynamic monito-
ring system detects
the delayed actuation
and prevents pressure
build-up at the working
connection 2 (A).
Connection 4 (B) is still
connected to the pres-
sure connection 1 (P) to
hold up any load that
has been raised.
3(R)
1(P)
5(S)
2(A)
4(B)
3(R)
1(P)
5(S)
2(A)
4(B)
3(R)
1(P)
5(S)
Y1 Y1
Y1
Y2 Y2 Y2
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
019

The working connec-
tion 2(A) is vented via
connection 3(R).
Pressure connection 1
(P) is closed.
There is no working
pressure at the working
connection 2 (A).
Pressure is applied
to the safety valve
simultaneously via the Z
connections.
Working connection 2
(A) is connected to the
pressure connection 1
(P).
The valve systems
monitor themselves
for correct operation
with every switching
procedure (dynamic
monitoring).
Pressure is applied to
the Zconnections with
a time difference of >
0.5 s.
The dynamic monito-
ring system detects the
delayed actuation and
prevents pressure build-
up at working connecti-
on 2 (A).
3 (R)
2 (A)
1 (P)
Z1Z2Z1Z2
3 (R)
2 (A)
1 (P)
3 (R)
2 (A)
1 (P)
Z1Z2
Incorporating
XSz8 - XSz50; XSz8V - XSz10V
02/22
Our policy is one of continued research and development. We therefore reserve the right to amend,
without notice, the specifi cations given in this document. © 2014 Norgren Ltd
020
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