Page | of 7 MOUNTING, OPERATING, TESTING & MAINTENANCE INSTRUCTIONS FOR ROTEX SOLENOID VALVE 3/2 DIRECT ACTING SOLENOID VALVE & 3/2 DIRECT ACTING SUBBASE MOUNTED SOLENOID VALVE CONTENTS 1. INTRODUCTION 2. SPECIFICATION OF THE SOLENOID VALVE 3. IDENTIFICATION ON THE SOLENOID VALVE 4. OPERATING PRINCIPLE 5. MOUNTING/INSTALLATION PROCEDURE 6. MATERIAL OF CONSTRUCTION 7. PRESSURE RATING 8. TESTING OF THE VALVE ON THE TEST BENCH 9. MAINTENANCE 10. STORING,CLEANING AND MOUNTING OF ELASTOMERS:SYNTHETIC RUBBER PRODUCT 11. TO DISMENTAL AND ASSEMBLE THE VALVE INTRODUCTION ROTEX retains all rights to this publication. The aim of this literature is to support the use of products in the correct manner. All technical details are provided within the catalogue. All details within this manual and the catalogue are subject to change without notice. ROTEX will not be responsible for any damage whatsoever arising from the use of the Solenoid Valve, due to misuse or incorrect installation or misinterpretation of the information contained herein. 2.__ SPECIFICATION OF THE SOLENOID VALVE TYPE + 3PORT 2 POSITION OPERATION DIRECT ACTING ORIFICE NW 08-7 (Refer Name Plate, Order Specification for Orifice) OPERATING PRESSURE 4-63bar (Refer Name Plate, Order Specification for Operating Pressure) CONNECTIONS CPE - FUNTION EXHAUST] 30125 S016 SUBBASE-SONIT 30112 | NC 3 TPE FUNCTION EXHAUST '30201,30206- SUBBASE-30217,30212 NO. 4 TYPE - FUNCTION OUT | EXHAUST] 30807 30510: SUBBASE-30311,0312| MIXING [131 2 | (CADocuments and Settings\.Saravanan\My Documents\DOCS\TECUINICAL\Manual 301251-|.8-2G+220V-SUHz.doeTYPE _ FUNCTION [IN| OUT _| EXHAUST [30301,30310- SUBBASE-30017,30312 | DIVERTING | 2 | 1.3 | - TYPE FUNCTION [IN| OUT | EXHAUST 30301,30310- SUBBASE-30317,30312 | UNIVERSAL |_* | * 3.___ IDENTIFICATION ON THE SOLENOID VALVE * Connect to any port Label on the ROTEX Solenoid Valve shows the following details Page 2 of 7 The label on the Solenoid Valve refers to the Model Number(Type), Number against W.0.No, Operating Pressure(ATM),and Month and the year of manufacturing(MFG). While ordering spares of the Solenoid Valve, reference to this W.O.No. with other details will provide us accurate details. ‘A Solenoid Valve with NPTF threading is normally marked N_ near the port, with Metric threads are marked #. For ports with BSP threads there is: nu marking. ‘There is a separate label for the Solenoid. Refer the details of this while ordering the Solenoid as Spare. NOTE : The product without Label is out of warranty and risk, CODING EXPLANATION FOR THE VALVE CODE AND SOLENOID CODE DETAILS,PLEASE REFER FCS CATALOGUE CADocuments and Settings\ Saravanan\My Documents\DOCS\TECHNICAL Manual 3012SB-1.8-2G+220V-S0Hz.docPage 3 of 7 4, OPERATING PRINCIPLE 1) NORMALLY CLOSED VALVE Media is connected at Port-1 (Inlet) which is blocked in de-energized condition of the Solenoid. When the Solenoid is energized, the Plunger(Part 30)moves up, Port -1(Inlet) gets connected to Port-2 (Outlet) and Port-3(Exhaust) is blocked by plunger top seat. When the Solenoid is de-energized the plunger(part 30) return to home position. Equipment connected to Port-2(Outlet) now exhaust through Port-3(Exhaust). 2) NORMALLY OPEN VALVE Media is connected to Port-3(Inlet). Port-3(Inlet) is intemally connected to Port-2(Outlet).In de-energized condition Media flows through Port-2(Outlet) and Port-1(Exhaust) is blocked by plunger bottom seat .When the Solenoid is energized, the Plunger(Part 30) moves up and Port-3(Inlet) gets disconnected Port-2 (Outlet) exhaust through Port-1 (Exhaust). 3)_ MIXING VALVE Media A is connected to Port-1.Media B is connected to Port 3.In the de-energized condition of the Solenoid the Media B flows to the container through Port-2.In energized condition of the Solenoid Port-3 is blocked. Now Media A flows to container through Port-2. Thus mixing media A and B in the container. 4) DIVERTING VALVE Media A is connected to Port-2.In de-energized condition of the solenoid, Media A flows to container X through Pori-3.in energized condition of the solenoid the piunger(Part 30) moves up Port-3 is closed. Media A connected to Port-2 now flows to container Y through Port-1.Thus diverting Media A to two containers. 5) UNIVERSAL VALVE The Solenoid Valve can be used in any of the above four configurations, with limitations on rated pressure. Refer FCS Catalogue for details. NOTE : All the above referred solenoid valves have same appearance. The functions are set by the Factory. Just by interchanging connection, one type of Solenoid Valve can not be used as an another type. ‘CADocuments and Settings\J.Saravanan\My Documents\DOCS\TECHNICAL Manual 30125B-1.8-2G+220V-S0Hz.dosPage 5 of7 ELECTRICAL Connect the power supply according to the voltage rating and type of current of the Solenoid. Ensure that the cover of the Junction Box/Terminal Box or Flame Proof solenoid is properly tightened, Install the valve in such a way that rain water /other process liquid dripping along the cable does not enter into the Junction/ Terminal Box. Fill n the space between the cable and gland entry with a proper sealant. If necessary, you may mount the valve in any suitable direction, Check for proper connections for the Solenoid which are polarity sensitive e.g, (a) Latched Solenoid (0) EExia Solenoid The Solenoid is provided with test-lead which can be used for testing / operating ofthe valve. However, the same is to be removed before final installation Refer separate manual for construction of the Solenoid and for specific instructions related to Solenoid .9.(a)EExia (b) Latcned Solenoid (c) EExd Solenoid (d) CES! 03 ATEX 344 (e)IP 67,IP 54 MATERIALS OF CONSTRUCTION Please refer to the catalogue, Each Model has a full description. 7._ PRESSURE RATING Please refer to the catalogue, Each Model has full details. 8._TESTING OF THE VALVE ON THE TEST BENCH 1) For Normally Closed Valve & Normally Open Valve Operation Test Apply rated pressure at Port-1(NC) inlet or Port-3(NO) inlet. Check operation by energizing and de-energizing the Solenoid... Apply 80% of the rated voltage. If the solenoid valve does not perform, replace the Plunger assembly & Guide. Reduce Pressure to 0.2 bar. Check operation of the valve at 0.2 bar in de-energized and energized condition. Check the leakage at the exhaust port in both condition. Increase the pressure to maximum rated pressure and check leakage in energized and de-energized condition. Check the satisfactory operation of the valve by pressing Manual Actuator (if provided) ensuring that the Solenoid is de-energized. Return the Manual Actuator to home position prior to “AUTO" Mode. 2)_RECOMMENDED SPARES Set of O Rings for valve type -3/2 Direct Acting-3/2 Subbase Mounted Solenoid Valve Plunger assembly -3/2 Direct Acting-3/2 Subbase Mounted Solenoid Valve Spare Solenoid. 3)_ RECOMMENDED TOOLS Guide Opening Tool : ROTEX Ref No. WN 1219 For SIZE | & Il Open Jaw Spanner 18:19,24:27, 4) RECOMMENDED MAINTENANCE PREVENTIVE ‘Apply light layer grease (Molykot M55) on each O Ring before replacement Replacement of complete set of O Ring Once every 3 year Replacement of Plunger Assembly Once every 3 year CADocuments and Settings Saravanan\My Documents\DOCS\TECHNICAL\Manval 301251-1,8-2G+220V-50Hz.doePage 6 of 7 9._MAINTENANCE ‘+ The Solenoid Valve must be removed from the site and has to be maintained under safe conditions. All connection to air and electrical supplies must be removed before disassembly. All spares used or replaced must be originals from ROTEX. It is important to verify the Model and the spares to be replaced. + Incase of difficulty you should contact the Agent, Distributor or ROTEX directly. + Replace complete set of O Rings. Replacing complete set of O Rings at time, will ensure trouble free ‘operation ofthe valve * Using Grease other than Silicon base Molykote M55, will lead to premature failure of O Rings of the ROTEX ‘Solenoid vaive. If necessary to clean the components, then DO NOT use Kerosene, Diesel, Petrol to clean valve as this damages the O Rings and other rubber material. Instead use LIGHT DETERGENT SOAP SOLUTION. + ROTEX provides service of repiacing/repairing seats of ROTEX make Plunger. Although, we recommend full plunger assembly to be replaced, + Using ROTEX genuine spares will Guarantee you trouble free operation and will avoid premature failure + _Itis recommended to apply torque of 0.2kgm to 0.38kgm for tightening the Solenoid nut to avoid ‘over tightening of Solenoid Do not ty or remove the Guide with pliers, it may jam the tube and the plunger. {tis important not to place the dismantied Valve Parts on any dity workbench or place of work but place them on a clean paper or cloth, in same sequence in which you have dismantled them. + itis recommended to replace the total valve if the major components are found damaged 10. STORING, CLEANING AND MOUNTING OF ELASTOMERS : SYNTHETIC RUBBER PRODUCTS ‘Store in cool, dry, dust free area. The air should be non circulating Optimum Humidity should be 65%. Avoid all light sources emitting ultra violet rays. Solvents, fuels, lubricants, chemicals, acids, disinfectants should be stored far away. + Store in polyethylene bags or boxes or paper bags lined with polyethylene. Bags should be welded closed. These packing methods protect the product from light. Alternatively, use glass jar with an airtight lid + Donat store near electrical equipment, motors or other equipment which may generate Ozone. Do not store in direct sunlight. ‘+ Should it become necessary to clean rubber products, rubbing with dry cloth after washing in luke-warm water is recommended. The use of wire brush, abrasive papericloth or any sharp object will damage the product. Drying of rubber parts should be natural and slow. ‘Avoid heating or radiating or direct heat. © Ring should be stretched uniformly and as litle as possible during instalation, Ensure that the mounting surface is free from dust, drt, lint and metal burrs, Ring should be cleaned before using Twisting of O Ring should be avoided. Ensure that the twist is removed before fiting the matching part + While closing the matching part, the matching part should be pushed in a straight line and turning motion should be avoided, + Pinching of © Ring at the groove comer at the time of closing gland should be avoided, ‘CADocuments and Seltings\.Saravanan\My Documents\DOCS\TECHNICAL Manual 30125B-1.8-2G#220V-S0Hz.docPage 4 of 7 rf —} |) facts ‘+ As Per Option Selected. 5. ___MOUNTING/INSTALLATION PROCEDURE. 4. BEFORE INSTALLATION ENSURE THAT : Fiush line before installing the valve. Pipe/Tube/Fitting from the source of pressure to the valve and to the connected equipment has an intemal Diameter which is > NW (Orifice) of the valve. * To avoid pressure drop, if more than one valve is being operated from common header(Manifold) Internal Diameter of the Header = YNWxn ‘n= Number of Valves operating at a time and which are connected to a common header. NW= Orifice of the Valve. ‘+ Incorporate at least 50} fiter in the line to avoid hard particles entering into the valve. Filter should have flow requirement larger than the Solenoid Valve. ‘+ Connect Pressure source at the Inlet Port of the Valve. Refer label specification, + Inlet pressure does not exceed rated pressure + The valve is installed for the Media for which itis intended for. This is to avoid the premature failure of the seals and malfunctioning of the valve. In case you intend to use valve for a Media ‘other than the one specified on that valve, kindly check compatibility of the Media to Body and Seal material. Consult ROTEX in case if necessary, + For BSP Connection use Locktite ® or Teflon tape. Do not cover first two threads with the tape. NPT threads are accurately threaded No need of any sealing for NPT threads. ‘+The threaded length should not be longer than the Standard Length. It may touch the interior parts of the Valve when tightened-in, Do not use ROTEX Valves to pull together two tubes cut too short. No additional holes are to be drilled on ROTEX Valve. It may perhaps damage the interior. If dirt is expected in the surrounding then the exhaust port should be protected by Muffler. CADocuments and Settings\.Saravanan\My Documents\DOCS\TECHNICAL Manual 30125B-1.8-2G+220V-S0Hz,doePage 7 of 7 14, TO DISMENTAL THE SOLENOID VALVE : Unscrew and remove the Adopter (94) in case of Normally Open Valve. Unscrew and remove the Plastic Nut (37) by using appropriate open jaw spanner. Slide Out the Solenoid (34) Remove Coil Gasket Unscrew and Remove Guide Assembly (33). Use recommended ROTEX Guide Opening Tool Pullout the Plunger assembly (30). Remove Guide O Ring (32). To Remove Manual Actuator If available) a) Remove PiniScrew from the Housing b) Pull out the M.A. Assembly. c) Remove MA. O Ring. ) Remove Spring, ‘+ The Components are ready for cleaning and examination 44, TO ASSEMBLE THE SOLENOID VALVE Push MA. duly fitted with © Ring and Spring in Housing Fix MA. Pin and the screw. Place Guide O Ring ( 32 ) in the position Push Plunger Assembly in the Guide (33) Screw the Guide (33). Tighten with Guide Opening Too! Place Coil Gasket (35). Push Solenoid (08) Tighten Nut (37), ‘Screw the Adopter (94) in case of Normally Open Valve. Test the Valve for the electrical and pneumatic operation ‘CADocuments and Settings\.Saravanan\My Documents\DOCS\TECHNICAL Manual 30125B-1.8-2G+220V-SOHz.doe