Asco Modulair 107-112 Soft-Start Device and Shut-Off Valve Systems Owner's manual

Brand: Asco

Model: Modulair 107-112 Soft-Start Device and Shut-Off Valve Systems

Type: Owner's manual

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Mise en service

ENSEMBLE VANNE DE COUPURE

ET DEMARREUR PROGRESSIF(1/8 à 1/2)

Installation

SHUT-OFF VALVE

AND SOFT-START DEVICE (1/8 to 1/2)

Inbetriebnahme und Wartung

STOPPVENTIL MIT PROGRESSIVEM

ANFAHRVENTIL (1/8 bis 1/2)

Messa in servizio

GRUPPO VALVOLA SEZIONATRICE DI CIRCUITO

E AVVIATORE PROGRESSIVO (1/8 a 1/2)

Puesta en marcha

CONJUNTO VÁLVULA DE CORTE

Y ARRANQUE PROGRESIVO (1/8 a 1/2)

In bedrijfstelling

EENHEID AFSLUITER EN

PROGRESSIEVE STARTER (1/8 tot 1/2)

(383 46 74)

MS-P710-3d

Avant toute mise en service, lire cette notice et respecter les recom-

mandations d'installation et de fonctionnement

Please read and follow the installation and operating instructions

contained in this manual prior to putting the assembly into operation.

Die in diesem Handbuch angegebenen Installations- und Betriebsan-

weisungen sind vor jeglicher Inbetriebnahme unbedingt zu beachten.

Prima della messa in funzione, si raccomanda di leggere il presente

manuale e rispettare le istruzioni di installazione e di funzionamento

Antes de cualquier puesta en marcha, leer esta hoja y respetar las

recomendaciones de instalación y de funcionamiento

Voor de inwerkingstelling deze handleiding doorlezen en de

aanbevelingen voor de installatie en werking opvolgen

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COURBES DE REMPLISSAGE ET VIDANGE D'UNE INSTALLATION

• AVEC DEMARREUR AUTO-PILOTE

Pression

Temps

Ces temps sont définis avec pression

d'alimentation (Pa) = 6,3 bar, une

capacité du circuit aval de 10 litres et

à 90 % de Pa.

Vidange de l'installation

La plage de réglage du temps de remplissage est comprise entre les courbes (1) et (2).

Le passage en plein débit s'effectue automatiquement dés que la pression aval atteint 60 à 70 % de la pression amont

Temps de remplissage et vidange (en secondes):

• AVEC DEMARREUR A COMMANDE ELECTROPNEUMATIQUE (type Modulair 112 uniquement)

Vidange de

l'installation

Pression

Pb: 60 à 70 % Pa

Contrairement au démarreur auto-piloté, cette version ne passe en position "plein débit" qu'après avoir reçu un signal électrique

maintenu (voir remarque çi-dessous).

La plage de réglage du temps de remplissage est comprise entre les courbes (1) et (2).

Temps de remplissage et vidange (en secondes):

Remarque : La mise en position "plein débit" est assurée par l'électrovanne

de commande, celle-ci doit être mise sous tension après contrôle que tous

les capteurs de fin de cycle soient actionnés. Elle permet aussi de déclen-

cher plus rapidement la mise en pression si l'arrêt d'urgence s'est produit en

fin de cycle (voir courbe A) ou proche de cette position

(voir courbes B

, B

, etc...)

Temps mini de remplissage (courbe A): 1s pour 6,3 bar de pression amont

et une capacité de 10l.

: courbe de remplissage du circuit aval

par l'ajutage (démarreur à l'état repos)

Modulair 107 Modulair 112

T1 (avec vis desserrée de 6 tours) 11,5 8

T2 (avec vis desserrée de 1 tour) 250 75

T3 (temps de vidange) 6,5 2

Ces temps sont définis avec pression d'alimentation (Pa): 6,3 bar, pression de basculement (Pb): 60 à 70 % Pa (non réglable)

et capacité du circuit aval de 10 litres.

Passage plein débit

déclenché par signal

électrique externe

Modulair 112

T1 (avec vis desserrée de 6 tours) 12

T2 (avec vis desserrée de 1 tour) 110

T3 (temps de vidange) 2

Le démarreur progressif à commande électrique permet également :

- D'effectuer en mode "automatique" un fonctionnement plein débit et en mode "réglage", un fonctionnement en vitesse lente, pour

approche manuelle en pas à pas.

- Lors de la remise en mode "automatique" possibilité d'effectuer le ou les premiers cycles en vitesse lente (tant que l'électrovanne

de commande n'est pas mise sous tension).

Temps

Series 343

Modulair

107-112

range

INSTALLATION AND MAINTENANCE

G1/8 to 1/2 SHUT-OFF AND SOFT-START

VALVE ASSEMBLY

solenoid/air operated

APPLICATION

●

This assembly provides

the two following main functions:

- Pneumatic system venting.

- Gradual pressurisation after an outage leading to venting

of the system.

●

These products allow for machines to meet compliance regulations.

OPERATING PRINCIPLE

■ ■

■ SHUT-OFF VALVE

The 3/2 NC shut-off valve, controlled by a solenoid valve of the CNOMO pad-mounting type, vents the system

by de-energising the solenoid valve.

■ ■

■ SOFT-START DEVICE

Upon pressurisation, when the soft-start device is in its initial position, an adjustable air flow ensures gradual

filling of the downstream circuit, so that the actuators move slowly. The transition to the full flow position depends

on which of the following soft-start devices is chosen:

●

AUTOMATIC SOFT-START DEVICE (Modulair 107-112)

Automatic switch-over to the full flow position as soon as the downstream pressure reaches

60 to 70% of the

supplied pressure (upstream pressure). Operating cycles take place at normal speed thereafter.

The soft-start device remains in the full flow position as long as the upstream pressure is maintained.

The device returns into its initial position when the air supply is cut off.

Note: In both soft-start device versions, the filling rate, i.e. the pressure build-up in the downstream circuit, is adjusted by means

of a fine-thread screw with can be locked to prevent unauthorised adjustment of regulated pressure.

●

SOLENOID/AIR CONTROLLED SOFT-START DEVICE (Modulair 112)

This device, which complies with technical CNOMO specifications (E05.03.135.N), can be used to gradually feed air into

the system whenever restarting after a shutdown or a pressure cut-off. The system is slowly returned into the end-of-

cycle position. As soon as this condition is reached, the solenoid pilot valve is energised in accordance with the automatic

control specified by the user. The soft-start device then switches to the full flow position allowing the subsequent

operating cycles to take place at normal speed.

The solenoid pilot valve must be kept energised under normal

operating conditions. Any de-energisation of the solenoid pilot valve sets the soft-start device into the low flow

position.Any de-energisation of the solenoid valve sets the soft-start device to the low flow position.

SPECIFICATIONS

MEDIUM : filtered 25 µm, non-lubricated

AMBIENT TEMPERATURE : 0°C to +50°C

OPERATING PRESSURE : 3 to 10 bar

Note:

refer to the "general specifications" (MS-P710-1) when combining this product with components of the Modulair

107 or 112 range.

ELECTRICAL CHARACTERISTICS

(1) The type 190 solenoid valve is dual voltage:

(24 V~,12 V=)(48 V~, 24 V=)(115 V~,48 V=)(230 V~, 110 V=).

Other voltages and 60Hz frequency, consult us.

Connection

Voltage

Inrush Holding

Consumption

Insu-

lation

class

Connector rotatable x 90°

ISO 4400-AFNOR NF E 48411

CM 10 (Pg 11P)

simplified connection type

Valve

serial

no°

CNOMO

mating

surface

Size 30

(E06.05.80)

Size 15

(E06.36.120N)

~ 24 V, 115 V, 230 V - 50/60 Hz 2,6 VA (2 W)

= 24 V 1 W

~ 24 V, 115 V, 230 V - 50 Hz 6 VA 3,5 VA (2,5 W)

= 24 V 2,5 W

~ 24 V, 48 V, 115 V, 230 V - 50 Hz 9 VA 4 VA (3 W)

= 12 V, 24 V, 48 V, 110 V 3 W

~ 24 V, 115 V, 230 V - 50 Hz 12 VA 6 VA (4 W)

= 24 V 5 W

302

189

190

(1)

192

Connector size 15 rotatable x 90°

CM 6 (Pg 7P)

Modulair

107 112

Connector size 22 rotatable

at 180° - CM 8 (Pg 9P)

Classification

(ATEX version -

Modulair 112)

●

●●

●

II3 D IP65

T85°C to T100°C

II3 D IP65

T85°C to T100°C

II3 D IP65

T85°C to T135°C

●

The Modulair 107 or 112 shut-off valve and soft-start

system exists in a version intended for use in potentially

explosive gaseous or dusty atmospheres in accordance with

ATEX directive 94/9/EC. Startup and maintenance are to be

performed as detailed below.

INSTALLATION AND MAINTENANCE

MOUNTING

NOTE -

The centre distances for mounting the main combinations of this assembly with other components or

accessories of the Modulair 107 or 112 range

are given in a table: see MS-P710-4.

- A silencer (accessory) can be fitted underneath the shut-off valve, see above.

(J1±5,5)

(J)

Ø W

Modulair 107

343 04 001

Modulair 112

343 03 001

Separate components and systems can be mounted in different ways (bolts not supplied)

Side mounting with brackets

(accessory)

Direct frontal mounting

4Ø L1

5,5

Modulair 107

343 04 003

Modulair 112

343 03 003

Modulair 107

346 00 002

Modulair 112

346 00 004

0,5

2 Ø L

MOUNTING OF SHUT-OFF AND SOFT-START VALVE ASSEMBLIES ORDERED SEPARATELY

SHUT-OFF VALVE + AUTOMATIC (Modulair 107-112) OR SOLENOID/AIR CONTROLLED SOFT-START DEVICE

(Modulair 112)

It is possible to combine components ordered separately using the assembly kit and side mounting brackets for installation

(fastenings to be ordered separately).

However, a unit consisting of separately ordered components is longer (Modulair 112) than the compact unit shown above.

C4 38 47,4

J 74 116

J1 110,5 155

K1 28 33,5

ØL 4,1 5,5

ØL1 4,5 5,5

M3 4

G1/4

G3/8

G1/2

(J ) 74 149

(J1) 110,5 188

Ø W

Modulair type

107 112

G1/8

G1/4

Modulair type

107 112

INSTALLATION

INSTALLATION AND MAINTENANCE

AS-SUPPLIED CONDITION

The shut-off valve and the soft-start device are supplied as a compact assembly.

The shut-off and solenoid/air controlled soft-start valve assembly is designed to receive 3/2 NC solenoid valves with a size 15

or 30 CNOMO mating surface (solenoid valves 302, 189, 190 or 192 supplied separately).

Manual override on solenoid valves: The assembly can only be piloted with solenoid valves without manual override or

with a non-locking manual override (impulse-type).

The shut-off and soft-start valve assembly must be mounted first in the pneumatic system, after the filter, filter/regulator or

filter + regulator and before any lubricator. The standard assembly kit (see below) enables direct connection of the assembly

to a FRL system of the MODULAIR type 107 or 112.

Modulair 107

343 04 001

Modulair 112

343 03 001

Modulair 107

343 04 001

Modulair 112

343 03 001

The components are designed for left-to-right flow (as indicated by the symbols). The air flow

direction is indicated on the front by an arrow. If you wish to obtain reversed mounting order

with air circulation from right to left: please consult us.

F-R

Pressure gauge for installation on soft-start

device to monitor downstream pressure

build-up.

A pressure gauge can also be mounted at

the outlet of the shut-off valve.

MOUNTING AND OPERATING INSTRUCTIONS

- The shut-off and soft-start valve assembly must be mounted as described above before the lubricator.

Make sure there is no oil.

- Do not obstruct exhaust port 3 on the shut-off valve.

- Make sure that port 3 cannot be obstructed inadvertently.

- In case of operation in dusty environments, mount an exhaust silencer on port 3 (available as

accessory).

- Make sure to meet the operating specifications (pressure, temperature, voltage, current) of the

assembly as described opposite.

- The solenoid valves must not be equipped with locking manual override.

- The shut-off valve must only be de-energised in case of need when the system is generally

shut down or in case of power supply failure. This product is not a limit stop switch.

- For systems which are operated only infrequently (e.g. in case of continuously operated machines),

the correct functioning of the shut-off and soft start valve assembly must be regularly checked

- at least once per month – by turning the power on and off several times (full exhaust and gradual

pressurisation of the system).

- Should a failure occur, please return the product to your distributor with a description of the operating

conditions and the problem.

Gauge

(0-12 bar)

343 00 041

(Ø 40 mm)

342 00 062

(Ø 50 mm)

Modulair 107

Modulair 112

In both soft-start device versions, the filling rate, i.e. the pressure build-up in the downstream circuit, is adjusted by means of a

fine-thread screw. Components are supplied with the screw fully in (closed position, zero flow).

Adjustment is as follows:

- Unscrew the screw by 0.5 to 6 turns to obtain the desired filling speed (Fig. 2).

- Perform a test.

- Regulate the setting by adjusting the screw. Before retesting, vent the installation with the shut-off valve.

- When the correct setting is obtained, insert the pin to lock the screw and prevent unauthorised adjustment of regulated

pressure (see Fig. 3). To change the adjustment, it is necessary to remove the upper cover and withdraw the pin (Modulair 112).

Note:

With a solenoid/air controlled soft-start device, the adjustment must be made with the electrical pilot installed (see Fig. 2).

To fit the locking pin, it is necessary to vent the installation and remove then reinstall the pilot (see Fig. 3 and 4).

ADJUSTMENT OF DOWNSTREAM PRESSURE BUILD-UP TIME

Version with automatic

soft-start device

Version with solenoid/air controlled

soft-start device

Fig. 2

Fig. 1

Fig. 3

Fig. 4

MODULAIR 107

Fig. 2

Fig. 3

MODULAIR 112

Fig. 2

Fig. 3

INSTALLATION AND MAINTENANCE

INSTALLATION OF SOLENOID PILOT VALVE(S)

SHUT-OFF VALVE

SOLENOID/AIR CONTROLLED SOFT-START DEVICE

Pilot(s) supplied separately

Connector size 15 rotatable by 90° increments (pilot 302)

Connector size 22 rotatable by 180° increments (pilot 189)

ISO 4400 connectors rotatable by 90° increments (pilot 190 or 192)

Coil rotatable x 360° (pilot 189 or 302)

Coil(s) rotatable by 90° increments (pilot 190 or 192)

Polarising stud(s) for installation of solenoid valve(s)

Pressurisation adjustment screw

Adjustment locking pin

SHUT-OFF VALVE

AUTOMATIC SOFT-START DEVICE

MODULAIR 107

MODULAIR 112

❉ Important: if a pilot is to be installed on the

solenoid/air controlled soft-start

device, the pin (6) must first be

removed (see Fig. 1 overleaf)

MODULAIR 112

Install solenoid valves in the position determined by the rear polarising stud(s)

882 63 001

Size 22 CNOMO pilot

series 302

Pilot type 302 is to be mounted on a size 15

CNOMO version shut-off valve type Modular 107

(with the size 15/30 CNOMO interface, code

882 63 001).

Install the adapter as indicated opposite to fit

the two polarising studs (4) side by side, then

install solenoid valve 302.

The mounting direction as shown in the

drawings below must be observed when installing

the pilot valve 189 00 007 (without manual

override) onto these products.

❉

190189

series 190

Size 30 CNOMO pilot

series 189

SYSTEM PRESSURISATION AND DEPRESSURISATION CURVES

• WITH AUTOMATIC SOFT-START DEVICE

Pressure

Time

These times correspond to a supply pressure (Pa) of 6.3 bar, a downstream capacity of 10 litres and a pressure of 90% Pa.

The adjustment range for pressurisation lies between curves (1) and (2).

The transition to full flow takes place automatically as soon as the downstream pressure reaches 60 to 70% of the upstream pressure.

Filling and venting times (in seconds):

• WITH A SOLENOID/AIR CONTROLLED SOFT-START DEVICE (Modulair 112 type only)

Pressure

Pb: 60 to 70% Pa

The full flow position is determined by the pilot valve which must be energised

after checking that all the end-of-cycle sensors are activated. It also enables

fast triggering of pressurisation if the shutdown occurs at the end of the cycle

(see curve A) or close to the end of the cycle (see curves B

, B

, etc.)

Minimum pressurisation time (curve A): 1s with an upstream pressure of

6.3 bar and a capacity of 10 litres.

: curve for pressurisation of downstream circuit in

accordance with the adjustment (soft-start device

in inactive position)

Depressurisation

of system

Depressurisation

of system

These times correspond to a supply pressure (Pa) of 6.3 bar, a transition pressure (Pb) of 60% to 70% Pa (not adjustable)

and a downstream capacity of 10 litres.

Modulair 107 Modulair 112

T1 (with screw loosened by 6 turns). 11,5 8

T2 (with screw loosened by 1 turn). 250 75

T3 (venting time) 6,5 2

Unlike the automatic soft-start vrsion, this version only authorises full flow on receiving a permanent electrical signal

(see note below).

The adjustment range for pressurisation lies between curves (1) and (2).

Filling and venting times (in seconds):

Modulair 112

T1 (with screw loosened by 6 turns) 12

T2 (with screw loosened by 1 turn) 110

T3 (venting time) 2

Transition to full flow

triggered by external

electrical signal

The solenoid/air controlled soft-start device also enables:

- Full flow operation in the "automatic" mode and slow speed operation in the "adjustment" mode for step-by-step manual air feed.

- On returning to the "automatic" mode, the first cycle(s) can be carried out at low speed (as long as the solenoid pilot valve is

not energised).

Baureihe 343

Modulair 107-112

INBETRIEBNAHME UND WARTUNG

STOPPVENTIL MIT PROGRESSIVEM

ANFAHRVENTIL G1/8 bis G1/2

elektropneumatisch gesteuert

Anmerkung: Bei beiden Modellen des Anfahrventils lässt sich die Füllgeschwindigkeit, d.h. der Druckanstieg in der

Pneumatikanlage, anhand einer Feingewindeschraube, die mit einem Haltestift fixiert werden kann, einstellen.

• ELEKTROPNEUMATISCH GESTEUERTES PROGRESSIVES ANFAHRVENTIL (Modulair 112)

Diese Einheit, die den technischen Normen gemäß CNOMO (E05.03.135.N) entspricht, ermöglicht eine

progressive Druckbeaufschlagung bei jedem erneuten Anfahren einer Anlage nach einer Abschaltung oder

einer Druckluftunterbrechung. Die Bewegungsabläufe erfolgen langsam, bis alle Sensoren die Endlagen der

Zylinder gemeldet haben. Sobald diese Zustand erreicht ist, setzt die vom Anwender definierte Steuerung

das Pilotventil unter Spannung. Das Anfahrventil schaltet in die Position „voller Querschnitt“ und ermöglicht

dadurch den Ablauf der nachfolgenden Zyklen bei normaler Geschwindigkeit. Das Pilotventil muss dann unter

normalen Anwendungsbedingungen unter Spannung gehalten werden. Jegliches Abschalten des Pilotventils

schaltet das Anfahrventil in die Position "gedrosselte Leistung" um.

FUNKTIONSPRINZIP

■ ■

■ STOPPVENTIL

Das Stoppventil 3/2 NC, das mit einem Pilotventil gemäß CNOMO betätigt wird, stellt die Entlüftung der

Anlage durch Unterbrechung der Stromzufuhr zum Pilotventil sicher.

• AUTOMATISCH GESTEUERTES PROGRESSIVES ANFAHRVENTIL (Modulair 107-112)

Automatischer Übergang zur Einstellung "voller Querschnitt", sobald der Arbeitsdruck 60 bis 70 % des

Versorgungsdrucks erreicht (Vordruck). Die darauffolgenden Bewegungsabläufe werden mit normaler

Geschwindigkeit ausgeführt. Das Anfahrventil bleibt in der Einstellung "voller Querschnitt", solange der Vordruck

gehalten wird. Ein Umschalten in die Ruhestellung wird durch die Unterbrechung des Versorgungsdrucks

erreicht.

ANWENDUNGSBEREICH

●

Die Einheit stellt die beiden folgenden Funktionen sicher:

- die Entlüftung pneumatischer Anlagen und

- die progressive Unterdrucksetzung der Anlagen nach

jedem Stillstand, der zu einer Entlüftung führte.

●

Diese Produkte tragen dazu bei, dass Maschinen den

Konformitätsanforderungen entsprechen.

■ ■

■ PROGRESSIVES ANFAHRVENTIL

Bei der Druckbeaufschlagung, in der sich das Anfahrventil in Grundstellung befindet, wird durch die einstellbare

Drossel ein progressives Befüllen der Pneumatikanlage ermöglicht. Die Zylinderbewegungen sind verlangsamt.

Der Zeitpunkt der Umschaltung auf den "vollen Querschnitt" hängt davon ab, welches Anfahrventil eingesetzt wird:

ALLGEMEINES

●●

●

Medium : Luft gefiltert 25 µm, ungeölt

●●

●

Umgebungstemperatur : 0 °C bis 50 °C

●●

●

Betriebsruck : 3 bis 10 bar

Anmerkung:

Bei der Zusammenstellung mit anderen Komponenten der Baureihe Modulair 107 oder 112 sind die "Allgemeinen

Spezifikationen (MS-P710-1) zu beachten.

(1) Das Magnetventil 190 ist für zwei Spannungen ausgelegt:

(24 V~,12 V=)(48 V~, 24 V=)(115 V~,48 V=)(230 V, 110V=).

Andere Spannungen und Frequenz 60 Hz auf Anfrage.

ELEKTRISCHE DATEN / PILOTVENTILE

Elektroanschluss

Spannungen

Anzug Halten

Leistung

Isolations-

klasse

(Magnet)

Leitungsdose um 90° umsetzbar

ISO 4400-AFNOR NF E 48411

CM 10 (Pg 11P)

mit vereinfachtem Anschluss

Ventil-

Baureihe

CNOMO

Aufflansch-

bild

Größe 30

(E06.05.80)

Größe 15

(E06.36.120N)

~ 24 V, 115 V, 230 V - 50/60 Hz 2,6 VA (2 W)

= 24 V 1 W

~ 24 V, 115 V, 230 V - 50 Hz 6 VA 3,5 VA (2,5 W)

= 24 V 2,5 W

~ 24 V, 48 V, 115 V, 230 V - 50 Hz 9 VA 4 VA (3 W)

= 12 V, 24 V, 48 V, 110 V 3 W

~ 24 V, 115 V, 230 V - 50 Hz 12 VA 6 VA (4 W)

= 24 V 5 W

302

189

190

(1)

192

Leitungsdose Größe 15 um 90°

umsetzbar - CM 6 (Pg 7P)

Modulair

107 112

Leitungsdose Größe 22 um 180°

umsetzbar - CM 8 (Pg 9P)

Klassifikation

(ATEX version -

Modulair 112)

●

●●

●

II3 D IP65

T85°C bis T100°C

II3 D IP65

T85°C bis T100°C

II3 D IP65

T85°C bis T135°C

●

Das Stoppventil mit progressivem Anfahrventil des Typs

Modulair 107 oder 112 steht in einer Version für den Einsatz in

explosionsfähigen Atmosphären, die durch Gase, Dämpfe, Nebel

oder Staub verursacht werden (ATEX-Richtlinie 94/9/EG), zur

Verfügung. Die Inbetriebnahme und Wartung hat nach den nach-

stehenden Anweisungen zu erfolgen.

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Asco Modulair 107-112 Soft-Start Device and Shut-Off Valve Systems Owner's manual

Brand: Asco

Model: Modulair 107-112 Soft-Start Device and Shut-Off Valve Systems

Type: Owner's manual

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Asco Modulair 107-112 Soft-Start Device and Shut-Off Valve Systems Owner's manual

Asco Modulair 107-112 Soft-Start Device and Shut-Off Valve Systems Owner's manual

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