INSTALLATION AND MAINTENANCE INSTRUCTIONS
Pneumatic valves island 622 series, ATEX zone 1-21
GB
GENERAL
These Installation and Maintenance Instructions are for pneu-
matic valves island 622 series, ATEX zone 1-21.
Malfunctions, damage, or injury may occur if these instruc-
tions are not followed.
This component is not a safety accessory, it is designed only
for the compliant use either as an individual component or
incorporated in apparatus, machinery, and installations.
Assembly, use, and maintenance operations must be per-
formed by qualifi ed, authorised personnel.
Personnel working with the components must be familiar
with the safety regulations and requirements relating to the
components, apparatus, machinery, and electrical installations
(for valves, solenoid valves, electronic control equipment, air
service equipment).
In case of problems, please contact ASCO Numatics or one
of its authorised representatives
DESCRIPTION
The valve island 622 ATEX Series (named “apparatus” here-
after), is a pneumatic fl uid power component.
Essential Health and Safety Requirements:
The apparatus is designed in accordance with Annex II of
European Directive 94/9/EC and standards EN 13463-1,
EN 13463-5, EN 60079-0, EN 60079-11, EN 60079-26,
EN 60079-31.
Other directive : EMC 2004/108/EC
This apparatus is designed to be installed in potentially
explosive atmospheres caused by gases, vapours or mists
of group II (category 2G) and dusts (category 2D). Make sure
that you understand and apply all specifi c conditions of use
outlined in the “SPECIAL CONDITIONS OF USE” section.
Classifi cation of ATEX components which constituent
the apparatus:
Valves:
II 2 GD c IIC T6 X
Pilots 302 IA: II 1 G Ex ia IIC Ga / II 1 D Ex ia
IIIC Da Solenoid valve, type 302 1. ...IA., is designed in ac-
cordance with IEC and EN Standards references: 60079-0,
60079-11 and 60079-26.
The certifi cates of conformity in compliance with these
standards are available at www.asconumatics.eu
EC type examination certifi cate no.: INERIS 03 ATEX 0249 X
IECEx Certifi cate of Conformity no.: IECEx INE 10.0002X
Signifi cation of the letter X:
The device must be installed in a control cabinet with a
protection degree of IP65 in conformance with stand-
ards EN 60079-0, or in a control cabinet certifi ed Ex e
in conformance with standard EN 60079-7 and Ex t in
conformance with standard EN 60079-31.
INSTALLATION
Preparation:
• Check the preliminary storage conditions required for the
component. They must be in accordance with the product’s
specifi cations.
• Carefully remove the components from their packaging.
• Power off and depressurise the apparatus, machinery,
or installation designed to receive the component. Stipulate
power off and depressurisation requirements to prevent from
any unauthorised intervention.
• Make sure that the apparatus, its components, and their
environment are clean, and protect them against damage.
• In order to protect the equipment, install an adequate
strainer or fi lter upstream from and as close as possible to
the component.
• Do not modify the device.
• Fluid used: air or neutral gas, fi ltered (50µm), Dew Point
-20°C
• Allowable ambient temperature: +5°C to +50°C
• The island must be installed in a non-corrosive environment.
• Ingress protection rating according to EN 60529 : IP20
Special conditions for safe use
ASCO Numatics components are intended for use according
to the technical characteristics specifi ed on the nameplate or
in the documentation.
The cabinet must have an EC type examination certifi cate in
accordance with 94/9/CE directive.
The ambient temperature of the components must not exceed the
limits (+5°C to +50°C) when the external maximum temperature
considered is reached for all possible conditions of use of the
devices
potential electrostatic charging hazard:
Precautions shall be taken to guard against any effect due
to the presence of circulating currents caused by stray mag-
netic fi elds.
Avoid build-up of electrostatic charges on the apparatus.
ELECTRICAL INSTALLATION
voltage (U
n
)
(maximum
ripple 10%)
power
rating (Pn)
typical functional ratings
ambient
temperature
range
(TS)
I
(ON)
min.
U
(ON)
mini.
U
(MAX)
recom-
mended
U
(OFF)
turn off
I
(OFF)
turn off
hot/cold
=
with
LED
(V)
(W) (mA) (V) (V) (V) (mA) (°C) (1)
24V 0,25
20 12,2 28 3,3 7 +5 to +50
Pn
safety parameters
U
i
= (DC)
I
I
P
I
L
I
C
I
(W) (V) (mA) (W) (mH) (µF)
0,25
28 300 1,6 0 0
TEMPERATURE CLASSIFICATION TABLE DC (=)
Pi
(watt)
maximum ambient °C (1)
surface temperature
T6
85°C
T5
100°C
T4
135°C
insulation class F (155°C) 100% E.D. (2)
1,6 40 60 60
(1) Minimum ambient temperature: +5°C
(2) Coil designed for permanent duty within maximum ambi-
ent temperature limits. The solenoid valve must be con-
nected to a special certifi ed electrical supply unit (barrier
or interface) installed in a non-dangerous zone.
Calculation of operating conditions:
I
l
(mA) =
[ V
s
- 1,2 - 0,002 (R
b
+ R
l
) ] x 1000
+ 2
(R
c
+ R
l
+ R
b
)
This value (I
l
) as well as the maximum current of the barrier/
interface (if it is non-linear) must exceed 20 mA.
I
l
(mA) Minimum supply current for the product
R
b
(Ω) Max. barrier resistance
T
a
(°C) Max. ambient temperature
R
l
(Ω) Max. resistance of connecting cables
V
s
(V) Min. no-load voltage of barrier/interface
R
c
(Ω) Max. coil resistance:
R
c
(Ω) =
563 (T
a
+ 234 + 10)
254
Depending on the ambient temperature/power rating, a heat
resistant cable suitable for the temperature indicated on the
coil must be used.
The apparatus must be installed under the responsibility of the
company operating the industrial site. The system as a whole
must conform to standard IEC 60079-0 and IEC 60079-15.
Install the cables so that there is no torque or bending forces
transmitted to the apparatus.
Place all the cables in the cable trays or wireways before
attaching them to the connectors.
Operation: Before pressurising the circuit, perform an electri-
cal test. Apply power to the coil several times and listen for
the metallic «click» indicating the solenoid valves are working.
Personnel working with the apparatus must be familiar with
electrical controls.
Use: The coils are designed for continuous energized opera-
tions and may therefore become hot. If the solenoid valve is
easily accessible, provide for means of protection to prevent
accidental contact that may cause burns. To avoid overheat-
ing, do not operate the solenoid valve in a confi ned space
without suffi cient ventilation.
502057-001 / A
Availability, design and specifi cations are subject to change without notice. All rights reserved.
INSTALLATION AND MAINTENANCE INSTRUCTIONS
Pneumatic valves island 622 series, ATEX zone 1-21
GB
PNEUMATIC CHARACTERISTICS
Fluid: air or neutral gas, fi ltered at 50 µm, without conden-
sate. Dew point -20°C
Operating pressure: 1,5 to 8 bar
Flow rate (Qv at 6 bar): 600 l/min (ANR)
Allowable temperature: +5°C to +50°C
Spool valve function: 5/2 monostable, spring return
Pneumatic pilot: Subbase with 4 valve positions (8 on
request): G1/8 (orifi ces 2-4), G1/4 (orifi ces 1-3-5)
CONNECTIONS
• Connect all ports that may come in contact with fl uids.
• Clean the conduits that will connect to the apparatus.
• Be sure to connect piping to the proper ports: 1 (G1/4)
pressure supply / 2,4 (G1/8) : pressure ports / 3,5 (G1/4)
exhaust ports). Observe the direction of fl ow of the fl uid.
• Use only the provided connection means.
• Ensure that no foreign matter
enters the circuit, in particular
when making the connection
leakproof.
• Be sure to observe the allowed
bend radius for tubing; do not
restrict the ports for fl uid circula-
tion.
• Tubes and connection elements
must not exert any force, torque,
or strain on the apparatus.
• Use appropriate tools and place
assembly tools as close as pos-
sible to the connection point.
• Be sure to observe the recommended torque when tighten-
ing piping connections.
• Connections shall be reliably installed by qualifi ed personnel.
PNEUMATIC VALVE ISOLATION
To ensure continued process capability, the pressure
shut-offs which are integrated in the subbase allow the
removal/replacement of a valve without having to shut
off the pressure supply to the island.
35
1
24
0
1
35
1
24
0
1
open closed
PRESSURE SHUT OFF
LOCKING DEVICE
0
1
2,5
Pressure shut-off
locking device
The locking system can not be locked while an isolator
is open.
A locking device provides protection from accidental or
unauthorised activation of the pressure supply.
Under normal operating conditions, an audible leak noise
occurs during valve replacement.
This leak does not have any adverse effect on the normal
operation of the other valves.
CAUTION
The solenoid valve must be connected to a special certifi ed
electrical supply unit installed in a non-dangerous zone.
This will also validate the apparatus approval for use in ex-
plosive atmospheres caused by gases or dusts.
WARNING: Unauthorised personnel are not permitted to disas-
semble or remove solenoid valves or connector assemblies.
Do not to damage the mating surfaces and seals when disas-
sembling or re-assembling the solenoid valves.
Wrong assembly will invalidate the approval.
ELECTRICAL CONNECTION
MALE CONNECTOR ON VALVE ISLAND
(non-polarised circuit)
EV1 EV2 EV3 EV4
1
2
3
4
5
6
7
8
1
8 EV4EV1
SERVICE
To prevent potential risks of personal injury or property damage,
do not touch the solenoid valve coil. The coil can become
hot under normal operation conditions. If the solenoid valve
is easily accessible, the installer must provide protection
against accidental contact.
To prevent electrostatic charging hazard, clean apparatus
surfaces with a damp cloth before performing any maintenance.
Do not use solvents.
MAINTENANCE
Valves (cat. n.: 52290001) and pilots (cat. n.: 30215310IAP)
are available as separate device for spare parts.
DISASSEMBLY / REASSEMBLY:
This operation must be carried out by suitably qualifi ed per-
sonnel.
Intrinsically safe protection mode allows the pilot to be removed
while power supply is on. To dismount the pilot unscrew the
2 screws (B). Before removing the valve, make sure that the
isolator is on “closed” (0) position or if needed, that main pressure
supply is off. To dismount the valve unscrew the 2 screws (A).
Reassemble in the reverse order of disassembly.
Screw the valve at a tightening torque of 0,6 Nm
±0,2
(A).
Alternatively, pre-install the 2 M3 x 20 screws at a tightening
torque of 0,3/0,5 Nm and tighten them at a tightening torque
of 1 Nm
±0,2
(B).
The manual override, which is indicated by the symbol ( ),
allows you to operate the valve without electrical power.
B
M3 x 20
A
B
TORX n°10
Wrong assembly will invalidate the approval.
If parts other then solenoid valves are replaced by the user,
the traceability of the fi nal product cannot be guaranteed
by ASCO Numatics and must be ensured by the user.
DECLARATION
We herewith declare that 622 Series Valve have been
tested at our laboratory and have been found to comply
with the Essential Health & Safety Requirements detailed
in Annex II of European Directive 94/9/EC
For more information, and for list of compatible interfaces,
see our website at: www.asconumatics.eu
5
4
2
3
6 ø M6 x 10mm
32
502057-001
502057-001
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