VAJ2FM013/GM013 SERIES SOLENOID OPERATED SPOOL VALVES

Transcription

1 Iss 22, Octber 2013 INSTALLATION, OPERATION AND MAINTENANCE MANUAL VAJ2FM013/GM013 SERIES SOLENOID OPERATED SPOOL VALVES 5/2 WAY 1

2 Iss 22, Octber INTRODUCTION This manual prvides infrmatin n installatin, peratin, and maintenance prcedures and related instructins fr the Rtex make VAJ2FM013/GM013 Series 5/2 WAY Slenid Operated Spl Valves. Adherence t the instructins prvided in this manual ensures imprved perfrmance f the valve. ENSURE SAFETY Cnfirm the area is nn-hazardus befre pening the cver f the enclsure fr making electrical cnnectins. Ensure clean air free frm il and dirt supply. 02. TECHNICAL DETAILS SELECTING THE SOV Refer ROTEX LIMIT SWITCH BOX catalgue r Cnsult Rtex Manufacturers and Engineers, Private Limited. The spl valve are 5/2 way type Check the cil vltage and current MOUNTING The slenid valves are designed with the threaded cver t suit the limit switch bx tapping. OPERATING MEDIUM Clean Air r nn-crrsive gas cmpatible with the internal materials f cnstructin. Dry r lubricated. Gas must be clean and filtered t minimum 100 micrn level. OPERATING CONDITIONS Supply pressure, max (Standard) Operating temperature, max (Standard) psi bar kg/cm Deg F Deg C TO 82 2

3 Iss 22, Octber INSTALLATION (Applicable t all Mdels) Ntes: Ensure the installatin meets the legal and regulatry requirements f the cuntry and state f use. Until the slenid valve is installed, keep it in its riginal packaging and stred between 40 F and 120 F (4 C and 49 C). Ensure the perating medium meets the abve requirements. Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Open the tp cver f limit switch bx n which the spl valve t be munted. Place the valve in psitin in the prt in the limit switch bx using the thread jint. Place the slenid valve n the pilt hle n the pilt cver inside the limit switch bx. Check the inlet, utlet and vent f the slenid valve prt cnnectins match with that f the spl valve Tighten the screws and ensure n leakage between the spl valve cver and the slenid valve Similarly munt the secnd slenid valve in case duble cil peratin. Bypass the remaining inlet and utlet prt f pilt hles using the blanking plate in case f single cil peratin Check the supply vltage and current are same as the slenid cil specificatins Make the electrical cnnectins fr the slenid cil Make the tubing and fitting fr pneumatic air supply t the inlet prt 1 (1/4 NPT) f the spl valve Make the tubing frm utlet prt 2 and 4 (1/4 NPT) f the spl valve t the actuatr inlet prt Step 12 Check the MA is free t perate Step 13 Start the air supply and slwly increase the pressure Step 14 Check fr any leakage in the jints and tubing Step 15 Check the flw directin f air is crrect and actuatr directin f rtatin is crrect Step 16 Clse the limit switch bx tp cver and the system is ready fr peratin 3

4 Iss 22, Octber OPERATION Prvide air cnnectins t the prts using prper fittings. Air supply t meet abve specificatins. Ensure air supply pressure is regulated t ensure maximum air supply is nt exceeded. Operating Principle NORMAL OPERATION INLET PORT-1 IS CONNECTED TO OUTLET PORT-4 OUTLET PORT-2 IS CONNECTED EXHAUST PORT-3 EXHAUST PORT IS ISOLATED. SOLENOID ENERGISED INLET PORT-1 IS CONNECTED TO OUTLET PORT-2 OUTLET PORT-4 IS CONNECTED TO EXHAUST PORT-5 EXHAUST PORT-3 IS ISOLATED MANUAL OPERATION PUSH THE KNOB INLET PORT-1 IS CONNECTED TO OUTLET PORT-2 OUTLET PORT-4 IS CONNECTED TO EXHAUST PORT-5 EXHAUST PORT-3 IS ISOLATED 4

5 Iss 22, Octber MAINTENANCE Ntes Carry ut maintenance invlving disassembling f slenid valve in a safe indr place free frm dust, water. Ensure that air supply has been discnnected. CHECKLIST ON VALVE OPERATION CAUSE REMEDY 1. PORT NOT CHANGING OVER MINIMUN OPERATING PRESSURE BELOW 2.5 BAR GET PRESSURE ABOVE 3 BAR 2. LEAKAGE THROUGH EXHAUST DURING COIL DE-ENERGISED 3. LEAKAGE THROUGH EXHAUST DURING COIL ENERGISED SPRING SEALING DUST PARTICLES PRESSURE LOW SEALS JAMMING DUE TO DIRT REPLACE IF FOUND WEEK REPLACE IF WORN OUT CLEAN AND RECHECK INCREASE PRESSURE TO ABOVE 3 BAR CLEAN AND RECHECK 4. EXHAUST PORT EXHAUST PORT CHECK FOR LEAKAGE CLEAN AND RECHECK 5

6 Iss 22, Octber 2013 DISASSEMBLY Ntes Fllw the sequences as given belw t ensure prper assembly. Cnsult Rtex Manufacturers and Engineers Pvt. Ltd. r fllw the instructins befre the disassembly peratin. Please prcure the seal kit befre carrying ut the disassembly prcess. Step 1 Step 2 Step 3 First remve all the tubing and fitting frm the valve. Lsen the hex scket head cap screws f the spring cver slwly using Allen key. Take ut the spring cver, O-ring and spring, and keep them n a clean dry place. Step 4 Push the knb n the pilt cver s the spl cmes ut f the bdy. Step 5 Pull the spl alng with its seals ut f the bdy and keep them n clean dry place. Step 6 Step 7 Step 8 Step 9 Step 10 Lsen the hexagn scket head cap screw frm the pilt cver using Allen key. Remve the Bdy, cver seal O ring, pistn and pistn seal; keep them n clean dry place. Slwly lsen the MA screw frm the pilt cver using minus head screw driver. Take care as the spring frce exists fr the knb Place the MA screw, O-ring, MA Spring, Guide bush and knb n clean dry place. 6

7 Iss 22, Octber 2013 Ntes ASSEMBLY Fllw the sequences as given belw t ensure prper assembly. Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Clean all the parts. Apply a small layer f grease n the spl and the bdy bre. Apply a small layer f grease fr all seals and O rings. Place the spl seals n the spl. Insert the spl slwly int the bdy withut damaging the seals. Place the O-ring n the MA screw t seal the leakage thugh MA. Place the MA screw int the pilt cver. Place the MA spring and spring guide bush n the screw Tighten the knb with the screw slwly using minus head screw driver by hlding the knb in hand. Step 10 Step 11 Step 12 Step 13 Step 14 Step 17 Place the O-ring n the pistn Place the pistn in the pilt cver Place the O-ring seals n the pilt cver fr sealing the jint between bdy and pilt cver Place the bdy in psitin with the pilt cver using the hexagn scket head cap screws. Place the O-ring seal in grve n spring cver between spring cver and bdy. Tighten the hexagn scket head cap screw t full trque t cmplete the assembly. 7

8 Iss 22, Octber CONSTRUCTION and BOM ITEM NO. DESCRIPTION MOC QTY ITEM NO. DESCRIPTION MOC QTY 1 PILOT COVER AL 1 11 BLANKING PLATE AL 1 2 BODY AL 1 12 ORING NBR 1 3 PISTON AL 1 13 ORING NBR 1 4 SPOOL AL 1 14 O-RING NBR 1 5 MA SCREW SS SPOOL SEAL AL 6 6 SPRING GUIDE BUSH AL 1 16 BALL SS KNOB PA SPRING FOR MA SS SPRING COVER AL 1 18 HEX. SOCKET HEAD SCREW SS ORING NBR 1 19 HEX. SOCKET HEAD SCREW SS ORING NBR 1 20 SPRING FOR SPRING COVER SS

9 Iss 22, Octber PACKAGING and STORAGE When nt in use, VALVE CONTROL BOX shuld be kept in a sealed plastic bag in a cardbard bx t prevent misture r dust frm cntacting prduct. VALVE CONTROL BOX shuld be stred in a dry place free frm water and dust. Stre at temperature between 40 and 120 F (4 C and 49 C). Lcate in an area t avid damage by impact. 08. WARNINGS Use nly genuine spare parts supplied by Rtex. Use nly the recmmended accessries and lubricants. Install, perate and maintain as per the instructins and recmmendatins f this manual. Any deviatin frm the abve warnings will cease the respnsibilities f Rtex. 09. ASSISTANCE Fr technical questins r assistance, cntact any authrized distributr f Rtex r: ROTEX MANUFACTURERS AND ENGINEERS PRIVATE LIMITED Manpada Rad, Dmbivli (East) Maharastra, INDIA. Tel: / / / Fax: rtexdbl@rtexautmatin.cm 9