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SPARE PARTS KITS

Installation and MaintenanceRecommendations

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V1195-GB-R4

INSTALLATION PRACTICES

Teflon tape or pipe joint compoundshould be used, but only on male pipethreads. To prevent foreign matter fromentering the valve, do not apply eithersealant to the first two male threads orto any of the female threads.

Two wrenches should be used to attachthe valve to its piping. Use a pipe wrenchto turn the pipe into the valve and asecond wrench on the flat of the valvebody. To prevent distortion of the valvebody, apply the second wrench to the sideof the valve into which the pipe is beinginserted.

Because the Teflon tape or pipe jointcompound reduces friction and makesturning easy, there is a tendency to overtorque when installing valves. This posespotential damage to the valve body, espe-cially aluminium or die-cast body valves.

Two wrenches should be used whenremoving or installing a solenoid valve.Stress on the valve body can be pre-vented by placing the wrench on thesame side of the valve as the pipe thatis being screwed out or into the valve.

Inlet and outlet piping must be properlysupported to prevent strain on the valvebody.

Wiring must comply with local safety codesand the National Electrical Regulation. Besure that the solenoid leads cannot bepulled from the coil. If you are not usingflexible conduit for transition into the valve,the supply conduit must be properly sup-ported to prevent stress on the solenoidassembly.

A considerable amount of foreign mattercan collect in a system, especially duringnew construction. So, always flush thesystem thoroughly before releasing it fornormal operation.Clean the strainers and filters after theline pressure and electric power havebeen shut off, but be sure to open thestrainer service cap slowly to releasetrapped pressure. A second flush may benecessary.

After electric power and fluid line pres-sure have been shut off, the first stepin valve disassembly is to remove thesolenoid mechanism.

GENERAL

ASCO/JOUCOMATIC has supported avalve kit program already for years. Eachkit includes the internal parts that requirereplacement in normal service includingdiscs, seats, springs, cores and all gas-kets. Diaphragms, piston rings and U-cupseals are also included where applicable.

Kits give you the following benefits:

1.Restore valves to like-new condition;ALL parts subject to wear are containedin the ASCO/JOUCOMATIC kit.

2.Costs are significantly less than a re-placement valve.

3.Service life of the valve is extended.

4.Easy to rebuild; exploded views anddetailed instructions are included.

5.Complete rebuilding can normally bedone without removing the valve fromthe system.

6.Downtime is greatly reduced.

7.Easy to order.

8.Kits are complete and easy to stock.

INSTRUCTIONS

Installation and Maintenance sheets pack-aged with ASCO/JOUCOMATIC kits in-clude exploded views and detailed step-by-step instructions to simplify rebuilding.

PARTS NOT INCLUDED IN ASCOKITS

Solenoid enclosure parts, solenoid baseand pressure boundary parts (such asbodies and bonnets) are not normallyincluded in kits. Special solenoid enclo-sure kits and hardware kits are also avail-able.

OBSOLETE VALVES

Many obsolete valves are not listed in thiscatalogue because few, if any, replace-ment parts are available. Since demand isinfrequent, the cost to manufacture partsin small quantities in uneconomical. Fur-ther, many valves have been redesignedto simpler, more economical construc-tions. In most cases a complete new valveis less expensive than the replacementparts for an obsolete valve.

CONTENTS OF SPARE PARTS KITS

Each ASCO/JOUCOMATIC spare partskit includes all the internal parts that wouldrequire replacement during normal serv-ice, such as the core, resilient disc, seats,springs and gaskets. Where applicable,diaphragms and piston rings or "U" cupseals are also included. Where practical,parts in the kits are furnished as assem-blies to save installation time. Also, spe-cial wrenches and inserts, if applicable,are provided in ASCO/JOUCOMATICspare parts kits to assure that you haveeverything you need to do the job.Installation and Maintenance sheets pack-aged with ASCO/JOUCOMATIC spare partskits include exploded views or cross sec-tional drawings of valves and show locationsof all parts in the valve to simplify rebuilding.Also, detailed step-by-step instructions areprovided.

TO ORDER ASCO/JOUCOMATICSPARE PARTS KITS

Refer to Kits and Coils catalogue X010for ASCO products and PR-EVT forJOUCOMATIC products, or, if you needhelp in ordering ASCO/JOUCOMATICspare parts kits or cannot find an exactlisting of your valve catalogue number,contact your nearest ASCO/JOUCOMATICsource and give them your valve cata-logue number, voltage and serial number.

HOW TO INSTALL AND MAINTAIN

Proper installation and maintenance pro-cedures go a long way toward prolongingvalve life. Read and follow the instructionpacked with each valve.

Nameplate data-voltage, pressure, etc.should be checked to ensure compatibilitywith system conditions. Check too, that thetype of solenoid enclosure is compatible withyour operating environment.

A strainer or filter should always beinstalled as close as possible to theinlet of a solenoid valve.

Some valves are designed to operate inany mounting position, while others mustbe oriented in a certain way to operateproperly. Whenever possible, however,all valves should be mounted with thesolenoid in a vertical and upright positionto reduce the possibility of foreign matteraccumulating in the core tube area. Thefirst line of defence against this occur-rence, however, is the installation of afilter or strainer as close as possible to thevalve inlet.

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V1195-2

To operate properly, a solenoid valvecore must move within the core tube andcontact the plugnut when the coil is ener-gized. You should hear a sharp metallicclick at energization. Absence of the clickusually indicates an electrical problem.For most valves, voltage applied to thecoil must be at least 85% of the nameplatevoltage rating.

If the valve coil is receiving the propervoltage, absence of a click may mean thatthe line pressure is higher than the valve'srating. Check that next.

If line pressure is OK, foreign matter maybe preventing the core from moving in thecore tube. Core movement can also berestricted if the top of the core has beenopened over millions of operations, if thedisc is swollen or cut, or if the core itselfhas been damaged.

A pilot-operated valve might fail to oper-ate when energized even though a clickhas been heard. A no-flow condition maybe caused by:

● Insufficient pressure drop across thevalve

● Ruptured diaphragm or damaged pis-ton ring

● Plugged or restricted pilot orifice

Both pilot-operated and direct-actingvalves can fail to operate when de-ener-gized because of:

● Faulty control circuit● Scale or other foreign matter in the

valve● Binding core or damaged core tube● Broken spring

Pilot-operated valves may also malfunc-tion when de-energized due to:

● Plugged bleed orifice● Damaged pilot seat or disc● Damaged diaphragm or piston● Insufficient pressure drop across the

valve

The solenoid core must move freelyin the core tube and should be freefrom signs of binding and exces-sive wear.

If there is excessive wear to the valvebody (e.g. wire drawing of the seat), thevalve should be replaced.

The disc at the end of the movable core orpiston should be checked for signs ofexcessive impacting. If deep impressionsare noted and the system involves liquids,a water hammer condition may exist. Toprotect the pipes and equipment in thesystem, install a water hammer cushionclose to the valve inlet, or replace thevalve by an ASCO slow closing valve.

After reassembly, check the valve opera-tion by energizing the solenoid coil. Asharp metallic click should be heard if thevalve is operating properly.

Pilot Operated ValvesCleaning and inspection procedures areessentially the same as for direct-actingvalves. However, pilot operated valvesalso have a diaphragm or piston withbleed holes which must be cleaned. Thepiston should move freely in its cylinderand the piston rings should rotate freely inthe groove.

ASCO/JOUCOMATIC offers rebuildkits which contain all componentsneeded to make a valve like new again.

HOW TO TROUBLESHOOTSOLENOID VALVES

Because there are so many potential rea-sons for solenoid valves to malfunction,they are often thought to be complex,trouble-prone devices. Actually, they arequite simple and very reliable. Many of theproblems originate outside the valvesthemselves, while others are caused bymis-application or improper installation.Troubleshooting should begin with a checkof the voltage and pressure input. Theproblem may be caused by an inoperativecontrol relay or a fluctuating pressureregulator. If voltage and pressure are cor-rect inspect the valve. The main reasonsa direct-acting solenoid valve fails to op-erate:

● Low or no voltage● Burned-out solenoid● Pressure higher than the valve's rating● Foreign matter in the valve● Binding core or damaged core tube

MAINTENANCE PROCEDURES

Cleaning of filters and strainers should bepart of your normal preventive mainte-nance program, along with cleaning andinspection of the valve. If the valve is notoperating properly and corrective stepsare required, confirm that the problem is inthe valve and not caused by other condi-tions in the system.

Foreign matter in the valve, such as pipejoint sealant, corrosion from pipes andprocess vessels, mineral deposits andother solids, is a major cause of solenoidvalve failure.

If valve disassembly is required, alwaysfollow the instructions supplied with thevalve for disassembly, cleaning and reas-sembly.

Before disassembling the valve, it is al-ways best to have on hand those partssubject to wear which are most likely torequire replacement. ASCO/JOUCO-MATIC offers rebuild kits containing allthe internal parts needed to restore thevalve to its like-new condition.

Dirt on the valve body and on internalparts should be wiped off with a lint-free cloth.

Except on very old valves, you will find therebuild kit number listed in the ASCO cata-logue X010 or in the JOUCOMATIC cata-logue (consult ASCO/JOUCOMATIC).These kits include comprehensive instruc-tions and an exploded view of the valve.(All our Installation and Maintenance Instructions andSpare Parts leaflets may be consulted and downloadedat: www.ascojoucomatic.com)

On all valves, always be sure to reinstallthe nameplate. The nameplate servessometimes as a retainer to hold the sole-noid to the valve.

MAINTENANCE TIPSDirect-Acting ValvesAlways turn off electrical and fluid sup-plies before disassembling a valve andloosen the solenoid base slowly to re-lease any trapped pressure.Remove internal parts and wipe themclean with a lint-free cloth.Examine the valve body for foreign mate-rials and deposits. Be especially carefulnot to scratch the valve seat or disc duringcleaning.The movable core and core tube shouldbe examined for signs of binding andwear. If present, all internal parts shouldbe replaced.

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V1195-3

Because faulty cylinder operation is oftencaused by the cylinder itself, it should bechecked for:

● Misalignment between the piston rodand connected load

● Lack of lubrication● Worn and leaking piston cups which

allow fluid to exhaust through the valve● Foreign matter in the speed controls● System overloading, low line pressure,

or undersized hoses or fittings

If the problems does not appear to be inthe cylinder, the valve should be checked.

When troubleshooting 4-way valves con-trolling cylinders, it is important to followthe instructions provided with the valve.Some 4-way valves require an oil-mistlubricator for proper operation. Pilot-acti-vated 4-way valves normally require full-size piping for pressure inlet and exhaust.In some of these valves, restrictive speedcontrol devices should be installed in thecylinder connections.

* In Explosionproof solenoids, a binding core, high-input voltage, or excessive ambient or fluid temperature may cause the solenoid's non-resettable thermal fuse to open. If this occurs, the solenoid must be replaced.

TROUBELSHOOTING GUIDE

Probable SolutionPossible CauseProblem

Direct acting valveValve will not operatewhen valve circuit isenergized

Pilot operated valveValve will not operatewhen valve circuit isenergized

Direct acting valveValve will not close orshift when valve circuitis de-energized

Pilot operated valveValve will not close orshift when valve circuitis de-energized

Wire drawing

Coil failure*

Check voltage at coil; for most valves, voltage should be at least 85%of nameplate rating.

See "Coil Failure" below.

Clean valve; install strainer close to valve inlet.

Replace parts.

Reduce pressure to valve nameplate pressure rating or install suitable valve.

Valve might be oversized; replace valve with one having a smaller orifice.Increase pressure, if possible.

Replace damaged parts.

Clean valve and pilot orifice.

Check electrical control circuit.

Clean valve; install strainer close to valve inlet.

Replace with new parts

Replace with new spring. Never elongate or shorten spring.

Clean orifice.

Replace with new parts.

Replace with new spring. Never elongate or shorten spring.

Valve might be oversized; replace valve by one having a smaller orifice.Increase pressure, if possible.

Replace valve body or install new valve; install suitable strainer close toinlet or valve.

Check voltage at coil; voltage must conform to nameplate rating.

Check for damaged core and core tube, or damaged spring. Check for scale orforeign matter on the core or inside the core tube. Clean thoroughly and replaceany damaged parts.

Reduce pressure or install suitable valve

Refer to the data listed for class E, F and H (page V1105)

Install missing solenoid housing and other metal parts or properly install incorrectlyassembled metal parts. The housing and other metal parts form part of themagnetic circuit and are required to provide the impedance needed to limit currentdraw

Waterproof the entrance conduit to prevent entry of moisture. If valve is mountedoutdoors, check to see that enclosure is weatherproof and that gaskets are in goodcondition; use appropriate sealant where required. If general purpose enclosure isused in a damp or humid atmosphere use watertight, moulded coils.

Low voltage or no voltage to solenoid coil

Burned out coil

Excessive foreign matter jamming core in core tube

Binding core or damaged core tube

Excessive fluid pressure

Same causes and solution as for direct acting -valve,plus:

Low pressure drop across valve

Ruptured diaphragm or piston ring

Plugged or restricted pilot orifice

Coil not de-energized

Excessive foreign matter jamming core in core tube

Damaged disc or seat causing internal leakage

Binding core or damaged core tube

Damaged spring

Same causes and solutions as for direct-acting valve,plus:

Plugged bleed orifice

Damaged pilot seat or pilot disc

Damaged diaphragm or piston

Damaged pilot spring

Insufficient pressure drop across the valve

Dirt or foreign matter is lodged on seat

Overvoltage

Damaged core or core tube causing inrush current to bedrawn continuously

Excessive foreign matter jamming core in core tube andcausing inrush current to be drawn continuously

Excessive fluid pressure causing inrush current to bedrawn continuously

Excessive ambient or fluid temperature

Missing solenoid parts

Moisture inside solenoid enclosure

Excessive solenoid noise (hum or chat-ter) can be caused by:

● Low voltage● Faulty relay or improper electrical con-

trol signal● Loose solenoid parts● Foreign matter on core or plugnut face● Worn core of plugnut face● Damaged spring● Excessive system pressure

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V1195-4