Installation

&
Maintenance Manual
Bin Arch breaking System
(Models: BAS-020 BAS-040 BAS-050)

Beijing bklitong bulk technology Co., LTD

www.bklitong.com
info@bklitong.com

INJECTOR HEADS OF SYSTEM INSTALLATION NOTES

Consult installation drawing (if provided) for proper injector heads location. It is important to
adhere to the recommended locations as the type, number and location of injector heads have
been selected for thorough " inject " coverage of the problem surfaces in bin or chute.
It is usually not necessary to clean out or empty the bin before installing the Injector heads.

CAUTION: NEVER ENTER A BIN WHILE INJECTOR HEADS ARE OPERATING.

If the material in the bin would have a tendency to run out of a hole cut in the bin wall, the level
of material in the bin should be dropped below the Injector head location before cutting the holes
in the bin wall.
When welding, a continuous bead should be used to fasten the mounting to the bin wall on
steel bins.
PIPING INSTALLATION
Follow the piping schematic that is a part of this instruction manual.
Never use smaller pipe size fittings or valves than the ones shown.
It is important that the header be installed below the level of the Injector heads so that any
condensation that may form in the lines will not drain into the Injector heads. If the header must
be installed above the level of the Injector heads, the feed lines for the individual Injector heads
must be taken off the top of the header (rather than the bottom) to minimize condensation
drainage into the Injector heads and solenoids. A full flow gate or ball valve is recommended as
it allows one the Injector head to be taken out of service without shutting down the entire system.
Using flexible air hose in lieu of rigid piping from the header to the solenoids is recommended
for ease of installation and for easy removal of the Injector head when service is required.
NOTE: USING SUITABLE SAFEGUARDS, always blow out all air supply lines thoroughly
before final hook up to solenoids. Dirt in supply lines may cause the solenoid valves
to malfunction.
When operating properly, and under material, the Injector heads are almost silent.
If an Injector head begins to chatter, vibrate or "machine gun", it is generally caused by a
solenoid valve malfunctioning due to dirt. If this occurs, SHUT OFF ELECTRIC & AIR SUPPLY
and DISCHARGE AIR in system, then clean solenoid thoroughly (see troubleshooting).

AIR USAGE NOTE

It is important to note that the lower limit of the interval timer is governed by how fast the air
receiver can recover its air loss from the preceding Injector head burst.
gauge should be installed on the air receiver tank or header.

If there is some doubt, a

For example, if the gauge initially

reads 95 psi when the receiver is fully pressurized, it should not drop below 80 psi for one burst
if the receiver has been properly sized.

The instant the receiver again recovers the 95 psi

after one Injector head is fired, it is then ready for another firing.

If the gauge never indicates

the original pressure, the Injector heads are firing faster than the air supply can recover.
GENERAL NOTES & SUMMARY:

Entire electrical system must be properly grounded for personnel safety.

Distance between air receiver and header has no limit as long as 2" pipe
(1 for BAS-020) & fittings are used throughout.

Slope header toward receiver 1/4"/ft. for moisture drainage.

Whenever possible, locate

header below Injector heads.

Always tap feed lines off top of header (even if header is above Injector heads) to
prevent moisture drainage into Injector heads.

Never use pipe or fittings smaller than sizes indicated.

Use location arrangement drawing (if provided) for Injector head location.

Whenever possible, complete header loop around the hopper.

Manual isolation valves (optional) must be gate valves or comparable full orifice valves, to
not induce flow restriction in system.

If hopper is outdoors, air receiver and filter should be located indoors whenever possible.

Air Supply: BAS-040 & BAS-050 ------ 80 min. to 100 max. PSIG
BAS-020 ------ 40 min. to 80 max. PSIG

IMPORTANT!

Solenoid valves must be located at Injector head air inlets and not any

distance upstream.

Purge all lines and unions before connecting to solenoid valves. Particulate in lines may
result in solenoid valve malfunction and excessive maintenance.

Use teflon tape on pipe joints rather than pipe dope, to avoid fouling of solenoid valves.

BAS-020 Injector head dimensions (no scale)

Mounting Coupling
(for curved walls)
BAS-020
Injector head

32mm

25mm
43mm

2.5mm

31.5mm

43mm

32.3mm
3/4" NPT sch. 40
connecting nipple (typ.)

62mm
Cone point
set screw (4 places)

"O" Ring
National Part

Injector head CONTROL BOX

The control box is the heart of the Injector head system. It is this device which fires the Injector
heads in a prescribed sequence and at a prescribed interval to assure on-demand or even
discharging of material from the bin, silo or chute. The firing order is from the discharge
(lowest unit) and up.
The burst signal, sent from the control box to the solenoid valves, is typically set at 0.25
seconds. It is this signal that is responsible for the actual firing of any given Injector head. In
some cases, more than one solenoid valve may be wired to the same output, to effect
simultaneous firing of two Injector heads.
The interval timer governs the "dwell" between successive firings.
The "dwell" should be set as long as possible without adversely affecting the flow of material. A
longer "dwell" will conserve air.
External controls, There provide a DCS port with a switch which can start or stop the Bin
Arch breaking System.

WARNING
NEVER ALLOW ANYONE TO LOOK INTO OR ENTER
BIN WHEN INJECTOR HEADS ARE OPERATING.
EYE OR OTHER INJURY MAY RESULT! SHUT OFF
ELECTRIC & AIR SUPPLY TO INJECTOR HEADS AND
DISCHARGE AIR IN SYSTEM BEFORE INSPECTING OR
SERVICING INJECTOR HEADS.

TYPICAL SYSTEM COMPONENTS

Mounting Coupling

injector head

Diaphragm Valve

Hopper

Flexible Hose

Pipe Header Loop

supply pipe

Pipe port
Ball Valve
Full-flow
Moisture Trap
Full-flow Regulator
Air Supply

Air receiver connection detail

TO SYSTEM AND HEADER

MOISTURE
TRAP

1" PIPE (FOR BAS-020 SYSTEMS)

2" PIPE (FOR BAS-040/050 SYSTEMS)

GAS FEED

Connect header supply to ASME inspection ports

1" PIPE (FOR BAS-020 SYSTEMS)

2" PIPE (FOR BAS-040/050 SYSTEMS)

Injector Header connection detail

MOUNTING SET
(COUPLING OR FLANGE)

INJECTOR HEAD
HOPPER WALL
CONNECTION TO
CONTROLLER
SOLENOID VALVE
FLEX.HOSE

LOOP PIPE

BAS-020 Mounting Coupling Installation

TYP

Bin Inside Wall

Mounting
Coupling
& Assembly

25mm

43mm

90 Degree
Countersink
After Correct Injector
head Position is
Determined

Align Front of Coupling

Flush With Inside of Bin Wall

BAS-020 Mounting Coupling Installation

1. Cut hole in hopper wall, diameter to fit (The 40mm diameter of coupling is recommended
to allow coupling to pass through curved wall).
2. Remove O-Ring, and apply splatter-guard in O-Ring groove.
Align coupling flush with inside of vessel wall and weld continuous bead to exterior of wall.
Replace O-Ring after flange has cooled. O-Ring groove should be cleaned and free of
debris or residue before replacing O-Ring.
3. Slide Injector head into position, so that front of body of Injector head is aligned with
front of coupling. This will properly position piston head within the bin.
4. After position of Injector head is determined to be correct, small countersink holes should
be drilled in Injector head body, to allow cone point set screw to engage fully with body.
Note: On sharply curved bin walls, body of Injector head will extend slightly into the bin at top &
bottom (12:00 & 6:00 positions), and should be flush at sides (3:00 & 9:00 positions).

Installation & Maintenance Instructions

SERIES

8016G

OPEN-FRAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS

SERVICE NOTICE

FOR BLACK ENCLOSURE TYPES 7 AND 9 ONLY

ASCO solenoid valves with design change letter G" in the catalog number
(example: 8210G 1) have an epoxy encapsulated ASCO Red Hat II
solenoid. This solenoid replaces some of the solenoids with metal enclosures
and open-frame constructions. Follow these installation and maintenance
instructions if your valve or operator uses this solenoid.

DESCRIPTION
Catalog numbers 8016G1 and 8016G2 are epoxy encapsulated pull-type
solenoids. The green solenoid with lead wires and 1/2 conduit connection
is designed to meet Enclosure Type 1-General Purpose, Type 2-Dripproof,
Types 3 and 3S-Raintight, and Types 4 and 4X-Watertight. The black
solenoid on catalog numbers prefixed EF" is designed to meet Enclosure
Types 3 and 3S-Raintight, Types 4 and 4X-Watertight, Types 6 and
6P-Submersible, Type 7 (A, B, C, & D) Explosionproof Class I, Division 1,
Groups A, B, C, & D and Type 9 (E, F, & G)-Dust-Ignitionproof Class II,
Division 1, Groups E, F, & G. The Class II, Groups F & G Dust Locations
designation is not applicable for solenoids or solenoid valves used for steam
service or when a class H" solenoid is used. See Temperature Limitations
section for solenoid identification and nameplate/retainer for service. When
installed just as a solenoid and not attached to an ASCO valve, the core has
a 0.250-28 UNF-2B tapped hole, 0.38 minimum full thread.

Series 8016G solenoids are available in:

 Open-Frame Construction
The green solenoid may be supplied with 1/4 spade, screw, or DIN
terminals (Refer to Figure 4).
 Panel Mounted Construction
These solenoids are specifically designed to be panel mounted by the
customer through a panel having a .062 to .093 maximum wall thickness.
(Refer to Figure 3 and section on Installation of Panel Mounted Solenoid).

Optional Features For Type 1 - General Purpose

Construction Only

 Junction Box
This junction box construction meets Enclosure Types 2,3,3S,4, and 4X.
Only solenoids with 1/4 spade or screw terminals may have a junction
box. The junction box provides a 1/2 conduit connection, grounding and
spade or screw terminal connections within the junction box (See Figure
5).
 DIN Plug Connector Kit No. K236034
Use this kit only for solenoids with DIN terminals. The DIN plug
connector kit provides a two pole with grounding contact DIN Type
43650 construction (See Figure 6).

OPERATION

When the solenoid is energized, the core is drawn into the solenoid base
sub-assembly. IMPORTANT: When the solenoid is de-energized, the
initial return force for the core, whether developed by spring, pressure, or
weight, must exert a minimum force to overcome residual magnetism created
by the solenoid. Minimum return force for AC construction is 11 ounces, and
4 ounces for DC construction.

INSTALLATION

Check nameplate for correct catalog number, service, and wattage. Check
front of solenoid for voltage and frequency.

WARNING: Electrical hazard from the accessibility

of live parts. To prevent the possibility of death,serious
injury or property damage, install the open - frame
solenoid in an enclosure.

MM

Form No.V6583R7

All Rights Reserved.

50 Hanover Road, Florham Park, New Jersey 07932

CAUTION: To prevent fire or explosion, do not install solenoid and/or valve

where ignition temperature of hazardous atmosphere is less than
165 C. On valves used for steam service or when a class H" solenoid is used, do
not install in hazardous atmosphere where ignition temperature is less than
180C. See nameplate/retainer for service.
NOTE: These solenoids have an internal non-resetable thermal fuse to
limit solenoid temperature in the event that extraordinary conditions occur
which could cause excessive temperatures. These conditions include high
input voltage, a jammed core, excessive ambient temperature or a shorted
solenoid, etc. This unique feature is a standard feature only in solenoids with
black explosionproof/dust-ignitionproof enclosures (Types 7 & 9).
CAUTION: To protect the solenoid valve or operator, install a
strainer or filter, suitable for the service involved in the inlet side as
close to the valve or operator as possible. Clean periodically
depending on service conditions. See ASCO Series 8600, 8601, and
8602 for strainers.

Temperature Limitations

For maximum valve ambient temperatures, refer to chart. The temperature

limitations listed, only indicate maximum application temperatures for field
wiring rated at 90C. Check catalog number prefix and watt rating on
nameplate to determine maximum ambient temperature. See valve
installation and maintenance instructions for maximum fluid temperature.
NOTE: For steam service, refer to Wiring section, Junction Box for
temperature rating of supply wires.
Temperature Limitations For Series 8016G Solenoids for use on
Valves Rated at 6.1, 8.1, 9.1, 10.6, or 11.1 Watts
Watt
Rating

Catalog
Number Coil
Prefix

Class of
Insulation

Maximum 
Ambient Temp.

6.1, 8.1,
9.1, & 11.1

None, FB, KF, KP,

SF, SP, SC, & SD

125F (51.7C)

6.1, 8.1,
9.1, & 11.1

HB, HT, KB, KH,

SS, ST, SU, & ST

140F (60C)

10.6

None, KF,
SF, & SC

104F (40C)

10.6

HT, KH,
SU, & ST

104F (40C)

Minimum ambient temperature -40F (-40 C).

Positioning

This solenoid is designed to perform properly when mounted in any position.

However, for optimum life and performance, the solenoid should be
mounted vertically and upright to reduce the possibility of foreign matter
accumulating in the solenoid base sub-assembly area.

Wiring

Wiring must comply with local codes and the National Electrical Code. All
solenoids supplied with lead wires are provided with a grounding wire which
is green or green with yellow stripes and a 1/2 conduit connection. To
facilitate wiring, the solenoid may be rotated 360. For the watertight and
explosionproof solenoid, electrical fittings must be approved for use in the
approved hazardous locations.

Additional Wiring Instructions For Optional Features:

 Open-Frame solenoid with 1/4 spade terminals

For solenoids supplied with screw terminal connections use #12-18 AWG
stranded copper wire rated at 90C or greater. Torque terminal block screws to
Printed in U.S.A.

www.ascovalve.com

Page 1 of 4

10 2 in-lbs [1,0 1,2 Nm]. A tapped hole is provided in the solenoid for
grounding, use a #10-32 machine screw. Torque grounding screw to 15 -20
in-lbs [1,7 - 2,3 Nm]. On solenoids with screw terminals, the socket head screw
holding the terminal block to the solenoid is the grounding screw. Torque the
screw to 15 - 20 in-lbs [1,7 - 2,3 Nm]. with a 5/32 hex key wrench.
 Junction Box
The junction box is used with spade or screw terminal solenoids only and is
provided with a grounding screw and a 1/2 conduit connection. Connect
#12-18 AWG standard copper wire only to the screw terminals. Within the
junction box use field wire that is rated 90C or greater for connections. For
steam service use 105C rated wire up to 50 psi or use 125C rated wire above
50 psi. After electrical hookup, replace cover gasket, cover, and screws.
Tighten screws evenly in a crisscross manner.
 DIN Plug Connector Kit No.K236-034
1. The open-frame solenoid is provided with DIN terminals to
accommodate the DIN plug connector kit.
2. Remove center screw from plug connector. Using a small screwdriver, pry
terminal block from connector cover.
3. Use #12-18 AWG stranded copper wire rated at 90C or greater for
connections. Strip wire leads back approximately 1/4for installation in
socket terminals. The use of wire-end sleeves is also recommended for
these socket terminals. Maximum length of wire-end sleeves to be
approximately 1/4.
Tinning of the ends of the lead wires is not
recommended.
4. Thread wire through gland nut, gland gasket, washer, and connector
cover.
NOTE: Connector cover may be rotated in 90 increments from position
shown for alternate positioning of cable entry.
5. Check DIN connector terminal block for electrical markings. Then make
electrical hookup to terminal block according to markings on it. Snap
terminal block into connector cover and install center screw.
6. Position connector gasket on solenoid and install plug connector. Torque
center screw to 5 1 in-lbs [0,6 1,1 Nm].
NOTE: Alternating current (AC) and direct current (DC) solenoids are built
differently. To convert from one to the other, it may be necessary to change
the complete solenoid including the core and solenoid base sub-assembly,
not just the solenoid. Consult ASCO.

Installation of Solenoid

Solenoids may be assembled as a complete unit. Tightening is accomplished

by means of a hex flange at the base of the solenoid. The 3/4 bonnet
construction (Figure 1) must be disassembled for installation and installed
with a special wrench adapter.

Installation of Panel Mounted Solenoid (See Figure 3)

Disassemble solenoid following instruction under Solenoid Replacement then
proceed.
3/4 Valve Bonnet Construction
1. Install retainer (convex side to solenoid) in 1.312 diameter mounting hole
in customer panel.
2. Then position spring washer over plugnut/core tube sub-assembly.
3. Install plugnut/core tube sub-assembly through retainer in customer
panel. Then replace solenoid, nameplate/retainer and red cap.
15/16  Valve Bonnet Construction
1. Install solenoid base sub-assembly through 0.69 diameter mounting hole
in customer panel.
2. Position spring washer on opposite side of panel over solenoid base
sub-assembly then replace.

Solenoid Temperature

Standard solenoids are designed for continuous duty service. When the
solenoid is energized for a long period, the solenoid becomes hot and can be
touched by hand only for an instant. This is a safe operating temperature.

MAINTENANCE
WARNING: To prevent the possibility of death,
serious injury or property damage, turn off electrical
power, depressurize solenoid operator and/or valve,
and vent fluid to a safe area before servicing.

Cleaning

All solenoid operators and valves should be cleaned periodically. The time
between cleaning will vary depending on medium and service conditions. In
general, if the voltage to the solenoid is correct, sluggish valve operation,
excessive noise or leakage will indicate that cleaning is required. Clean
strainer or filter when cleaning the valve.

Preventive Maintenance

 Keep the medium flowing through the solenoid operator or valve as free
from dirt and foreign material as possible.
 While in service, the solenoid operator or valve should be operated at least
once a month to insure proper opening and closing.
 Depending on the medium and service conditions, periodic inspection of
internal valve parts for damage or excessive wear is recommended.
Thoroughly clean all parts. Replace any worn or damaged parts.

Causes of Improper Operation

 Faulty Control Circuit: Check the electrical system by energizing the

solenoid. A metallic click signifies that the solenoid is operating. Absence
of the click indicates loss of power supply. Check for loose or blown fuses,
open-circuited or grounded solenoid, broken lead wires or splice
connections.
 Burned-Out Solenoid: Check for open-circuited solenoid. Replace if
necessary. Check supply voltage; it must be the same as specified on
nameplate/retainer and marked on the solenoid. Check ambient
temperature and check that the core is not jammed.
 Low Voltage: Check voltage across the solenoid leads. Voltage must be at
least 85% of rated voltage.

Solenoid Replacement

1. On solenoids with lead wires disconnect conduit, coil leads, and grounding
wire.
NOTE: Any optional parts attached to the old solenoid must be reinstalled
on the new solenoid.
2. Disassemble solenoids with optional features as follows:
 Spade or Screw Terminals
Remove terminal connections, grounding screw, grounding wire, and
terminal block (screw terminal type only).
NOTE: For screw terminals, the socket head screw holding the terminal
block serves as a grounding screw.
 Junction Box
Remove conduit and socket head screw (use 5/32 hex key wrench) from
center of junction box. Disconnect junction box from solenoid.
 DIN Plug Connector
Remove center screw from DIN plug connector. Disconnect DIN plug
connector from adapter. Remove socket head screw (use 5/32 hex key
wrench), DIN terminal adapter, and gasket from solenoid.
3. Snap off red cap from top of solenoid base sub-assembly.
4. Push down on solenoid. Then using a suitable screwdriver, insert blade in
slot provided between solenoid and nameplate/retainer. Pry up slightly
and push to remove. Then remove solenoid from solenoid base
sub-assembly.
5. Reassemble using exploded views for parts identification and placement

Disassembly and Reassembly of Solenoids

1. Remove solenoid, see Solenoid Replacement.

2. Remove finger washer or spring washer
from solenoid base
sub-assembly.
3. Unscrew solenoid base sub-assembly.
NOTE:
Some solenoid constructions have a plugnut/core tube
sub-assembly, bonnet gasket and bonnet in place of the solenoid base
sub-assembly. To remove bonnet use special wrench adapter supplied in
ASCO Rebuild Kit. For wrench adapter only, order ASCO Wrench Kit
No.K218948.
4. The core is now accessible for cleaning or replacement.
5. If the solenoid is part of a valve, refer to basic valve installation and
maintenance instructions for further disassembly.
6. Reassemble using exploded views for identification and placement of
parts.
ORDERING INFORMATION FOR ASCO SOLENOIDS
When Ordering Solenoids for ASCO Solenoid Operators or Valves, order
the number stamped on the solenoid. Also specify voltage and frequency.

Page 2 of 4

Form No.V6583R7
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Torque Chart
Part Name
solenoid base sub-assembly
valve bonnet (3/4 bonnet construction)
bonnet screw (3/8 or 1/2 NPT pipe size)

Torque Value in Inch-Pounds

175 25
90 10
25

Torque Value in Newton-Meters

19,8 2,8
10,2 1,1
2,8

bonnet screw (3/4 NPT pipe size)

40

4,5

Remove red cap and

push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.

red cap
nameplate/
retainer

solenoid
with 1/2 NPT

grounding wire green or green with

yellow stripes

For special wrench

adapter order kit
No. K218948

wave
washer
valve
bonnet

spring washer

0.750-28 UN-2A
thread

bonnet
gasket

solenoid base
sub-assembly

plugnut/core tube
sub-assembly
Tapped hole in core
0.250-28 UNF-2B
0.38 minimum full thread.

core

3/4 Bonnet Construction

Remove red cap and

push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.

0.9375-26 UNS -2A

thread
core
core
(AC)
(DC)

Side View
finger
washer
collar to face
valve body
Alternate
Construction

15/16 Bonnet Construction

Figure 1. Series 8016G solenoids
red cap

See torque chart

for bonnet screws

nameplate/retainer

red cap

solenoid with 1/2 NPT

grounding wire green or green with
yellow stripes

nameplate/
retainer
spacer

1.312 diameter
mounting hole

solenoid
finger
washer
valve
bonnet
core
tube

retainer
spring
washer
valve
bonnet
bonnet
gasket

Remove red cap and

push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.

finger washer
0.69 diameter
mounting hole

.062 to .093 maximum

thickness of panel
for mounting
For special wrench
adapter order kit
No. K218948
plugnut/core tube
sub-assembly

solenoid base
sub-assembly
core

core
Bolted Bonnet
Construction

3/4 Bonnet Construction

Figure 2. Series 8016G solenoid

15/16 Bonnet Construction

Figure 3. Series 8016G panel mounted solenoids

Form No.V6583R7
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Page 3 of 4

Torque Chart
Part Name
terminal block screws
socket head screw
center screw

Torque Value in Inch-Pounds

10 2
15 - 20
51
Open-Frame Solenoid
with Screw Terminals.
Socket head screw is
used for grounding.

Open-Frame Solenoid
with 1/4 Spade Terminals

See
torque chart
above

Open-Frame Solenoid
with DIN Terminals.

Indicates parts supplied

in Termination Module
Kit No. K256104

screw terminal
adapter

terminal
block
screw

tapped hole for

#10-32 grounding screw
(not included)

Torque Value in Newton-Meters

1,1 0,2
1,7 - 2,3
0,6 0,1

gasket

DIN terminal
adapter

socket head
grounding screw
(5/32 hex key wrench)

socket head screw

(5/32 hex key wrench)

Figure 4. Open-frame solenoids

screw terminal block
(see note)

Junction Box Solenoid

with 1/4 Spade Terminals
or Screw Terminals

cover screw

See
torque chart
above

cover
cover gasket
grounding screw
and cup washer

junction box gasket

Note:
Junction box with screw terminals
shown. With screw terminal
block removed, remaining parts
comprise the junction box for
spade terminal construction.

junction box with

1/2 conduit connection
and grounding terminal

socket head screw

(5/32 hex key wrench)

Figure 5. Junction box (optional feature)

Open-Frame Solenoid
with DIN Terminal
Plug Connector

Indicates that these parts are included

in DIN plug connector Kit No. K236034

gasket
DIN terminal
adapter

See
torque chart
above

connector

gland nut

gasket
gland gasket
socket head screw
(5/32 hex key wrench)

Notes:
1. Connector cover may be
rotated in 90 increments from
position shown for alternate
position of cable entry.
2. Refer to markings on DIN
connector for proper
electrical connections.

DIN connector
terminal block
(see note 2)

washer

center screw
connector cover
(see note 1)

Figure 6. DIN plug connector kit No. K236034 (optional feature)

Page 4 of 4

Form No.V6583R7
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

50 Hanover Road
Florham Park, New Jersey 07932
Tel. (973) 966-2000
Fax (973) 966 2628

1561 Columbia Highway

Aiken, South Carolina 29801
Tel. (803) 641-9200
Fax (803) 641-9290

SCIENTIFIC
50 Hanover Road
MMIl
All Rights Reserved. Printed in U.S.A. Form No. V6950R5
Florham Park, New Jersey 07932
Tel. (973) 236-6160
Fax (973) 966 6461
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Page 1 of 2

DESSIN
DIBUJO

DRAWING
DISEGNO

ZEICHNUNG
TEKENING

SERIES
353

1*

DESSIN
DIBUJO

DRAWING
DISEGNO

GB
1.
2.
3.
4.
5.
6.
7.

FR
3
4

DESCRIPTION
Retaining clip
Coil & nameplate
Gasket
Connector assembly
Washer, spring
Sol. base sub-assembly
Silencer

Clip de maintien
Bobine & plaque didenti.
Joint dtanchit
Montage du connecteur
Rondelle lastique,
ressort
6. Sol. sous-ensemble de
base

6*
B

DE

IN

7*

8*

GB
FR

9*

DE
ES
IT

C
10

NL

* Supplied in spare part kit

* Livres en pochette de rechange
* Enthalten im Ersatzteilsatz
* Incluido en Kit de recambio
* Disponibile nel Kit parti di ricambio
* Geleverd in vervangingsset

11

TORQUE CHART
C
B
A
ITEMS

12*

13

Catalogue number
Code lectrovanne
Katalognummer
Cdigo de la electrovalvula
Codice elettrovalvola
Katalogus nummer

111
203
0.60.2

10010
17525
52

NEWTON.METRES INCH.POUNDS
Spare part kit
Code pochette de rechange
Ersatzteilsatz
Cdigo del kit de recambio
Kit parti di ricambio
Vervangingsset
~

3/4
1

SCG353A43
SCG353A44

=
C113-444
C113-444

ASCO/JOUCOMATIC
P.O. Box 3, 3925 ZG Scherpenzeel, The Netherlands
Tel. +31 33 277 79 11- Fax +31 33 277 45 61

1.
2.
3.
4.
5.
6.
7.
8.

ES
1.
2.
3.
4.
5.
6.
7.
8.

IT
1.
2.
3.
4.
5.
6.
7.
8.

NL
1.
2.
3.
4.
5.
6.
7.

8.
9.
10.
11.
12.
13.

Spring, core
Core assembly
Screw (4x)
Bonnet
Diaphragm assembly
Valve body

DESCRIPTION

1.
2.
3.
4.
5.

5*

IM901-10-1-4

ZEICHNUNG
TEKENING

7.
8.
9.
10.
11.
12.

Silencieux
Ressort, noyau mobile
Noyau
Vis (4x)
Couvercle
Montage de la membrane
13. Corps

BESCHREIBUNG
Klammerhalterung
Spule & typenschild
Dichtung
Gertesteckdose
Federscheibe
Halte- mutter
Schalldmpfer
Feder, magnetanker

9.
10.
11.
12.
13.

Magnetankerbaugr.
Schraube (4x)
Ventildeckel
Membranbaugruppe
Ventilgehuse

DESCRIPCION
Clip de sujecin
Bobina y placa de caract.
Guarnicin
Conjunto del conector
Arandela, resorte
Sol. conjunto de la base
Silenciador
Resorte, nucleo

9.
10.
11.
12.
13.

Conjunto del ncleo

Tornillo (4x)
Tapa
Conjunto del diafragma
Cuerpo de la valvula

DESCRIZIONE
Clip di fissaggio
Bobina e targhetta
Guarnizione
Gruppo connettore
Ghiera, molla
Gruppo cannotto
Anello di sfasamento
Molla, nucleo

9.
10.
11.
12.

Gruppo nucleo
Vite (4x)
Coperchio
Gruppo della
membrana
13. Corpo

BESCHRIJVING
Clip
Spoel met typeplaatje
Afdichting
Steker
Veerring
Kopstuk/ deksel
Geluiddemper

8.
9.
10.
11.
12.
13.

Plunjerveer
Plunjer
Schroef (4x)
Klepdeksel
Membraan
Afsluiterhuis

INSTALLATION AND MAINTENANCE INSTRUCTIONS

single stage, integral pilot operated
3/4 to 1
DESCRIPTION
Series 353 are 2-way, normally closed, integral pilot operated,
single stage pulse diaphragm valves. The valve body is aluminium construction with threaded pipe connections.
INSTALLATION
ASCO/JOUCOMATIC components are intended to be used
only within the technical characteristics as specified on the
nameplate. Changes to the equipment are only allowed after
consulting the manufacturer or its representative. Before installation depressurise the piping system and clean internally.
The equipment may be mounted in any position.
The flow direction and pipe connection of valves are indicated
on the body.
The pipe connections have to be in accordance with the size
indicated on the nameplate and fitted accordingly.
CAUTION:
Reducing the connections may cause improper operation
or malfunctioning.
For the protection of the equipment install a strainer or filter
suitable for the service involved in the inlet side as close to
the product as possible.
If tape, paste, spray or a similar lubricant is used when tightening, avoid particles entering the system.
Use proper tools and locate wrenches as close as possible
to the connection point.
To avoid damage to the equipment, DO NOT OVERTIGHTEN pipe connections.
Do not use valve or solenoid as a lever.
The pipe connections should not apply any force, torque or
strain to the product.
ELECTRICAL CONNECTION
In case of electrical connections, they are only to be made by
trained personnel and have to be in accordance with the local
regulations and standards.
CAUTION:
Turn off electrical power supply and de-energise the electrical circuit and voltage carrying parts before starting work.
All electrical screw terminals must be properly tightened
according to the standards before putting into service.
Dependent upon the voltage electrical components must
be provided with an earth connection and satisfy local regulations and standards.

AJN: 123-620-529

The equipment can have one of the following electrical terminals:

Spade plug connections according to ISO-4400 (when correctly installed this connection provides lP-65 protection).
Embedded screw terminals in metal enclosure with Pg
cable gland.
Flying leads or cables.
PUTTING INTO SERVICE
Before pressurising the system, first carry-out an electrical test.
In case of solenoid valves, energise the coil a few times and
notice a metal click signifying the solenoid operation.

IM901-10-1-X-R1

IN

GB

SERVICE
Most of the solenoid valves are equipped with coils for continuous duty service. To prevent the possibility of personal or
property damage do not touch the solenoid which can become
hot under normal operation conditions. If the solenoid valve is
easily accessible, the installer must provide protection preventing accidental contact.
SOUND EMISSION
The emission of sound depends on the application, medium
and nature of the equipment used. The exact determination of
the sound level can only be carried out by the user having the
valve installed in his system.
MAINTENANCE
Maintenance of ASCO/JOUCOMATIC products is dependent
on service conditions. Periodic cleaning is recommended, the
timing of which will depend on the media and service conditions. During servicing, components should be examined for
excessive wear. A complete set of internal parts is available
as a spare parts kit. If a problem occurs during installation/
maintenance or in case of doubt please contact ASCO/
JOUCOMATIC or authorised representatives.
VALVE DISASSEMBLY
Disassemble in an orderly fashion. Pay careful attention to exploded views provided for identification of parts.
1. Remove retaining clip and slip the entire solenoid enclosure off the solenoid base sub-assembly. CAUTION: when
metal retaining clip disengages, it can spring upwards.
2. Unscrew solenoid base sub-assembly and remove core assembly, core spring and silencer.
3. Unscrew bonnet screws (4x) and remove bonnet and diaphragm assembly.
4. All parts are now accessible for cleaning or replacement.
VALVE REASSEMBLY
Reassemble in reverse order of disassembly paying careful attention to exploded views provided for identification and placement of
parts.
1. NOTE: Lubricate all gaskets/O-rings with high quality silicone grease. Replace diaphragm with the marking THIS
SIDE OUT facing the bonnet. Position bleed hole in alignment with cavity in valve body and bonnet. The external
contours of diaphragm, valve body and bonnet must all be
in alignment.
2. Replace bonnet and torque the bonnet screws in a crisscross manner according to torque chart.
3. Replace core assembly, core spring, silencer and the solenoid base sub-assembly, and torque solenoid base subassembly according to torque chart.
4. Replace spring washer, solenoid and retaining clip.
5. After maintenance, operate the valve a few times to be sure
of proper operation.
A separate Declaration of Incorporation relating to EECDirective 89/392/EEC Annex II B is available on request.
Please provide acknowledgement number and serial numbers of products concerned. This product complies with
the essential requirements of the EMC-Directive 89/336/
EEC and amendments as well as the 73/23/EEC + 93/68/
EEC Low Voltage Directives. A separate Declaration of Conformity is available on request.

INSTRUCTIONS D'INSTALLATION ET D'ENTRETIEN

simple pilotage, commande assiste
3/4 1
DESCRIPTION
Les vannes de la srie 353 sont des vannes deux voies
normalement fermes, commande assiste, membrane impulsion simple pilotage. Le corps est en aluminium avec
raccordements de tubes tarauds.
MONTAGE
Les composants ASCO/JOUCOMATIC sont conus pour les
domaines de fonctionnement indiqus sur la plaque signaltique
ou la documentation. Aucune modification ne peut tre ralise
sur le matriel sans laccord pralable du fabricant ou de son
reprsentant. Avant de procder au montage, dpressuriser les
canalisations et effectuer un nettoyage interne.
Les lectrovannes peuvent tre mont dans nimporte quelle position.
Le sens de circulation du fluide est indiqu par repres sur le corps
et dans la documentation.
La dimension des tuyauteries doit correspondre au raccordement
indiqu sur le corps, ltiquette ou la notice.
ATTENTION:
Une restr iction des tuyauteries peut entraner des
dysfonctionnements.
Afin de protger le matriel, installer une crpine ou un filtre
adquat en amont, aussi prs que possible du produit.
En cas dutilisation de ruban, pte, arosol ou un lubrifiant lors
du serrage, veillez ce quaucun corps tranger ne pntre
dans le circuit.
Utiliser un outillage appropri et placer les cls aussi prs que
possible du point de raccordement.
Afin dviter toute dtrioration, NE PAS TROP SERRER les
raccords des tuyauteries.
Ne pas se servir de la vanne ou de la tte magntique comme
dun levier.
Les tubes de raccordement ne devront exercer aucun effort,
couple ou contrainte sur le produit.
RACCORDEMENT LECTRIQUE
Le raccordement lectrique doit tre ralis par un personnel
qualifi et selon les normes et rglements locaux.
ATTENTION:
Avant toute intervention, coupez lalimentation lectrique pour
mettre hors tension les composants.
Toutes les bornes vis doivent tre serres correctement avant
la mise en service.
Selon la tension, les composants lectriques doivent tre mis
la terre conformment aux normes et rglements locaux.
Selon les cas, le raccordement lectrique seffectue par:
Connecteurs dbrochables ISO-4400 (avec degr de protection IP-65 lorsque le raccordement est correctement effectu).
Bornes vis solidaires du bobinage, sous botier mtallique
avec presse-toupe tanche Pg.
Fils ou cbles solidaires de la bobine.
MISE EN SERVICE
Avant de mettre le circuit sous pression, effectuez un essai
lectrique. Dans le cas dune lectrovanne, mettre la bobine sous
tension plusieurs fois et couter le clic mtallique qui signale le
fonctionnement de la tte magntique.

IN

FR

FONCTIONNEMENT
La plupart des lectrovannes comportent des bobinages prvus pour mise
sous tension permanente. Pour viter toute brlure, ne pas toucher la tte
magntique qui, en fonctionnement normal et en permanence sous tension, peut atteindre une temprature leve. Si llectrovanne est facilement
accessible, linstallateur doit prvoir une protection empchant tout contact accidentel.
BRUIT DE FONCTIONNEMENT
Le bruit de fonctionnement varie selon lutilisation, le fluide et le type de matriel
employ. Lutilisateur ne pourra dterminer avec prcision le niveau sonore
mis quaprs avoir mont le composant sur linstallation.
ENTRETIEN
Lentretien ncessaire aux produits ASCO/JOUCOMATIC varie avec leurs
conditions dutilisation. Il est souhaitable de procder un nettoyage
priodique dont lintervalle varie suivant la nature du fluide, les conditions
de fonctionnement et le milieu ambiant. Lors de lintervention, les
composants doivent tre examins pour dtecter toute usure excessive.
Un ensemble de pices internes est propos en pices de rechange pour
procder la rfection. En cas de problme lors du montage/entretien ou
en cas de doute, veuillez contacter ASCO/JOUCOMATIC ou ses
reprsentants officiels.
DEMONTAGE DE LA VANNE
Dmonter en suivant lordre indiq sur les vues en clat fournies dans la
pochette et destines lidentification des pices.
1. Oter le clip de maintien et faire glisser lensemble du botier du solnode
hors du sous-ensemble de la base du solnode. ATTENTION: lorsque le
clip de maintien mtallique est t, il peut bondir vers le haut.
2. Dvisser le sous-ensemble de base du solnode et enlever le montage du noyau, le ressort du noyau et le silencieux.
3. Dvisser les vis du couvercle (4x) et enlever le couvercle et lassemblage
de la membrane.
4. Vous pouvez ds prsent nettoyer ou remplacer toutes les pices.
REMONTAGE DE LA VANNE
Remonter en sens inverse.
1. NOTE: Lubrifier tous les joints dtanchit/joints toriques avec de la
graisse silicone de haute qualit. Remplacer la membrane en veillant
ce que le repre THIS SIDE OUT soit en face du couvercle. Trou de
purge de positionnement en alignement avec la cavit du corps de la
vanne et du couvercle. Les contours externes de la membrane, du corps
de la vanne et du couvercle doivent tous tre aligns.
2. Remplacer le couvercle et raccorder les vis du couvercle en les
entrecroisant selon le schma de couple.
3. Remplacer le montage du noyau, le ressort du noyau, le silencieux et
le sous-ensemble de la base du solnode et raccorder le sous-ensemble de la base du solnode en suivant le schma de couple.
4. Remplacer la rondelle lastique, le solnode et le clip de maintien.
5. Aprs lentretien, faire fonctionner la vanne quelques fois afin de
sassurer quelle souvre et se ferme correctement.
Conformment la directive CEE 89/392/CEE Annexe II B, une
Dclaration dincorporation peut tre fournie sur demande. Veuillez
nous indiquer le numro daccus de rception (AR) et les rfrences
ou codes des produits concerns. Ce produit est conforme aux exigences essentielles de la Directive 89/336/CEE sur la Compatibilit
Electromagntique, et amendements et les directives Basse Tension 73/23/CEE + 93/68/CEE. Une dclaration de conformit peut tre
fournie sur simple demande.

TROUBLE SHOOTING
PROBLEM

POSSIBLE CAUSE

1. Diaphragm Valve fails to operate (open)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

No pressure in header
Low or no power to coil
Coil inoperative
Pilot valve plunger jammed shut
Pilot orifice blocked
Secondary bleed-hold blocked
Main diaphragm perforated
Secondary diaphragm perforated
Pilot valve connecting line too long
Silencer, if fitted, may be blocked

1.
2.
3.
4.

Pilot valve plunger jammed open

Foreign matter under pilot valve
Secondary diaphragm spring broken
Foreign matter under secondary
diaphragm
Main diaphragm spring broken
Foreign matter under main diaphragm
Main diaphragm seating disc damaged
Main bleed hole blocked
Secondary bleed hole blocked
Leak in line connecting pilot valve

2. Diaphragm Valve fails to shut

5.
6.
7.
8.
9.
10.
3. Unable to build header pressure

1. Excessive leakage from main diaphragm

seat
2. Broken main valve spring
3. Secondary diaphragm not seating
4. Foreign matter under main
or secondary diaphragm
a) seat or under pilot valve seat
5. Air supply line too small
6. Compressor too small
4.

Sluggish operation of diaphragm valve

1. Partial blockage of one of the bleedholes
2. Silencer, if fitted, may be blocked

SPECIAL NOTE
To prevent premature failure of a diaphragm valve, special attention must be paid to the
quality of the compressed air/gas being handled.
An adequate moisture and oil removal system must be incorporated that takes into
account:
relative humidities likely to be experienced
ambient temperatures
system operating temperatures
pressure drops (and associated temperature drops) through the valve and also through
the blow tube holes (dew point problem)
Also, small traces of chlorine and other aggressive gases, often present in filter systems,
can be absorbed in wet areas resulting in corrosion and premature failure.
Apart from valve failures, systems may not perform to expectation for a number of
reasons including the following:
inaccurate mounting/positioning of theInjector head(s) relative to the vessel wall
inadequately sized header and/or air supply
incorrect pulse time
incorrect intervals between pulses
improper adjustment or wear ofInjector head(s) piston head

Maintenance
After the control device is powered on, 5V, 12V and 24V LED indicator on the circuit board is not lit. It is necessary to
check if power line is loose with connection terminal, if 0.315A fuse of power supply is broken, if power transformer is
normal and if there is any phenomena like a broken line, loose soldering, etc. in the power supply part.
If 5V or 12V LED indicator is not lit, it shows that there is a short circuit in the load, and some component is damaged.
It is necessary to check one by one. If load is disconnected, 5V or12V is still abnormal, and 3-terminal stabilized
circuit must be checked to see if it is normal.
If 24V LED indicator is not lit, the general status is that there is overload or short circuit of electromagnetic pulse valve
and lead at the load side.
After the control device is powered on, nixie light display and key input is normal:
(1)Output LED indicator is not lit and electromagnetic pulse valve does not work. And it is possible that SD-M-3002
circuit is damaged.
(2)Output LED indicator is lit and electromagnetic pulse valve does not work. And it is possible that the
corresponding electronic switch tube is damaged.
If a electromagnetic pulse valve is always magnetized, it must be checked if the corresponding electronic switch tube
is in electric leakage or broken-down.
If electromagnetic pulse valve is not always magnetized, it must be checked if the connection outside of the terminal
of common lead of the valve is correct and reliable.

ASME HORIZONTAL AIR RECEIVERS

30, 60, 80 Gallon

DIMENSIONS

Port size (NPT)

Tank
Size

Gal

14 X 48

30

14

48

33

14

5 9/16

20 X 48

60

20

48

26

18

7 7/8

12

12

20 X 63

80
20 63 36 18
All dimensions in inches

All receivers are built in accordance with the ASME section VIII Division I code latest
addition. All vessels are U stamped and registered with National Board.
Note: California requirements special please call.
Design pressure to 200 PSIG, test pressure 300 PSIG.
Design temperature: -20 to 650 F.
Type 1, 2:1 elliptical heads. All seams submerged arc welded.
Painted with one coat of standard gray shop primer.

ASME VERTICAL AIR RECEIVERS: 30, 60, 80 gallon

F
1/4" NPT

ASME
Nameplate

TL
HT
OD
B
C
G

D
1/2"
NPT
E (Bolt Circle)

9/16"

7/8" SLOT (4 places)

Gal

OD

Length
(TL)

Height
(HT)

F (NPT)

G (NPT)

30

16

38

40.81

12.56

30.06

25.06

2.81

15

.75

1.5

60

20

48

50.75

13.75

39.75

33.75

2.75

17

.75

80

24

46

49.19

13.06

39.31

34.31

3.19

21

1.25

All dimensions in inches

ASME STANDARD HORIZONTAL AIR RECEIVERS

120, 200, 240

Gal.

DIMENSIONS

Port size (NPT)

Tank
Size

Gal

24 x 69

120

24

69

42

22

10

30 x 72

200

30

72

38

28

12

50

28

12

30 x 84

240
30
84
All dimensions in inches

ASME STANDARD VERTICAL AIR RECEIVERS

120, 200, 240

Gal.

DIMENSIONS

Port size (NPT)

Tank
Size

Gal

30 X 46

120

30

46

12

NPT
Flat.Flange

2 NPT
Rad.Flange

2 NPS

NPT
Flat.Flange

1 NPT
Flat.Flange

1 NPT
Rad..Flange

30 X 72

200

30

72

15

16

15

13

NPT
Flat.Flange

2 NPT
Rad.Flange

2 NPS

NPT
Flat.Flange

1 NPT
Flat.Flange

1 NPT
Rad..Flange

30 X 84

240

30

84

19

20

19

13

NPT
Flat.Flange

2 NPT
Rad.Flange

2 NPS

NPT
Flat.Flange

1 NPT
Flat.Flange

1 NPT
Rad..Flange

All dimensions in inches

Plug
Plug
Plug

INJECTOR HEAD MAINTENANCE INSTRUCTIONS

Maintenance Requirements
Inspection of all components every 6 months is recommended for signs of wear or fatigue. Failure
to perform routine inspections may result in sudden failure and possible contamination of material
and/or damage to production equipment.

Isolation
Should it be necessary to overhaul any Injector heads while the system is working, it will be
necessary to first close the valve(s) isolating the Injector head(s) on that part of the hopper.
Next, switch on the Injector head control system for one full cycle. This will allow compressed
air to clear from all isolated pipes around the hopper, by cycling all Injector heads within the
system at least once.
CAUTION: to avoid injury, pressure must be relieved from header piping before
maintenance is started.

Dismantling
Having first disconnected the electrical leads and the air piping, the Injector head may be
withdrawn by loosening hex setscrews or lock nut and removing Injector head from mounting
flange/plate or coupling.
(NOTE: mark Injector head body to insure proper re-alignment with interior wall.)
At the work bench the solenoid valve should be unscrewed from the Injector head.
Holding the front of the valve cap in a vise, loosen and remove the jam nut and elastic stop nut
from the valve stem.
The compression washer, compression spring, spring guide and valve stem can then be
taken out. Inspect all parts for signs of wear or fatigue. Particularly note threads of the
valve stem and the front seat of the valve cap. Replace worn or damaged parts.

Reassembly
Reassemble valve assembly. Tighten elastic stop nut to 3mm (1/8") of internal stop (front spring
guide). Check 1/8" dimension by manually pushing on rear of valve stem to extend
(front) cap from body. Reinstall jam nut, and tighten against elastic stop nut. Reassemble with
solenoid and place back in hopper.

IMPORTANT: Front of Injector head valve body must align with interior of
hopper wall.

Jam Nut
Elastic Stop Nut
Compression Washer

Set Screws

Compression Spring

Mounting
Coupling

O Ring

Spring Guide

Mounting
Flange
Valve Body

Rubber
Gasket

Valve Stem
(Piston)

BAS-020 Injector head assembly with mounting

Qty
1
1*
1*
1*
1*
1*
1*
1
1

DESCRIPTION
Valve Body
Valve Stem
Spring Guide
Compression Spring
Compression Washer
Elastic Stop Nut
Jam Nut
Mounting Coupling
O-Ring**

CARBON STEEL
VB-020
VCW-020
SG-020
CS-020
CW-020
ESN-020
JN-020
MC-020
OR-020

STAINLESS STEEL
VB-020-SS
VCW-020-SS
SG-020-SS
CS-020-SS
CW-020-SS
ESN-020-SS
JN-020-SS
MC-020-SS
OR-020

Note: (*) denotes part included in rebuild kit.

Order RK-020 for carbon steel construction, RK-020-SS for stainless steel construction.
**For temperatures above 250 F, specify Viton O-ring (OR-020-V) .

3/4Flexible Hose Assemblies

Specifications
i.d. X 24 overall length
Bellows: SUS 316L
Wire Braids:SUS304
Temperature Range: -20CF to 180 C
Working Working Pressure: 16Kgf/cm2
Nipples: SUS 316L , NPT
Bellows O.D. : 30.5mm
Total length: normal 500-600mm (also according to client.)