I&M V_9958_AA
ASCO Redundant Control System
2oo3B Enclosure without Diagnostics
2oo3BP Panel Mount without Diagnostics
Operation & Maintenance Guide
ASCO Valves® E301722 - 10/2020 All Rights Reserved. I&M V_9958_AA
©
ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com Page 1 of 7
Operation & Maintenance Guide
Redundant Control System
Table of Contents
PRODUCT DESCRIPTION.................................3
GENERAL SPECIFICATIONS ..............................4
INSTALLATION ..........................................4
Section 1. - Normally Closed............................... 6
1. General Operation and Testing ..........................................6
2. Maintenance: Valve Replacement........................................6
Section 2................................................ 7
1. Functional Test Certication ...........................................7
2. Spare Parts .........................................................7
3. Packaging ..........................................................7
4. Disclaimer .........................................................7
Page 2 of 7 I&M V_9958_AA
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ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
Documentation Conventions
MOUNTING BRACKETS TOP (2)
PNEUMATIC MANIFOLD
MOUNTING BRACKETS BOTTOM (2)
PNEUMATIC CONNECTIONS
BREATHER/DRAIN
EXTERNAL GROUNDING/
EARTHING CONNECTION
INTERNAL GROUNDING/
EARTHING CONNECTION
FIELD WIRING TERMINAL BLOCK
ENCLOSURE NEMA 4, 4X
SIZE: 20" x 16" x 8"
SOLENOID OPERATED VALVE (S0V 1)
SOLENOID OPERATED VALVE (S0V 2)
SOLENOID OPERATED VALVE (S0V 3)
This guide uses the following typographic conventions:
EXAMPLE
NOTE
Notes containing supplementary information.
This symbol precedes information about
potential equipment damage.
This symbol precedes information about
potential personnel hazards.
Description
User Experience Prerequisites
To eectively use the Pneumatic RCS, users should have some
experience with pneumatic systems.
Warnings!
READ THIS ENTIRE MANUAL AND ALL RELATED
PUBLICATIONS PERTAINING TO THE WORK TO BE
PERFORMED BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.
• Follow all appropriate safety codes and standards.
• Failure to follow instructions may result in personal injury
and/or property damage.
• Use extreme caution when working around powerinput cables. These cables may have potentially lethal or
dangerous voltages.
• Prior to energizing the equipment, have qualified personnel
verify all wiring and connections against vendor drawings.
PRODUCT DESCRIPTION
The RCS is a Two-Out-Of-Three (2oo3) solenoid operated valve
system designed for use as a component in safety instrumented
systems. It functions as a redundant pneumatic tripping device to
control the pilot air signal to a process valve actuator. The RCS
uses 2oo3 voting solenoids to enhance the reliability of the circuit.
The RCS consists of three electrically actuated solenoid valves
(SOVl, SOV2 & SOV3).
The RCS is available with a NEMA 4, 4x enclosure with terminal
strips (2oo3B) or as a stand alone panel mount version without
enclosure (2oo3BP).
Under normal operating conditions:
The RCS allows for periodic testing of the solenoids by cycling
one solenoid valve and then the other either manually or automati-
Incorrect wiring and/or connections can result in equipment
damage or serious system failure. If you have questions or
need more information on installing and operating ASCO
equipment, contact ASCO.
Avertissements!
LISEZ LE MANUEL COMPLET AINSI QUE LES
PUBLICATIONS RELATIVE AU TRAVAIL À
EFFECTUER AVANT D’INSTALLER, D’UTILISER OU
DE MAINTENIR CET ÉQUIPEMENT.
• Suivez toutes les procédures et normes relatives à la
sécurité appropriées.
• Le non-respect des instructions peut entrainer des blessures
corporelles et/ou des dommages matériels
• Travaillez avec une extrême précaution à proximité des câbles
de puissance. Ces câbles peuvent présenter potentiellement
des tensions mortelles ou dangereuses.
• Avant de mettre l’équipement sous tension, faites vérifier le
câblage et les connexions par du personnel qualifié par rapport
aux plans du fournisseur. Un câblage et/ou des connexions
erronée peuvent endommager l’équipement et provoquer
une grave défaillance du système. Si vous aves des questions
ou avez besoin de plus d’informations sur l’installation et
l’utilisation des équipements ASCO, contactez ASCO.
cally therefore attaining the desired safety availability. This testing
is performed online without the need for bypassing of the safety
action and without interruption of the process.
Normally Closed Construction: The RCS supplies air to the process
valve actuator through the “Process” port when energized.
When a trip occurs:
Normally Closed Construction: the RCS blocks the incoming
pneumatic signal and connects the “Process” port to the “Exhaust”
port. This vents the air signal from the process valve actuator and
allows the actuator return spring to move the process to its fail-safe
position.
For proper operation, a pneumatic pressure of 0 -150 PSI must be
supplied to the RCS INLET connection, and a pressure of 40 -150
psi supplied to the PILOT connection.
Figure 1A. RCS 2oo3B with Enclosure Components (Approx. Weight 29.5 kg., 65 lbs.)
Page 3 of 7 I&M V_9958_AA
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ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
SOLENOID OPERATED VALVE (S0V 1)
PLUGS
DO NOT REMOVE
PILOT
(SUPPLY)
1/8" NPT
EXHAUST
1/2" NPT
PROCESS OUT
1/2" NPT
INLET
(SUPPLY)
1/2" NPT
SOLENOID OPERATED VALVE (S0V 2)
SOLENOID OPERATED VALVE (S0V 3)
PNEUMATIC CONNECTIONS
Figure 1B. RCS 2oo3BP Panel Mount Components (Approx. Weight 9.4 kg., 21 lbs)
GENERAL SPECIFICATIONS
Solenoid Operator:
12, 24, 48 or 120 Volt DC Low Power, Class
F coil-1.4 watts.
120/60-110/50 or 230/50-240/50 AC
10.1 Watts, Class H Coil.
Pneumatic Valve:
ISO-3; 5/2 air-spring valve; solenoid
operated/Requires external pilot air supply.
Manifold:
3- station ISO base; unique pneumatic
circuit design.
Pneumatic Connections:
Pilot:
1/8” NPTF .
Pilot Pressure:
40-150 psi.
Inlet & Process:
1/2” NPTF.
Exhaust Port:
1/2” NPTF.
Inlet Pressure Range:
0 psi to 150 psi.
Air Quality:
Instrument air per ANSI/ISA 7.0.01-1996
Particle size ≤ 40 microns.
Materials:
Enclosure: 2oo3B
Stainless Steel (304 SS, 316SS) or Fiberglass
Mounting Bracket: 2003BP
Stainless Steel (304SS).
Weight:
2oo3B: With Enclosure, 29.5 kg. (65 lbs.)
2oo3BP: Panel Mount, 12.6 kg. (28 lbs.)
Manifold:
Anodized aluminum.
INSTALLATION
MOUNTING BRACKET (2)
PNEUMATIC MANIFOLD
Valves:
Body – Die-cast Aluminum alloy, SealingNitrile (NBR) and Polyurethane (PUR),
Spool-Stainless Steel.
Solenoid Coil:
Epoxy encapsulated.
Environmental:
Ambient temperature range:
Consult panel nameplate to verify.
-40 °F to 140 °F (-40 °C to 60 °C).
Approvals:
Exida
Certified SIL 3 capable (Standard Normally
Closed construction, see SIL certificate for
special constructions).
This section provides the information needed to install the RCS.
Unpacking:
Upon receipt of the RCS, unpack it carefully and visually check
for damage. The packing list shows the complete model number
and describes the features of the unit.
1. If the unit is damaged, immediately contact ASCO.
2. If everything is in order, proceed to the instructions in the
following sections.
Mounting Location Considerations:
The RCS is designed to be field mounted near the process valve
to be actuated. The following factors should be considered when
selecting a mounting location:
• Accessibility: Allow ample space for door operation, and for
wiring and tubing runs.
• Temperature: Consider the amount of heat generated by
equipment in the mounting area. The RCS is intended for
WARNING:
Explosion Hazard! Do not remove or
replace any component while circuit is live unless the area is
known to be non-hazardous.
AVERTISSEMENT:
Risque d’explosion. Ne pas retirer
ou remplacer les composants lorsque le circuit est sous
tension sauf en atmosphère non explosible.
ASCO 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.
Mounting:
The RCS is designed to be mounted using the four mounting
brackets provided, as shown in the figure 2A and 2B on the
next page. It is recommended that four 3/8” or 10 mm diameter
bolts be used.
operation in ambient temperatures from - 40 °C to 60 °C (RCS-R)
• Environment: Ensure that RCS unit is compatible with
respect to water ingress and corrosion resistance.
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ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
254 mm
356 mm
641,1 mm
508 mm
PLUGS
DO NOT REMOVE
PILOT
(SUPPLY)
1/8" NPT
EXHAUST
1/2" NPT
PROCESS OUT
1/2" NPT
INLET
(SUPPLY)
1/2" NPT
ASSEMBLY: 540394
SOLENOID VALVES (3)
MOUNTING BRACKET (2)
PLUGS
DO NOT REMOVE
PILOT
(SUPPLY)
1/8" NPT
EXHAUST
1/2" NPT
PROCESS OUT
1/2" NPT
INLET
(SUPPLY)
1/2" NPT
164 mm
200.3 mm
247 mm
263 mm
192 mm
406 mm
541 mm
241 mm
Figure 2A. Mounting Dimensions
2oo3B Enclosure
Field Connections:
Pneumatic Connections (Figure 3A)
WARNING:
replace any component while circuit is live unless the area is
known to be nonhazardous.
AVERTISSEMENT:
ou remplacer les composants lorsque le circuit est sous
tension sauf en atmosphère non explosible.
The RCS should be mounted as closely to the process valve
as possible. In order to insure proper operation of the process
valve, tubing runs should be as straight and short as possible.
Recommended piping for the inlet and outlet pneumatic
connections to the RCS is ½” stainless steel tubing. Recommended
piping for pilot supply is 1/8” stainless steel tubing.
Explosion Hazard! Do not remove or
Risque d’explosion! Ne pas retirer
Figure 2B. Mounting Dimensions 2oo3BP Panel Mount
25
mm
483
mm
25
mm
178 mm
Left
side
Enclosure openings are
permitted in shaded
areas. Multiple openings
must have a minimum
of 102 mm. spacing.
Maximum number of
enclosure openings is 4
per side.
Stainless Steel
Enclosures
178 mm
Right
side
165
mm
25
mm
483
mm
Figure 3B. Enclosure Openings
EXTERNAL GROUNDING/
EARTHING LOCATION
Figure 3A. RCS 2oo3B/BP Pneumatic Connections
INTERNAL GROUNDING/
EARTHING LOCATION
(STUD NOT VISIBLE)
Figure 3C. 2oo3B Enclosure Grounding Connections
Page 5 of 7 I&M V_9958_AA
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ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
Wiring Guidelines: 2oo3B With Enclosure
The following general guidelines apply to all wiring discussed in
this document.
WARNING:
Circuit power must be removed from the
device prior to disconnecting the wiring on either the eld or
internal side of the terminal strip.
AVERTISSEMENT:
L’alimentation électrique du
circuit doit être coupée avant de déconnecter le câblage
ou le bornier interne de l’équipement.
• Wiring shall be according to the National Electrical Code
(ANSI-NFPA 70), Zone 1 ATEX requirements or other
applicable codes.
• Wire size: stranded 16 and 18 AWG.
• The terminal clamps are designed for one wire only; DO NOT
attempt to terminate multiple wires into one terminal.
• Use care when running signal wiring near to or crossing
conduit or wiring that supplies power to motors, solenoids,
lighting, horns, bells, etc.
• AC power wiring should be run in a separate conduit from
DC power. All power wiring to and from the RCS should be
in grounded conduit.
Electrical Connection (Customer Responsibility):
General (Figure 3B)
1. In all cases follow local and national electrical codes and conrm
compliance with Zone 1 ATEX requirements.
2. Placement of the conduit connection is up to the customer,
in compliance with Zone 1, ATEX requirements, based on
location and ease of installation. The upper or lower left side
of the box will give the shortest run to the wire terminal.
3. Cable/conduit connections can be added in location as shown
on Figure 3B. Entry of external conductors and cables must
be through properly installed and suitable certified flameproof
cable entry devices and in accordance with ATEX Zone 1
increased safety requirements. Assemble and install cable
glands per manufacturer’s instructions. Connect cable ground
connections to the grounding/ earthing terminal blocks or
grounding / earth studs provided internally and externally.
4. It is recommended that standard industry practices are followed
to prevent condensation from entering the enclosure and, in
some cases of Class I, Div 2 or ATEX Zone 1 conditions, to
prevent hazardous gasses and vapours from migrating through
the conduit to the control room or open ignition source.
Section 1. - Normally Closed
1. General Operation and Testing
The RCS is a two-out-of-three (2oo3) voting solenoid operated
valve system, designed for use as a component in safety
instrumented systems. It functions as a redundant pneumatic
tripping device to control the pilot signal to a process valve
actuator. All three, or at least two of the three solenoids must be
de-energized (De-Energized-To-Trip) in order to move the process
valve to its fail safe position.
The RCS allows for periodic testing of the solenoids by cycling
one solenoid valve and then the other manually with a customer
supplied local initiation of SOV test or automatically by the
customers Diagnostic Control System, thereby maintaining the
desired safety availability. This testing is performed online without
the need for bypassing of the safety action and without interruption
of the system process.
Under normal operating conditions, the RCS supplies pilot air to
the process valve actuator through the “Process” port of the RCS.
When a trip occurs, the RCS blocks the incoming pneumatic
signal and connects the “Process” port to the “Exhaust” port. This
vents the air signal from the process valve actuator and allows
the actuator return spring to move the process valve to its fail
safe position.
Reference Table 1: RCS States for the various conditions of
supplying or venting the air supply to the process valve, based
on the combinations of energizing or de-energizing the solenoid
valves SOVl, SOV2 and SOV3.
Table 1 - RCS States, Normally Closed, De-Energize To Trip
States SOV1 SOV2 SOV2
1 Energized Energized Energized Air Supply
2 De- Energized De- Energized De- Energized Vented
3 De- Energized Energized Energized Air Supply
4 Energized De- Energized Energized Air Supply
Process/
Outlet
Grounding and Earthing. (Figure 3C)
5 Energized Energized De- Energized Air Supply
The RCS should be connected to a high quality instrument grade
ground with #14 AWG or heavier wire. A grounding stud is
6 De- Energized De- Energized Energized Vented
provided both inside and outside the enclosure.
Ground/earth the product in accordance with local and national
7 De- Energized Energized De- Energized Vented
electric codes as well as ATEX Zone 1 requirements. Green
earthing terminal blocks are provided for easy installation of
8 Energized De- Energized De- Energized Vented
conductor up to 4 mm sq.
Only insert one conductor per terminal block. Grounding studs
are provided inside and outside of the enclosure for additional
grounding/earthing requirements (See Figure 3C).
RCS-R Base Unit (without on-board PLC)
1. Connect the power source to the designated terminals
(SOV1, SOV2) as per wiring diagram provided with the
RCS unit. Wiring diagrams are available on the Internet at:
www.ascovalve.com/rcscongurator
Wiring 2oo3BP: Panel Mount
SOV solenoids are equipped with 18 AWG - 18” leads with
ground wire and 1/2 NPT female conduit connection for the
customer connection.
2. Maintenance: Valve Replacement
WARNING:
Use wet or damp cloth when cleaning any non-metallic/
painted surfaces.
AVERTISSEMENT:
électrostatique. Utilisez un chion humide quand vous
nettoyez toutes les surfaces non métalliques ou peintes.
CAUTION:
pressure is maintained or vented as necessary prior to
removing power source to the unit. Failure to do so will
initiate a power shutdown.
ATTENTION:
Potential Electrostatic Charging Hazard.
Risque potentiel de décharge
Ensure that the downstream process
Assurez-vous que la pression du
processus en aval est maintenue ou purgée au besoin
avant de déconnecter l’alimentation de l’équipement. Le
non-respect de cette consigne entrainera une coupure
d’alimentation.
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ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
This equipment must be bypassed and vented prior to removing
power and performing any maintenance or service, to ensure
process is not interrupted.
After maintenance or service, power and pressure must be restored
to this equipment and bypass removed.
Failure to do so will prevent this equipment from properly
controlling the process.
The Pneumatic RCS requires no routine maintenance except for
periodic inspection for loose wires and fittings. Versions with an
enclosure should be opened occasionally and the components
checked to make sure they are tight, clean and dry. The Breather
Drain should be inspected for obstruction to make sure it is
free from debris.
SOV Valve Replacement
WARNING:
DOWNSTREAM PROCESS HAZARD
Ensure that all process connections and equipment
are correctly installed downstream of this system prior
to servicing this equipment. Failure to do so could
result in death or serious injury.
AVERTISSEMENT:
DANGER LIÉ AU PROCESSUS
EN AVAL. Assurez vous que toutes les connections et
équipements sont correctement installées en aval de
l’équipement avant de réparer ce dernier. Le non-respect de
cette consigne pourra entrainer la mort ou des blessures
graves.
1. Bypass this equipment as necessary to maintain
function to process.
2. Verify that pressure is removed from this equipment and that
INLET, PROCESS & EXH connections to this equipment
are fully vented.
3. Turn off power to this equipment.
4. Components can then be removed and replaced without
interrupting the process. Remove device (coil,solenoid valve)
and install the new device following instruction supplied.
If replacing a solenoid valve, apply a small amount antiseize to the screw threads and torque to 160–170 in-lbs., in
a criss-cross pattern. Reconnect coil wires to terminal block
or power supply.
5. Turn on power to the system.
6. Restore pressure and remove bypass to this equipment to
return to normal operation. Verify that each device has power
and is in the correct sate (See Table 1).
7. Have the control room run through the programmed test to be
sure the system is operating properly.
Section 2.
1. Functional Test Certication
Once assembled and inspected the RCS is cycled through a generic
program to validate two-out-of-three (2oo3) shut down function.
2. Spare Parts
3. Packaging
While the package for RCS is designed to handle the weight of the
unit, there are always hazards in shipping. Upon receipt of product,
unpack and check the product against the packing slip. If there is
damage to the product, immediately contact the Authorized ASCO
sales representative.
4. Disclaimer
Because of the variety of uses for the ASCO Redundant Control
System (RCS), the user and those responsible for applying this
equipment must satisfy themselves as to the acceptability of the
RCS for each application.
The illustrations in this manual are solely intended to illustrate
the text of this manual. Because of the many variables and
requirements associated with this particular installation, ASCO
cannot assume responsibility or liability for actual use based upon
the illustrative uses and applications.
In no event will ASCO be responsible or liable for indirect or
consequential damages resulting from the use or application
of this equipment. ASCO disclaims any implied warranties of
merchantability or fitness for a particular purpose.
ASCO DISCLAIMS ANY IMPLIED WARRANTY OR
FITNESS FOR A PARTICULAR PURPOSE.
No patent or copyright liability is assumed by ASCO with respect to
use of information, circuits, equipment or software described in this
text.
Reproduction of the content of this manual, in whole or in part,
without written permission from ASCO is prohibited.
WARNING:
Replacement parts are only to be obtained
from ASCO or an authorized distributor or the certications
may be invalidated or there may be a risk of explosion.
AVERTISSEMENT:
Le pièces de rechange doivent
uniquement être approvisionnées auprès d’ASCO ou d’un
de ses distributeurs agréés, sinon les certicats pourraient
être invalidés et il pourrait y avoir un risque d’explosion.
VALVES AND COILS
APPLICATION VOLTAGE VALVE COIL
De-Energize-To-Trip 12/DC 323531 238714-903-D
De-Energize-To-Trip 24/DC 323406 238714-902-D
De-Energize-To-Trip 48/DC 323533 238714-912-D
De-Energize-To-Trip 120/DC 323535 238714-904-D
De-Energize-To-Trip 120/60-110/50 323404 238814-032-D
De-Energize-To-Trip 230/50-240/50 323537 238814-059-D
Page 7 of 7 I&M V_9958_AA
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ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
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