ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
Documentation Conventions
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 power-input
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) 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 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
(SOV1, SOV2, SOV3) and a pneumatically operated (Manually
Controlled) bypass valve, and four proximity sensors. The
proximity sensors provide solenoid state feedback and are used
during on-line testing of the RCS unit. The bypass valve allows for
maintenance of the solenoid valves without having to shut down
the process valve. The use of the Maintenance Bypass Valve is not
required for functional testing of the RCS unit. The 2oo3 RCS is
available as a normally-closed construction.
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
automatically 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.
For all constructions, four proximity sensors are included to
provide indication of each solenoid-operated valve and bypass
valve position.
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.
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.
HARDWARE
For proper operation, a pneumatic pressure of 0-150 PSI must
be supplied to the RCS [process connection] while a pressure
of 40-150 PSI must be supplied to the [pilot connection]. It is
housed in a 24” x 20” x 10” enclosure. The primary components
include:
• Hard anodized aluminum manifold body
• Three low power solenoid-operated ISO-3 valves
• A key-actuated bypass valve. (Lever, Optional)
• Four Proximity Sensors
• An electrical terminal block for wiring termination (ATEX
Air Quality:
Instrument air per ANSI/ISA 7.0.01-1996
Particle size ≤ 40 microns.
Materials:
Enclosure:
Stainless Steel (316SS)
Size:
24”x 20”x 10”
PNEUMATIC CONNECTIONS
BREATHER/DRAIN
SOLENOID VALVE
(SOV1)
SOLENOID VALVE
(SOV2)
SOLENOID VALVE
(SOV3)
BYPASS VALVE
B/P
MOUNTING BRACKETS BOTTOM (2)
Weight:
Approximately 48.2 kg (106 lbs.)
Mounting Panel
Painted Steel
Manifold:
Anodized aluminum.
Valves:
Body – Die-cast Aluminum alloy, SealingNitrile (NBR) and Polyurethane (PUR),
Spool - Stainless Steel.
Solenoid Coil:
Epoxy encapsulated.
Proximity Sensors/Switches:
316 Stainless Steel
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).
INSTALLATION
This section provides 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:
ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
• 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
operation in ambient temperatures from - 40 °C to 60 °C.
• Environment: Ensure that RCS unit is compatible with respect
to water ingress and corrosion resistance.
WARNING:
Explosion Hazard! Do not remove or
replace any component while circuit is live unless the area
is known to be nonhazardous.
AVERTISSEMENT:
Risque d’explosion! Ne pas retirer
ou remplacer les composants lorsque le circuit est sous
tension sauf en atmosphère non explosible.
EXTERNAL GROUNDING/EARTHING LOCATION
PLUGS
DO NOT REMOVE
PROCESS OUT
1/2" NPT
EXHAUST
1/2" NPT
PLUG
DO NOT REMOVE
INLET (SUPPLY)
1/2" NPT
PILOT (SUPPLY)
1/8" NPT
EXTERNAL GROUNDING/EARTHING LOCATION
INTERNAL GROUNDING/
EARTHING LOCATION
(STUD NOT VISIBLE)
ASSEMBLY: 540454
356 mm
641,1 mm
508 mm
292 mm
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. The surface temperature classification depends on
the voltage, wattage and ambient temperature which are stated on
the nameplate. Depending on the ambient/operation temperature,
heat resistant cabling capable for the temperature as indicated on the
nameplate must be used.
Mounting:
The RCS is designed to be mounted using the four mounting brackets
provided on the enclosure corners as shown in the gure below. It is
recommended that four 3/8” or 10 mm diameter bolts be used.
Wiring Guidelines
The following general guidelines apply to all wiring discussed in
this document.
WARNING:
device prior to disconnecting the wiring on either the eld
or internal side of the terminal strip.
AVERTISSEMENT:
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
Circuit power must be removed from the
L’alimentation électrique du circuit
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.
• The RCS should be connected to a high quality instrument
grade ground with #14 AWG or heavier wire. A grounding
stud is provided both inside and outside the enclosure.
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 5B. 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
Figure 2. Mounting Dimension
Field Connections:
Pneumaric Connections (Figure 3A)
WARNING:
Explosion Hazard! Do not remove or
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 vapors from migrating through the conduit to
the control room or open ignition source.
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.
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.
25
mm
585
mm
229 mm
Left
25
side
mm
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
299 mm
Right
side
Figure 3B. Enclosure Openings 2oo3D
Grounding and Earthing. (Figure 3C)
Internal and external grounding studs are provided on the RCS
product. Ground/earth the product in accordance with local and
national electric codes as well as ATEX Zone 1 requirements.
Green earthing terminal blocks are provided for easy installation
of conductor up to 4 mm sq.
Only insert one conductor per terminal block. Grounding studs
Figure 3A. Pneumatic Connections
are provided inside and outside of the enclosure for additional
grounding/earthing requirements. (see Figure 3C)
ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
175
mm
25
mm
585
mm
INTERNAL GROUNDING/
ASSEMBLY: 540454
EARTHING LOCATION
(STUD NOT VISIBLE)
RCS-R Base Unit
1. Connect the power source to the designated terminals (SOV1,
SOV2, SOV3) as per wiring diagram provided with the RCS
unit. Wiring diagrams are available on the Internet at: www.
ascovalve.com/rcscongurator
2. Wire the four proximity sensors (PS1, PS2, PS3 & PS4) as per
wiring diagram.
3. Wire optional accessories.
Section 1. - Normally Closed
1. General Operation
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 air signal to a process valve
actuator. All three or at least two of the three solenoids must be
de-energized (De-Energize-To-Trip Version) prior to moving
the process to its fail-safe position. Four proximity sensors are
included to provide indication of each solenoid-operated valve
and bypass valve position.
The RCS allows for periodic testing of the solenoids by cycling
one solenoid valve and then the other either manually (when
ordered with a local initiation of SOV test option) or automatically
by the system DCS, therefore 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. 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
EXTERNAL GROUNDING/
EARTHING LOCATION
Figure 3C. Grounding Connections
return spring to move the process valve actuator to its fail-safe
position.
The proximity sensors report solenoid valve positions as
shown in Table 1:
RUN MODE: De-Energize-To-Trip:
• If any two of the three or all three solenoid valves SOV1,
SOV2 and SOV3 are in the energized position, INLET
pressure is directed to the PROCESS port.
• If any two of the three, or all three solenoid valves SOV1,
SOV2 and SOV3 are in the de-energized position, INLET
pressure is blocked and pressure from the PROCESS port is
vented to EXHASUT port.
• Refer to Table 1 for the various states of solenoid
energization, and the resulting status of the PROCESS/
OUTLET port and PS proximity sensor contact state.
BYPASS MODE: De-Energize-To-Trip:
The manually actuated bypass switch has two positions:
NORMAL for system run and MAINTENANCE BYPASS for
maintenance of the solenoid valves. To change positions simply
rotate the key to the desired position, indicated on the switch. (A
lever option is available in the place of the key).
• The manually operated bypass switch is used to isolate and
depressurize the solenoid valves during maintenance. The
maintenance bypass valve position is indicated by proximity
sensor No .4 contacts (PS4).
• In the Bypass mode, the RCS INLET port is directly connected
to the PROCESS PORT. The solenoid valves are vented to
the EXHAUST port.
• In the Bypass mode, the Normally Open contacts of PS1, PS2
and PS3 are closed, and PS4 is open, indicating that no pressure
is on the solenoid valves.
• Refer to Table 1 for the various states of SOV solenoid
valve energization and the resulting status of PS proximity
sensor contact state.
• energization and the resulting status of PS proximity sensor
contact state.
2. Testing and Maintenance:
Testing:
Solenoid-operated valve testing
The solenoid-operated valves and their associated proximity
sensors can be tested online without interruption of the process.
This testing is implemented by cycling each solenoid-operated
valve and comparing the associated proximity sensor contact
reading to the test table.
Partial Stroke testing
A partial stroke of the process valve can be performed online
without interruption of the process. This testing is implemented
by performing solenoid-operated valve testing, then moving the
process valve toward the safe state for a predetermined time. At the
end of the predetermined time, the process valve is returned to the
normal position.
Table 1 - RCS States, Normally Closed, De-Energize to Trip
ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
Testing can be automated using a programmable logic controller
(PLC), a distributed control system (DCS).
CAUTION:
(De - Energize - To - Trip Version) Deenergizing two solenoid valves at the same time will initiate
a shutdown.
ATTENTION:
(version « De-Energize-To-Trip ») la
coupure électrique de deux électrovannes simultanément
déclenchera un arrêt.
1. At all times during testing, two out of the three solenoid-
operated valves must be in the energized position (De-EnergizeTo-Trip Version).
2. IF, during the test process, the proximity sensors do not indicate
what is expected according to the test Table 1. The remaining
solenoid-operated valve must not be de-energized.
Maintenance:
WARNING:
Potential Electrostatic Charging Hazard.
Use wet or damp cloth when cleaning any non-metallic/
painted surfaces.
AVERTISSEMENT:
Risque potentiel de décharge
électrostatique. Utilisez un chion humide quand vous
nettoyez toutes les surfaces non métalliques ou peintes.
The Pneumatic RCS requires no routine maintenance except
periodic inspections for loose wires and fittings. The enclosure
should be opened occasionally and the components checked to
make sure they are tight, clean, and dry. The Breather/Drain
valve shall be inspected for obstruction and that it is free of
debris during routine maintenance cycles and during manual
proof testing.
Manually-Actuated Bypass Valve
If it is necessary to replace a solenoid- operated valve or coil
during normal operation, the manually- operated bypass valve
is used.
This valve is used to isolate and depressurize the solenoid valves
for maintenance only.
When the switch is rotated to the bypass position, the RCS
manifold channels the inlet pressure directly to the process
port. Pressure to the solenoid valves is vented to “exhaust”.
The Normally Open contacts of PS1, PS2 and PS3 are closed
and PS4 is open which signals the PLC/DCS that the RCS is in
bypass and not in shut down.
Explosion Hazard. Do not open the
enclosure unless area is known to be non-hazardous.
AVERTISSEMENT:
Risque d’explosion. Ne pas ouvrir
le boitier dans une atmosphère explosible.
1. Turn the key clockwise from “Normal” to “Maintenance Bypass”.
The system pressure is now bypassed directly from “inlet” to
“process” so that the process valve position is maintained.
2. Verify that all four proximity sensor contacts are indicating the
RCS is in Bypass. Refer to Table 1.
WARNING:
Remove the maintenance bypass key
from the switch and place the key in the bottom of the
enclosure until maintenance has been completed.
AVERTISSEMENT:
Retirez la clé de dérivation de
maintenance du commutateur et placez là au bas du boitier
jusqu’à ce que la maintenance soit terminée.
WARNING:
Explosion Hazard. Do not remove or
replace any component while circuit is live unless 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.
3. Turn off power to the RCS; disconnect appropriate wires from
terminal block.
4. Remove device (coil, solenoid valve) and install the new device
following instructions supplied. If replacing a solenoid valve,
apply a small amount of anti-seize to the bolt threads and torque
to 160-175 in-lbs in a crisscross pattern. Reconnect wires to
appropriate terminal, (see wiring diagrams).
5. Turn on power to the RCS. Verify that each device has power and
is in the correct state. (see Table 1).
6. Replace key in the Maintenance Bypass and rotate counterclockwise to the “Normal” position.
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;
solenoid valve status, proximity sensor indication and manual
bypass function.
2. Spare Parts
WARNING:
from ASCO or an authorized distributor or the certications
may be invalidated or there may be a risk of explosion.
AVERTISSEMENT:
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
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.