ASCO Maintenance Guide: I&M RCS 2oo3D Basic Sheet Manuals & Guides

I&M V_9959_AA
ASCO Redundant Control System
2oo3D Enclosure with Proximity Sensor Diagnostics
Operation & Maintenance Guide
ASCO Valves® E301722 - 10/2020 All Rights Reserved. I&M V_9959_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 ...................................................6
2. Testing and Maintenance: .............................................6
Section 2 ............................................... 7
1. Functional Test Certication ...........................................7
2. Spare Parts .........................................................7
3. Packaging ..........................................................7
4. Disclaimer .........................................................7
Page 2 of 7 I&M_V_9959_AA
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 eectively 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
rated Ex e IIC)
Associated wiring.
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ASCO, L.P. 160 Park Avenue, Florham Park, New Jersey 07932 www.emerson.com
EXTERNAL GROUNDING/ EARTHING LOCATION
INTERNAL GROUNDING/
EARTHING LOCATION
(STUD NOT VISIBLE)
ASSEMBLY: 540454
ENCLOSURE NEMA 4, 4X
EXHAUST
1/2" NPT
PLUG
DO NOT REMOVE
356 mm
641,1 mm
508 mm
292 mm
SIZE: 24" x 20" x 10"
MOUNTING BRACKET TOP (2)
MANUALLY ACTUATED BYPASS SWITCH
PNEUMATIC MANIFOLD
FIELD WIRING TERMINAL BLOCK
PROXIMITY SENSOR/SWITCH (4)
INTERNAL GROUNDING/
EARTHING CONNECTION
EXTERNAL GROUNDING/
EARTHING CONNECTION
Figure 1A. RCS 2oo3D With Enclosure Components
Approx Weight 48.2 kg (106 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.
Bypass Valve: ISO-3; 5/2 air-spring valve; manually operated/Requires external pilot air supply.
Manifold: 4-station ISO base; unique pneumatic circuit design
Proximity Sensors/Switches: 4 each
Switch Type: SPDT switches, hermetically sealed, Stainless Steel
Switch Contact Rating: Silver contacts Resistive load
4 Amps @ 120 VAC 2 Amps @ 240 VAC 3 Amps @ 24 VDC
1.25 Amps @ 12 VDC
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: 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:
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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 conrm
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)
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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/rcscongurator
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
State SOV1 SOV2 SOV3 Bypass Valve
1 Energized Energized Energized Normal Operation Open Open Open Closed Air Supply
2 De-Energized De-Energized De-Energized Normal Operation Closed Closed Closed Closed Vented
3 De-Energized Energized Energized Normal Operation Closed Open Open Closed Air Supply
4 Energized De-Energized Energized Normal Operation Open Closed Open Closed Air Supply
5 Energized Energized De-Energized Normal Operation Open Open Closed Closed Air Supply
6 De-Energized De-Energized Energized Normal Operation Closed Closed Open Closed Vented
7 De-Energized Energized De-Energized Normal Operation Closed Open Closed Closed Vented
8 Energized De-Energized De-Energized Normal Operation Open Closed Closed Closed Vented
9 * * * Maintenance Bypass Closed Closed Closed Open Air Supply
* - SOV valves are vented to exhaust when in Maintenance Bypass mode.
Normally Open Contact State
PS1 PS2 PS3 PS4
Process/
Outlet
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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 chi󰀨on 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.
Manual Bypass Valve Operation (for maintenance only)
WARNING:
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 Certication
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 certications
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 certicats pourraient
être invalidés et il pourrait y avoir un risque d’explosion
APPLICATION VOLTAGE
De-Energize-To-Trip 12/DC 326424 238714-903-D De-Energize-To-Trip 24/DC 325909 238714-902-D De-Energize-To-Trip 48/DC 326425 238714-912-D De-Energize-To-Trip 120/DC 326426 238714-904-D De-Energize-To-Trip 120/60-110/50 326427 238814-032-D De-Energize-To-Trip 230/50-240/50 326428 238814-059-D
Bypass ALL 323493 None
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.
Replacement parts are only to be obtained
Le pièces de rechange doivent
VALVES AND COILS
VALVE
including proximity
sensor/
switch
COIL
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