Asco RCS Operation & Maintenance Manual

I&M No. V_9512_R9

Operation & Maintenance Guide

THIS DOCUMENT CONTROLLED BY

RCS Ex CERTIFICATION

ASCO Valves

©

ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com Page 1 of 18

®

E258615 - 09/2015 All Rights Reserved. I&M No. V_9512_R9

Operation & Maintenance Guide

Redundant Control System

Table of Contents

Product Description 3
ATEX Environmental Ratings 4

General Specications 4

Nameplate Information (ATEX Versions Only) 5

Section 1-Normally Closed 7

1. General Operation 7

2. Testing and Maintenance 9

Section 2-Normally Open 10

1. General Operation 10

2. Testing and Maintenance 11

Section 3-Double Acting 12

1. General Operation 12

2. Testing and Maintenance 13

Section 4 14

1. Functional Test Certication 14

2. Spare Parts 14

3. Packaging 14

4. Limited Warranty 14

5. Tools Required for Routine Service 14

RCS Base Unit Wiring Diagram (A) 15

RCS Base Unit with PLC Wiring Diagram (B) 16
RCS N.C. Piping Diagrams 17

RCS N.O. Piping Diagrams 18

Page 2 of 18 I&M No. V_9512_R9

©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.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 effectively 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 qualied personnel

verify all wiring and connections against vendor drawings.
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.

OPERATIONAL ATMOSPHERE CONSIDERATIONS:
The ATEX version of the Redundant Control System (hereafter

referred to as RCS) is designed in accordance with Annex II of
the European Directive 94/EC and European standards EN 60079-

0, EN 60079-1, EN 60079-7, and EN 600079-18. Classication : II

2G Ex d e mb IIC Gb IP-56.

MODELS COVERED BY ATEX APPROVAL:
ATEX Approval applies to RCS products having an ASCO Part
Number beginning with “5RC”, and that contain any combination
of the following features:

Manifold Architecture: Normally Closed, Normally Open, or
Double Acting.

Enclosure Material: 304 SS, 316 SS
System Voltage: 12 VDC, 24 VDC, 48 VDC, 120 VDC, 110/50-

120/60, 230/50-240/50

Operational Mode: Energized to trip or De-energized to trip
Optional Features: Common Alarm, Local Initiation of SOV test,

Local Initiation of Partial Stroke test, Bypass indication, Silver
Contact for relay logic or Lever type bypass switch.

User dened lights and push buttons: Any combination of standard
catalog lights and push buttons.

Options not covered by ATEX Approval:

• RCS products having an ASCO Part Number beginning with “5RC”

that include Local Manual Reset or a Composite Enclosure

• RCS units containing a PLC

PRODUCT DESCRIPTION

The RCS is a two-out-of-two (2oo2) or one-out-of-one hot standby
(1oo1 HS) 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 2oo2 or 1oo1
HS voting solenoids to enhance the reliability of the circuit. The
RCS consists of two electrically actuated solenoid valves (SOV1,
SOV2) and a pneumatically operated (Manually Controlled) bypass
valve, and three pressure switches. The pressure switches 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 RCS is available as a base unit (5R) and base
unit with on-board PLC (5L). The 5L unit with on-board PLC is
programmed with the logic required for proper operation. The type
of operation (2oo2 NC, 2oo2 NO, 2oo2 DA, 1oo1HS NC, 1oo1HS

NO) must be specied by the customer at the time of order. During

normal operation of a 5L construction power is routed through the
PLC to SOV1 and SOV2. Pressure switches (PS1, PS2 and PS3)
are monitored by the PLC. In the event of a PLC failure, SOV1 and
SOV2 will be connected directly to the Diagnostic Control System
(hereafter referred to as DCS) output, allowing the DCS to have
supervisory control of SOV1 and SOV2. Normal operation of the
processed valve unit will not be effected during this event. The RCS
unit will continue to function with restricted capabilities.

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, three pressure switches are included to
provide indication of each solenoid-operated valve and bypass valve
position.

Normally Closed Construction: the RCS supplies air to the
process valve actuator through the “Process” port when energized.

Page 3 of 18 I&M No. V_9512_R9

©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Normally Open Construction: the RCS blocks the incoming
pneumatic signal and connects the “Process” port to the “Exhaust”
port when energized.

Double Acting Construction: the incoming pneumatic control
signal passes through the RCS to one side (C2) of the process valve
actuator while the other side (C1) of the process valve actuator
is vented through the RCS when energized. The 1oo1 HS mode

cannot be used with the double acting construction.

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 fail­safe position.

Normally Open Construction: the RCS supplies air to the process
valve actuator through the “Process” port. This allows the actuator
to move the process to its fail-safe position.

Double Acting Construction: (C2) of the process valve actuator is
vented through the RCS while the pneumatic control signal is applied
to (C1) of the process valve actuator. This causes the process valve
actuator to move from its normal operating position to its fail-safe
position.

HARDWARE

For proper operation, a pneumatic pressure of 3-150 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 20”
x 16” x 8” enclosure. The primary components include:

• Hard anodized aluminum manifold body

• Two low power solenoid-operated ISO-3 valves

• A key-actuated bypass valve.

• Three pressure switches (ATEX rated Ex d IIC).

• An electrical terminal block for wiring termination (ATEX

rated Ex e IIC)

• Associated wiring.

• An on-board digital processor (RCS-L only)

3

-150 PSI

must

pressure

is

components

valves

(meets

A

key

-actuated bypass

valve.

Three p

ressure

switches

(meets UL Class I, Div. 2 and

ATEX rated Ex

d

IIC)

.

An electrical terminal block for wiring

termination

(ATEX rated Ex e

II)

Associated

wiring.

An

on

-board digital processor

(RCS-L only).

RCS-5R

eld wiring termination block

RCS-5L With Onboard PLC

Figure 1. General Appreance of the RCS

mounting brackets (2 on top)

on-board digital processor (RCS-L only)

pneumatic manifold

solenoid valves (2)

bypass valve

internal grounding/earthing connection

breather/vent

external grounding/earthing connection

Figure 2. RCS Components (Normally Closed shown)

ATEX ENVIRONMENTAL RATINGS

CE 0344 II 2G
Ex d e mb IIC T* Gb

• Ex : Explosion Protection Marking

• II: Equipment Group Other than Mines

• 2G: Category 2; Gas Atmosphere

• Ex : Explosion Protected

• d : Flameproof Protection Method

GENERAL SPECIFICATIONS

Solenoid Operator:
12, 24, 48 or 120 Volt DC Low Power,

Class F coil-1.4 watts and 1.7 watts
(1.7 watts does not apply to ATEX
versions)

120/60-110/50 or 230/50-240/50 AC

10.1 Watts

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:
3- station ISO base; unique pneumatic
circuit design

• e : Increased Safety Protection Method

• mb : Encapsulation safety method (solenoid only)

• IIC : Atmosphere Group: Acetylene & Hydrogen

• *T180°C : Temperature Class 180°C-120/60-110/50 or 230/50-240/50 Applications

• *T6 : Temperature Class 85°C-12/DC, 24/DC, 48/DC or 120/DC Applications

• Gb : Equipment Protection level (“High” Level)

Pressure Switches:

3 each (ATEX rated Ex II 2G D Ex IIC T6)
Pressure Switch Type:

SPDT switches, hermetically sealed,
Anodized Aluminum

Switch Contact Rating:
Gold contacts (std) 1 amp suppressed
resistive load; .5 amps inductive load @
28 VDC.
Silver contacts (opt) 5 amps suppressed
resistive load; 3 amps inductive load @ 28
VDC.

Connection & Setting:
¼” NPTF; 3 psi increasing/ 1 psi decreasing;
non-adjustable.

Electrical:

Digital Processor (PLC):
RCS-L only, 14 inputs, 10 outputs

manually actuated bypass valve

pressure switches (3)

pneumatic connections

mounting brackets (2 on bottom)

Pneumatic Connections:

Pilot:
1/8” NPTF

Pilot Pressure:
40-150 psi

Inlet & Process:
1/2” NPTF

Exhaust Port:
1/2” NPTF
Process Pressure Range:

3 psi to 150 psi

Air Quality:
Instrument air per ANSI/ISA 7.0.01-1996

Particle size ≤ 40 microns.

Materials:

Enclosure:
Stainless Steel (304 SS, 316SS) or Fiberglass
(Fiberglass does not apply to ATEX versions)

Page 4 of 18 I&M No. V_9512_R9

©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Size:
24”x 16”x 8”

Weight:
Approximately 75 lbs.

Mounting Panel
Painted Steel

Manifold:
Anodized aluminum.

Valves:

Body – Die-cast Aluminum alloy, Sealing­Nitrile (NBR) and Polyurethane (PUR),

Solenoid Coil:
Epoxy encapsulated.

Pressure Switches:
316 Stainless Steel Wetted Surfaces

Environmental:

Ambient temperature range:
Consult panel nameplate to verify.

• RCS-R = -40°F to 140°F (-40°C to 60°C)

• RCS-R with local manual reset option

= -4°F to 140°F (-20°C to 60°C)

• RCS-L = -4°F to 131°F (-20°C to 55°C)

Approvals:

Exida

Certied SIL 3 capable (Standard

Normally Open and Normally Closed

constructions, see SIL certicate for

special constructions).

Spool and Stainless Steel.

NAMEPLATE INFORMATION (ATEX VERSIONS ONLY)

name of manufacturer

CE marking and number of
notied body responsible for

quality system (CE 0344)

ambient temperature rating

certicate number

serial number

including date code

120/60 - 110/50 or 230/50 - 240/50 Volt AC Applications

name of manufacturer

CE marking and number of
notied body responsible for

quality system (CE 0344)

™

ENCLOSURE TYPE 4, 4X, IP-66

Ex d e mb IIC T180°C Gb

Tamb -40°C to +60°C
ITS 07ATEX15746

MAX. AMBIENT TEMP

MODEL NO.

SERIAL NO./DATE

FLORHAM PARK, NEW JERSEY, USA

™

ENCLOSURE TYPE 4, 4X, IP-66

explosion protection marking

equipment group II category 2

type of explosive atmosphere
G=gas, vapor or mist

POWER MAX.

VOLTAGE AIR.

electrical parameters

INLET (PSI) AIR.

PILOT (PSI)

address of manufacturer

explosion protection marking

equipment group II category 2

type of explosive atmosphere
G=gas, vapor or mist

temperature T code T6=85°C/185°F
12/DC, 24/DC, 48/DC or 120/DC
applications

ambient temperature rating

certicate number

serial number

including date code

Page 5 of 18 I&M No. V_9512_R9

©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

Ex d e mb IIC T6 Gb

Tamb -40°C to +60°C
ITS 07ATEX15746

POWER MAX.

MAX. AMBIENT TEMP

MODEL NO.

SERIAL NO./DATE

FLORHAM PARK, NEW JERSEY, USA

VOLTAGE AIR.

INLET (PSI) AIR.

PILOT (PSI)

12, 24, 48 or 120 Volt DC Applications

electrical parameters

address of manufacturer

INSTALLATION

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 eld 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 operation in ambient
temperatures from - 40°C to 60°C (RCS-R), -20°C to 60°C (RCS-R
with local manual reset option), from -20°C to 55°C (RCS-L).

WARNING: Explosion Hazard! Do not remove
or replace any component while circuit is live

unless the area is known to be nonhazardous.

ASCO components are intended to be used only within the

technical characteristics as specied on the nameplate. Changes to

the equipment are only allowed after consulting the manufacturer
or its representative. The Redundant Control System with ATEX

certication is intended for installation in potentially explosive

atmospheres, ATEX category 2G, gas Group IIC. The surface

temperature classication 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.

Field Connections:

Pneumatic Connections (Figure 5 A)

WARNING: Explosion Hazard! Do not remove
or replace any component while circuit is live

unless the area is known to be nonhazardous.

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.

process
1/2” NPT

inlet (supply)
1/2” NPT

inlet (supply)
1/2” NPT

Normally Closed

exhaust
1/2” NPT

pilot (supply)
1/8” NPT

exhaust
1/2” NPT

254 mm

406 mm

Figure 4. Mounting Dimensions

541 mm

241 mm

process
1/2” NPT

inlet (supply)
1/2” NPT

C2 process
1/2” NPT

Normally Open

Double Acting

Figure 5A. Pneumatic Connections

Page 6 of 18 I&M No. V_9512_R9

©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com

pilot (supply)
1/8” NPT

exhaust
1/2” NPT

C1 process
1/2” NPT

pilot (supply)
1/8” NPT