E-STOP09
Gas Shutoff Timer
ASSEMBLY INSTRUCTIONS CARE, USE, AND SAFETY MANUAL
© AEI CORPORATION 2021
IMPORTANT
Please read these assembly
instructions carefully before attempting to
assemble, use, or service this product.
Please keep this manual for your future
reference. If you have any questions,
please feel free to call us at 949-474-3070
Monday through Friday 7AM to 4PM Pacific
Time.
General Hazard Warning:
Improper installation, adjustment,
alteration, service or maintenance of this
product can result in death or cause injury
or property damage. Please read the
installation, operation, and maintenance
instructions thoroughly before installing or
servicing this appliance.
For your safety- If you smell gas:
1. Open windows
2. DO NOT try to light any appliances
3. DO NOT use electrical switches
4. DO NOT use any telephone in your building.
5. Leave the building immediately.
6. Immediately call your gas supplier after
leaving the building. Follow their directions.
7. If you cannot reach your local gas supplier
Call the Fire Department.
Please read all operating instructions
before using and operating this appliance.
Please handle metal parts with care to avoid
injury. Please follow all steps as outlined.
Never allow children to use this product!
1
1. The assembly and installation of this appliance must conform with local codes or in the
absence of local codes, to the National Fuel Gas Code ANSI Z223.1-1988.
2. Test all fittings and connections with a soapy solution prior to use. Never use an
open flame or open flame device.
Please note the following very important safety precautions:
Children should be carefully supervised when near the gas timer shutoff. This timer
is not a toy and children should not be allowed to push or climb on the timer. THESE
ACTIONS COULD CAUSE SERIOUS INJURY, PROPERTY DAMAGE, OR DEATH.
Installation and repair of the gas timer shutoff should be done by a qualified service
technician.
Any part, sub-assembly, or component removed for cleaning or maintenance must be
properly re-installed before using the gas timer shutoff.
The preceding pages attempt to highlight only the most important safety aspects and
guidelines for using your gas timer shutoff. We have made every effort to thoroughly
address all safety, assembly, and use issues for this product in the manual to follow. We
strongly encourage that you read and understand the materials contained in the manual
before using your gas timer shutoff. If you have any questions, whatsoever, regarding
the safe assembly, or use, of your gas timer shutoff, please call us directly at
© AEI CORPORATION 2021
WARNING-California Proposition 65-The burning of gas cooking or
heating fuels (and certain components contained in this product) generates
some by products which are on a list of substances known by the state of
California to cause cancer or reproductive harm. California law requires
businesses to warn customers of potential exposure to such substances. To
minimize exposure to such substances always operate this appliance in
accordance with our Use & Care Guide (Owner’s Manual) ensuring you provide
good ventilation when cooking with gas. For detailed information please see
official California Proposition 65 website www.P65WARNINGS.CA.GOV
2
© AEI CORPORATION 2021
Thank you very much for purchasing a Gas Timer Shutoff. This manual contains very
important information detailing the proper assembly, operation, and maintenance of this
product. This product has been designed with the latest in safety technology. Important
safety information is presented throughout this manual for your safety and that of any users.
We have designed this product to provide you with many years of convenience when operated
and maintained properly. If you have questions as to the assembly or safe operation of the
gas timer shutoff please call us directly, at 949 474-3070, Monday through Friday 7 AM to 4
PM Pacific Coast Time.
3
© AEI CORPORATION 2021
Table of Contents
PAGE #
1-3
4
5-6
7
8
9
BASIC SAFETY AND OPERATIONAL DATA
TABLE OF CONTENTS
TECHNICAL DATA, ASSEMBLY TIPS, AND TOOLS NEEDED
SCHEMATICS
BOX WIRING INSTRUCTIONS, TIMER SETTINGS, AND TIMER
OPERATING INSTRUCTIONS
E-STOP BUTTON FUNCTION AND OPERATION
ASCO VALVE INSTALLATION & MAINTENANCE INSTRUCTIONS
TESTING FOR GAS LEAKS
IMPORTANT WARNINGS AND SAFETY POINTS
SERVICE AND WARRANTY INFORMATION
LEGAL RIGHTS
BLANK PAGE
WARRANTY REGISTRATION FORM
10-22
23-24
25
26
27
28
29
4
© AEI CORPORATION 2021
Technical Data: Model
ESTOP09
This unit is designed and configured
for use with Natural Gas and Liquid
Propane.
Assembly Tips
When starting the assembly process please take all
of the parts out of the boxes and check if anything is
missing. Please check the Timer box and Solenoid
Valve with the following parts breakdown. Even
though we exercise extreme quality control
procedures, occasionally, we will have a missing
part, or a part may have been damaged in transit. If
anything is missing, please contact us directly at
949-474-3070. We will immediately help you. The
same holds true for any questions you may have
regarding assembly or operation. When in doubt,
please ask. We’re at your service.
Owner Notes:
5
© AEI CORPORATION 2021
You will need the following tools and materials to assemble the Gas Shutoff Timer:
Teflon tape or gas sealant/pipe compound
Adjustable crescent wrench or socket driver Standard Phillips Head #3 screw driver
Channel Locks or Pliers-Minimum 1 ½” capacity
Soapy water solution for leak testing
All male pipe thread connections will require Teflon tape or other approved sealant. Teflon
tape FOR NATURAL GAS AND PROPANE works the best and is the easiest to use.
PLEASE NOTE: The proper assembly of this
gas timer shutoff requires a qualified gas
appliance technician. Installation is the
responsibility of the customer.
All repair or services should be done by a
qualified gas appliance technician.
Warning
Improper installation, adjustment, alteration, service, or maintenance can cause
property damage, injury or death. Read the assembly, installation, operating, and
maintenance instructions thoroughly before use, installing or servicing the
appliance.
Warning
Do NOT store or use gasoline or any other flammable vapors and
liquids in the vicinity of this or any other appliance.
FOR YOUR SAFETY: If you smell gas:
1. Shut off gas to the appliance
2. Extinguish any open flames
3. If odor continues, immediately call your gas
supplier.
6
ValVe Dimensions:
• height: 4.5”
• WiDth: 4”
• Depth: 2.25”
Box Dimensions:
• height: 9.5”
• WiDth: 5.75”
• Depth:
- Box: 3.75”
- incluDing Button: 5.5”
7
MODEL: T101R
�• LR3730
C US
A WARNING
_
Risk of or c Shock
°
A ERTISSEMENT
°
a
CLOCK MOTOR: 120 VAC, 60 HZ.
D.
,:
°
120V. 240V. 240V.
INTERMATIC INCORPORATED
8
E-STOP Function:
NFPA 79 requires that push-button emergency stops be of the “self-latching” type,
which means that after an emergency stop actuator is depressed and the contacts
open, the emergency stop device must remain in the actuated position until it is
deliberately reset. If the E-STOP function has been activated, to turn off the gas
supply, you must check for leaks, or reason for activation, before resetting.
Resetting Instructions
Resetting the E-STOP means a person manually intervenes and unlatches the
button by rotating the button to the right.
Tamper Resistant:
The Emergency Stop Button is secure and is not easily removable from the
enclosure.
Safeguarding:
Emergency Stop devices are not a replacement for proper safeguarding or
automatic safety devices. Instead, it should be used as a backup measure. In ad-
dition, the activation of the emergency stop should not impair the effectiveness of
the other safety devices.
9
lnstallaon & Maintenance Instrucons SERIES
8003G/H
8007G/H
8202G/H
l&M V 6584 R16 sec1
OPEN-FRAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS
ASCO® solenoid valves with design change letter
“G” or “H’’ in the catalog number ( ex. 821 0G I) 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.
See separate instructions for basic valve.
* 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 con-
tact DIN Type 43650 construction (See Figure 6).
OPERATION
Series 8003G/H and 8007G/H - 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,pres-
sure, or weight, must exert a minimum force to overcome re-
sidual magnetism created by the solenoid. Minimum return
force for AC construction is 11 ounces, and 5 ounces for DC
construction.
Series 8202G/H - When the solenoid is energized, the disc
holder assembly seats against the orice. When the solenoid is
de-energized , the disc holder assembly returns. IMPORTANT:
Initial return force for the disc or disc holder assembly,
whether developed by spring, pressure, or weight, must
exert a minimum force to overcome residual magnetism
created by the solenoid. Minimum return force is 1 pound, 5
ounces.
INSTALLATION
Check nameplate for correct catalog number, service, and watt-
age. Check front of solenoid for voltage and frequency.
A WARNING: Electrical hazard from the acces-
sibility of live parts. To prevent the possibility of
death, serious injury or property damage, install
the open • frame solenoid in an enclosure.
FOR BLACK ENCLOSURE TYPES 7 AND 9 ONLY
ACAUTlON: To prevent re or explosion, do not install
solenoid and/or valve where ignition temperature of hazard-
ous 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 180’C. 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).
A CAUTION: To protect the solenoid valve or operator,
install a strainer or lter, 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 and 8601 for strainers.
DESCRIPTION
Catalog numbers 8003G/H, 8007G/H and 8202G/H and are ep-
oxy encapsulated pull-type soleoids. The green solen01d with
lead wires and 1/2 conduit connection is designed to meet En-
closure Type !-General Purpose, Type 2-Dripproof, Types 3 and
3S-Raintight, and Types 4 and 4X-Watertight. The black solenoid
on catalog numbers prexed “EF” or “EV” is designed to meet
Enclosure Types 3 and 3S-Raintight, Types 4 and 4X-Watertight,
Types 6 and 6P-Submersible, Type7, Explosionproof Class I,
Division! Groups A, B, C, & D and Type 9, -Dust-lgnitionproof-
Class II, Division! 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” so-
lenoid is used. See Temperature Limitations section for solenoid
identication 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 or 0.63 minimum full
thread.
NOTE: Catalog number prex “EV” denotes stainless steel
construction.
Solenoid catalog numbers 8202G/HI, 8202G/H3, 8202G/ H5 and
8202G/H7 are epoxy encapsulated push-type, reverse-acting so-
lenoids having the same enclosure types as previously stated for
Catalog numbers 8003G/Hl and 8003G/ H2. 8007G/H are 3-way
solenoid operators with a pipe port or adapter, exhaust protector
or vent at the top of the solenoid base sub-assembly.
Series 8003G/H, 8007G/H and 8202G/H solenoids are avail-
able 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 speci-
cally designed to be panel mounted by the customer. Refer to
Figures specied in this l&M and the section on Installation
of Panel Mounted Solenoid for details.
Optional Features For Type 1 • General Purpose Construction
OnlyJunction 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)
- SERVICE NOTICE-
l&M V 6584 R16 sec1
©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932
www.ascovalve.com
10
Temperature Limitations
For maximum valve ambient temperatures, refer to chart.
The temperature limitations listed, only indicate maximum application
temperatures for eld wiring rated at 90'C. Check catalog number prex
and watt rating on nameplate to determine maximum ambient temperature.
See valve installation and maintenance instructions for maximum uid
temperature.
NOTE: For steam service, refer to Wiring section, Junction Box for
temperature rating of supply wires.
§ Minimum ambient temperature 40’F (40°C).
¹ = EF, EV data applies to Explosionproof coils only.
² = Some DC solenoid valves can be operated at maximum ambient
temperature of 55°C/ 131°F with reduced pressure ratings. See valve
I&M for maximum operating pressure dierential ratings.
³ = Steam Service Valves have a maximum ambient temperature of 55°
C/ 131°F.
Positioning
This solenoid is designed to perform properly when mounted
in any position. However, for optimum life and perfonnance,
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 ttings must be ap-
proved for use in the approved hazardous locations.
ii.CAUTION: Cryogenic Applications - Solenoid lead
wire insulation should not be subjected to cryogenic
temperatures. Adequate lead wire protection and routing
must be provided.
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 90°C or greater.
Torque tenninal block screws to 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 tenninals, the
socket head screw holding the tenninal 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 sole-
noids 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
eld wire that is rated 90°C or greater for connections. For
steam service use 105°C rated wire up to 50 psi or use 125°C
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. K236034
The open-frame solenoid is provided with DIN terminals to
accommodate the plug connector kit.
Remove center screw from plug connector. Using a small
screwdriver) pry tenninal block from connector cover.
Use #12-18’AWG stranded copper wire rated at 90°C or
greater for connections. Stri}) wire leads back approximate-
ly 1/4” for 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 recom-
mended.
Tbread wire through gland nut, gland gasket, washer and
connection cover.
4.
3.
1.
2.
l&M V 6584 R16 sec1
www.ascovalve.com
©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932 11
l&M V 6584 R16 sec1
©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932
www.ascovalve.com
NOTE: Connector housing may be rotated in 90° increments from
position shown for alternate positioning of cable entry.
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.
Position connector gasket on solenoid and install plug connector.
Torque center screw to 5±1 in-lbs [0,6±1,1 Nm].
6.
5.
NOTE: Alternating current (AC) and direct current (DC) sole-
noids are built dierently and cannot be converted from one to the
other by changing the coil.
Installation of Solenoid
Solenoids may be assembled as a complete unit. Tightening is
accomplished by means ofa hex ange at the base of the solenoid.
Installation of Panel Mounted Solenoid (See Figures 1 and 2)
Install solenoid base sub-assembly through customer panel.
8202H panel mounted solenoids include a retainer to adapt the
solenoid base sub-assembly to the customer panel. (See Figure 2)
Position nger washer on opposite side of panel over solenoid
base sub-assembly.
Replace solenoid, nameplate/retainer and red cap.
Make electrical hookup, see Wiring section.
Disassemble solenoid following instruction under Solenoid
Replacement then proceed.
2.
3.
4.
1.
5.
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
A WARNING: To prevent the possibility of death,
serious injury or property damage, turno electrical
power, depressurize solenoid operator and/or valve,
and vent uid to a safe area before servicing.
Cleaning
All solenoid operators and valves should be cleaned
periodically. The time between cleaning will vary depend-
ing 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 lter when cleaning the valve.
Preventive Maintenance
•Keep the medium owing through the solenoid opera-
tor or valve. as free from dirt and foreign· material as
possible.
• Periodic exercise of the valve should be considered if
ambient or uid conditions are such that corrosion, elas-
tomer degradation, uid contamination build up, or other
conditions that could impede solenoid valve shifting are
possible. The actual frequency of exercise necessary will
depend on specic operating conditions. A successful op-
erating history is the best indication of a proper interval
between exercise cycles.
• 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 signies 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 leadwires or
splice connections.
• Burned-Out Solenoid: Check for open-circuited so-
lenoid. Replace if necessary. Check supply voltage; it
must be the same as specied 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. Disconnect conduit, coil leads, and grounding wire.
NOTE: Any optional parts attached to the old solenoid must
be reinstalled on the new solenoid. For 3-way construction,
piping or tubing must be removed from pipe adapter.
2. Disassemble solenoids with optional features as follows:
• Spade or Screw Terminals
Remove terminal connections, grounding screw, ground-
ing 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.
12
©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932 l&M V 6584 R16 sec1
www.ascovalve.com
Remove red cap or retainer from top of solenoid base
sub-assembly. For 3-way construction with pipe adapter
(Figure 3), remove pipe adapter, nameplate and solenoid.
Omit steps 4 and 5.
Push down on solenoid: Then using a suitable screwdriver,
insert blade between solenoid and nameplate/retainer. Pry
up slightly and push to remove. NOTE: Series 8202O/H
solenoids have a spacer between the nameplate/retainer and
solenoid.
Remove solenoid from solenoid base sub-assembly.
Reassemble in reverse order of disassembly. Use exploded
views for identication and placement of parts.
Torque pipe adapter to 90 inch-pounds maximum [10,2 Nm
maximum]. Then make up piping or tubing to pipe adapter
on solenoid.
3.
4.
5.
6.
7.
Disassembly and Reassembly of Solenoids
Remove solenoid, see Solenoid Replacement.
Remove spring washer from solenoid base sub-assembly.
For 3-way construction, remove pipe adapter and plugnut
gasket.
1.
2.
Unscrew solenoid base sub-assembly from valve body.
Remove internal solenoid parts for cleaning or replacement.
Use exploded views for identication and placement of
parts.
If the solenoid is part of a valve, refer to basic valve instal-
lation and maintenance instructions for further disassembly.
Torque solenoid base sub-assembly and adapter to 175±25
in-lbs [19,8±2,8 Nm].
3.
4.
5.
6.
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.
lnstallaon & Maintenance Instrucons
13
ASCO Valves
(Section2of2)
Installation & Maintenance Instructions SERIES
OPEN-- FRAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS
r
I&M No.V6584R11
8003G/H
8202G/H
NOTICE: See Installation and Maintenance Instructions, I&M No. V6584R12 --- Section 1 of 2 for detailed instructions.
Torque Chart
Part Name Torque Value in Inch---Pounds Torque Value in Newton---Meters
solenoid base sub---assembly 175 ± 25 19,8± 2,8
pipe adapter 90 maximum 10,2 maximum
Series 8202G
without adapter
red cap
solenoid with
1/2INPT
core (small end up)
retainer gasket
finger washer
grounding wire---
green or green
with yellow stripes
Air Only Construction
Alternate Construction
Figure 1. Series 8003G/H Solenoids
Figure 2. Series 8202G/H Solenoids
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
finger washer
Side View
collar to face
valve body
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
red cap
nameplate/
retainer
grounding
w i r e --- g r e e n
or green with
yellow stripes
solenoid with
1/2INPT
0.9375---26UNS---2A
thread
core
(AC)
core
(DC)
Tapped hole in core
0.250 --- 28UNF --- 2B
0.63 minimum full thread (AC)
0.38 minimum full thread (DC)
.062” to .093”
(1.57 to 2.36mm)
max. thickness of
panel for mounting
finger washer
solenoid base
sub ---assembly
0.69” (17.5mm)
diameter mounting
hole
Panel Mount
spacer
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
solenoid base
sub ---assembly
bonnet washer
solenoid base gasket
plugnut assembly
retainer
stem
disc
disc spring
cutaway view to
show positioning
of retainer in
gasket recess
adapter
disc holder assembly
disc holder spring
pipe adapter
plugnut gasket
adapter gasket
nameplate/
retainer
Vent to Atmosphere
Series 8202G
with adapter
Figure 3.
1.312” (33.3mm)
diameter
mounting hole
.075”[14GA]
(1.9mm) max.
thickness for
panel mounting
exhaust protector
none
3 --- W a y C o n s t r u c t i o n
red cap
Possible configurations
I&M No. V 6BR_sec2
14
All Rights Reserved
I&M No.V6584R11
EASCO Valve, Inc.R50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
To rq u e C h ar t
Part Name Torque Value in Inch--Pounds Torque Value in Newton-- Meters
terminal block screws 10 ± 2 1,1 ± 0,2
socket head screw 15 --- 20 1,7 --- 2,3
center screw 5±1 0,6 ± 0,1
screw terminal
adapter gasket
DIN terminal
adapter
socket head screw
socket head
grounding screw
Open ---Frame Solenoid
Open--- Frame Solenoid Open--- Frame Solenoid
with Screw Terminals.
Socket head screw is
used for grounding.
with DIN Terminals.
tapped hole for
# 1 0 --- 3 2 g r o u n d i n g s c r e w
(not included)
See
torque chart
above
terminal
block
screw
with 1/4ISpade Terminals
(5/32Ihex key wrench) (5/32Ihex key wrench)
Indicates parts supplied
in Termination Module
Kit No. K256104
z
z
z
z
z
z
z
Figure 4. Open---frame solenoids
cover screw
cover gasket
cover
junction box gasket
junction box with
and grounding terminal socket head screw
screw terminal block
(see note)
grounding screw
and cup washer
Junction Box Solenoid
Note:
Junction box with screw terminals
shown. With screw terminal
block removed, remaining parts
comprise the junction box for
spade terminal construction.
See
torque chart
above
or Screw Terminals
(5/32Ihex key wrench)
1/2Iconduit connection
with 1/4ISpade Terminals
Figure 5. Junction box (optional feature)
gland nut
gland gasket
washer
socket head screw
gasket
DIN terminal
connector
connector cover
center screw
adapter
gasket
(see note 1)
DIN connector
terminal block
(see note 2)
Indicates that these parts are included
Open ---Frame Solenoid
in DIN plug connector Kit No. K236034
See
torque chart
above
with DIN Terminal
Plug Connector
Notes:
1. Connector cover may be
position shown for alternate
position of cable entry.
2. Refer to markings on DIN
connector for proper
electrical connections.
rotated in 90_increments from
(5/32Ihex key wrench)
Figure 6. DIN plug connector kit No. K236034 (optional feature)
15
I&M No. V 6584 R16_sec2
©ASCO Valve, Inc. 50 Hanover Road, Florham Park, New Jersey 07932 l&M V 6584_R16_sec2
www.ascovalve.com
16
ASCO Valves® All Rights Reserved. I&M No. V 5538 R8
©ASCO Valve, Inc.® 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
E226722 - 5/12
I&M No. V 5538 R8
Installation & Maintenance Instructions
2-WAY DIRECT-ACTING SOLENOID VALVES
NORMALLY CLOSED OPERATION — 3/8” , 1/2” , 3/4” , 1” OR 1 1/4” NPT
AIR OR FUEL GAS SERVICE
Positioning
This valve 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.
Mounting
For mounting bracket (optional feature) dimensions, refer to
Figure 1.
SERIES
8040
8041
[42]
1.66
Ø
.28 dia.
2 mounting holes
Figure 1. Mounting bracket dimensions
NOTICE: See separate solenoid installation and
maintenance instructions for information on: Wiring,
Solenoid Temperature, Causes of Improper Operation,
Coil or Solenoid Replacement.
DESCRIPTION
Series 8040 valves are 2-way normally closed direct-acting
solenoid valves designed for air or fuel gas service. Valve
bodies are made of rugged aluminum with trim and internal
parts made of steel and stainless steel. Series 8040 valves are
provided with a general purpose solenoid enclosure.
Series 8041 and EF8040 valves are the same as Series
8040 except they are provided with an explosionproof or
explosionproof/watertight solenoid enclosure.
Provisions for Pressure and Seat Leakage Testing
(See Figure 2)
Series 8040G valves are provided with two 1/8” tapped and
plugged holes. One upstream for pressure testing; one down
stream for seat leakage testing. Leakage testing frequency
shall be at least annually in accordance with NFPA-86 or
original equipment manufacturer recommendations. Testing
is also required after valve disassembly and reassembly for
inspection, cleaning or rebuilding.
OPERATION
Normally Closed: Valve is closed when solenoid is de-
energized; open when energized.
NOTE: No minimum operating pressure differential required.
INSTALLATION
Check nameplate for correct catalog number, pressure, voltage,
frequency, and service. Never apply incompatible fl uids or
exceed pressure rating of the valve. Installation and valve
maintenance to be performed by qualifi ed personnel.
Temperature Limitations
For valve ambient and fl uid temperatures, refer to chart below.
Piping
Connect piping to valve according to markings on valve body.
Apply pipe compound sparingly to male pipe threads only. If
applied to valve threads, the compound may enter the valve
and cause operational diffi culty. Avoid pipe strain by properly
supporting and aligning piping. When tightening the pipe, do
not use valve or solenoid as a lever. Locate wrenches applied
to valve body or piping as close as possible to connection
point. Valves should be checked for external leakage at piping
connections after installation, see Testing for External Leakage
section.
CAUTION: To avoid damage to the valve body, DO
NOT OVERTIGHTEN PIPE CONNECTIONS. If PTFE
tape, paste, spray or similar lubricant is used, use
extra care when tightening due to reduced friction.
CAUTION: To protect the solenoid valve, install a
strainer or fi lter suitable for the service involved in
the inlet side as close to the valve as possible. Clean
periodically depending on service conditions. See
ASCO Series 8600 and 8601 for strainers.
[ 7.1]
Catalog
Number
Catalog
Number
Prefi x
Min. and Max.
Ambient
Temperatures
Min. and Max.
Fluid
Temperatures
8040G21
8040G22
8040G23
None, KF,
SF, SC or EF
-40°F (-40°C)
to 125°F (52°C)
-40°F (-40°C)
to 125°F (52°C)
HT, KH, ST,
SU or EFHT
-40°F (-40°C)
to 140°F (60°C)
-40°F (-40°C)
to 140°F (60°C)
8040A021
8040A022
8040A023
U, MU 32°F (0°C) to
125°F (52°C)
32°F (0°C)
to 125°F (52°C)
17
I&M No. V 5538 R8
©ASCO Valve, Inc.® 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Testing for External Leakage
WARNING: To prevent the possibility of
severe personal injury or property damage,
extinguish all open fl ames and avoid any type
of sparking or ignition.
1. Block gas fl ow on downstream side of valve.
2. Apply pressure to valve within nameplate rating and
energize solenoid.
3. Apply a soapy solution or a commercially available leak
detecting solution to the pipe connections and check for
bubbles. If the valve has been tested for seat leakage or
disassembled and reassembled for inspecting, cleaning, or
rebuilding apply the solution around solenoid base sub-
assembly, bonnet/body joint and pipe plugs.
4. If leakage exists, depressurize valve and turn off electrical
power supply. Tighten connections as required and retest
following the above steps.
MAINTENANCE
WARNING: To prevent the possibility of
severe personal injury or property damage,
turn off electrical power, depressurize valve,
extinguish all open fl ames, and avoid any
type of sparking or ignition. Vent hazardous
or combustible fl uid to a safe area before
servicing the valve.
NOTE: It is not necessary to remove the valve from the pipeline
for repairs.
Cleaning
All solenoid valves should be cleaned periodically. The time
between cleanings will vary depending on the medium and
service conditions. In general, if the voltage to the coil is correct,
sluggish valve operation, excessive noise or leakage will indicate
that cleaning is required. In the extreme case, faulty valve
operation will occur and the valve may fail to open or close.
Clean strainer or fi lter when cleaning the valve.
Preventive Maintenance
•Keep the medium fl owing through the valve as free from
dirt and foreign material as possible.
•While in service, the 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. If parts
are worn or damaged, install a complete ASCO Rebuild Kit.
Causes of Improper Operation
•Incorrect Pressure: Check valve pressure. Pressure to
valve must be within range specifi ed on nameplate.
•Excessive Leakage: Disassemble valve and clean all parts.
If parts are worn or damaged, install a complete ASCO
Rebuild Kit.
Valve Disassembly(Refer to Figure 3)
1. Disassemble valve in an orderly fashion using exploded
view for identifi cation and placement of parts.
2. Remove solenoid enclosure. See separate instructions.
3. Unscrew solenoid base sub-assembly from valve bonnet.
4. Remove bonnet screws, valve bonnet, solenoid base gasket,
core assembly (with core spring, rider ring and core guide)
and body gasket from valve body.
5. All parts are now accessible for cleaning or replacement.
If parts are worn or damaged, install a complete ASCO
Rebuild Kit.
Valve Reassembly
1. Lubricate body gasket and solenoid base gasket with DOW
CORNING® 200 Fluid lubricant or an equivalent high-
grade silicone fl uid.
2. Position body gasket and core assembly in valve body.
3. Replace valve bonnet, solenoid base gasket and bonnet
screws.
4. Install bonnet screws and hand thread screws as far as
possible, then torque bonnet screws in a crisscross manner
to 110 ± 10 in-lbs [12 ± 1 Nm].
5. Install solenoid base sub-assembly and torque to 175 ± 25
in-lbs [19,8 ± 2,8 Nm].
6. Install solenoid. See separate instructions.
WARNING: To prevent the possibility of
personal injury or property damage, check
valve for proper operation before returning
to service. Also perform internal seat and
external leakage tests (with a nonhazardous,
noncombustible fl uid if practical).
7. Check valve for external leakage as indicated under the
Piping section, and for internal (seat)leakage as follows.
18
Upstream for
pressure testing
(upper tap & plug)
Partial side view of valve body
showing location of tapped and
plugged holes for pressure and
seat leakage testing
OUT
FLOW
IN
Downstream for
seat leakage testing
(lower tap & plug)
Downstream tap & plug on
bottom of valve body for
3/4” NPT construction
1/8” pipe plug
(3/16 hex key wrench)
Figure 2. Provisions for pressure and seat leakage testing.
Testing for Internal (Seat)Leakage
CAUTION: Be sure valve can be tested without
affecting other equipment.
1. Using a 3/16 hex key wrench, remove the 1/8” pipe plug
from the downstream side of the valve body. Then install
suitable test piping (e.g.; two short nipples and an elbow
or tubing) to check for leakage.
2. Block fl ow downstream of valve.
3. Restore electrical power supply and pressurize valve to
nameplate rating.
4. With valve de-energized, immerse end of test piping in
a cup of water for 20-30 seconds and look for bubbles,
which would be indicative of seat leakage. Repeat this
procedure at several progressively lower pressures, down
to approximately 1/4 psi. Between each test, remove cup
of water and operate valve.
5. If seat leakage is detected, turn off electrical power and
depressurize valve. Disassemble and check for proper
placement of parts, or any foreign matter that may have
entered the valve. Clean as necessary, reassemble and re-
test valve for both external and internal leakage.
6. If no seat leakage is detected, remove test piping. Apply a
small amount of Loctite Corporation’s PST Pipe Sealant
567 (or equivalent) to the pipe plug threads. Reinstall the
pipe plug and tighten securely.
7. Test for external leakage as described in Piping section.
8. When maintenance is complete, operate the valve a few
times to be sure of proper operation. A metallic click
indicates the solenoid is operating.
ORDERING INFORMATION FOR
ASCO REBUILD KITS
Parts marked with an asterisk(*) in the exploded view are
supplied in Rebuild Kits. When Ordering Rebuild Kits for
ASCO Valves, order the Rebuild Kit number stamped on the
valve nameplate. If the number of the kit is not visible, order
by indicating the number of kits required, and the Catalog
Number and Serial Number of the valve(s) for which they are
intended.
I&M No. V 5538 R8
©ASCO Valve, Inc.® 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com 19
Part Name
bonnet screws
solenoid base sub-assembly
Indicates Parts Supplied
In ASCO Rebuild Kits
solenoid base
sub-assembly
solenoid base
gasket
valve bonnet
core
assembly
body gasket
valve body
(see note)
Torque Chart
Torque Value in Inch-Pounds
mounting bracket
two positions
(optional)
3/8” , 1/2” & 3/4” NPT Construction
110 ± 10
175 ± 25
Torque Value in Newton-Meters
bonnet screw (4)
rider ring
core guide
core spring
(small end down)
core assembly
12 ± 1
19,8 ± 2,8
1” & 1 1/4” NPT Construction
Note:
Provisions (tapped & plugged holes) for pressure and seat leakage
testing not shown in this view, see Figure 2.
Figure 3. Series 8040 valve without solenoid.
I&M No. V 5538 R8
©ASCO Valve, Inc.® 50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
20
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