Install Instructions

50-60 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Form No.V8525
Page 2 of 3
Testing for External Leakage
1. Block gas flow on downstream side of valve.
2. Apply pressure to valve within nameplate rating and
energize solenoid.
3. Apply a rich soap and water 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 apply the solution around the
base of the pipe plug.
4. If leakage exists, depressurize valve and turn off
electrical power supply. Tighten pipe connections, or
plug and retest following the above steps.
MAINTENANCE
Preventive Maintenance
 Prepare and follow a routine inspection schedule based
on the media, environment, and frequency of use. This
should include periodic internal and external leakage
checks.
 Keep the medium flowing through the valve as free from
dirt and foreign material as possible. Depending on
medium and service conditions, clean valve strainer, filter
or drip leg as required to keep the valve free of
contamination. In the extreme case, contamination will
cause faulty valve operation and the valve may fail to open
or close, and an explosion or fire can occur.
 While in service, the valve should be operated at least
once a month to ensure proper opening and closing.
Testing for Internal (Seat) Leakage
(Refer to Figure 2)
1. Shut off both the upstream and downstream manual
gas cocks. The downstream manual gas cock should
remain closed throughout the entire test procedure.
2. Program the control system to operate the valve
through five cycles. Listen carefully for the solenoid
coil to click indicating proper operation.
3. Open the upstream manual gas cock. Program the
control system to energize and maintain the valve in
the open (energized) position.
4. Shut off the upstream manual gas cock and
de-energize valve. Remove the plug from the leak test
tap or downstream pressure tap in the valve body.
Connect leak test equipment with the test petcock in
the closed position see Figure 2.
5. Open the upstream manual gas cock. Program the
control system to energize the valve to the full open
position, then immediately de-energize it to seat the
valve operationally.
6. Immerse the 1/4 leak test tubing vertically into a jar of
water to a depth of about 1/2. Slowly open the test
petcock. Bubbles may appear in the water as the
pressure equalizes.
7. After the rate of bubbles coming through the water
stabilizes, count the number of bubbles appearing in a
10 second period. The allowable leakage in 10 seconds
for an orifice diameter of 1 inch (25.4 mm) or less is 6
bubbles (3 cc/min). If leakage exceeds this rate, replace
valve.
NOTE: The leakage rate above recognizes that some wear
and contamination from use can result in a slight amount of
leakage. The allowable leakage rate is well within the
leakage limits as recognized by applicable approval
agencies.
8. Close the upstream manual gas cock and the test
petcock. Then remove the test equipment. Apply a
small amount of Loctite Corporation's PST Pipe
Sealant 567 (or equivalent) to the pipe plug threads.
Reinstall pipe plug and torque to 50 in-lbs [5, 72 Nn].
9. Turn on the gas supply at the upstream manual gas
cock.
10. Open the upstream manual gas cock. Program the
control system to energize and maintain the valve in
the open (energized) position. Check the 1/8 NPT
pipe plug connection for external leaks with a rich soap
and water solution or a commercially available leak
detecting solution.
11. De-energize the valve. Open the downstream manual
gas cock.
12. Restore the system to normal operation.
ORDERING INFORMATION
FOR ASCO GENERAL CONTROLS
SOLENOIDS OR REPLACEMENT VALVES
When Ordering ASCO General Controls Solenoids or
Replacement Valves, specify catalog number, serial number,
voltage and frequency.