Extra Valve Information - AAA Products International

AAA Products International Inc.
7114 Harry Hines Blvd.
Dallas, Texas 75235
214-357-3851

Valve Data Extra Information

During the creation of this website and over 10,000 different valve configurations, we have come across pages of general information that apply to particular valves. To assist customers in accessing this information without going through the process of selecting the particular valve configuration we have compiled these pages in a drop down list.

"Classic" Operator & Coil - Standard

The "Classic" solenoid operators sturdy and tough construction with a 1/2" NPT conduit connection. The stem exhaust is tapped 10-32. Voltage must be specified when ordering valves that use this operator. If no voltage is specified, then 120/60 is provided. Other voltages not shown below are available. Coil can be rotated in any direction on operator stem when space is available. Caution must be used when rotating coil so not to untighten the stem from the adaptor block. Standard leads are 18", longer leads available on request. When connecting to an electrical source either black wire can be connected to hot (+) and the other connected to neutral (-).

Voltage	Pick-Up	Holding	Resistance	Operator	Spare Coil*
24 volts, 60 Hz	1.72 amps	1.10 amps	5.39 ohms	AY-38-4	V-67-4
120 volts, 60 Hz	0.36 amps	0.23 amps	135 ohms	AY-38-11	V-67-11
240 volts, 60 Hz	0.18 amps	0.12 amps	546 ohms	AY-38-17	V-67-17
12 volts D-C		1.20 amps	12.8 ohms	AY-38-5	V-67-5
24 volts D-C		0.58 amps	61 ohms	AY-38-8	V-67-8

Materials: Steel, stainless steel, thermoset polyester molded resin coil, Buna-N seat & O-Ring.
Repair Kit: RKPSV-1 includes plunger, spring & O-Ring.
Ambient Temperature: -4°F to +120°F.
Relative Duty Cycle: 100%.
Degree of Protection: NEMA 1.
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Orifice Size: 3/64" base, 1/16" stem.
Insulation Class: B
*Coils: The encapsulated coils are UL approved. The coil is marked or embossed with QC130, QC155, or QC180. UL Document.

"Classic" Operator & Coil - Standard w/Dust Excluder Nut

The "Classic" solenoid operators sturdy and tough construction with a 1/2" NPT conduit connection. The stem exhaust is vented through a FM-1 muffler/dust excluder. Voltage must be specified when ordering valves that use this operator. If no voltage is specified, then 120/60 is provided. Other voltages not shown below are available. Coil can be rotated in any direction on operator stem when space is available. Caution must be used when rotating coil so not to untighten the stem from the adaptor block. Standard leads are 18", longer leads available on request. When connecting to an electrical source either black wire can be connected to hot (+) and the other connected to neutral (-).

Voltage	Pick-Up	Holding	Resistance	Operator	Spare Coil*
24 volts, 60 Hz	1.72 amps	1.10 amps	5.39 ohms	AY-38L-4	V-67-4
120 volts, 60 Hz	0.36 amps	0.23 amps	135 ohms	AY-38L-11	V-67-11
240 volts, 60 Hz	0.18 amps	0.12 amps	546 ohms	AY-38L-17	V-67-17
12 volts D-C		1.20 amps	12.8 ohms	AY-38L-5	V-67-5
24 volts D-C		0.58 amps	61 ohms	AY-38L-8	V-67-8

"Classic" Operator & Coil - Standard w/Tapped Exhaust

The "Classic" solenoid operators sturdy and tough construction with a 1/2" NPT conduit connection. The stem exhaust is tapped 1/8" NPTF. Voltage must be specified when ordering valves that use this operator. If no voltage is specified, then 120/60 is provided. Other voltages not shown below are available. Coil can be rotated in any direction on operator stem when space is available. Caution must be used when rotating coil so not to untighten the stem from the adaptor block. Standard leads are 18", longer leads available on request. When connecting to an electrical source either black wire can be connected to hot (+) and the other connected to neutral (-).

Voltage	Pick-Up	Holding	Resistance	Operator	Spare Coil*
24 volts, 60 Hz	1.72 amps	1.10 amps	5.39 ohms	AY-38T-4	V-67-4
120 volts, 60 Hz	0.36 amps	0.23 amps	135 ohms	AY-38T-11	V-67-11
240 volts, 60 Hz	0.18 amps	0.12 amps	546 ohms	AY-38T-17	V-67-17
12 volts D-C		1.20 amps	12.8 ohms	AY-38T-5	V-67-5
24 volts D-C		0.58 amps	61 ohms	AY-38T-8	V-67-8

"Classic" Operator & Coil - DIN Style

The "Classic" DIN solenoid operator with a ISO 4400 din pattern connection (Form A, DIN 43650-A, 18 mm contact distance). DIN caps are ordered as a separate line item. The stem exhaust is tapped 10-32. Voltage must be specified when ordering valves that use this operator. If no voltage is specified, then 120/60 is provided. Other voltages not shown below are available. Coil can be rotated in any direction on operator stem when space is available. Caution must be used when rotating coil so not to untighten the stem from the adaptor block. An approved cap must be used when connecting to an electrical source. The longer tab is the ground (earth). Either shorter tab can be connected to hot (+) and the other connected to neutral (-).

Voltage	Pick-Up	Holding	Resistance	Operator	Spare Coil*
120 volts, 60 Hz	0.36 amps	0.23 amps	135 ohms	AY-38ED-11	V-67ED-11
240 volts, 60 Hz	0.18 amps	0.12 amps	546 ohms	AY-38ED-17	V-67ED-17
12 volts D-C		1.20 amps	12.8 ohms	AY-38ED-5	V-67ED-5
24 volts D-C		0.58 amps	61 ohms	AY-38ED-8	V-67ED-8

Materials: Duroplast/thermoset resin, Buna-N seat & O-Ring.
Repair Kit: RKPSV-1 includes plunger, spring & O-Ring.
Ambient Temperature: -4°F to +120°F.
Relative Duty Cycle: 100%.
Degree of Protection: NEMA 4 & 4X with connector.
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Orifice Size: 3/64" base, 1/16" stem.
*Coils: The encapsulated coils are UL approved. The coil is marked or embossed with QC130, QC155, or QC180. UL Document.

"Classic" Operator & Coil - Explosion Proof

The "Classic" explosion proof solenoid operators are sturdy and tough construction with a 1/2" NPT conduit connection. The stem exhaust is tapped 1/8"-27 NPT. Voltage must be specified when ordering valves that use this operator. If no voltage is specified, then 120/60 is provided. Other voltages not shown below are available. Coil can be rotated in any direction on operator stem when space is available. Caution must be used when rotating coil so not to untighten the stem from the adaptor block. The explosion proof operator carries the UL & CSA label for Class I, Division 1, Group C and D (gasoline vapors, etc.), Class II, Division 1, Groups E, F and G (coal , coke and grain dusts). Temperature code: T4A. Standard leads are 18". When connecting to an electrical source either black wire can be connected to hot (+) and the other connected to neutral (-). The green wire is the ground (earth). The housing of all "Classic" explosion proof solenoids cannot be rotated or serviced in the field. If coil orientation is not specified at time of order, the 1/2" conduit will be rotated towards the 2 port side of valve body.

Voltage	Pick-Up	Holding	Resistance
24 volts, 60 Hz	1.72 amps	1.10 amps	5.39 ohms
120 volts, 60 Hz	0.36 amps	0.23 amps	135 ohms
240 volts, 60 Hz	0.18 amps	0.12 amps	546 ohms
12 volts D-C		1.20 amps	12.8 ohms
24 volts D-C		0.58 amps	61 ohms

Materials: Steel, stainless steel, thermoset polyester molded resin coil, Buna-N seat & O-Ring.
Ambient Temperature: -4°F to +120°F.
Relative Duty Cycle: 100%.
Certifications: UL & CSA label for Class I, Division 1, Group C and D, Class II, Division 1, Groups E, F and G. CSA file number 087427_0_000. UL file number E37005
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Orifice Size: 3/64" base, 1/16" stem.
Insulation Class: B

Commonly Asked Questions

Q: Can I use a piece of equipment approved for use in a Division 1 hazardous location in a Division 2 hazardous location?
A: Yes. If equipment has been approved for use in a Division 1 hazardous location, it can be used in a Division 2 hazardous location, providing it is in the same class and group.

Q: Can equipment approved for a Class I hazardous location be used in a Class II hazardous location?
A: No. Equipment used in Class I and Class II hazardous locations are made for different purposes. Equipment approved for Class I hazardous locations must contain an internal explosion, while Class II approved equipment must seal out dust. They are not interchangeable.

"Classic" Operator & Coil - Mold-Over

The "Classic" Mold-Over solenoid operator with a 1/2"-14 NPT conduit connection. The stem exhaust is tapped 10-32. Voltage must be specified when ordering valves that use this operator. If no voltage is specified, then 120/60 is provided. Other voltages not shown below are available. Coil can be rotated in any direction on operator stem when space is available. Caution must be used when rotating coil so not to untighten the stem from the adaptor block. Standard leads are 18", longer leads available on request. When connecting to an electrical source either black wire can be connected to hot (+) and the other connected to neutral (-). The green wire is the ground (earth).

Voltage	Pick-Up	Holding	Resistance	Operator	Spare Coil*
120 volts, 60 Hz	0.36 amps	0.23 amps	135 ohms	AY-38M-11	V-67M-11
240 volts, 60 Hz	0.18 amps	0.12 amps	546 ohms	AY-38M-17	V-67M-17
12 volts D-C		1.20 amps	12.8 ohms	AY-38M-5	V-67M-5
24 volts D-C		0.58 amps	61 ohms	AY-38M-8	V-67M-8

Materials: Zinc plated steel hub, molded coil, Buna-N seat & O-Ring.
Repair Kit: RKPSV-1 includes plunger, spring & O-Ring.
Ambient Temperature: -4°F to +120°F.
Relative Duty Cycle: 100%.
Degree of Protection: NEMA 4 & 4X.
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Orifice Size: 3/64" base, 1/16" stem.
*Coils: The encapsulated coils are UL approved. The coil is marked or embossed with QC130, QC155, or QC180. UL Document.

"Classic" Override - Locking Solenoid Twist

Manual override provides a method to shift the valve in case of an electrical failure or during proofing of the electrical control circuit. A knurled knob, operated by hand, physically lifts the poppet off its seat. Air pressure to the solenoid is required to shift the internal spool. The knob will remain either in the ON or OFF position. Twist the knob clockwise to lift the poppet.

"Classic" Override - Non-Locking Twist

Manual override provides a method to shift the valve in case of an electrical failure or during proofing of the electrical control circuit. A knurled knob, operated by hand, physically lifts the poppet off its seat. Air pressure to the solenoid is required to shift the internal spool. The knob will only remain in the ON position while held, once released it will move back to the OFF position. Twist the knob clockwise to lift the poppet.

"Classic" Override - Non-Locking Push

Manual override provides a method to shift the valve in case of an electrical failure or during proofing of the electrical control circuit. A push button, operated by hand, physically lifts the poppet off its seat. Air pressure to the solenoid is required to shift the internal spool. The button will only remain in the ON position while held, once released it will move back to the OFF position. Push down on the button to lift the poppet.

"Classic" High Pressure - 300 psi Solenoid Operator

High pressure solenoid operator allows up to 300 psi pilot pressure on the operator. Supply pressure can be either internal or external. Some valves can be rated for iternal pressures higher than the stated 250 psi. This must be requrested at time of order.

"E-Series" Coil - Standard

The standard coils are a DIN 43650-B style with a 11mm/Industrial Type B connector pin pattern (mini connector, 11 mm contact distance). DIN caps are ordered as a separate line item. Voltage must be specified when ordering. If no voltage is specified, then 120/60 is provided. Other voltages not shown below are available. Coil can be rotated in 90° increments on operator stem when space is available. An approved cap must be used when connecting to an electrical source. The longer tab is the ground (earth). Either shorter tab can be connected to hot (+) and the other connected to neutral (-).

Voltage	Pick-Up	Holding	Resistance	Spare Coil
24 volts, 50/60 Hz	7.1 VA	5.8 VA	27.4 ohms	V-551-2
48 volts, 50/60 Hz	7.7 VA	6.2 VA	97.9 ohms	V-551-3
110 volts, 50 Hz, 120 volts, 60 Hz	7.8 VA	6.3 VA	619 ohms	V-551-1
240 volts, 50/60 Hz	7.8 VA	6.3 VA	3400 ohms	V-551-4
12 volts D-C		4.6 Watts	27.4 ohms	V-551-2
24 volts D-C		4.8 Watts	97.9 ohms	V-551-3
60 volts D-C		4.3 Watts	619 ohms	V-551-1

Molding Material: Thermoplastic.
Ambient Temperature: -20°C to +50°C.
Relative Duty Cycle: 100%.
Degree of Protection: IP65 with connector (IP67 possible with accessories).
Certifications: This coil carries the UL certificate of compliance both the standard and Canadian certification. A copy of the certification is available here. The rating only applies to the coil and not the entire valve.
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Insulation Class: F

"E-Series" Coil - Option A - Intrinsically Safe

When related to solenoid valves, intrinsic safety means that the coil's current draw and resulting temperature is held to such a low level (when used with an approved safety barrier) that the valve no longer has the capability of igniting a mixture of flammable or combustible material, either during normal operation or under fault conditions. Typically, they are used in situations where fire and explosive hazards exist due to the presence of flammable gases, vapors or liquids, combustible dusts or easily ignitable fibers. Intrinsically safe coils and operators are sold as a matched set and must be ordered as V-564 (individual components are not available). Solenoid operator maximum pressure is 115 psi.
These operators are equipped with the standard V-562 nut but can be ordered with a V-567W bronze muffler nut (option L) or a V-562 side exhaust nut (option C).
These 24 VDC coils are approved according to EN 50 020 respectively DIN VDE 0170/0171 part 5 for hazardous location. Class I, groups A, B, C and D; Class II, groups E, F and G; Class III. This coil is an ISO 4400 DIN style pin pattern. A non-indicator, cord grip style cap is provided. A copy of the certification is available here. An approved cap (included) must be used when connecting to an electrical source. The longer tab is the ground (earth). Either shorter tab can be connected to hot (+) and the other connected to neutral (-).

Material: Brass, steel, stainless steel, Viton seat.
Molding Material: Thermoset resin.
Ambient Temperature: -20°C to +50°C.
Internal Diameter Orifice: 0.8mm
Relative Duty Cycle: 100%.
Degree of Protection: IP65 with connector.
Certifications: This coil carries the following certificate of compliance. The rating only applies to the coil/operator and not the entire valve.
Insulation Class: F
Electrical Characteristics: 21.6 - 28 VDC

"E-Series" Intrinsically Safe Barrier

The proper use of the intrinsically safe solenoid operator requires the use of a barrier in the non-hazardous location with the solenoid operator in the hazardous location. We do not recommend nor endorse any barrier manufacturer or product but include a list to start your research. It is up to the user to verify barrier information. (Company and contact information may change.)
Barrier Schematic

COMPATIBLE BARRIER MANUFACTURERS

Pepperl & Fuchs Inc. - Telephone (330) 425-3555 - FAX: (330) 425-4607
Pepperl+Fuchs, Inc., 1600 Enterprise Parkway, Twinsburg, Ohio 44087
E-mail: sales@us.pepperl-fuchs.com - www.pepperl-fuchs.com
Models: KFD2-SLS-EX2 and KFD2-SD-EX1.36

Eaton
Process Safety Automation Measurement
www.eaton.com/us/en-us/products/process-safety-automation-measurement/intrinsic-safety
Model: MTL5525

STAHL, INC - Telephone: (800) 782-4357
R. Stahl, Inc.
13259 N. Promenade Blvd, Stafford, TX 77477
E-Mail: sales.us@r-stahl.com - www.rstahl.com
Model: 9275/10-24-48-11s

"E-Series" Coil - Option H - High Temperature

The high temperature coils utilize a Form A/ISO 4400 DIN style connection (DIN 43650-A, 18 mm contact distance) with one ground tab and two voltage tabs. DIN caps are ordered as a separate line item. The coil is 30mm wide. Coil can be rotated in 45° increments on operator stem when space is available. An approved cap must be used when connecting to an electrical source. The longer tab is the ground (earth). Either shorter tab can be connected to hot (+) and the other connected to neutral (-).

Voltage	Pick-Up	Holding	Resistance	Spare Coil
120 volts, 60 Hz		6.8 VA	741 ohms	V-603-1
12 volts D-C		4.5 Watts	55 ohms	V-603-2

Molding Material: Thermoset resin.
Ambient Temperature: -20°C to +80°C.
Relative Duty Cycle: 100%.
Degree of Protection: IP65 with connector.
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Insulation Class: H

"E-Series" Coil - Option J - 1/2" Conduit Mold-Over

The mold-over coil has a 1/2" NPT conduit connection with three 18" long wires. The coil is 22mm wide. Coil can be rotated in 90° increments on operator stem when space is available. When connecting to an electrical source either black wire can be connected to hot (+) and the other connected to neutral (-). The green wire is the ground (earth).

Voltage	Pick-Up	Holding	Resistance	Spare Coil
24 volts, 60 Hz	7.1 VA	5.8 VA	31.6 ohms	V-600-2
48 volts, 60 Hz	7.7 VA	6.2 VA	121 ohms	V-600-3
120 volts, 60 Hz	7.8 VA	6.3 VA	820 ohms	V-600-1
240 volts, 60 Hz	7.8 VA	6.3 VA	3400 ohms	V-600-4
12 volts D-C		4.6 Watts	31.6 ohms	V-600-2
24 volts D-C		4.8 Watts	121 ohms	V-600-3
60 volts D-C		4.3 Watts	820 ohms	V-600-1

Molding Material: Thermoset resin.
Ambient Temperature: -20°C to +80°C.
Relative Duty Cycle: 100%.
Degree of Protection: IP65.
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Insulation Class: F

"E-Series" Coil - Option M - 18" Flying Lead

The flying lead coil has two 18" long wires. The coil is 22mm wide. Coil can be rotated in 90° increments on operator stem when space is available. When connecting to an electrical source either black wire can be connected to hot (+) and the other connected to neutral (-).

Voltage	Pick-Up	Holding	Resistance	Spare Coil
24 volts, 60 Hz	7.1 VA	5.8 VA	27.4 ohms	V-569-2
48 volts, 60 Hz	7.7 VA	6.2 VA	97.9 ohms	V-569-3
120 volts, 60 Hz	7.8 VA	6.3 VA	619 ohms	V-569-1
240 volts, 60 Hz	7.8 VA	6.3 VA	3400 ohms	V-569-4
12 volts D-C		4.6 Watts	27.4 ohms	V-569-2
24 volts D-C		4.8 Watts	97.9 ohms	V-569-3
60 volts D-C		4.3 Watts	619 ohms	V-569-1

Molding Material: Thermoplastic.
Ambient Temperature: -20°C to +50°C.
Relative Duty Cycle: 100%.
Degree of Protection: IP65.
Certifications: This coil carries the UL certificate of compliance both the standard and Canadian certification. A copy of the certification is available here. The rating only applies to the coil and not the entire valve.
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Insulation Class: F

"E-Series" Coil - Option T - ATEX

The ATEX/IEC coil is molded with 3 meters of 3 wire cord. The wire has one green/yellow ground (earth) wire, one brown wire and one blue wire. Either the brown or blue wire can be hot (+) and the other neutral (-). The coil is 30mm wide. These coils are rated by the European standards PTB 03 ATEX 2018 X, IECEx PTB 04.0002X. See below for exact approvals. Coil can be rotated in 45° increments on operator stem when space is available.

Voltage	Pick-Up	Holding	Resistance	Spare Coil
24 volts D-C		0.136 amps	177 ohms	V-612-3

Molding Material: Thermoplastic.
Ambient Temperature: -20°C to +50°C.
Relative Duty Cycle: 100%.
Degree of Protection: IP65 (IP67 possible with accessories).
Certifications: This coil carries the ATEX/IEC certificate of conformity. A copy of the certification is available here. The rating only applies to the coil and not the entire valve.
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Insulation Class: H

"E-Series" Coil - Option X - Explosion Proof

The explosion proof coils are a 1/2" NPT conduit connection with one green ground wire and two black wires. When connecting to an electrical source either black wire can be connected to hot (+) and the other connected to neutral (-). The green wire is the ground (earth). The coil is 36mm wide. On some valves this may interfere with mounting and a spacer may be used under the valve. These coils are rated explosion proof for Class I, Division 1, Groups A, B, C and D (gasoline vapors, etc.), Class II, Groups E, F, and G (coal, coke and grain dusts), Class III. See below for exact approvals. Other voltages not shown below are available. Coil can be rotated in 90° increments on operator stem when space is available.

Voltage	Holding	Resistance	Spare Coil
120 volts, 60 Hz	6.8 VA	530 ohms	V-593-1
12 volts D-C	4.5 Watts	31.6 ohms	V-593-2
24 volts D-C	4.6 Watts	121 ohms	V-593-3
240 volts, 60 Hz	6.8 VA	2345 ohms	V-593-4

Molding Material: Thermoplastic.
Conduit Material: on V-593-1 thru -3, stainless steel. On V-593-4, zinc plated.
Ambient Temperature: -20°C to +60°C.
Relative Duty Cycle: 100%.
Degree of Protection: IP65 with connector (IP67 possible with accessories).
Certifications: This coil carries both a FM and CSA approval rating; CSA CLASS 2258 02, process control equipment for hazardous locations; FM CLASS 3600, 3611, 3615, 3810, hazardous (classified) location electrical equipment. A copy of the certification is available here. The rating only applies to the coil and not the entire valve.
Voltage Tolerance: ± 10%.
Resistance Tolerance: ± 8% at 20°C.
Insulation Class: H

Commonly Asked Questions

"E-Series" Operator - Standard

The standard operator is equipped with a non-locking manual push override and a 1/8" NPT external pilot port. For external pilot operation, the internal pilot pressure must be blocked and the plug must be removed and external pilot source must be provided (150 psi maximum). All operators have internally threaded exhaust stems. The thread fits 10-32 UNF or 5mm-0.8 fittings. Solenoid operator is equipped with a non-locking manual override on the side of the solenoid structure. To activate manual override, the inset red plunger must be depressed, red plunger returns when released. For replacement operators order ESPK which is a V-550-1 operator and an EMG3 gasket (individual operator components are not available).

Material: Brass, steel, stainless steel, Viton seat.
Molding Material: Thermoplastic.
Ambient Temperature: -20°C to +50°C.
Internal Diameter Orifice: 1.3mm

"E-Series" Operator - Twist Style Locking Override

This operator is equipped with a locking manual twist style override and a 1/8" NPT external pilot port. For external pilot operation, the internal pilot pressure must be blocked and the plug must be removed and external pilot source must be provided (150 psi maximum). All operators have internally threaded exhaust stems. The thread fits 10-32 UNF or 5mm-0.8 fittings. Solenoid operator is equipped with a locking manual override on the side of the solenoid structure. To activate manual override, twist the yellow lever clockwise to engage override. For replacement operators order ESPKO which is a V-599-1 operator and an EMG3 gasket (individual operator components are not available)

Material: Brass, steel, stainless steel, Viton seat.
Molding Material: Thermoplastic.
Ambient Temperature: -20°C to +50°C.
Internal Diameter Orifice: 1.3mm

General - 1-1/2" & 2" Valve Operation

Normal assembly of all standard 1-1/2" & 2" valves is for internal pilot operation, in which the air pressure for shifting the large spool is internally tapped off the valve inlet. If the main spool is to handle pressures lower than 50 PSI or more than 150 PSI on solenoid models or from 50 to 250 psi on all other models, the valve should be factory ordered for "external pilot operation" by adding suffix "Z" after the regular model number. Or, the valve can easily be converted in the field to external piloting as described below. This pressure limitation applies to all 1-1/2" and 2" manual lever, solenoid, pilot or differential pilot valves.

Conversion to External Piloting: Remove the entire control valve from the main body and lay it aside. Install a 1/16"-27 NPT pipe plug in the treaded hole uncovered in the body mounting pad. Re-mount the control valve in the same orientation as before. Connect a pilot pressure air source (50 to 150 PSI on solenoid models and 50 to 250 psi on all other models) to the 1/4" NPTF external pilot port. This port is located on the side and near the top of the main body and stamped "EXT P", on the side opposite the MFC flow controls.

INTERNAL OPERATION
2 POSITION VALVES

EXTERNAL OPERATION
2 POSITION VALVES

INTERNAL OPERATION
3 POSITION VALVES

EXTERNAL OPERATION
3 POSITION VALVES

General - Converting to "EXTERNAL PILOT" Operation

Always stamp the name tag with a "Z" suffix to indicate external pilot operation when converting valve.

On 1/4" and 3/8" models (with solenoid assemblies mounted on the ends), remove 4 screws holding the solenoid structure to the main body and remove the entire solenoid assembly. Rotate the entire solenoid assembly 180° and re-mount on the body. Connect a source of external pilot pressure, 50 to 150 psi, to the ext. pilot port of each solenoid structure. On double solenoid valves, both solenoids must be modified in this manner, and the source of external pilot pressure must be connected to the pilot port on both structures.
On 1/4" and 3/8" models (with solenoid assemblies piggy-backed on top of valve), remove 4 screws holding the piggy back structure to the main body and remove the entire assembly. Leave gasket as orientated on the main body and rotate the piggy back assembly 180° and re-mount on the body. Connect a source of external pilot pressure, 50 to 150 psi, to the ext. pilot port of piggy back structure.
On 1/2", 3/4" and 1" models, take out 4 screws and remove end cap assembly from end of valve body. Rotate gasket with the end cap assembly 90° in either direction. This will block the internal pilot passages. Connect a source of pilot pressure, 50 to 150 psi, to the 1/8" NPT pilot port on the side of the end cap structure. On double solenoid valves, both solenoids must be modified in this manner, and the source of external pilot pressure must be connected to the pilot port on both structures.
On 1-1/2" and 2", remove entire pilot valve assembly on top and install a 1/16"-27 pipe plug in the threaded hole uncovered in the main body. Re-mount the pilot valve and connect an external source of pilot pressure, 50 to 150 psi, into the ext. pilot port on the main body.

General - Differential Pilot Operation

Differential Pilot models are special types in which full line pressure is maintained on both ends of the main spool. To shift the spool, one or the other bleed buttons on the end caps must be momentarily pressed. This vents pressure from one end, permitting pressure on the other end to shift the spool.
A minimum of 25 psi is required for reliable shifting of non-spring models. Minimum pressure for spring offset and 3 position models is 50 psi. They will not operate correctly on compressed air lines of less than 25 psi. They are not suitable for liquids. By careful design they can be built in a 3 position, spring centered configuration.
The bleed buttons can be removed from the valve body and mounted on 1/4" hose or tube extensions for shifting the valve from a few feet away. Any other 2-way normally closed (N.C.) valve, manual, cam or solenoid valve can be substituted for either or both bleed buttons.

DIFFERENTIAL OPERATION

General - Installation & Maintenance

Valves should be installed with reasonable accessibility for service. Exercise care in keeping tubing lengths to a minimum. Plumbing should be free of contamination. Pipe joint compound should be used sparingly applied only to the thread, never the valve body. Over tightening of pipe threads can fracture the joint causing leaks or failure. Protect the valve from exposure to extreme temperatures, dirt and moisture to maximize life.
Bulletin A-113: Operating & Maintenance Instructions.
Installation: Valve Fitting Installation.

WARNING:These products can expose you to chemicals which is(are) known to the State of California to cause cancer or reproductive harm. For more information, go to www.P65Warnings.ca.gov. Contact us for specific chemicals or materials used in a product.

General - LO23/Lock-out Hasp

Lock-out hasp, part number LO23 is required when you want to use multiple locks. Size: 6-3/4" x 2-3/8", manufactured out of steel. The shackle diameter is 1/4".

Dimension PDF STP File

General - 7LJ Masterlock

7LJKAP Masterlock can be used to lock the movement of the handle. The shackle diameter is 3/16".

Dimension PDF STP File

General - Lubrication, Standard

All valves are pre-lubricated at the factory using Magnalube-G Teflon based all purpose grease. Valves are suitable for, and perform best in a non-lube service. For long life, use an air line filter/lubricator installed no further than 10-ft. from the valve. The filter should be rated 25 pm or finer. Use a good grade of petroleum base lubricating oil no heavier than SAE 10W. DO NOT OVER-LUBRICATE. This could cause the spool to stick. CAUTION! Do not use questionable fluids in air line lubricators. Do not use petroleum oil with detergent additives. Detergents, volatile or aromatic fluids may swell rubber seals in valves and cylinders. Never use cooking or vegetable oil as a lubricant. When cleaning AAA valves after extended service, lubricate the valve spool with AAA high film strength grease, or, use O-ring grease which is usually available from supply houses which sell O-rings. Magnalube-G is included in all valve repair kits for proper valve maintenance. If an additional amount of Magnalube-G grease is required, a 0.75 ounce tube is available under part number VGK-3. Never use any kind of oil, cup grease, or automobile chassis lubricant.

The shelf life of Magnalube-G regularly lasts for 10+ year intervals in closed packaging due to the extremely long operating life of the Elastomer-PTFE gelling agent and premium parafiinic mineral base oil. If the valve is stored for over 2 years, then a small reapplication of grease is suggested.

Magnalube-G Technical Document
Magnalube-G MSDS Document

An alternative grease for low temperature application, refer to Dow-55 grease.

General - Lubrication, DOW-55

Valves that are required to operate at temperatures lower than 32°F, we recommend using DOW 55 grease. This grease is not as sluggish as Magnalube-G is at these low temperatures. DOW 55 grease is not required and Magnalube-G has worked well for low temperatures. It is only an anecdotal recommendation. Valves are suitable for, and perform best in a non-lube service. For long life, use an air line filter/lubricator installed no further than 10-ft. from the valve. The filter should be rated 25 pm or finer. Use a good grade of petroleum base lubricating oil no heavier than SAE 10W. DO NOT OVER-LUBRICATE. This could cause the spool to stick. CAUTION! Do not use questionable fluids in air line lubricators. Do not use petroleum oil with detergent additives. Detergents, volatile or aromatic fluids may swell rubber seals in valves and cylinders. Never use cooking or vegetable oil as a lubricant. When cleaning AAA valves after extended service, lubricate the valve spool with AAA high film strength grease, or, use O-ring grease which is usually available from supply houses which sell O-rings. DOW 55 is included in all valve repair kits that specify DOW 55 for proper valve maintenance. Never use any kind of oil, cup grease, or automobile chassis lubricant.

To specify the use of Dow-55 grease, use the suffix "W" to the end of the valve part number. This should be the last letter in the part number structure.

If the valve is stored for over 2 years, then a small reapplication of grease is suggested.

Molykote-55 Technical Document
Molykote-55 MSDS Document

The standard grease for most applications, refer to Magnalube-G grease.

General - O-Ring Information

Unless otherwise specified, all 1/4" and 3/8" soft seal valves come standard with Viton O-rings and all 1/2", 3/4", 1", 1-1/2" and 2" soft seal valves come standard with Buna-N O-rings. If a different material is required, use the dash numbers following the basic valve numbering code. For example, model RY3G-2 will have Silicone O-rings installed for a low temperature application. On valves larger than 1" consult factory on availability of O-ring materials. Additional O-ring material information.

Dash No.	O-ring Description	Temperature Rating
-2	Silicone	-80°F to 400°F
-3	Viton for most aromatic gases	-20°F to 400°F, 600°F for short time
-7	Urethane, 70 Durometer	-65°F to 200°F
-9	Buna-N	-40°F to 250°F

We are constantly researching O-ring materials to evaluate performance and durability in the AAA valve product line. Above is a compilation of the most commonly requested O-ring materials and the associated dash number. If you have a particular application that requires an O-ring material that is not listed, please contact us. Since we utilize standard O-ring dimensions in our valves, we can respond to the most obscure O-ring material request.

General - O-Ring Materials

Dash No.	Material	Description
-2	Silicon	Silicone is a semi-organic elastomer with outstanding resistance to extremes of temperature. Specially compounded, it can provide reliable service at temperatures as low as -80°F (-60°C) to as high as 400°F (205°C) continuously. Silicone also has good resistance to compression set. Low physical strength and abrasion resistance combined with high friction limit silicone to static seals. Silicone is used primarily for dry heat static seals. Although it swells considerably in petroleum lubricants, this is not detrimental in most static sealing applications. Advantages: Excellent at temperature extremes Excellent compression set resistance Disadvantage: Poor physical strength Poor wear resistance
-3	Viton	Fluorocarbon combines resistance to a broader range of chemicals than any of the other elastomers. It constitutes the closest available approach to the universal O-ring elastomer. Although most fluorocarbon compounds become quite hard at temperatures below -20°F (-29°C), they do not easily fracture, so they are serviceable at much lower temperatures. Fluorocarbon compounds provide a continuous 400°F (205°C) high temperature capability. Advantages: Excellent chemical resistance Excellent heat resistance Good mechanical properties Good compression set resistance Disadvantage: Fair low temperature resistance
-7	Urethane	Urethane material has outstanding wear and tear resistance, very low compression set ensuring maximum service life. Due to exceptional material strengths, O-Rings do not require Back-Up Rings when operating at high temperatures and/or pressures. Serviceable temperature range of -65°F to 200°F (-54°C to 93°C). Advantages: Flexibility Resistance to Water, Oil & Grease Performance in Harsh Environments Disadvantage: Short life
-9	Buna-N	Nitrite is the most widely used elastomer in the seal Industry. The popularity of nitrite is due to its excellent resistance to petroleum products and its ability to be compounded for service over a temperature range of -40°F to 250°F (-40°C to 121°C). Nitrite is a copolymer of butadiene and acrylonitrile. Variation in proportions of these polymers is possible to accommodate specific requirements, an increase in acrylonitrile content increases resistance to heat plus petroleum base oils and fuels but decreases low temperature flexibility. Military AN and MS O-ring specifications require nitrite compounds with low acrylonitrile content to insure low temperature performance. Nitrite provides excellent compression set, tear, and abrasion resistance. The major limiting properties of nitrite are its poor ozone and weather resistance and moderate heat resistance. Advantages: Good balance of desirable properties Excellent oil and fuel resistance Good water resistance Disadvantage: Poor weather resistance Moderate heat resistance

General - Solenoid Valve Operation

Standard solenoid and "Classic" solenoid operated valves utilize pressure to shift the internal spool which directs the gas flow through ports. The way ports are internally connected depends upon the configuration of the spool and valve connections. The standard configuration for solenoid valve is "Internal Pilot", they can be ordered as "External Pilot" by ording valve with the suffix "Z" or converted in the field. See Bulletin A-113:Operating and Maintenance Instructions shipped with every valve for assistance.

INTERNAL PILOT

EXTERNAL PILOT

Basic Operation:
When the coil is supplied with the correct power, a magnetic field is generated that pulls in a plunger. The plunger directs the inlet of gas to the end of the internal spool. At the same time, the solenoid exhaust through the stem is blocked, preventing the escape of gas and allowing pressure to build. The increase in the pressure on the end of the spool will shift the spool. Pressure of 25 psi for non-spring models and 50 psi for spring return or spring centered models is required for reliable spool shift (150 psi maximum). When the coil is de-energized, the plunger is returned to position via an internal spring which blocks the inlet of gas to the internal spool. At the same time, the solenoid exhaust is opened and the pressure at the end of the internal spool is allowed to exhaust.
The solenoid can be used as a simple 3-way valve that directs a gas source to the end of the spool or allows the gas from the internal spool to vent. The solenoid vent can be plumbed for direction of exhaust gases.

The return shift of the internal spool is controlled either by a spring, second solenoid, or various mechanical or piloted options.
The inlet of gas to shift the spool can be derived from either internally or externally supplied gas.

Additional Considerations:

If the solenoid exhaust is blocked, thus preventing the reduction of pressure of the internal spool, the valve may not return or function properly.
The exhaust of the solenoid can be pressurized to shift the internal spool, but caution must be used so adequate pressure differentials between the end chambers of the internal spool will allow the shifting of the internal spool. Testing must be performed to assure correct valve operation.
Do not energize the coil while it is not on the solenoid stem. This will cause the coil to burn up and no longer create the needed magnetic field.
Higher power then what the coil is rated for can be applied for short periods. This may however reduce the life span of the coil.
When bench testing of internally piloted valves, adequate back pressure on the operating ports is required to allow sufficient pressure to shift the internal spool.

Mounting - Inline or Side Port Connections

Inline or side port connections are a way to plumb a pneumatic valve. All connections are made to the valve through ports available in the main body or auxiliary components. When changing out a valve, all connections will need to be reconnected to the new valve. Port sizes are 1/4" NPTF, 3/8" NPTF, 1/2" NPTF, 3/4" NPTF, 1" NPTF and 1-1/2" NPTF. We have provided custom BSPP, BSPT and various other port fittings, current or old fashion. Please consult factory for options.

1/4" & 3/8" NPTF

Brass - 1/4" & 3/8" NPTF

Stainless - 1/4" & 3/8" NPTF

1/2" NPTF

3/4" & 1" NPTF

1-1/2" NPTF

Mounting - Bottom Port Connections

Subplated valves require a mounting base. This mounting base is pre-plumbed to existing control lines. Due to the nature of the plumbing lines fixed to a mounting base, replacing subplate mounted valves is rapid and quick. All port connections, excluding "External Pilot" or "Pilot Return" ports, if used, are made through O-ring sealed holes in the base of the valve through a subplate. O-ring seals and mounting screws are furnished with each subplate valve. Because the connections to a base mount can be of any size and configuration, subplate mounted valves are assigned a designation derived from a basic valve body size. A 3P size subplate valve will have the same flow characteristics as a 3/8" NPTF side ported valve body. Consult factory on the possibility of routing external pilot or pilot return sources through the subplate.

3/8" Subplate

1/2" Subplate

1" Subplate

2" Subplate

Mounting - Namur

Namur is the specification for a standard interface between actuators and control valves developed by the Standards committee of Measurement and Control in Europe. The valve mounts directly to the actuator while pressure and exhaust ports are connected through ports in the valve. AAA Products Internationals' Namur mounting valves are designed to meet the recommendations of the actuator industry compact design per VDI/VDE 3845.

1/4" NPTF

Brass - 1/4" & 3/8" NPTF

Usage - 3 Way

A 3-way application is typically a cylinder that is returned by an internal spring. Only air to extend the cylinder is required.

3-WAY N.O. APPLICATION

3-way application diagram

3-WAY N.C. APPLICATION

Usage - 3 Way - Namur Only

Standard Namur valves are assembled for 5 port operation. A valve may be converted to operate using only 3 ports. To convert, remove the 5/16"-32 plug on the side of body and install same plug into threaded bottom port. When port 2 is plugged, the standard NSO2 works as a normally open "NO" valve using port 4. Pressure in port 1 is directed to port 4 when the solenoid is de-energized. When the solenoid is energized port 4 is connected to exhaust port 5, port 1 is blocked. To configure valve for a normally closed "NC" operation, switch the operators located on each end and flip the internal spool and/or spring. Or order a valve with the operators pre-swapped like a NOS2. In this reversed configuration, port 4 is connected to exhaust port 5 when the solenoid is de-energized. When the solenoid is energized port 1 is directed to port 4.

NSO2 Standard
4-Way Usage

NSO2 with port 2 plugged
3-Way Normally Open

NOS2 with port 2 plugged
3-Way Normally Closed

Usage - 4 Way

A 4-way application is one using one inlet pressure that is directed to two separate ports. When one port is pressurized, the other port is directed to an exhaust port. The most typical applications for a 4-way valve are the control of a cylinder or air motor.

All valves are tested at the factory for 4-way service. If a port other than port 1 is pressurized, inform the factory and additional testing will be performed.

4-WAY APPLICATION

Usage - 5 Way

A 5-way application is one using two inlet pressure levels or in which inlet pressure is derived from two different sources for use in the same circuit. Another type of 5-way application is for conserving air on the return stroke of double-acting cylinders.

Standard AAA soft seal valves may be ordered for 5-way service with these exceptions: Solenoid valves must be re-connected to use an external source of 50 PSI to 150 PSI pilot pressure. Stack valve sections and differential pilot valves cannot be used for 5-way service.

5-WAY APPLICATIONS

Flow Pattern - "Classic" Solenoid Valves

1/4" through 1":When a solenoid is energized causing the internal spool to shift, port 1 will connect to the port closest to the energized coil (ports 2 or 4). The furthest port will connect to the appropriate exhaust port (ports 3 or 5).
1-1/2" and 2":These larger valves use a "Piggy-Back" valve mounted to the top of the larger valve. The flow through the larger valve is the same as above.

Reversing Valve Operators

The end actuators on most AAA soft seal valves can be changed from one end to the other to put the inlet port and cylinder ports on the desired side for convenience in plumbing. If actuators are desired on opposite ends of the valve from standard assembly, just reverse the valve operators in the valve model number when ordering (e.g.; HO2 represents standard assembly. In comparison, OH2 has the handle switched to the opposite end - reverse build). Consult factory for infield modifications.

HO2 Valve

OH2 Valve

Understanding Valve Numbers

AAA valves use a simplified model code which calls out the most important characteristics with a minimum of coding. In the example, model SY3G is a double solenoid valve, 3/8" size, spring centered spool, float center type.

The first two letters in the code (SY) designate the type of operator on the left and right ends respectively when viewing toward the side with the "2 or A" and "4 or B" ports. The numeral (3) gives valve size in 8ths of an inch. This completes the model code for many valves. If, however, additional features are desired, one or more suffix letters can be added.


Valve Operators		Size	Typical Options
C = Cam E = Friction Position F = Foot Pedal G* = Direct Pilot H = Manual Lever K = Palm Button O = Spring Offset	P = Piston R = Pilot S = Solenoid T = Treadle Y = Spring Centering D (in 1st pos.) = Bleeder D (in 2nd pos.) = Detent	2 = 1/4" 3 = 3/8" 4 = 1/2" 6 = 3/4" 8 = 1" 12 = 1-1/2" 16 = 2"	D = Regenerative Spool Type G = Float Center Spool Type P = Subplate Mounting Q = 2-Position Detent X = Explosion Proof Operator Z = External Pilot Operation Others Availible.
*Special prefix for 1-1/2" and 2" air valves to designate valve body only, without a piggy back operator.

All Solenoid Valves: We have changed our standard solenoid assembly to a new PLC friendly solenoid. To differentiate this style from our "Classic" solenoid valves, please use a prefix of "E" to all new solenoid valves. (E.g.; on SO2 to specify new solenoid style use ESO2).

Stack Series Valves: B-Series valves are similar in construction to the 1/4" & 3/8" side ported valves. B-Series are only available in 1/4" & 3/8" NPTF port sizes. To order a 1/4" manual lever valve, spring return in a stack valve you would add the prefix "B" to the part number (e.g. BHO2). On ESO2 with the new solenoid style use EBSO2 to denote stack valve.

Namur Series Valves: N-Series valves are similar in construction to the 1/4" & 3/8" side ported valves. N-Series are only available in 1/4" NPTF port sizes. To order a 1/4" solenoid valve, spring return in a Namur valve you would add the prefix "N" to the part number (e.g.; NSO2). Namur valves are only available with the new selnoid style, so the prefix "E" is omitted.

Brass Valves: The prefix "Z" denotes a brass 1/4" or 3/8" side ported body. Some valves and options are unavailble in brass. Consult factory for available options.

Dash: The suffix of a "-" then a number denotes body - O-Ring material. (E.g.; The part number SO3-9, would specify (-9) Buna-N material for the body O-Rings. For O-Ring materials and valid dash numbers see O-Rings.

W Suffix: The suffix of "W" denotes the optional use of DOW-55 grease. The sandard grease is Magnalube-G. For some low temperature applications it is recommended to use DOW-55.