Explosion-Proof SAE Valves for Hazardous Locations Product Catalog

Key Features and Design Advantages

The AV explosion-proof SAE valves incorporate several features that set them apart in hazardous-location pneumatic control. Their compact spool design uses balanced spool construction for reliable shifting. The solenoid pilot uses full air line pressure to shift the valve, and every solenoid is guaranteed against burnout. The bidirectional tapered Tee-Seal eliminates sticking problems and has been tested according to SAE specifications with rust and water injected every 864,000 cycles for a proven 20-million-cycle lifespan. A push-type, non-locking manual override allows the solenoid valve to be operated manually in case of electrical failure or for quick cycle testing. The valves are also easily field-convertible to an external pilot supply when system requirements dictate separate pilot pressure.

Certifications and Hazardous Location Ratings

These valves carry Factory Mutual (FM) approval for explosion-proof service in Class I, Division 1, Groups A, B, C, and D (T4, Ta = 60°C), encapsulation/explosion-proof for Class I, Zone 1 (AEx m II T4), dust-ignition proof for Class II and III, Division 1, Groups E, F, and G, non-incendive for Class I, Division 2, and suitable for Class II/III Division 2 hazardous locations. They also hold CSA approval for Class I Division 1 and 2, and carry an Ex m II T4 rating. In addition, the valves have achieved Functional Safety Approval up to SIL 2 per IEC 62061:2001, along with a Declaration of Conformity and Certificate of Compliance.

Technical Specifications and Operating Conditions

The explosion-proof SAE valves are available in 5/2 (5-way, 2-position) and 5/3 (5-way, 3-position) configurations. The 5/3 models offer closed center, open center, and power center options to suit different circuit requirements. The actuation method is solenoid pilot controlled for electrical operation, and pressure controlled for pneumatic operation. Mounting options include sub-base and manifold configurations with bottom cylinder ports or bottom/side cylinder ports. All connections use NPTF threaded ports.

Operating Pressure and Temperature Ranges

The 5/2 valves operate at pressures from 35 to 150 psig (2.4 to 10.3 bar), while the 5/3 valves require 50 to 150 psig (3.4 to 10.3 bar). External pilot supply pressure follows the same ranges. The ambient and media operating temperature range is 0°F to 123°F (-18°C to 50°C). For temperatures below 40°F (4°C), the air supply must be free of water vapor to prevent ice formation. The flow media is filtered air.

Electrical Data and Solenoid Options

DC solenoid options include 24-volt and 12-volt models with a power consumption of 4.5 watts per solenoid. AC options are available in 120-volt 60 Hz and 240-volt 60 Hz with a power consumption of 6.5 VA. The enclosure rating is NEMA 7, IP65, and the electrical connection is a 1/2-inch conduit coil with 24-inch leads. Both single solenoid pilot and double solenoid pilot actuations are available. All solenoids are rated for continuous duty.

Available SAE Sizes and Flow Capacity

The catalog covers four SAE sizes, each offering different flow capacities and port sizes to match application requirements. SAE Size 125 (A04) uses 3/8-inch ports and delivers a CV of 2.4 (2,400 Nl/min) for 5/2 valves and 1.9 (1,800 Nl/min) for 5/3 valves. SAE Size 250 (A06) offers port options from 1/2 inch to 1 inch and delivers a CV of 8.6 (8,500 Nl/min) for 5/2 and 6.7 (6,600 Nl/min) for 5/3 configurations. SAE Size 500 (A10) uses 3/4-inch to 1-inch ports with a CV of 13.7 (13,000 Nl/min) for 5/2 and 11.5 (11,000 Nl/min) for 5/3 valves. The largest, SAE Size 1000 (A20), uses 1-inch to 1-1/2-inch ports with a CV of 22.7 (22,000 Nl/min) for 5/2 and 17.7 (17,000 Nl/min) for 5/3 valves.

Construction Materials

The valve body is constructed from cast aluminum, with SAE Size 500 also available in aluminum bar stock. The solenoid body is made from Polyamid 66. Spools are machined from aluminum. Seal options include Buna-N as standard and fluoroelastomer for applications requiring greater chemical resistance, with fluoroelastomer seals available for SAE Size 125 and 250.

Ordering Information and Model Number Configuration

The catalog provides detailed model number configurators for both 5/2 and 5/3 valve configurations. The model number encodes the SAE size, valve type, mounting option, base port size, actuation type, solenoid voltage, coil type (explosion-proof), and certification (CSA/FM). Additional options include dustproof vent ports, external pilot supply, and seal material selection. For example, model 407B43S3S3-DB represents a 5/2 double solenoid pilot valve in SAE Size 125 with 24V DC explosion-proof coils and CSA/FM certification.

Sub-Bases, Manifolds, and Accessories

Sub-bases are available for all four SAE sizes with NPTF threaded ports. Manifold options include bottom cylinder port and bottom/side cylinder port configurations for SAE Sizes 125, 250, and 500. Manifold accessories include blocking disks for unused stations, blank station covers to block air passages, and end plate kits. The catalog also details interposed flow controls for restricting airflow between ports, sandwich single and dual pressure regulators for controlling inlet and cylinder pressure, analog pressure gauges, and high-flow zinc-plated steel exhaust silencers in sizes from 3/8 inch to 1-1/2 inch.

Dimensional Data and CAD Models

The product catalog includes comprehensive dimensional drawings for all SAE sizes in both single and double solenoid configurations. Dimensions are provided in both inches and millimeters for ease of integration into global designs. For SAE Size 125, a single solenoid valve measures approximately 4.29 inches (109 mm) in length for the 5/2 configuration. The SAE Size 1000 double solenoid valve measures approximately 11.50 inches (292 mm) in length. Sub-base dimensions, manifold station dimensions, and accessory dimensions are all detailed in the catalog with complete technical drawings. Downloadable CAD models are available for all valves, sub-bases, manifolds, and accessories to support system design and integration.

Frequently Asked Questions

What hazardous location classifications are the AV explosion-proof SAE valves approved for?

The AV explosion-proof SAE valves carry FM approval for Class I, Division 1, Groups A, B, C, and D; Class II and III, Division 1, Groups E, F, and G; and Class I, Division 2. They also carry CSA approval for Class I, Division 1 and 2, as well as Ex m II T4 ratings. This makes them suitable for environments with flammable gases, vapors, combustible dust, and ignitable fibers.

What SAE sizes are available in the explosion-proof valve lineup?

The explosion-proof SAE valves are available in four sizes: SAE 125 (A04), SAE 250 (A06), SAE 500 (A10), and SAE 1000 (A20). Each size offers progressively higher flow capacity, ranging from a CV of 2.4 for SAE 125 up to a CV of 22.7 for SAE 1000 in 5/2 configurations.

Can these explosion-proof valves be used with an external pilot supply?

Yes, all AV explosion-proof SAE valves are easily field-convertible to an external pilot supply. This is useful in applications where the main line pressure is reduced below the minimum operating threshold by a downstream pressure regulator.

What voltage options are available for the solenoid coils?

DC options include 24V and 12V, with a power consumption of 4.5 watts per solenoid. AC options include 120V at 60 Hz and 240V at 60 Hz, consuming 6.5 VA. Other voltages are available upon request by consulting Automatic Valve.

What is the safety integrity level (SIL) rating of these valves?

The AV explosion-proof SAE valves have achieved Functional Safety Approval up to SIL 2 per IEC 62061:2001, making them suitable for use in safety-related control systems in process and manufacturing industries.