EMERSON AS1 Pressure Regulator Valve RGS RGP Filter Pressure Regulator Valve Instruction Manual

Operating instructions
R412013434-BAL-001-AH 2021-07, Replaces: 2018-10
AVENTICSTM AS1 / AS2 / AS3 / AS5
Pressure regulator valve (RGS/RGP), filter pressure regulator valve (FRE)

About This Documentation

Read this documentation completely, especially chapter g 2. Safety before working with the product. These instructions contain important information on the safe and appropriate assembly, operation, and maintenance of the product and how to remedy simple malfunctions yourself.

Additional documentation

In addition to this documentation, you will obtain further documents on the product or the machine/system where it is installed.

Observe all documents supplied with the system or machine.
Additionally always observe the following regulations:

• General, statutory and other binding rules of the European and national laws.
• Applicable regulations for accident prevention and environmental protection.

Presentation of information

Warnings
Warnings of personal injury and damage to property are highlighted in this documentation. The measures described to avoid these hazards must be followed.

Display as highlighted box
Warnings are displayed in the form of highlighted boxes with the following structure:

SIGNAL WORD
Hazard type and source
Consequences of non-observance
Precautions

Presentation with highlighted signal word
Instructions and lists often contain warnings that are integrated into the text. They are introduced with a bold signal word:
CA U TION! Do not exceed permissible bending radii.

Meaning of the signal words

Failure to observe these notices will result in serious health consequences, including death.
Warning| Possible danger to the life and health of persons.
Failure to observe these notices can result in serious health consequences, including death.
Caution| Possible dangerous situation.
Failure to observe these notices may result in minor injuries or damage to property.
Notice| Possibility of damage to property or malfunction.
Failure to observe these notices may result in damage to property or malfunctions, but not in personal injury.

Symbols
Recommendation for the optimum use of our products. Observe this information to ensure the smoothest possible operation.

Safety

About this chapter

The product has been manufactured according to the accepted rules of current technology. Even so, there is danger of injury and damage to equipment if the following chapter and safety instructions of this documentation are not followed.

• Read this chapter and this documentation completely before working with the product.
• Keep this documentation in a location where it is accessible to all users at all times.
• Always include the documentation when you pass the product on to third parties.

General safety instructions

• Observe the valid regulations for accident prevention and environmental protection for the country where the device is used and at the workplace.
• Only use AVENTICS products that are in perfect working order.
• Examine the product for obvious defects, such as cracks in the housing or missing screws, caps, or seals.
• Do not modify or convert the product. The warranty will not apply if the product is incorrectly assembled.
• Persons who assemble, operate, disassemble, or maintain AVENTICS products must not consume any alcohol, drugs, or pharmaceuticals that may affect their ability to respond.
• Do not place any improper mechanical loads on the product under any circumstances.
• Product warnings and information must be legible, i.e. not covered by paint, etc.

Intended use

• The product may only be commissioned after it has been installed in the machine/system for which it is intended.
• Observe the technical data and the listed specified operating conditions and performance limits.
• Only use Compressed air as the medium. The product is intended for professional use only.
• Intended use includes having read and understood these instructions completely, especially the section “Notes on Safety”.

Personnel qualifications

The work described in this documentation requires basic knowledge in the following areas, as well as knowledge of the appropriate technical terms:

• Mechanics
• Pneumatics
• Electrics

In order to ensure safe use, these activities described in this documentation may therefore only be carried out by qualified technical personnel or an instructed person under the direction and supervision of qualified personnel.
Qualified personnel are those who can recognize possible dangers and institute the appropriate safety measures, due to their professional training, knowledge, and experience, as well as their understanding of the relevant regulations pertaining to the work to be done. Qualified personnel must observe the rules relevant to the subject area.

Safety instructions related to the product and technology

• Lay cables and lines so that they cannot be damaged and no one can trip over them.
• Do not operate the product in aggressive ambient air (e.g., solvent vapors).

The substances listed as examples in the following table, which contain solvents in various concentrations, can lead to an aggressive ambient air/compressed air in the application area of compressed air preparation devices and in the suction area of air compressors.

compressor oils, brake fluid, ammonia, bonding and sealing agents, plasticizers,
anti-freeze, coolants/lubricants.

• No soiling may be allowed to collect on or in the filters, reservoirs or windows. Replace reservoirs if soiling cannot be removed from the drain (drain may become clogged).

Also observe the “Customer information on material resistance in compressed air preparation” (MNR R412025273)

Scope of delivery

• 1x Pressure regulator valve or filter pressure regulator valve (see: Order)
• Optional: Pressure gauge enclosed separately
• 1x Operating instructions

Product description

Pressure regulator valves and filter pressure regulator valves are components of maintenance units. These valves serve to reduce the applied system pressure to a maximum, regulated working pressure. Filter pressure regulator valves form a compact unit and are also used for coarse compressed air filtering.

Assembly, commissioning and operation

CAUTION
Danger of injury if assembled under pressure or voltage! Assembling when under pressure or voltage can lead to injuries and damage to the product or system components.

1. Make sure the relevant system part is without voltage or pressure prior to assembly.
2. Protect the system against being restarted.

CAUTION
Sudden pressure increase during commissioning! The system is exposed to sudden pressure on commissioning if no SSU filling unit is used! This may result in dangerous erratic cylinder motions.

When commissioning a system without an SSU filling unit, make sure that the cylinders are in their end position. For cylinders not in the end position, make sure they do not present any danger.

CAUTION
System is operating under pressure! Incorrect installation could damage the product and cause serious injury. u Before commissioning, check that all connections, ports and maintenance equipment have been correctly installed.

Mounting fastening elements W01 ­ W05

See g Fig. 8 to g Fig. 12

Mounting the pressure gauge

See g Fig. 1 (I)

If a pressure gauge is not mounted, the blanking screw must be screwed into the pressure regulator valve and sealed. The blanking screw must be ordered separately.

Pressure gauge with radial seal

1. Firmly screw the pressure gauge by hand into the pressure gauge thread until the seal is completely screwed into the thread.
2. Tighten the pressure gauge with an open-end wrench (SW 14) by at least a 1/2 turn and align it visually at the same time.

Pressure gauge with axial (metal) seal
If the pressure gauge was ordered separately, the compression ring is supplied as a separate part.

1. Mount the compression ring on the pressure gauge.
2. Turn the pressure gauge into the pressure gauge thread until the compression ring is flush against the sealing face.
3. Seal off the connection while aligning the pressure gauge at the same time by tightening with max. one turn (open-end wrench SW 14). Max. tightening torque 7 ­ 8 Nm.

Before commissioning

Let the product acclimatize for several hours before commissioning. Otherwise, water may condense in the housing.
Check that all electrical and pneumatic connection ports are connected or plugged. Only operate a fully installed product.

Adjusting the pressure

See g Fig. 2

1. Pull the handwheel (a) up.
2. Turn the handwheel (a) to set the desired pressure.
3. Push down the handwheel (a). This relocks the handwheel.

The safety eyelets need to be retracted fully for any pressure readjustment.

Retracting the safety eyelets
Turn the top rim of the handwheel clockwise until the safety eyelets are fully retracted.

Locking the handwheel

See g Fig. 3
To prevent any unauthorized change of the pressure setting, the pressure regulator valve handwheel can be locked using a key (AS1) or a padlock (AS2 ­ AS5).

AS1
To lock handwheel:
Turn key clockwise and then pull it out.
To unlock hand wheel:
Turn key counterclockwise and then pull it out.
AS2 ­ AS5
To attach padlock:

1. Push down the handwheel (a).
2. Turn the top rim (b) of the handwheel in counterclockwise direction to locking position. This extends the safety eyelets (c).
3. Hang the padlock into one of the safety eyelets (c) and lock it.

5.4.3 AS1 ­ AS5 (E11)
Version with E11 locking

Supplied without key. Key must be ordered separately.
To lock handwheel:
  Turn key clockwise and then pull it out.

To unlock handwheel:
Turn key counterclockwise and then pull it out.

RGP precision pressure regulator valves and some RGS pressure regulator valves permanently release the internal air consumption to the atmosphere. A leakage noise is emitted during this process.

Semi- and fully automatic condensate drain

CAUTION
Potential impairment of compressed air system by condensate!
In the case of the semi-automatic condensate drain, condensate is only discharged when the reservoir is not under pressure. If in operation for an extended period, the condensate may exceed the maximum filling level and find its way into the compressed air system. This may result in damage to the compressed air system.

1. Regularly check the filling level in the reservoir.
2. Drain condensate manually once it reaches the maximum filling level.
3. Do not allow the condensate to enter the environment in an uncontrolled manner.

Semi-automatic condensate drain
See g Fig. 4 (I)

The condensate drain opens and closes depending on operating pressure:

• Pressure < 1.5 bar: drain open
• Pressure > 1.5 bar: drain closed

Setting the semi-automatic mode
Turn the drain screw all the way counterclockwise.
You may leave the screw one turn deep in the thread or remove it completely.

Draining condensate manually
See g Fig. 4 (III) The condensate can also be manually drained (b = maximum filling level).

1. Turn the drain screw (a) all the way clockwise (closed position).
2. Turn the drain screw (a) counterclockwise a few turns until condensate runs out.

Fully automatic condensate drain
See g Fig. 4 (II) The fully automatic condensate drain is available in versions “open without pressure” and “closed without pressure”. In both versions the valve opens automatically as soon as the floater reaches the highest point and closes again when the it reaches the lowest point.

Version “open without pressure”
The condensate drain opens and closes depending on operating pressure:

• Pressure < 1.5 bar: drain open
• Pressure > 1.5 bar: drain closed

Setting the automatic mode
Turn the drain screw clockwise as far as it will go.

Version “closed without pressure”
The condensate drain is closed regardless of the operating pressure.

Draining condensate manually
See g Fig. 4 (III)
The condensate can also be manually drained (b = maximum filling level).
Turn the drain screw (a) counterclockwise as far as it will go.
If the drain screw is screwed in all the way anti-clockwise, the automatic drainage is blocked.

Disassembly, exchange

CAUTION
Danger of injury if disassembled under pressure or voltage! Disassembling when under pressure or voltage can lead to injuries and damage to the product or system parts.

1. Make sure the relevant system part is without voltage or pressure prior to disassembly.
2. Protect the system against being restarted.

Replacing the pressure gauge

Fig. 1 (II)

1. Unscrew the old pressure gauge from the pressure gauge thread.
2. Mount the new pressure gauge as described in the g 5.2. Mounting the pressure gauge section.

Exchanging the filter

CAUTION
System is operating under pressure! Opening the system while under pressure may damage the product and cause personal injury.
Ensure that the system is not under pressure before you open the reservoir.

INFO: The filters clog up over time and need to be replaced regularly, at the latest after a year. This, however, is just a guidance value, since the intervals depend on the compressed air quality and airflow rate. Use the material numbers below when placing your orders. The addresses of the international agencies are available at www.emerson.com/contactus.

Table 1: Wearing parts

Standard filter element, 5 µm, material: polyethylene
AS1/AS2| 1829207061
AS3| 1829207068
AS5| R961403328
Standard filter element, 25 µm, material: polyethylene
AS1/AS2| R961400004
AS3| R961400005
AS5| R961400006
Standard filter element, 40 µm, material: polyethylene
AS1/AS2| R961403385
AS3| R961400142
AS5| R961403332
Standard filter element, 40 µm, material: sintered bronze
AS1| R961400009

Procedure for series AS1 FRE
See g Fig. 5

1. Make sure the relevant system part is not under pressure and exhaust the system.
2. Turn reservoir counterclockwise and remove (a, b).
3. Screw out the filter piece (c, d).
4. Remove the top twist cap and replace the filter insert (e).
5. Reassemble the individual parts (f).
6. Screw in a new filter insert and tighten gently by hand (g).
7. Screw in the reservoir as far as it will go in a clockwise direction (h, i).
8. Apply pressure to the system again.

Procedure for series AS2 AS3 AS5 FRE
See g Fig. 6

1. Make sure the relevant system part is not under pressure and exhaust the system.
2. Pull the release (a) downward, then turn the reservoir at first counterclockwise (b) and then remove (c).
3. Screw out the filter disk (d).
4. Replace filter insert (e).
5. Screw the filter disk back in together with the new filter (f) and tighten gently by hand (g).
6. Insert the reservoir rotated by 45° (h) and turn clockwise until the release engages audibly (i).
7. Apply pressure to the system again.

Conversion and extension

CAUTION
Danger of injury if extension or conversion work is performed under pressure or voltage! Extension and conversion when under pressure or electrical voltage can lead to injuries and damage to the product or system parts.

1. Make sure that the relevant system part is without pressure and voltage before extending or converting the product.
2. Protect the system against being restarted.

Disposal

Dispose of the product in accordance with the national regulations in your country.

Troubleshooting

Technical data

This section contains an excerpt of the key technical data. Further technical data can be found in the online catalog.

General

Specifications

Mounting orientation| Filter pressure regulator valve: vertical Pressure regulator valve: any
---|---
Medium/ambienttemperature min./max.| -10 – +50°C
Max. internal air consumption| RGP: 2.6 l/min
RGS: 1.5 l/min

Maximum permissible pressure, temperature range, and thread connection are indicated on the products.

Appendix

Figures: View varies according to the series.

Fig. 1: I: Mounting the pressure gauge, II: Replacing the pressure gauge | Series AS2, AS3, AS5
III: Integrated pressure gauge | Series AS1
Fig. 2: Adjusting the pressure (P1 = input pressure, P2 = output pressure) | Series AS1, AS2, AS3, AS5

Fig. 3: Locking the pressure regulator valve

Fig. 4: Condensate drain | Series AS1, AS2, AS3, AS5
I: Semi-automatic condensate drain, II: Fully automatic condensate drain,
III: Manually draining condensate

Fig. 5: Exchanging the filter|Series AS1 FRE
Series AS1 FLP/FLC/FLA

Fig. 6: Exchanging the filter|Series AS2, AS3, AS5 FRE

Fig. 7: Converting the filter pressure regulator valve (FRE) and pressure regulator valve (RGS and RGP)
Series AS2, AS3, AS5

Fig. 8: W01 | Mounting with mounting plate

Fig. 9: W02 | Mounting with mounting bracket

Fig. 10: W03 | Block assembly and mounting with mounting clip

Fig. 11: W04| Block assembly with block assembly kit

Fig. 12: W05 | Block assembly and mounting with block assembly kit

The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging.
An example configuration is depicted on the title page. The delivered product may thus vary from that in the illustration.
Translation of the original operating instructions. The original operating instructions were created in the German language.
Subject to modifications. © All rights reserved by AVENTICS GmbH, even and especially in cases of proprietary rights applications. This document may not be reproduced or given to third parties without our consent.
The Emerson logo is a trademark and service mark of Emerson Electric Co. AVENTICS is a mark of one of the Emerson Automation Solutions family of business units. All other marks are property of their respective owners.

Emerson Automation Solutions
AVENTICS GmbH, Ulmer Straße 4
30880 Laatzen, GERMANY
phone +49 511 2136-0
fax +49 511 2136-269
www.emerson.com/aventics
aventics@emerson.com
Further addresses:
www.emerson.com/contactus

References

• AVENTICS – Smart, reliable solutions for pneumatic automation | Emerson US
• Contact Us | Emerson US
• Contact Us | Emerson US

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