EMERSON AVENTICS 645 Pressure Regulator Instruction Manual

Operating instructions
548325-001
2021-09; Replaces:
AVENTICS™ 645
Pressure regulator for railway applications

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.

Documentation validity

This documentation applies to pressure regulators for railway applications, series 645. This documentation is intended for: System owners, system planning engineers, machine manufacturers, installers

Additional documentation

Apart from this documentation, you will not receive any further documentation on the product or on the system or machine in which the product is installed. 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 that are displayed in the form of highlighted boxes have 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. Inline warnings are introduced with a bold signal word:
CAUTION!
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.
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 operating instructions when you pass the product onto third parties.

Intended use

The product is a pneumatic system component. The product was manufactured for the following applications:

• The product is intended for professional use and not for private use.
• The product is exclusively intended to be installed in an end product (such as a machine or system) or to be assembled with other components to form an end product.

Application area
The product is designed only for use in the following areas:

• Railway applications
• Marine applications
• Industrial applications

Operating site

• Only use the product indoors.
  IN F O: If the product is to be used in a different area: Obtain an individual license from the relevant authorities or inspection center.

• The product must first be installed in the machine/system for which the product is intended. The product may only then be commissioned.

• Observe the technical data and the specified operating conditions and performance limits.

• Intended use also includes having read and understood these instructions in full, in particular the section on → 2. safety.

Improper use

Any use other than that described in the section “Intended use” is considered improper and is not permitted.
AVENTICS GmbH is not liable for any damages resulting from improper use. The operator alone bears the risks of improper use of the product.

Obligations of the operator

Compliance with regulations

• Observe the regulations for accident prevention and environmental protection.
• Comply with the national safety rules and regulations.

Basic regulations for use

• Only use the product if it is in perfect working order.
• Follow all the instructions on the product.
• Observe all specifications in the documentation.
• Ensure that the conditions for use meet the requirements for safe use of the product.

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

Hazards

The following section gives you an overview of the basic hazards that arise when working with the product.

Notes on safety
To eliminate risks, observe the following instructions:

DANGER
High danger of injury or death
Non-compliance is very likely to result in serious injury or death.
► In the following, observe all specifications marked with “accident prevention”.

WARNING
High danger of injury Non-compliance can result in serious injury or death. u In the following, observe all specifications marked with “accident prevention”.

NOTICE
Material damage
Non-compliance can lead to material damage and malfunctions.
► In the following, observe all specifications marked with “material protection”.

Scope of delivery

• 1x Pressure regulator according to the order
• Optional: Pressure gauge (enclosed separately)
• Optional: Adjustment screw lock (enclosed separately)
• 1x Operating instructions

Product description

Brief description

Pressure regulators are components of air preparation units. Pressure regulators serve to reduce the applied system pressure to a maximum, controlled operating pressure.

Identification

Name plate
On the standard name plate, you will find the following information (the name plates shown are only samples):

1. Manufacturer logo
3. Maximum pressure
5. Date of manufacture| 2. Material number
4. ISO-Symbol
6. Temperature range
---|---

Product identification
The ordered product is clearly identified by the material number.
Check the material number (MNR) on the name plate to determine whether the delivered product matches the number on your order confirmation or delivery note.

Versions

The product is available in the following versions:

Fig. 2: Inline version with low flow dimensions

Fig. 3: Inline versions with high flow dimensions

Fig. 4: Crimped version with low flow dimensions

Fig. 5: Crimped version with high flow dimensions

Transport and storage

Transporting the product

Hazards during transportation
To eliminate risks during transport, observe the following instructions:

• Proceed with caution and observe the information on the packaging when unloading and transporting the packaged product to the destination.
• Ensure that the product cannot fall down before the product is released from the mountings (accident prevention, material protection).
• Do not stand under suspended loads (accident prevention).
• Take steps to avoid damage when lifting the product (accident prevention, material protection).
• Heavy products and components must be carried by two people or by one person with lifting aids (accident prevention, material protection).
• Wear appropriate protective clothing (e.g. sturdy footwear).

Storing the product

Damage due to incorrect storage
Unfavorable storage conditions can result in corrosion and material deterioration.

• Comply with the limits: see section g 13. Technical data.
• Only store the product in locations which are dry, cool, and prevent corrosion.
• Avoid direct sunlight.
• Keep the product in the original or delivery packaging until the time of installation.
• Observe the storage requirements in these instructions. Also observe any additional storage information on the product packaging.

Compressed air connections

1. Ensure that all compressed air connections are protected against contamination by protective caps.
2. Tape open compressed air connections or provide them with suitable protective caps.

Returning the product

Proceed as follows to return the product:

1. If the product has already been mounted: Dismount the product (see section → 10. Dismounting).

2. Package the product in its original packaging.
   If the original packaging is no longer available: Select suitable replacement packaging in consultation with EMERSON (contact details: see back cover).

3. If the product cannot be returned immediately: Observe the storage conditions (see section → 5. Transport and storage).

4. Return the product.

Assembly and installation

Before you start with the installation: Familiarize yourself with the basic specifications for assembly as early as possible in advance: see sections → 6.1. Planning and → 6.2. Preparation.

Planning

In the following, you will read which basic requirements must be met so that you can successfully and safely assemble the product.
Do not carry out the preparation and installation steps until you have successfully completed the planning.

Basic requirements
The following specifications apply to the assembly of all products.

Installation conditions

• Observe the installation conditions: see section → 6.1.3. Installation conditions.

Ambient conditions

• Only use the product in non-aggressive industrial atmospheres (explosion protection). Only then can explosion protection be guaranteed.
• If the ambient air contains aggressive substances: Get in touch with our contact address to determine whether use of the product is still  possible (contact data: see back cover).
• Let the product acclimatize for a few hours before installation. Otherwise water may condense in the housing.

Limits

• Comply with the limits (accident prevention, material protection). Limits: see section → 13. Technical data.

Accessibility
Install the product in the system part so that the following connections and operating parts are always accessible or have enough room:

• Electrical connections
• Pneumatic connections
• Cable and tubing

Personnel qualifications
Assembly only by qualified personnel (see section → 2.5. Personnel qualifications ).

Set-up regulations in the country of use

• Observe the set-up regulations in the country of use

Notes on safety
To eliminate risks during assembly, observe the notes on safety: see section → 2.6.1. Notes on safety.

Installation conditions
The installation conditions include the specifications that apply specifically to the product family that your product belongs to.

General requirements

• Make sure that the product is installed in a manner that protects it from all types of mechanical loads.
• Install the product in an area protected from UV radiation.

Product-specific requirements
Mounting orientation

• Mounting orientation: see section g 13. Technical data.

Required material and tools
Mounting material

• Mounting bracket (optional)
• Panel nut
• Padlock or similar to lock adjustment screw (optional)

If you use AVENTICS mounting material, see the online catalog for the relevant data. Important information for assembly:

• Dimensions
• Tightening torques: Observe the values in the online catalog.

If no information is given on tightening torques or you use your own mounting material, the generally recognized rules of technology apply to assembly.

Tool

• For versions with low flow: Open-end wrench, wrench size 11/32″
• For versions with high flow: Open-end wrench, wrench size 13
• Open-end wrench, wrench size 14
• Allen key, wrench size 3
• Allen key, wrench size 4
• Allen key, wrench size 5
• Small screwdriver

Preparation

Notes

• Do not carry out any work on the system during preparation (accident prevention).

Unpacking and checking the product

1. Unpacking the product.
   NOTICE! Do not remove sealing plugs on pneumatic connections immediately, but only when performing the assembly. This prevents  contamination and possible malfunction (material protection).

2. Check the material number to see if the product matches your order.
   The material number can be found on the housing of the product.

3. Check the product for transport and storage damage.
   Do not install a damaged product. Return damaged products together with the delivery documents (address: see back cover).

4. Prepare required accessories, materials and tools.

Implementing safety measures Procedure

Preparation

All work has to be prepared as follows:

1. Close off dangerous areas (accident prevention).
2. Make sure the system or system part is not under pressure or voltage.
3. Protect the system against being restarted.
4. Allow the product and adjacent system parts to cool down (accident prevention).
5. Wear protective clothing (accident prevention).

Installation

Mounting the product
Mounting options

• A: Inline versions: with panel nut through suitable hole
• B: Inline versions: with mounting bracket
• C: Crimped versions

Inline versions: Mounting with panel nut through a suitable hole (A)

1. If necessary, drill a suitable through hole for assembly.
   Size: see dimensions in section g 4.3. Versions.

2. Guide product through hole and fasten with panel nut (1) from the other side (1/4 turn).

3. Check for firm fastening.

Inline versions: Mounting with mounting bracket (B)

1. Mount the mounting bracket at a suitable location.
   Use suitable mounting materials (not included in the scope of delivery).

2. Slide the mounting bracket (2) over the adjustment head from above.

3. Slide the nut (3) over the adjustment head and tighten with a 1/4 turn.

4. Check for firm fastening.

Crimped versions (C)

1. Mount the product with 4 screws to a distributor or base with suitable dimensions and interfaces.
   Version with low flow:
   – Dimensions: see → Fig. 4
   – Tightening torque: 2°Nm Version with high flow:
   – Dimensions and interfaces: see → Fig. 5
   – Tightening torque: 4°Nm

2. Check for firm fastening.

Assembling the pressure gauge (only inline version with high flow)
Assembly options

• A: If the pressure gauge was ordered separately, an adapter must first be mounted on the product.
• B: If the product was ordered with a pressure gauge, the adapter is premounted.
  If the pressure gauge is not used: Screw the blanking screw into the regulator and seal (material protection).

Assembly with separate adapter (B)

1. Insert the pressure gauge (1) into the adapter (2).

2. Place the crimp ring (3) on the pressure gauge.

3. Place the adapter with pressure gauge on the intended location on the product. Tighten the mounting screws on the adapter with a screwdriver.
   Max. tightening torque: 0.45 Nm.

4. Screw the pressure gauge (1) into the pressure gauge thread until the crimp ring (3) is completely screwed into the thread.

5. Seal off the connection in the thread, e.g. with Loctite® 565™, while aligning the pressure gauge at the same time by tightening with max. 3/4 turn forward or backward.

Assembly with pre-mounted adapter (B)

Fig. 6: Adapter (2) is pre-mounted on the product

1. Remove the blanking screw (4) from the pre-mounted adapter (2) with a hex key (wrench size 5).
2. Screw the pressure gauge into the pressure gauge thread.
3. Seal off the connection in the thread, e.g. with Loctite® 565™, while aligning the pressure gauge at the same time by tightening with max. 3/4 turn forward or backward.
   Max. tightening torque: 1.9 Nm.

Connecting the pneumatics Prerequisites

• All safety measures have been implemented. See section g 6.2.3. Implementing safety measures.
• Installation has been completed successfully. See section g 6.3. Installation.

Basic requirements

• Only use suitable tubing and fittings from the online catalog (accident prevention).
• Observe the flow direction (see marking on product).

Procedure

1. Connect the compressed air tubing on both sides.
2. Check for firm fastening.
3. Apply pressure and check the connection for potential leaks and defects.

Setting the pressure

Prerequisites

• All safety measures have been implemented. See section g 6.2.3. Implementing safety measures.
• The pneumatics have been connected successfully. See section g 6.4. Connecting the pneumatics.

Procedure

Fig. 7: Setting the pressure

1. Open the adjustment screw: Turn the nut (2) with an open-end wrench.
   – Version with high flow: wrench size 13
   – Version with low flow: wrench size 11/32″

2. Set the pressure: Turn the adjustment screw (1).

3. Lock the adjustment screw: Turn the hexagon screw (2).
   Tightening torques:
   – Version with high flow: 19 Nm
   – Version with low flow: 2 Nm

Optional: Attaching the adjustment screw lock

For versions with adjustment screw lock.

Fig. 8: Attaching the adjustment screw lock

1. Place the adjustment screw lock on the adjustment screw.
2. Push the locking bracket through the adjustment screw lock.
3. Lock the locking bracket with a suitable device, e.g. a padlock.

Commissioning

Follow the steps below to carry out commissioning.

Basic requirements

Personnel qualifications
Commissioning only by qualified personnel (see section g 2.5. Personnel qualifications).

Limits

• Comply with the limits (accident prevention, material protection). Limits: see section g 13. Technical data.

Notes on safety

To eliminate risks during commissioning, observe the notes on safety: see section → 2.6.1. Notes on safety.

Preparation

General requirements

• Make sure that all plugs and connections have been mounted correctly.

Step-by-step commissioning

If you have carried out and completed all preparation work, you can commission the system.

Operation

Basic requirements

The following points must be observed during operation.

General requirements

• Do not touch the product or any connected parts during operation (accident prevention).
• Never switch off, modify or bypass safety devices.

Limits

• Comply with the limits (accident prevention, material protection). Limits: see section g 13. Technical data.
• Make sure that there are no ferromagnetic sources near the product (material protection).

Service

• Carry out service work in the designated time intervals: see section g 9. Service.

In case of malfunctions during operation

• In case of a malfunction that presents an immediate danger for employees or systems: Switch off product.
• Carry out analysis and troubleshooting of malfunctions according to the following specifications: see section → 12. Troubleshooting.
• If a malfunction cannot be remedied: Inform the customer service. Contact data: see back cover.

Service

The following operation-related activities are necessary to ensure safe use of the product with minimal wear and tear:

• Inspection, see section g 9.2. Inspection
• Cleaning, see section g 9.3. Cleaning
• Maintenance, see section g 9.4. Maintenance

Notes on safety

To eliminate risks during service, observe the notes on safety: see section → 2.6.1. Notes on safety.

Inspection

During inspection, check the product for damage and contamination at regular intervals.

General requirements
Use in normal ambient conditions

• Inspection interval: The product must be checked monthly.
• The operator is responsible for inspection of the product and the overall system.

Use in aggressive ambient conditions
Aggressive ambient conditions include, for example:

• High temperatures

• Heavy accumulation of dirt

• Proximity to grease-dissolving liquids or vapors
  Aggressive ambient conditions lead to further requirements for inspection:

• Adapt the inspection interval for seals to the ambient conditions.
  NOTICE! Seals age faster under aggressive ambient conditions. Inspect seals more frequently.

• Enter the adapted inspection intervals in the system-specific maintenance plan (accident prevention, material protection).

Procedure
Preparation
All work has to be prepared as follows:

1. Close off dangerous areas (accident prevention).
2. Make sure the system or system part is not under pressure or voltage.
3. Protect the system against being restarted.
4. Allow the product and adjacent system parts to cool down (accident prevention).
5. Wear protective clothing (accident prevention).

Visual inspection
Visually inspect for integrity.

Detailed inspection

• Check identifications and warnings on the product: Labels and identifications must be legible (accident prevention, material protection).
  Replace hard-to-read labels or identification immediately.

• Check the lines.

• Check the seals.

• Check to make sure that all fittings are properly connected.

• Check the safety devices on the system.

• Check the product functions.

Cleaning

General requirements

Cleaning intervals

• The system owner specifies the cleaning intervals in line with the ambient conditions at the operating site.
• Observe the information in the system documentation.

Aids

• Only clean the product with damp cloths.
• Only use water for cleaning and a mild detergent, if necessary (material protection).

Notes
Penetrating fluids destroy seals and cause damage to the product.

Procedure
Preparation
All work has to be prepared as follows:

1. Close off dangerous areas (accident prevention).
2. Make sure the system or system part is not under pressure or voltage.
3. Protect the system against being restarted.
4. Allow the product and adjacent system parts to cool down (accident prevention).
5. Wear protective clothing (accident prevention).
6. Close all openings with suitable safety devices so that no cleaning agent can enter into the system.

Cleaning

1. Remove all dust deposits from the product and the adjacent system parts.
2. If necessary, remove other production-related deposits from the product and the adjacent system parts.

Maintenance

In normal ambient conditions, the product is maintenance-free.

Notes

• Observe the maintenance plan for the overall system: Further maintenance tasks may result from the maintenance plan for the overall system and the maintenance intervals specified therein.

After service

After completion of the service work, carry out the following steps:

1. Remove all tools and devices from the work area.
2. Remove all installed barriers and notices.
3. Clean the work area, mop up any liquids and remove work materials.
4. Log any service work in the respective plan.
   If no damage has been detected and the operator has not reported any malfunctions, the product can be reconnected to the power supply and put back into operation.

Dismounting

Disassembly is only required if the product has to be exchanged, installed in a different location or disposed off.

Basic requirements

• Make sure that there is sufficient space.
• Secure larger product or system parts so that they cannot fall down or topple (accident prevention).

Handling suspended loads

• Do not stand under suspended loads (accident prevention).

Avoid contamination

• Make sure that the environment is not contaminated with grease or lubricants during disassembly (material protection).

Notes on safety

To eliminate risks during disassembly, observe the notes on safety: see section → 2.6.1. Notes on safety.

Preparation

1. Close off dangerous areas (accident prevention).

2. Make sure the system or system part is not under pressure or voltage.
   DANGER! Slowly exhaust the system to avoid uncontrolled movements of the system components.

3. Protect the system against being restarted.

4. Allow the product and adjacent system parts to cool down (accident prevention).

5. Wear protective clothing (accident prevention).

Procedure

1. Remove the compressed air tubing on both sides.

2. For crimped version: Remove screws.
   For inline version: Remove panel nut.

3. Disassemble the product.

Disposal

Improper disposal of the product and packaging will lead to pollution of the environment. Furthermore, the materials can no longer be recycled.
► Dispose of the product and the packaging in accordance with the applicable national regulations.

Troubleshooting

If you cannot remedy a malfunction, get in touch with our contact address (contact data: see back cover).

Basic requirements

General requirements for repair

• Never dismantle or convert the product (accident prevention, material protection).
• Do not carry out any unauthorized repair attempts (accident prevention, material protection).

Permissible spare parts and reconditioning kits

• Only use spare parts and reconditioning kits from the online catalog (accident prevention, material protection).

Notes on safety

To eliminate risks during troubleshooting, observe the notes on safety: see section → 2.6.1. Notes on safety.

Procedure

Step 1: Check the system
► In case of malfunctions, first check the system or the system part where the product is installed. Check the following items:

• Are all connections connected to the product?
• Does the operating voltage comply with the requirements? See section → 13. Technical data.
• Does the operating pressure comply with the requirements? See section → 13. Technical data.

Step 2: Check the product

1. Make sure the system or system part is not under pressure or voltage.
2. Exchange the device.

Technical data

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

General

| Inline version
with low flow| Inline version
with high flow| Crimped version
with low flow| Crimped version
with high flow
---|---|---|---|---
Measuring medium| Non-aggressive gases, compressed air
Dimensions| See section g 4.3. Versions
Weight| 130 g| 247 g| 153 g| 385 g
Ambient temperature| -40 °C … 70 °C
Storage temperature| -40 °C … 70 °C

Performance data

| Specifications for all versions
---|---
Function| Reduce system pressure to operating pressure
Adjustment options| • Adjustment screw
• T-handle
• Adjustment screw with adjustment screw lock

Assembly

| Inline version
with low flow| Inline version
with high flow| Crimped version
with low flow| Crimped version
with high flow
---|---|---|---|---
Mounting orientation| Any
Mounting type| • Panel nut
• Mounting
bracket| • Panel nut
• Mounting
bracket| Mounting plate| Mounting plate
Connection size
of measuring
medium| • 1/4″ NPTF
• 1/4″ G
• 1/4″ Rc| • 1/4″ NPTF
• 1/4″ G
• 1/4″ Rc| No threaded connection| No threaded connection

Pneumatics

| Inline version
with low flow| Inline version
with high flow| Crimped version
with low flow| Crimped version
with high flow
---|---|---|---|---
Medium| Compressed air as per DIN ISO 8573-1:2010
Medium temperature| -40 °C … 70 °C
Max. particle size| 40 µm
Pressure dew
point| Min. 15 °C (below ambient/medium temperature) max. 3 °C
Oil content| Max. 40 mg/m³
Pressure range:
input| Max. 203 PSIG /
14 bar| Max. 232 PSIG /
16 bar| Max. 203 PSIG /
14 bar| Max. 232 PSIG /
16 bar
Pressure range: output| • 3 … 60 PSIG / 0.2 … 4 bar
• 7 … 125 PSIG / 0.5 … 8 bar
• 7 … 145 PSIG / 0.5 … 10 bar
Flow range1)| 207 SLPM
(7.3 SCFM)| 1650 SLPM
(58.3 SCFM)| 198 SLPM
(7.0 SCFM)| 1133 SLPM
(40 SCFM)
1) Values determined under the following conditions:
Input pressure: 10 bar (145 PSIG); set pressure: 6.3 bar (90 PSIG) with ∆P = 1 bar (14.5 PSIG)
Resistance to overpressure| 30 bar
Set point accuracy| • 0 … +70 °C ± 0.2 bar
• -25 … 0 °C ± 0.2 bar
• -40 … -25 °C ± 0.3 bar| • 0 … +70 °C ± 0.3 bar
• -25 … 0 °C ± 0.3 bar
• -40 … -25 °C ± 0.4 bar| • 0 … +70 °C ± 0.2 bar
• -25 … 0 °C ± 0.2 bar
• -40 … -25 °C ± 0.3 bar| • 0 … +70 °C ± 0.3 bar
• -25 … 0 °C ± 0.3 bar
• -40 … -25 °C ± 0.4 bar

Standards and directives complied with

| For all versions
---|---
EN 61373, Cat. 1, Class B| Shock and vibration
ISO 9227| Corrosion resistance (salt spray test: 250 hrs)
EN 45545, HL3| Railway applications – Fire protection on railway vehicles

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

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. 

References

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

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