Clarke CAT192 Intermediate Air Filter Regulators Instruction Manual

Clarke CAT192 Intermediate Air Filter Regulators

INTRODUCTION

Thank you for purchasing this CLARKE Air Filter/Regulator. Before attempting to use this product, please read this manual thoroughly and follow the instructions carefully. In doing so you will ensure the safety of yourself and that of others around you, and you can look forward to your purchase giving you long and satisfactory service. Your Filter/Regulator has been designed to give long and trouble-free service. If, however, having followed the instructions in this booklet carefully, you encounter problems, take the unit to your local CLARKE dealer.

SPECIFICATIONS

GENERAL SAFETY RULES

CAUTION:
FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

WORK ENVIRONMENT

1.  Keep the work area clean and tidy.
2.  Dress appropriately – do not wear loose clothing or jewelry. Tie long hair out of the way.
3.  Keep children and visitors away – do not let children handle the tools.
4.  Do not operate air tools where there are flammable liquids or gases.

USE OF AIRLINE EQUIPMENT

1.  Stay alert and use common sense – do not operate an air tool when you are tired or under the influence of alcohol, drugs or medication.
2.  Do not overreach – Keep proper footing and balance at all times.
3.  Never use oxygen, CO2, combustible gases or any type of bottled gas as a source of power for air tools.
4.  Do not exceed the maximum pressure for the airline component stated in the specification.
5.  Check airline hoses for leaks or worn condition before use and ensure that all connections are secure.
6.  Keep the air supply hose away from heat, oil and sharp edges.
7.  Avoid damaging the component for example by applying excessive force of any kind.
8.  Always maintain the air tool with care. Keep it clean for the best and safest performance.

COMPRESSED AIRLINE REQUIREMENTS

WARNING:
COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF COMPRESSORS AND COMPRESSED AIR SUPPLY.

Use only clean, dry, regulated compressed air as a power source. Air compressors must comply with the appropriate European Community Safety Directives. A build-up of moisture in the air compressor will accelerate wear and corrosion in the air tool. Ensure any moisture is drained from the compressor daily and the airline filter is kept clean. If an unusually long air hose is required, (over 8 metres), the line pressure or the hose inside diameter may need to be increased. The air hose must be rated at least 150% of the maximum operating pressure of the air tool. A typical air line layout is shown below. If an automatic in-line filter/regulator is used it will keep the tool in good condition. The lubricator should be adjusted to approx 2 drops per minute and SAE 10 oil should be used.

Never exceed the maximum operating pressure for the air tool. Ensure that air pressure does not exceed that stated in the specification for the tool when running. Higher pressures and contaminated air will shorten the life of the air tool due to faster wear and is a possible safety hazard.

INSTALLATION

1.  Shut off the air pressure from the air system.
2.  Install the filter/regulator vertically with the bowl vertically down. Ensure that the filter/regulator is installed with inlet/outlet airflow in the direction of the arrow on the unit.
3.  The filter/regulator should be installed upstream of any lubricator and cycling valve(s) in the airline and should be as close as possible to the air tools when used as a mainline filter/regulator and/or as a final filter/regulator.
4.  The filter/regulator must be installed in such a way that no mechanical strain occurs.
5.  Fit the mounting bracket to a suitable support, situated in line with the compressed air supply.
   •  Ensure sufficient free space above the regulator for future adjustments.
6.  Note the arrow mark on the regulator body, indicating the direction of airflow. Connect pipes to the inlet and outlet ports using pipe thread sealant tape on male threads only. When screwing pipes together, prevent ingress of shavings and sealant to the interior of the unit. Contaminations in the unit may cause it to fail.
7.  Remove the blanking plugs from the connection ports and connect to the supply and delivery hoses.
8.  Install a pressure gauge to either of the gauge ports facing the operator. The other gauge port should be plugged or can be used as an additional air outlet for regulated air.
9.  Fit the regulator to the mounting bracket from below and secure with the retaining ring.
10.  Make sure that all connections are tight and secure.
11.  Push the bowl, or bowl with guard, into the filter/regulator body and turn fully clockwise before pressurizing.
12.  Your filter regulator is now ready for use.

USE AND CARE IN SERVICE

1.  Ensure that the airline pressure does not exceed 150psi.
2.  Air pressure can be set by turning the knob. Pull the knob upwards until you hear the click, turn it clockwise to increase the pressure or anti-clockwise to decrease the pressure. When the desired pressure is obtained, press the knob downwards until you hear the click to secure the setting.
   •  + and – are marked on the knob.
3.  The air pressure set is displayed on the pressure gauge.
4.  The filter/regulator is equipped with a manual drain. Turn the manual drain valve to drain accumulated liquid inside the bowl. Take care to drain the liquid from the bowl whenever necessary and always keep the liquid below the baffle.
5.  The filter element should be replaced when the pressure drop across the element exceeds 15 psi. When an excessive pressure drop across a saturated but uncontaminated element occurs, it may indicate that the tool being operated exceeds the maximum flow rate (CFM) of the filter/regulator (See Specifications). Refer to the maximum flow rate of your filter/regulator and make sure that the required CFM of the air tool is within the maximum flow rate of your filter/regulator for best air tool operation.

MAINTENANCE

DISASSEMBLY

1.  The filter/regulator can be disassembled without removal from air line.
2.  Shut off the inlet pressure. Reduce pressure in inlet and outlet lines to zero.
3.  Turn the adjustment knob fully anti-clockwise.
4.  Remove the bowl by pushing into the body and turning counterclockwise.
5.  Disassemble in general accordance with the parts illustrated on page 7. Do not remove the drain unless replacement is necessary. Remove and replace only if the drain malfunctions or if converting to automatic drain.

CLEANING

1.  Clean the plastic bowl with warm water only. Clean other parts with warm water and soap.
2.  Rinse and dry all parts. Blow out internal passages in the body with clean, dry, compressed air. Blow air through the filter element from inside to remove surface contaminants.
3.  Inspect all parts and replace any found to be damaged.

ASSEMBLY

1.  Lubricate all o-rings, adjusting screw threads and tip, outer circumference and both sides of thrust washer, portion of the manual drain body that contacts the bowl, hole in the manual drain body that accommodates the stem of the drain valve and valve stem with o-ring grease.

2.  Assemble as shown on page 7 using the torque values listed in the table.
   Torque Settings

   Part| Inch Pounds (N-m)
   Screw (a) & screw (b)| 20 to 25 (2.3 to 2.8)
   Screw (c)| 15 to 30 (1.7 to 3.4)
   Baffle, Louvre| 10 to 20 (1.1 to 2.3)
   Nut| 20 to 25 (2.3 to 2.8)

3.  Push the bowl into the body and turn fully clockwise.

COMPONENT PARTS

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