EMERSON AVENTICS NL1 Filter Pressure Regulator Instruction Manual

: June 3, 2024
: Emerson

Table of Contents

Safety instructions
Scope of delivery
Assembly, commissioning, and operation
Service and repairs
- CAUTION
Troubleshooting
Technical data
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

EMERSON AVENTICS NL1 Filter Pressure Regulator Instruction Manual

About this documentation

These instructions contain important information for the safe and appropriate assembly and commissioning of the product. Read these instructions carefully, especially chapter g 2. Safety instructions before you start working with the product.

Additional documentation

Also follow the instructions for the other system components.
Please also observe the generally relevant, statutory, and other binding regulations of European and national legislation and the national regulations for accident prevention and environmental protection in your country. Presentation of information

Warnings
In this documentation, there are warning notes before the steps whenever there is a risk of personal injury or damage to equipment. The measures described to avoid these hazards must be followed.

Structure of warnings

SIGNAL WORD

Hazard type and source
Consequences of non-observance

Precautions

Meaning of the signal words

CAUTION

Possible dangerous situation. Failure to observe these notices may result in minor injuries or damage to property.

Symbols

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

Safety instructions

The product has been manufactured according to the accepted rules of current technology. Even so, there is a risk of injury or damage if the following general safety instructions and the specific warnings given in this instruction manual are not observed.

Please read all these instructions carefully before working with the product.
Keep these instructions in a location where they are 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 exclusively intended for installation in a machine or system, or for combination with other components to form a machine or system. The product may only be commissioned after it has been installed in the machine/system for which it is intended. Use is permitted only under the operating conditions and within the performance limits listed in the technical data. Only use compressed air as the medium. The product is technical equipment and is intended for professional use only. Intended use includes having fully read and understood these instructions, especially chapter g 2. Safety instructions.

Personnel qualifications
All tasks associated with the product require basic mechanical, pneumatic, and electrical knowledge, as well as knowledge of the respective technical terms. In order to ensure operational safety, these tasks may only be carried out by qualified personnel or an instructed person under the direction 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.

General safety instructions

Observe the valid local regulations to protect the environment in the country of use and to avoid workplace accidents.
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.
Persons who assemble, operate, disassemble, or maintain AVENTICS products must not consume any alcohol, drugs, or pharmaceuticals that may affect their ability to respond.
The warranty will not apply if the product is incorrectly assembled.
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.

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 or allow it to come into contact with aggressive media. 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.

Solvents: Acetone, paint thinners, alcohols, ester

Detergents: Trichloroethylene, perchlorethylene, benzene, gasoline

Other media: Synthetic oils, drilling oil, high-alloyed oils, certain compressor oils, brake fluid, ammonia, bonding and sealing agents, plasticizers, anti freeze, coolants/lubricants

A pressurized polycarbonate reservoir may corrode in an aggressive ambient air/compressed air and explode as a result. If the presence of the substances stated in the table cannot be avoided, such as in gluing machines or vulcanization plants, the use of metal reservoirs is required.
If a lubricator is used, please only use a suitable pneumatic oil, see online catalog.
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 or filter pressure regulator according to order (optionally: pressure gauge enclosed separately)
1 set of operating instructions

About this product

Pressure regulators and filter pressure regulators are components of air preparation units. Pressure regulators and filter pressure regulators serve to reduce the applied system pressure to a maximum, regulated working pressure. Filterpressure regulators 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 electrical voltage can lead to injuries and damage to the product or system components.

Make sure that the relevant system component is without pressure and voltage before you assemble the product.
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.

Please ensure when commissioning a system without a SSU filling unit that the cylinders are in their end position or that no danger can emit from those not in end position.

CAUTION

System is operating under pressure!
Incorrect installation may damage the air preparation unit/apparatus and cause serious injury.

Before commissioning, check that all connections, ports, and maintenance equipment have been correctly installed.

Mounting fastening elements W01, W02, W04 and W05

Please heed figures g Fig. , g Fig. 11, g Fig. , g Fig. 12, g Fig. 13 and g Fig. 15.

Mounting the pressure gauge

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

Pressure gauge with radial seal

Firmly screw the pressure gauge for installation into the pressure gauge thread until the seal is completely screwed into the thread.
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.

Mount the compression ring on the pressure gauge.
Rotate the pressure gauge into the pressure gauge thread until the compression ring is flush against the sealing face.
Seal off the connection whilst 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

During commissioning

Let the product acclimatize for several hours before commissioning, otherwise, water may condense in the housing.
Check that all the electrical and pneumatic connections are allocated or closed. Only commission fully installed products.

Adjusting the pressure
g Fig. 2

Push up the handwheel (a).
Set the required pressure by turning the handwheel (a).
Push down the handwheel (a). This relocks the handwheel.

Lock handwheel
g Fig. 3
The pressure regulator handwheel can be secured by a key to prevent unauthorized changing of the pressure setting.

Version with E11 locking

To lock handwheel: Turn key to right and then pull it out.
To unlock handwheel: Turn key to left and then pull it out.

RGP precision pressure regulators and some RGS pressure regulators 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 without 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.

Regularly check the filling level in the reservoir.
Drain condensate manually once it reaches the maximum filling level.
Do not let the condensate run off into the surroundings.

Semi-automatic condensate drain
The condensate drain opens and closes depending on operating pressure:

Pressure < 1.5 bar: drain open
Pressure > 1.5 bar: drain closed
Set semi-automatic mode:
Open the drain screw by turning it all the way to the left. You may leave the screw one turn deep in the thread or remove it completely.

Draining condensate manually
The condensate can also be manually drained (b = maximum filling level).

Turn drain screw (a) all the way to the right (closed position).
Turn drain screw (a) to the left a few times until condensate runs out.

Fully automatic condensate drain
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 to the right as far as it will go.
Version “closed without pressure”
The condensate drain is closed regardless of the operating pressure.
Draining condensate manually
The condensate can also be manually drained (b = maximum filling level).
Turn the drain screw (a) to the left as far as it will go.

If the drain screw is screwed in all the way anti-clockwise, the automatic drainage is blocked.

Service and repairs

Cleaning and servicing

Close all openings with suitable safety devices so that no cleaning agent can enter into the system.
Never use solvents or aggressive detergents. Only clean the product using a slightly damp cloth. Only use water and, if necessary, a mild detergent.
Do not use high-pressure cleaners for cleaning.
Do not use compressed air for cleaning (blowing off) the air preparation unit or equipment.

Exchanging filter element (filter pressure regulator (FRE))

CAUTION

System is operating under pressure!
Opening the system while under pressure may damage the air preparation unit/apparatus and cause serious injury.

Please ensure that the system is not under pressure before you open the reservoir.

The filters clog up over time and need to be exchanged regularly, at the latest after a year. However, this is only approximate, because intervals depend on the quality of compressed air and flow rate. Please use the material numbers listed below to order. The addresses of the international agencies are available at www.emerson.com/contactus.

Wearing parts (c/b) Series NL Material no.

Standard filter element, 5 µm,
Material: polyethylene
NL1/NL2 1829207061
NLB4 1829207070
Standard filter element, 8 µm,
Material: polyethylene
NL6 1829207045
Standard filter element, 5 µm,
Material:sinteredbronze
NL4 R961400010
Standard filter element, 25 µm,
Material: polyethylene
NL1/NL2 R961400004
Standard filter element, 40 µm,
Material: polyethylene
NL1/NL2 R961403385
NL6 1829207040
Standard filter element, 40 µm,
Material: sintered bronze
NL1 R961400009
NL4 R961400012

Exchanging the filter element (NL1, NL2, NL4):

with polycarbonate reservoir With metal reservoir

Release the protective guard (g Fig. 5 a, b), if
present, and pull it off downwards (g Fig. 5 c).

Unscrew the reservoir (g Fig. 5 d) from the housing.

Pull down the unlocking device (g Fig. 5
a), turn the reservoir (g Fig. 5 b) in an anticlockwise direction, and then pull it down and remove

Remove the filter seat (g Fig. 6 a).
Exchange the filter piece (g Fig. 6 b, c).
Slide the filter unit (filter seat and filter piece) back together (g Fig. 6 b, c).
Connect the filter unit to the filter and tighten it slightly by hand (g Fig. 6 d, c).

with polycarbonate reservoir With metal reservoir

Remount the reservoir and, if present, the protective guard in reverse order as shown in Figure g Fig. 5.
Remount the reservoir in the reverse order shown in Figure g Fig. 5. Insert reservoir at a 45° offset and turn it to the right until the release audibly latches.

Exchanging the filter element (NL6):

Make sure the relevant system part is without pressure.
Exhaust the system.
Release the 4 screws on the underside of the housing.
Pull the bottom part of the housing, the taper including condensate reservoir, carefully down and off (a).
Remove the filter seat.
Exchange the filter seat (b, c).
Slide the filter unit (filter seat and filter piece) back together (b, c).
Connect the filter unit to the filter and tighten it slightly by hand (d).
Reinstall the bottom part of the housing, the taper including condensate
reservoir, in the reverse order.

Disassembly, exchange

CAUTION

Danger of injury in case of disassembly or replacement under pressure or voltage!
Disassembling or replacement when under pressure or electrical voltage may lead to injuries and damage to the product or system components.

Make sure that the relevant system part is without pressure or voltage before disassembling the product or exchanging parts.
rotect the system against being restarted.

Disposal
Dispose of the product and condensate in accordance with the national regulations in your country

Conversion and extension
CAUTION
Danger of injury in case of disassembly or replacement under pressure or voltage! Disassembling or replacement when under pressure or electrical voltage may lead to injuries and damage to the product or system components.

Make sure that the relevant system part is without pressure or voltage before disassembling the product or exchanging parts.
Protect the system against being restarted.

Exchanging the pressure gauge

Unscrew the old pressure gauge from the pressure gauge thread.
Mount the new pressure gauge as described in the “g 5.2. Mounting the pressure gauge” section.
Change flow direction
On delivery the flow direction is from left (1, IN) to right (2, OUT). The following conversion on the product is necessary if the flow direction is to be changed:

Filter pressure regulator (FRE) conversion and pressure regulator (RGS and RGP)

On all components, the flow direction change is performed by rotating an installation by 180° around the vertical axis. The housing cover and pressure gauge need to be replaced for the purpose.

Changing the pressure gauge and housing cover

Changing the housing cover is not possible on the NL1.

Remove the mounted pressure gauge by unscrewing it from the thread in an anti-clockwise direction.
Remove the blanking plug and screw it in at the other side.
Remove the side cover caps on the compressed air connections by sliding a suitable tool under the cover cap vanes, carefully lifting them up and taking them off.
Lift the front and rear cover cap by pushing the lock-in bolts (2 on each side) up on the latches.

Remove the cover caps carefully and evenly so that the 4 lock-in bolts do not break off.

Now lift the front and rear cap evenly by carefully levering them open with a suitable tool and taking them off.
Mount the cover caps on the opposite sides in the reverse order. The cover cap with the AVENTICS logo should be facing to the front.
Screw the pressure gauge into the opposite side (see g 5.2. Mounting the pressure gauge).
Screw the blanking plugs into the opposite side.

Turning the reservoir with bayonet catch

Release reservoir.
Rotate reservoir 180° and click it back into place. The release is now pointing to the front.

Pressure regulator conversion with continuous pressure supply

No conversion is required for pressure regulators and precision pressure regulators RGS-DS and RGP-DS with continuous pressure supply. On these devices, air can be supplied from the left as well as the right.