EMERSON AVENTICS AS1 Filter Pressure Regulator Valve Instruction Manual

EMERSON AVENTICS AS1 Filter Pressure Regulator Valve

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

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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:

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.
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.
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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.

CAUTION! 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, only use a suitable pneumatic oil.
• 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.

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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.

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

Mounting fastening elements W01 – W05

See Fig. 8 to  Fig. 12

Mounting the pressure gauge

See  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.
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Pressure gauge with radial sea

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.
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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  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.
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Retracting the safety eyelets

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

Locking the handwheel

See  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.

AS1 – AS5 (E11)

Version with E11 locking

| Supplied without key. Key must be ordered separately
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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.
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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.

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Semi-automatic condensate drain

See 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  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  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  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.
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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.

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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.

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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

Procedure for series AS1 FRE

See  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  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.

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Changing the flow direction (AS2, AS3, AS5)

| No conversion is necessary on the AS1 series. The “right/left flow” version has a separate order number.
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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:

Converting the filter pressure regulator valve (FRE) and pressure regulator valve (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 | Series AS2, AS3, AS5

See  Fig. 7

1. Remove the mounted pressure gauge by unscrewing it from the thread in a counterclockwise direction.

2. Remove the blanking plug and screw it into the opposite side.

3. Remove the side cover caps on the compressed air connections by sliding a suitable tool under the cover cap wings, carefully lifting them up and taking them off.

4. Lift the front and rear cover cap by pushing the lock-in bolts (2 on each side) up on the latches.
   CAUTION! Remove the cover caps carefully and evenly so that the 4 lock-in bolts do not break off.

5. Lift the front and rear caps evenly by carefully levering them open with a suitable tool and taking them off.

6. 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.

7. Screw in the pressure gauge on the opposite side (see chapter g 5.2. Mounting the pressure gauge)

8.  Screw the blanking plug into the opposite side.

Rotating the reservoir (AS2, AS3, AS5)

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

Pressure regulator valve conversion with continuous pressure supply

| No conversion is required for pressure regulator valves and precision pressure regulator valves RGS-DS and RGP-DS with continuous pressure supply. On these devices, air can be supplied from the left as well as the right.
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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!
• Do not use high-pressure cleaners for cleaning!
• Do not use compressed air for cleaning (blowing off) the maintenance unit or equipment.

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

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Mounting orientation| Filter pressure regulator valve: vertical
Pressure regulator valve: any
Medium/ambient temperature min./ max.

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.
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1. Fig. 1: I: Mounting the pressure gauge, II: Replacing the pressure gauge | Series AS2, AS3, AS5
   III: Integrated pressure gauge | Series AS1
   

2. Fig. 2: Adjusting the pressure (P1 = input pressure, P2 = output pressure) | Series AS1, AS2, AS3, AS5
   

3. Fig. 3: Locking the pressure regulator valve
   

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

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

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

7. Fig. 7: Converting the filter pressure regulator valve (FRE) and pressure regulator valve (RGS and RGP) Series AS2, AS3, AS5
   ![Changing the pressure gauge and housing cover | Series AS2,

AS3, AS5](https://manuals.plus/wp-content/uploads/2022/12/EMERSON-AVENTICS-AS1 -Filter-Pressure-Regulator-Valve-Instruction-Manual-13.png)

8. Fig. 8: W01 | Mounting with mounting plate
   

9. Fig. 9: W02 | Mounting with mounting bracket
   

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

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

12. 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.

Customer Support

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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