EMERSON AVENTICS NL1 FRE Filter Regulator Instruction Manual

AVENTICS NL1 FRE Filter Regulator
Instruction Manual

About this documentation

These instructions contain important information for the safe and appropriate assembly and commissioning of the product.
Read this documentation completely, especially chapter → 2. Notes on safety before working with the product.
1.1 Additional documentation

1. Also follow the instructions for the other system components.
2. 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.

1.2 Presentation of information
1.2.1 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.
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.
1.2.2 Symbols
Recommendation for the optimum use of our products.
Observe this information to ensure the smoothest possible operation.

Notes on safety

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.

1. Please read all these instructions carefully before working with the product.
2. Keep these instructions in a location where they are accessible to all users at all times.
3. Always include the operating instructions when you pass the product on to third parties.

2.1 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 → 2. Notes on safety.

2.2 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.

2.3 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.

2.4 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, plasticizes, anti-freeze, coolants/lubricants

• A pressurized poly carbonate 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.

• 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

• 1 x lubricator as ordered
• 1 set of operating instructions

About this product

The standard oil-mist lubricator → Fig. 1 and micro oil-mist lubricator are components of air preparation units. They are used to meter and dispense oil to compressed air. Typical implementation areas include cylinders with speeds

1 m/s, metallic sealing valves and pneumatic tools.

Assembly, commissioning and operation

Let the product acclimatize for several hours before commissioning, otherwise, water may condense in the housing.
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.

1. Make sure that the relevant system component is without pressure and voltage before you assemble the product.
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.
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/maintenance equipment and cause serious injury.
Before commissioning, check that all connections, ports, and maintenance equipment have been correctly installed.
CAUTION
Harmful oil mist!
The use of oil in the compressor unit creates oil mist which is a hazard to health.
Only operate the lubricator in closed pneumatic systems.

5.1 Mounting fastening elements W01, W04 and W05
Please heed figures →  Fig. 12, →  Fig. 13, →  Fig. 11, →  Fig. 14 and →  Fig. 10.

5.2 Mounting the reservoir and protective guard
→ Fig. 2
5.2.1 Mounting the poly carbonate reservoir with the protective guard
→  Fig. 2- I

1. Slide the reservoir onto the lubricator housing (a) and tighten it firmly (b).
2. Slide the protective guard over the lubricator reservoir (c) onto the housing.
3. Position the protective guard in the provided recess (d), tighten firmly (e) and simultaneously click in the bayonet catch.

5.2.2 Mounting the metal reservoir with bayonet catch
→  Fig. 2- II

1. Slide the reservoir onto the lubricator housing (a).
2. Tighten the reservoir (b) and simultaneously click in the bayonet catch (c).

5.3 Connecting the optional electrical level detection (NL2, NL4)
→ Fig. 3
Connect the sensor to the connection socket on the bottom of the oil reservoir with an M12 plug.
When the oil reaches its minimum level, the sensor is actuated by the internal magnets.

5.4 Filling the standard oil-mist lubricator and micro oil-mist lubricator
→ Fig. 4
The system must be exhausted before refilling the oil. To do this, we recommend installing a 2/2 shut-off valve on the primary side and a 3/2 manual spool valve on the secondary side of the air preparation unit.

5.4.1 Fill oil reservoir manually
→ Fig. 4
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.

1. Make sure that the relevant system component is without pressure and voltage before you assemble the product.
2. Protect the system against being restarted.

Regularly check the oil level and refill if the oil has reached the minimum level indicated on the reservoir. Proceed as follows:

Standard oil-mist lubricator

1. Make sure the relevant system part is without pressure.
2. Release filling screw ( b).
3. Fill the reservoir with suitable pneumatic oil until the oil reaches the maximum level indicated on the reservoir (g Fig. 4). For suitable pneumatic oil see the online catalogue.

NOTICE:
If the oil is filled too high, the oil can enter the system and cause damage.
Tighten filling screw ( b) again.

Micro oil-mist lubricator/standard oil-mist lubricator

Release the protective guard (→ Fig. 6 I – a, b), if present, and pull it off downwards (→ Fig. 6 I c).|
Release the sensor’s M12 plug from the connection socket on the bottom of the oil reservoir (→ Fig. 7 I).|
Unscrew the reservoir (→ Fig. 6 I d) from the housing.| Pull down the unlocking device (→ Fig. 6 II a), turn the reservoir (→ Fig. 6 II b) in an anti-clockwise direction, and then pull it down and remove (→ Fig. 6 II c).
Fill the reservoir with suitable pneumatic oil until the oil reaches the maximum level indicated on the reservoir (→ Fig. 4 a).|
NOTICE:
If the oil is filled too high, the oil can enter the system and cause damage.|
Remount the filled reservoir and, if present, the protective guard in reverse order as shown in → Fig. 6 I.  (see also → Fig. 2 I).| Remount the filled reservoir in the reverse order as shown in → Fig. 6 II (see → Fig. 2 II).
Connect the sensor to the connection socket on the bottom of the oil reservoir with an M12 plug (→ Fig. 7 III).|

5.4.2 Adjusting the oil quantity
→ Fig. 5

1. Set the oil quantity using the metering screw on the oil-mist lubricator’s drop attachment.
2. Determine the quantity of oil dispensed by observing the number of drops in the drop dispenser.
   Guide values:
   Standard oil-mist lubricator: 1 – 2 drops/min (qv = 1000 Nl/min);
   Micro oil-mist lubricator: 10 – 20 drops/min (qv = 1000 Nl/min).

With a standard oil-mist lubricator, all of the supplied drops end up in the compressed air system.
With a micro oil-mist lubricator, approx. 10% of the supplied drops end up in the compressed air system.

Service and repairs

6.1 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 maintenance equipment.

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.

1. Make sure that the relevant system part is without pressure or voltage before you assemble the product or replace parts.
2. Protect the system against being restarted.

7.1 Replacing the sensor for electrical level detection
→ Fig. 7
The sensor for electrical level detection cannot be exchanged separately and must be exchanged along with the reservoir. Proceed as follows:
Table 1: Exchange the reservoir with sensor:

Release the protective guard (→ Fig. 6 I a, – b), if present, and pull it off downwards (→ Fig. 6 I c).|
Release the sensor’s M12 plug from the connection socket on the bottom of the oil reservoir (→ Fig. 7 I).|
Unscrew the reservoir (→ Fig. 6 I d) from the housing.| Pull down the unlocking device (→ Fig. 6 II a), turn the reservoir (→ Fig. 6 II b) in an anti-clockwise direction, and then pull it down and remove (→ Fig. 6 II c).
Exchange the old reservoir for a new one (→ Fig. 7 II b, c).|
Mount the new reservoir with sensor and, if present, the protective guard in reverse order as shown in Fig. → Fig. 6 I (see also Fig. → Fig. 2 I).| Mount the new reservoir with sensor in reverse order as shown in Fig. → Fig. 6 II (see also Fig. → Fig. 2).
Connect the sensor to the connection socket on the bottom of the oil reservoir with an M12 plug (→ Fig. 7 III).|

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.

1. Make sure that the relevant system part is without pressure or voltage before you assemble the product or replace parts.
2. Protect the system against being restarted.

9.1 Changing the flow direction (NL1, NL2, NL4, NL6)
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:
9.1.1 Lubricator conversion
→ Fig. 9
On all components, the flow direction change is performed by rotating an installation by 180° around the vertical axis. The housing covers need to be changed for the purpose.
9.1.2 Changing the housing cover (NL2, NL4, NL6)
→ Fig. 8
Changing the housing cover is not possible on the NL1.

1. 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.

2. Lift the front a 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.

3. Now lift the front and rear cap evenly by carefully levering them open with a suitable tool and taking them off.

4. 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.

9.1.3 Turning the reservoir with bayonet catch

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

Troubleshooting

Oil content of compressed air
too low| Oil has fallen below minimum filling level in the reservoir| Top up oil in the reservoir
Dosage is too low| Increase no. of drops
Ambient temperature is lower than at time of adjustment| Please use oil with a lower viscosity level
Oil content of compressed air
too high| Oil has been filled to over the max. filling level in the reservoir| Empty oil to the max. filling level in the reservoir
Dosage is too high| Reduce no. of drops
Ambient temperature is higher than at time of adjustment| Please use oil with a higher viscosity level

Technical data

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

General data

Mounting position| Vertical
Medium/ambient temperature min./max.| -10 °C /+60 °C

Further technical data can be found in our online catalogue.

Appendix

Figures: View varies according to the series.

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 ageing.
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
R412015555-BAL-001-AE 2021-08;
Replaces: 2016-03 DE/EN/FR/IT/ES/SV

References

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

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