APQ S.A. R-120 HP User manual

REGULATOR R-120 ES
REGULATOR R-120 HP
www.apq.cc
EU Product / Spain code RIR120ES00
code RIR120HP00
DESCRIPTION
R 120 …/B regulators are designed to regulate gas for
medium and high pressure applications. They use a direct
action type of regulation with a balanced seat disc,
membrane action and adjustment spring.
They are used both for G.N., G.L.P. and other non-corrosive
gas installations as well as stage 1 regulators.
They can also be fitted with a VIS safety valve with minimum
and maximum pressure - this model is the R-120/B.
It consists of the regulator with the output pressure gauge
fitted as an option and the block group, in model R-120…/B.
MODELS
Two models are manufactured, covering the most typical
ranges of pressure in gas installations:
Model R-120 ES, with outlet pressure from 150 to 800 mbar
Model R-120 HP, with outlet pressure from 600 to 4000 mbar
INSTALLATION
Before installing the regulator, ensure that:
The regulator selected (see label) coincides with
the needs of the installation.
The fluid passes through the body of the
regulator in the correct direction, as indicated on
the arrow on the body of the regulator.
The tubing has been previously clean and the
gas reaches the regulator perfectly clean and
dry.
The regulator must positioned so that there is
sufficient room for maintenance to be carried out
and for the outlet pressure to be adjusted and so
that it complies with maximum and minimum
safety levels.
The regulator is protected from rain and from
direct sunlight.
There is a tank that, with the regulator at
maximum flow, has a capacity of 240 litres for
the R-120ES model and 120 litres for the R-120
HP model. For lower flow levels, the size of the
tank can be reduced proportionally.
Where condensation effects are anticipated,
install the regulator upside down (position A),
first making a 2mm hole in the lower plastic
cover. It can be installed side on (position B and
C), installing the venting cover on the lower side.
1
2
3
5
4
6
10
8
7
12
9
11

TYPICAL CHART
STARTING UP THE REGULATOR WITHOUT VIS
Provide a light flow of gas downstream from the regulator. For example, using the bleed valve V2
Slowly open the gas shutoff valve V1 slightly, situated upstream from the regulator.
Check that the gas pressure is correct, using the inlet pressure gauge M1.
Check that the pressure is stable, using the outlet pressure gauge M2.
If the outlet pressure is not correct, adjust the regulator via the inspection hole (2)
Finish opening the shutoff valve V1 slowly, located at the filter inlet F1.
Slowly finish opening the shutoff valve V3, located downstream from the regulator.
Close the bleed valve V2.
START UP THE REGULATOR WITH MAXIMUM VIS (AND MINIMUM)
Provide a light flow of gas downstream from the regulator. For example, using the bleed valve 4
Slowly open the gas flow valve 1 slightly, situated upstream from the regulator.
Check that the gas pressure is correct, using the inlet pressure gauge M1.
Check that the pressure is stable, using the outlet pressure gauge M2.
If there is no outlet pressure, rearm the regulator:
oRemove the protective cover (7)
oSlowly press the button (12), opening the internal bypass
oWhen the regulating pressure is reached at the outlet, the resistance on the button will reduce and it will be
possible to finish pressing the button and it should maintain this position unassisted.
Finish opening the shutoff valve V1 slowly, located at the filter inlet F1.
Slowly finish opening the shutoff valve V3, located downstream from the regulator.
Close the bleed valve V2.
The time required to press down the button opening the internal bypass will depend on the differential of pressure between the
inlet and outlet and the volume of the outlet tank.
ADJUSTMENTS
Regulators are supplied with springs suitable for the customer's requirements. These springs allow a range of specific
adjustments, described in the catalogue. Where other values are required, the regulating spring must be replaced Where the
regulator has VIS, the springs may also need to be changed.
REGULATION:
Remove the plastic cover (1)
Using a 27 mm socket wrench, tighten the mobile nut (2). Turning the nut clockwise increases the outlet pressure.
Turning it anticlockwise will reduce the outlet pressure.
Put back the plastic cover (1)
MINIMUM VIS (optional)
Remove the plastic cover (7)
Using a 13 mm socket wrench, tighten the mobile nut (9). Turning the nut clockwise increases the minimum operating
level. Turning it anticlockwise has the opposite effect.
Put back the plastic cover (7)
MAXIMUM VIS (optional)
Remove the plastic cover (7)
Using a 27 mm socket wrench, tighten the mobile nut (9). Turning the nut clockwise increases the maximum operating
level. Turning it anticlockwise has the opposite effect.
Put back the plastic cover (7)
To avoid dirt or damage when closing the regulator, a gas filter should be installed before the regulator, with a minimum filter
grade of 5 microns (F1).
V1
F1
R
V2
V3
M1
M2

CHECK
Regulator without VIS and without VES
Check that the valve (V1) at the inlet to the regulator (R), the valve (V3) at the outlet to the regulator and the bleed
valve (V2) are closed.
Slowly open the inlet valve (V1) and use the pressure gauge (M1) to check that the pressure is correct at the inlet to the
regulator (R). Use the pressure gauge (M2) to check that the pressure increases at the inlet to the regulator (R) until it
is stabilised to the adjusted pressure in the regulator (R).
Close the inlet valve again (V1)
Use the inlet pressure gauge (M1) to check that there are no leaks at the inlet to the regulator (R)
Use the outlet pressure gauge (M2) to check that there are no leaks at the outlets of the regulator (R)
Regulator without VIS and with VES
Make the adjustments described above
Connect an external source of pressure via the bleed valve (V2) in the tank located along the stretch between the outlet
to the regulator (R) and the outlet valve (V3).
Slowly increase the pressure until the VES is activated. If it is necessary to vary the firing point of the VES, make the
appropriate adjustments at the inspection hole (4)
Regulator with VIS at minimum
Make the adjustments described above
Start up the regulator (R), checking that the outlet has the correct regulation pressure.
Close the gas inlet valve (V1) and slowly reduce the pressure to the outlet via the bleed valve (V2) until the minimum
pressure VIS valve is activated. If it is necessary to vary the firing point of the VIS, make the necessary adjustments at
the inspection hole (9)
Regulator with VIS at maximum
Make the adjustments described above
Connect an external source of pressure via the bleed valve (V2) in the tank located along the stretch between the outlet
to the regulator (R) and the outlet valve (V3).
Slightly increase the pressure in the tank until you see that the VIS maximum pressure valve is activated. If it is
necessary to vary the firing point of the VIS, make the necessary adjustments at the inspection hole (8).
PROBLEMS, CAUSES AND SOLUTIONS
The regulator does not close
Dirt in the regulating bar
oExternal filter (F1) in poor condition, clean filter and closing bar
Damaged rubber seat disc or orifice
oReplace regulator
Internal mechanism dirty or worn
oReplace regulator
The maximum pressure safety valve discharges
The seat disc or orifice it is not watertight
oPossible dirt in the seat disc
Water hammering at the outlet, due to abrupt closure of electro valves or manual shut-off valves
oSmall tank outlet
oReduce this effect by installing a VES valve in the regulator outlet tank.
Where there is no flow, increase the temperature in the outlet stretch due to the sun or nearby sources of heat.
oEliminate sources of heat and activate the VES below the maximum VES
The minimum pressure safety valve discharges
The outlet pressure is adjusted below or very close to the minimum safety adjustment level
oReduce the taring of the minimum VIS
Excessive flow for the inlet and outlet pressure values available in the regulator.
oLower the flow requested.
oIncrease the inlet pressure.
Very high instant consumption
oRaise the volume of the tank situated at the regulator outlet

REPLACING THE REGULATING SPRING
Disassembly
Close gas inlet valve (V1) located at the inlet to the installation.
Close gas inlet valve (V3) located at the outlet to the regulator.
Open bleed key (V2), located at the outlet to the regulator, until the area is depressurised.
Remove the plastic cover (1) in order to access the regulating nut (2)
Use a 24 mm tube spanner to turn the nut (2) anticlockwise and remove it.
Remove the regulating spring.
Installation
Choose from the list below the most suitable regulating spring for the required outlet pressure.
Carry out the operations described under "disassembly" in reverse order. It should be borne in mind that only those
screws indicated in the table below should be fitted. The fitting of other springs could cause damage to the regulator.
TOOLS FOR MAINTAINING THE R-120.../B REGULATOR
Open-ended spanner
00 –00 - 00
10 x 1.6 screwdriver
Tweezers
Hexagonal tube spanner
00 - 00 - 00
OUTLET PRESSURE ADJUSTMENT SPRINGS / VES
Wd (regulation)
Wrv (differential with regard to Pd)
Version
Spring code
Adjustment
fiel
d
in mbar
Version
Spring code
Spring range
in mbar
R-120ES
ZM3.00.000000
150 to 300
R-120ES
ZM3.00.000000
000 a 000
R-120ES
ZM3.00.000000
250 to 600
R-120ES
ZM3.00.000000
000 to 000
R-120ES
ZM3.00.000000
400 to 800
R-120HP
ZM3.00.000000
000 to 000
R-120HP
ZM3.00.000000
700 to 1800
R-120HP
ZM3.00.000000
000 to 000
R-120HP
ZM3.00.000000
1600 to 4000
R-120HP
ZM3.00.000000
000 to 000
VIS MAXIMUM/MINIMUM ADJUSTMENT SPRINGS
Wdo (maximum)
Spring code
Adjustment field
in mbar
ZM3.00.000000
000 to 000
ZM3.00.000000
000 to 000
ZM3.00.000000
000 to 000
ZM3.00.000000
000 to 000
ZM3.00.000000
000 to 000
ZM3.00.000000
000 to 000
Wdu (minimum)
Spring code
Adjustment field
in mbar
ZM3.00.000000
000 to 000
ZM3.00.000000
000 to 000
ZM3.00.000000
000 to 000
ZM3.00.000000
000 to 000
APQ SA Crtra. Ripollet 51 P.Ind. Foinvasa T.0034 935 647 550 F.0034 935 647 211 E-mail [email protected] website apq.cc
Technical Features
bpu 1÷20 bar (inlet pressure range)
Ps 20 bar (design pressure)
Pu 20 bar (maximum inlet pressure)
Wd (outlet pressure regulating
range)
R-120 ES 150 ÷ 800 mbar
R-120 HP 600 ÷ 4000 mbar
Wdo 300 ÷ 6000 mbar (maximum safety
range)
Wdo 100 ÷ 2500 mbar (minimum safety
range)
Wrv +10 ÷ +30% Pd (VES firing range)
Ac 20 % (degree of regulating pressure)
Sg 30 % máx. (degree of regulating
pressure)
T -20ºC ÷ 60ºC (operating temperature)
Inlet connection 1” Gas thread
Outlet connection 1” Gas thread
Connection layout Axial
Weight R-120 ES 2 –2.5 kg
Weight R-120 HP 2.5 –3 kg