Dixon R119 Series Installation and maintenance instructions

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Relieving Regulator
Adjustable
Non-Relieving Regulator
Adjustable
Introduction
Follow these instructions when installing, operating, or servicing
the product.
Application Limits
These products are intended for use in general purpose
compressed media systems only.
Operating Pressure:
kPa PSIG bar
Maximum Inlet Pressure 2068 300 21.0
Ambient Temperature Range: 4°C to 49°C
(40°F to 120°F)
Symbols
Installation
1. The regulator should be installed with reasonable
accessibility for service whenever possible - repair service
kits are available. Keep pipe and tubing lengths to a
minimum with inside clean and free of dirt and chips. Pipe
joint compound should be used sparingly and applied only
to the male pipe - never into the female port. Do not use
PTFE tape to seal pipe joints - pieces have a tendency to
break off and lodge inside unit, possibly causing
malfunction.
2. Install regulator so that media flow is in the direction of
arrow. Installation must be upstream (high pressure) side
and as close to the devices it is to service (valve, cylinder,
tool, etc.). Mounting may be in any position.
3. Gauge ports are located on both sides of the regulator
body for your convenience. It is necessary to install a
gauge or pipe plugs into each port during installation.
4. For protection against rust, pipe scale, and other foreign
matter, install a filter on the upstream (high pressure) side
as close to the regulator as possible.
Operation
1. Before turning on the media source turn the T-handle
counterclockwise until compression is released from the
Control Spring. Then turn on media source and adjust
regulator to desired secondary pressure by turning T-handle
clockwise.This permits pressure to build up slowly, preventing
any unexpected operation of the valve, cylinders, tools, etc.,
attached to the line. Adjustment to desired secondary
pressure can be made only with primary pressure applied
to the regulator.
2. To decrease regulator pressure setting, always reset from a
pressure lower than the final setting desired. For example,
lowering the secondary pressure from 550 to 410 kPa (80
to 60 PSIG) is best accomplished by dropping the secondary
pressure to 350 kPa (50 PSIG), then adjusting upward to
410 kPa (60 PSIG). Tighten the Locking Nut on the T-handle
to lock the pressure setting.
Reduced Pressure Spring Ranges
“A” Range = 1 – 25 PSI (1/4", 3/8", 1/2" Only)
“B” Range = 2 – 60 PSI (1/4", 3/8", 1/2" Only)
“C” Range = 2 – 125 PSI (ALL)
“D” Range = 5 – 250 PSI (ALL)
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WARNING
To avoid unpredictable system behavior that can cause personal injury
and property damage:
• Disconnect electrical supply (when necessary) before installation,
servicing, or conversion.
• Disconnect media source and depressurize all media lines
connected to this product before installation, servicing, or
conversion.
• Operate within the manufacturer’s specified pressure, temperature,
and other conditions listed in these instructions.
• Medium must be moisture-free if ambient temperature is below
freezing.
• Service according to procedures listed in these instructions.
• Installation, service, and conversion of these products must be
performed by knowledgeable personnel who understand how
pneumatic products are to be applied.
• After installation, servicing, or conversion, media and electrical
supplies (when necessary) should be connected and the product
tested for proper function and leakage. If audible leakage is present,
or the product does not operate properly, do not put into use.
• Warnings and specifications on the product should not be covered
by paint, etc. If masking is not possible, contact your local
representative for replacement labels.
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WARNING
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF
THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR
RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND
PROPERTY DAMAGE.
This document and other information from The Company, its
subsidiaries and authorized distributors provide product and/or system
options for further investigation by users having technical expertise. It
is important that you analyze all aspects of your application, including
consequences of any failure and review the information concerning
the product or systems in the current product catalog. Due to the
variety of operating conditions and applications for these products or
systems, the user, through its own analysis and testing, is solely
responsible for making the final selection of the products and systems
and assuring that all performance, safety and warning requirements
of the application are met.
The products described herein, including without limitation, product
features, specifications, designs, availability and pricing, are subject to
change by The Company and its subsidiaries at any time without notice.
EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR
INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE
THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE.
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WARNING
Product rupture can cause serious injury.
Do not connect regulator to bottled gas.
Do not exceed maximum primary pressure rating.
Installation & Service Instructions
IS-R119
R119, 1/4", 3/8", 1/2", 3/4", 1",
1-1/4", 1-1/2" Series Regulators
ISSUED: July, 2005
Supersedes: January, 2004
Doc. #ISR119, ECN #050983, Rev. 2
Pneumatic Division
Richland, Michigan 49083
269-629-5000

R119, 1/4", 3/8", 1/2", 3/4", 1", 1-1/4", 1-1/2" Series Regulators IS-R119
Lightly grease with provided lubricant.
Inspect for nicks, scratches, and surface imperfections. If present,
reduced service life is probable and future replacement should
be planned.
Clean with lint-free cloth.
Service
Caution: Disconnect or shut off air supply and exhaust
the primary and secondary pressures before servicing
unit. Turning the T-handle counterclockwise does not
vent downstream pressure on non-relieving regulators.
Downstream pressure must be vented before servicing
regulator.
Caution: Grease packets are supplied with kits for
lubrication of seals. Use only mineral based grease or
oils. Do not use synthetic oils such as esters. Do not
use silicones.
Note: After servicing unit, turn on air supply and adjust regulator
to the desired downstream pressure. Check unit for leaks. If
leakage occurs, do not operate - conduct repairs and retest.
A. Servicing the Bonnet and Diaphragm Assembly
1. Turn the T-handle counterclockwise until the compression is
released from the Pressure Control Spring.
2. Remove Bonnet Mounting Screws, Bonnet Assembly,
Pressure Control Spring and Spring Button. Remove
Diaphragm Assembly. Next, disassemble, clean, and carefully
inspect parts for wear and / or damage. Wipe parts, clean
with soapy water or denatured alcohol. If using compressed
air to blow dry, be sure to wear appropriate eye protection. If
replacement is necessary, use parts from service kits.
3. Install Diaphragm Assembly, Pressure Control Spring, Spring
Button as shown below. Then, install Bonnet Assembly to
Body with Mounting Screws and tighten in an alternating or
star pattern to the following torque specifications:
1/4", 3/8", 1/2" ..................... 2.3 to 4.5 Nm (20 to 40 in. lb.)
3/4", 1-1/4", 1-1/2" ............... 6.8 to 7.9 Nm (60 to 70 in. lb.)
B. Servicing the Poppet Assembly
1. Exhaust system media pressure as previously described.
Then remove Bottom Plug by unscrewing it from Body.
Next, remove Bottom Plug, O-ring, Bottom Spring and Inner
Valve Assembly.
2. Next, disassemble, clean, and carefully inspect parts for
wear and / or damage. If replacement is necessary, use
parts from service kits.
3. Lubricate O-ring and sliding surfaces using grease supplied
with service kit.
4. Install parts as shown.
5. Lubricate Bottom Plug O-ring and install it in o-ring groove
on Bottom Plug. Be sure Inner Valve Stem fits into center
area of Diaphragm Assembly before installing Bottom Plug.
Then screw Bottom Plug into Body until it bottoms out in
body. Tighten to 3.5 to 5.1 Nm (35 to 45 in. lb.).
6. Turn on media source and adjust to desired secondary
pressure as described in the Operation section. Check
regulator for leakage. If leakage occurs, DO NOT OPERATE
— conduct repairs again.
If you have questions concerning how to service this unit, contact
your local authorized dealer or your customer service
representative.
Service Kits Available
Description Kit Number Regulator Size
Bottom Plug Only 118Y2 1/4", 3/8"
118A2 1/2"
119B2-2 3/4" thru 1-1/2"
Bottom Plug O-ring Only 118Y102 1/4", 3/8"
118A101 1/2"
118B101 3/4" thru 1-1/2"
Mounting Bracket Kit SA15Y57 1/4", 3/8"
18A57 1/2"
18B57 3/4" thru 1-1/2"
Panel Mount Conversion Kit 4202 1/4", 3/8"
4204 1/2"
Regulator Repair Kit* RK119Y 1/4", 3/8"
(Relieving) RK119A 1/2"
RK119A250 1/2" (“D” Range)
RK119B 3/4", 1"
RK119D 1-1/4", 1-1/2"
Regulator Repair Kit* RK118Y 1/4", 3/8"
(Non-Relieving) RK118A 1/2"
RK118A250 1/2" (“D” Range)
RK118B 3/4", 1"
RK118D 1-1/4", 1-1/2"
T-handle Kits TK16Y 1/4", 3/8"
TK119A 1/2"
TK119B 3/4" thru 1-1/2"
Accessories
Gauges
0 to 60 PSI (0 to 4 bar) 275Y60S
0 to 160 PSI (0 to 11 bar) 275Y160S
0 to 300 PSI (0 to 20 bar) 275Y300S
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T-handle Adjusting Screw
Lock Nut
Spring Button
Control Spring
Spring, Bottom
Diaphragm Assembly
(Includes Upper Diaphragm Plate
& Lower Diaphragm Button
Inner Valve
Assembly
Body
Bottom Plug
O-ring
Spring Cage (Bonnet) - Torque:
1/4", 3/8", 1/2" – 2.3 to 4.5 N
m
(20 to 40 in. lb.
)
3/4", 1-1/4", 1-1/2" – 6.8 to 7.9 N
m
(60 to 70 in. lb.
)
Bottom Plug - Torque:
3.9 to 5.1 Nm (35 to 45 in. lb.)