Elster J125B Training manual

J125B
Service Regulator
Inlet Pressure up to 8.6 bar
Commissioning Instructions
General Arrangements
Parts Lists
Maintenance Instructions
For: J125 MKII Regulator with balanced valve
1 ½”, 2” and 50mm size

2
J
125B: Commissioning Instructions
FITTING REGULATOR INTO PIPEWOR
K
•Ensure that this product is suitable for the chosen application.
•Installation, adjustment and maintenance by authorised, trained personnel only.
•When being fitted to an appliance, refer to the appliance manufacturers
instructions.
1. The unit should not be installed in a corrosive environment.
2. The ambient temperature (surface temperature) should be within the
limits stated on the regulator catalogue.
3. Check the maximum allowable pressure on the regulator nameplate
against the installation specification.
4. Remove the protection plugs from inlet and outlet ports.
5. Ensure that installation pipework is thoroughly clean.
6. The direction of gas flow must be the same as the arrows on the
regulator body. See Fig. 1.
7. Install the regulator into pipework using jointing compound approved
to national standards.
8. In order to fit the regulator into confined spaces it may be necessary
to rotate the diaphragm case. This is achieved by slacking off the two
cap screws, rotating the diaphragm case, and then re-tightening the
cap screws evenly. See Fig. 2.
9. For units with no OPSS fitted it is advised that a slam shut device is
fitted to protect downstream equipment.
INSTALLATION OF VENT LINE.
1. Remove clip and vent screen from regulator top cover.
2. Connect the vent line (2"), using a jointing compound approved to
national standards, and lead to atmosphere in accordance with
national standards. Ensure that no water can penetrate vent pipeline.
See Fig. 3.
3. If the regulator is fitted with an internal relief valve, ensure that the
vent line is of sufficient diameter to carry gas vented by the relief valve
to a safe outside location. Reference to any national standard
INSTALLATION OF IMPULSE LINE
1. Remove the plastic protection plug.
2. Connect the impulse line (½"), using a jointing compound approved
to national standards, and lead to a point downstream not less than
fifteen times the nominal pipe diameter from the outlet. See Fig. 4.
FOR PRE-SET UNITS ONLY.
1. Turn off downstream valves.
2. Slowly turn on inlet supply.
3. If safety shut-off device is not fitted, go to instruction 6.
Warning! Incorrect installation, adjustment, modification, operation and maintenance may
cause injury or damage.
Read the instructions before use. This control must be installed in accordance with the rules in
force.
Fig. 1
Fig. 2
Fig. 3
Fig. 4

3
J125B: Commissioning Instructions
4. If safety shut-off device is fitted unscrew reset spindle end cap and
firmly pull. Hold in this position until the outlet pipework is fully
pressurised, then release reset spindle end cap gently. See Fig. 5.
5. Re-screw reset spindle end cap into body, ensuring not to jam reset
spindle.
6. Commission downstream appliances.
WARNING: DO NOT UNDER ANY CIRCUMSTANCES WEDGE OPEN SAFETY
SHUT-OFF RESET END CAP AS THIS WILL NOT ALLOW THE SAFETY DEVICE(S)
TO FUNCTION IN ADVERSE PRESSURE CONDITIONS.
SETTING THE REGULATOR & SAFETY
SHUT OFF DEVICE PRESSURES.
OPSS = Over Pressure Safety Shut-off.
UPSS = Under Pressure Safety Shut-off.
1. Turn off inlet and outlet valves.
2. Remove top cap from regulator cover.
3. Insert an 11/4" A/F socket over the top of the adjustment screw.
4. Turn anticlockwise (-) to reduce loading on regulator spring to
minimum. See Fig. 6 (If no safety devices are fitted go to instruction 10).
5. Remove top cap from safety shut-off device cover (If UPSS only go to
instruction 8).
6. Insert a flat bladed screwdriver into one of the partial slots on the
OPSS spring holder. See Fig. 7.
7. Turn clockwise (+) to increase loading on OPSS spring to maximum.
8. If UPSS fitted, insert a pozidriv screw driver (No.2 point) into UPSS
adjusting screw in bottom spring holder. See Fig. 8.
9. Turn anticlockwise (-) to reduce loading on UPSS spring, making sure
screw head does not protrude from the bottom spring holder.
10. Slowly open inlet valve(s).
11. If safety device fitted, re-cock by unscrewing reset spindle end cap
and pulling firmly. Hold in this position until the outlet pipework is fully
pressurised, then release reset spindle end cap gently. Re-screw
reset spindle end cap into body. See Fig. 5.
12. Turn regulator adjustment screw clockwise (+) to increase the loading
on the spring until the required outlet pressure, plus approximately
2.5mbar (1"wg) is obtained. (This is an allowance for the regulator
being set with zero flowrate).
If UPSS only go to instruction 20, if no safety device go to instruction 27.
13. Block vent valve opening to prevent relief valve from operating.
14. Apply external pressure source to a suitable point on the outlet
pipework. Increase pressure to that required for OPSS trip-off.
Note: If pressure test point on underside of slam shut unit is used as
external source point, care must be taken to ensure pressures are
equalised across restricted orifice within test point.
15. Slowly turn OPSS spring holder anticlockwise (-) until OPSS device trips
off. See Fig. 7.
16. Reduce external pressure source to level set in instruction 12.
Fig. 5
Fig. 6
Fig. 7

4
J125B: Commissioning Instructions
17. Re-cock OPSS device by unscrewing reset spindle end cap and firmly
pull. Hold in this position until the outlet pipework is fully pressurised,
then release reset spindle end cap gently. Re-screw reset spindle end
cap into body. See Fig. 9.
18. Slowly increase external pressure to check for OPSS trip-off. Trim
adjustment if necessary and repeat instructions 16 - 18.
19. Remove external pressure source.
NOTE: OPSS device is now set.
20. Close inlet valves.
21. Reduce inlet pressure to approximately 140mbar (2 PSI).
22. Reduce outlet pressure by introducing a slow controlled bleed until
the required UPSS trip-off pressure is obtained and close bleed.
23. Slowly turn UPSS adjusting screw clockwise (+) until UPSS device trips
off. See Fig. 8.
24. Slowly open inlet valve to regain inlet pressure up to approximately
140mbar (2 PSI), then close inlet valve.
25. Re-cock UPSS device by unscrewing reset spindle end cap and firmly
pull. Hold in this position until the outlet pipework is fully pressurised,
then release reset spindle end cap gently. Re-screw reset spindle end
cap into body. See Fig. 9.
26. Slowly reduce outlet pressure to check for UPSS trip-off. Trim
adjustment if necessary and repeat instructions 24 – 26.
NOTE: UPSS device is now set.
27. Commission installations.
28. Trim the regulator outlet pressure if necessary once normal flow rates
have been achieved.
29. Unblock vent opening.
30. Replace all top caps (seal if necessary).
WARNING: DO NOT UNDER ANY CIRCUMSTANCES WEDGE OPEN SAFETY
SHUT-OFF RESET END CAP AS THIS WILL NOT ALLOW THE SAFETY DEVICE(S)
TO FUNCTION IN ADVERSE PRESSURE CONDITIONS.
Fig. 8
Fig. 9

5
J125B: Commissioning Instructions
IF THE REQUIRED REGULATOR OUTLET PRESSURE CANNOT BE
ACHIEVED WITH THE SPRING FITTED
31. Remove top cap from regulator cover.
32. Choose a loading spring from catalogue or page 17 that will give the
required outlet pressure range.
33. Fully unscrew and remove the adjustment screw, See Fig. 11.
34. Remove spring and replace with new one. See Fig. 10.
35. Screw adjustment screw back in place.
36. Adjust the outlet pressure as described previously.
37. Replace the top cap (seal if necessary).
NOTE: Outlet pressure is now set
IF THE REQUIRED TRIP-OFF PRESSURES CANNOT BE ACHIEVED WITH
THE SPRINGS FITTED
A) OPSS spring
38. Remove top cap from the safety shut-off device cover.
39. Choose an OPSS spring from the catalogue or page 17 that will give
the required pressure range.
40. Fully unscrew and remove top spring holder. See Fig. 12.
41. Remove spring and replace with new one. See Fig. 10.
42. Screw spring holder back in place, ensuring that castellated spigot is
uppermost in chimney. See Fig. 12.
43. Adjust the trip-off pressure as described previously.
44. Replace the top cap (seal if necessary).
NOTE: OPSS pressure is now set
B) UPSS spring.
45. Remove top cap from the safety shut-off device cover.
46. Choose an UPSS spring from the catalogue or page 17 that will give
the required pressure range.
47. Fully unscrew and remove top spring holder. See Fig. 12.
48. Remove OPSS spring (or spacer tube if UPSS only).
Fig. 10
Fig. 11
Fig. 12

6
49. Remove bottom spring holder and UPSS top spring holder.
50. Remove UPSS spring and replace with new one. See Fig. 13.
51. Replace UPSS spring holder, ensuring that spigot locates in UPSS
spring.
52. Replace bottom spring holder locating three webs into slots in bottom
of cover, ensuring not to disturb UPSS spring and UPSS spring holder.
53. Replace OPSS spring (or spacer tube if UPSS only).
54. Screw top spring holder back in place, ensuring that castellated
spigot is uppermost in chimney. See Fig. 11. (If UPSS only ensure that
spacer tube is firmly clamped)
55. Adjust the trip-off pressure as described previously
56. Replace the top cap (seal if necessary).
NOTE: UPSS pressure is now set.
Fig. 13
J125B: Commissioning Instructions

7
J125B: General Arrangement
S1, S2, S3 Assembly – Fig 14
S1 VERSION
(NO RELIEF VALVE)
S3 VERSION
(LIMITED RELIEF VALVE)
DIAPHRAGM CASE
ASSEMBLY
SEE FIG. 17
S2 VERSION
(FULL CAPACITY RELIEF VALVE)
41 38
39
40
42
44 46
16
94
43

8
J125B: General Arrangement
S4, S5, S10 Assembly- Fig 15
DIAPHRAGM CASE
ASSEMBLY
SEE FIG. 17
S4 VERSION
(FULL CAPACITY RELIEF VALVE)
41 38
39
40
44 46
16
94
S10 VERSION
(NO RELIEF VALVE)
S5 VERSION
(LIMITED RELIEF VALVE)
OPSS
SAFETY
SHUT OFF
ASSEMBLY
SEE FIG. 18

9
J125B: General Arrangement
S6, S7, S8, S9, S11, S12 Assembly- Fig 16
DIAPHRAGM CASE
ASSEMBLY
SEE FIG. 17
S8 VERSION
(FULL CAPACITY RELIEF VALVE)
41 38
39
40
44 46
16
94
S11 & S12 VERSION
(NO RELIEF VALVE)
S7 & S9 VERSION
(LIMITED RELIEF VALVE)
OPSS/UPSS
SAFETY
SHUT OFF
ASSEMBLY
SEE FIG. 19
S6, S7 & S11 VERSIONS
UPSS ONLY
SEE FIG. 20

10
J125B: General Arrangement
Diaphragm Case Assembly – Fig 17
S1, S10, S11 & S12
VERSIONS
(NO RELIEF VALVE)
S3, S5, S7 & S9
VERSIONS
(LIMITED RELIEF VALVE)
33
34
35
36
11
95
35
36
37
S2, S4, S6 & S8
VERSIONS
(FULL RELIEF VALVE)
13
97
10
96
15
12
14
45
7
8
9
95
6 5 4 3 2 1 32 31 30 29 28 27
26
25
24
23
22
21
20
19
18
16
17