Parker 1R402F Installation and maintenance instructions

Installation & Service Instructions:
1R402F
Mini Filter / Regulators,
Mini & Economy Regulators
1/8" & 1/4" Ports
ISSUED: November, 2003
Supersedes: April, 2003
Doc.# 1R402, ECN# 030539, Rev.8
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Miniature Filter / Regulator
Manual Drain Filter
(Relieving)
Miniature & Economy Regulators
(Relieving)
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 air supply and depressurize all air 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, air 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.
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.
Operation of Regulator
1. Before turning on air supply, turn adjusting handle counterclockwise until
compression is released from control spring. Then turn on air supply and
adjust regulator to desired secondary pressure by turning adjusting 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).
Operation of Filter / Regulator
1. Both free moisture and solids are removed automatically by the
Filter / Regulator.
2. Manual drain filters must be drained regularly before the separated moisture
and oil reaches the bottom of the element holder. Automatic drain models
(pulse drain) will collect and dump liquids automatically. They are actuated
when a pressure drop occurs within the filter.
3. The filter element should be removed and replaced when the pressure
differential across the filter is excessive.
Service
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Caution: SHUT OFF AIR SUPPLY and exhaust the primary and
secondary pressure before disassembling unit. (Units may be serviced
without removing them from the air line.)
Servicing Regulator:
Note: See Figure 1, 2, 3 & 4 to aid with this procedure.
1. Unlock the adjusting knob by pulling upward (with the unit in an upright
position.) Then turn adjusting knob counterclockwise until compression of the
control spring has been removed.
2. Remove the bonnet from body. Then remove o-ring (7), piston, lip seal (9),
and control spring to service the bonnet subassembly. Unscrew seat (8) to
service the poppet (17), return spring (5), and/or poppet seal (6), o-rings (25
& 27), and washer (26).
Note: On Filter / Regulator units, the poppet assembly & poppet return spring
may be accessed by removing filter element.
3. Clean old grease from unit and inspect seals for sign of wear (nicks, cuts,
and scratches). Repair kits are available which contain the parts which are
typically replaced.
4. Apply a light film of grease to all seals and sliding surfaces using the grease
packet supplied with repair kit.
Note: Refer to Figures to determine the correct position and orientation of the
various parts during assembly.
5. On Relieving Economy Regulator units, gently and firmly press vent seal into
piston using a blunt instrument.
6. Install lip seal onto piston with the lips of the seal facing away from the
support flange. Then insert control spring and piston assembly into bonnet.
7. On Economy Regulator units, place balancing o-ring (27) and washer (26)
into body’s bore. Then insert poppet return spring and poppet assembly,
followed by seat o-ring (25) and seat. On Mini Regulator and Filter / Regulator
units, place poppet return spring and poppet assembly into bore, followed by
poppet seal and seat.
Introduction
Follow these instructions when installing, operating, or servicing the product.
Application Limits
These products are intended for use in general purpose compressed air systems
only. Compliance with the rated pressure and temperature is necessary.
Maximum Operating (Inlet) Pressure: kPa PSIG bar
Mini Regulator (Plastic Body) 827 120 8.3
Mini Filter / Regulator (with Plastic Bowl) 1030 150 10.3
Mini Filter / Regulator (with Metal Bowl) 1720 250 17.2
Mini Regulator (Metal Body) 2000 300 20.0
Economy Regulator (Metal Body) 1720 250 17.2
Ambient Temperature Range: 0°C to 52°C (32°F to 125°F)
Symbols
Installation
1. This unit 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 compounds
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 the unit, possibly causing malfunction.
2. Install unit so that air flow is in the direction of arrow. Installation must be
upstream of and close to devices it is to service (valve, cylinder, tool etc.).
Mounting of Regulators may be in any position; mounting of Filter / Regulators
must be vertical as shown in figure.
3. Gauge ports are located on both sides of the regulator body for your
convenience. It is necessary to install a gauge or pipe plug into each port
during installation.
4. To protect Regulator units against rust, pipe scale, and other foreign matter,
install a filter on the upstream (high pressure) side as close to the regulator
as possible.
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Caution: For proper assembly of units having plastic bodies, fittings
must be installed hand-tight and then tightened by wrench 1/2 turn. To
prevent leakage past threads, apply thread sealant to fitting. Prestolok
fittings are recommended. Use of hard pipe is not recommended.
EXCESSIVE TURNING OF FITTINGS BY WRENCH MAY RESULT IN
PERMANENT DAMAGE AND RENDER THE REGULATOR INOPERABLE.
Pneumatic Division
Richland, Michigan 49083
269-629-5000
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Torque:
Finger Tight
Mini Filter / Regulators, Mini & Economy Regulators 1/8" & 1/4" Ports 1R402F
8. On Economy Regulator units, tighten seat from 0.6 to 0.8 Nm (5 to 7 in-lbs).
On Mini Regulator and Filter / Regulator units, tighten seat to body from 0.9
to 1.1 Nm (8 to 10 in-lbs) of torque. Tighten bonnet onto body from 5.6 to
7.3 Nm (50 to 65 in-lbs) of torque.
9. Make sure that the control spring is still uncompressed before turning on
the air supply. Turn on air supply, then slowly adjust the knob clockwise to
increase downstream pressure until the desired pressure has been reached.
10. 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).
11. When the desired secondary pressure setting has been reached, push the
adjusting knob down to lock it.
12. Check for leaks. If leaks occur, shut off the air supply, exhaust system air
pressure, and make necessary adjustments to eliminate leakage.
Servicing Filter Element:
Note: See Figure 1 to aid with this procedure.
1. Unscrew threaded bowl and element holder. Then remove filter element,
deflector, and gaskets.
2. Clean all internal parts, bowl, and body before re-assembling unit. See
Polycarbonate bowl cleaning section.
3. Install deflector, filter element, and gaskets.
4. Attach element holder. Torque 0.9 to 1.4 Nm (8 to 12 in-lbs).
5. To assist with retaining bowl’s o-ring while installing bowl, lubricate the o-ring
(with a mineral based oil or grease). Then place it on the bowl.
6. Screw bowl into body until it is stopped by body; then back off bowl 1/8 turn.
7. Apply pressure to the system and check for leaks. If leaks occur, shut off the
air supply, de-pressurize the system and make necessary adjustments to
eliminate leakage.
If you have questions concerning how to service this unit, contact your local
authorized dealer or your customer service representative.
Parts Identification List
Item# Description
1 Bowl (Mini Filter / Regulator)
2 Filter Element (Mini Filter / Regulator)
3 Deflector (Mini Filter / Regulator)
4 O-ring - bowl to body (Mini Filter / Regulator)
5 Poppet Return Spring
6 Poppet Seal
7 O-ring - body to bonnet
8 Seat
9 Lip Seal - piston to bonnet
10 O-ring - piston to poppet (Mini Regulator and Filter / Regulator
relieving units)
11 Piston (relieving shown)
12 Control Spring
13 Knob
14 Hex Nut
15 Adjusting Screw
16 Bonnet Assembly
17 Poppet (Mini Regulator and Filter / Regulator) & Poppet Assembly
(Economy Regulator)
18 Body
19 Gasket - deflector to body (Mini Filter / Regulator)
20 Gasket - element holder to filter element (Mini Filter / Regulator)
21 Element Holder (Mini Filter / Regulator)
22 O-ring - body to drain (Mini Filter / Regulator)
23 Twist Drain (Mini Filter / Regulator)
24 Vent Seal - poppet assembly to piston (relieving units)
(Economy Regulator)
25 O-ring - seat to body (Economy Regulator)
26 Washer (balanced units)
27 O-ring (balanced units) - poppet assembly to body
Service Kits Available
The following service kits contain the appropriate seals and parts necessary
for ordinary field service.
Description Mini Mini Economy
Filter / Regulator Regulator Regulator
Poppet Kit - Balanced N/A N/A PS455B
Piston Kit - Non-Relieving N/A N/A PS422
Piston Kit - Relieving N/A N/A PS423
Piston & Poppet Kit - Unbal. Rel. PS426 PS426 N/A
Piston & Poppet Kit - Bal. Rel. PS427 PS427 N/A
Piston & Poppet Kit - Unbal. Non-Rel PS428 PS428 N/A
Piston & Poppet Kit - Bal. Non-Rel. PS429 PS429 N/A
Bonnet Assembly L01369 L01369 L01369
Mounting Bracket Kit (plastic ring) PS417B PS417B PS417B
Mounting Bracket Kit (aluminum ring) PS466 PS466 PS466
Knob Tamperproof Clip P01265 P01265 P01265
5 Micron Element Kit PS403 N/A N/A
40 Micron Element Kit PS401 N/A N/A
Polycarbonate Bowl w/Manual Drain PS404 N/A N/A
Polycarbonate Bowl w/Automatic Drain PS408 N/A N/A
Metal Bowl w/Manual Drain PS447B N/A N/A
Metal Bowl w/Automatic Drain PS451 N/A N/A
SAFETY: Transparent Bowls
CAUTION
Polycarbonate bowls, being transparent and tough, are ideal for use with Filters
and Lubricators. They are suitable for use in normal industrial environments, but
should not be located in areas where they could be subject to direct sunlight, an
impact blow, nor temperatures outside of the rated range. As with most plastics,
some chemicals can cause damage. Polycarbonate bowls should not be exposed
to chlorinated hydrocarbons, ketones, esters and certain alcohols. They should
not be used in air systems where compressors are lubricated with fire resistant
fluids such as phosphate ester and di-ester types.
Metal bowls are recommended where ambient and/or media conditions are not
compatible with Polycarbonate bowls. Metal bowls resist the action of most such
solvents, but should not be used where strong acids or bases are present or in
salt laden atmospheres. Consult the factory for specific recommendations where
these conditions exist.
TO CLEAN POLYCARBONATE BOWLS USE MILD SOAP AND WATER ONLY!
DO NOT use cleansing agents such as acetone, benzene, carbon tetrachloride,
gasoline, toluene, etc., which are damaging to this plastic.
Bowl guards are recommended for added protection of Polycarbonate bowls where
chemical attack may occasionally occur.
FIGURE 1: Mini Filter / Regulator -
(Un-balanced, Relieving
Unit Shown with
Metal Bowl and Twist Drain)
FIGURE 2: Mini Regulator -
(Un-balanced, Relieving Unit Shown)
FIGURE 3: Economy Regulator -
(Balanced, Relieving Unit Shown)
FIGURE 4: Detail of Poppet Seal -
for Mini Regulators & Mini Filter / Regulator Units
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27
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25
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6
817
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