Pneumatic Division 05E Installation and maintenance instructions

Installation & Service Instructions:
2FR100G
05E, 06E, 07E, & 12E Filter / Regulators
27E Precision Filter / Regulator
ISSUED: November, 2003
Supersedes: April, 2003
Doc.# 2FR100, ECN# 030539, Rev. 10
Installation
1. The Filter / Regulator should be installed with reasonable accessibility for
service whenever possible – repair service kits are available. Keep pipe or
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 the unit,
possibly causing malfunction. Also, new pipe or hose should be installed
between the Filter / Regulator and equipment being protected.
2. The upstream pipe work must be clear of accumulated dirt and liquids.
3. Select a Filter / Regulator location as close as possible to the equipment
being protected.
4. Install Filter / Regulator so that air flows in the direction of arrow on body.
5. Install Filter / Regulator vertically with the bowl drain mechanism at the
bottom. Free moisture will thus drain into the sump (“quiet zone”) at the
bottom of the bowl.
6. Gauge ports are located on both sides of the filter/regulator body for your
convenience. It is necessary to install a gauge or socket pipe plugs into
each port during installation.
Operation
1. Both free moisture and solids are removed automatically by the filter.
Units with coalescing elements (e.g. 12E series) also remove oil. For
coalescing units, a 5 micrometer pre-filter is recommended to protect and
prolong the life of the coalescent filter element.
2. Manual drain filters must be drained regularly before the separated moisture
and oil reaches the bottom of the baffle or end cap.
3. The filter element should be removed and replaced when pressure
differential across the filter is 69 kPa (10 PSIG).
4. Before turning on the air supply, turn the knob counterclockwise until
compression is released from the pressure control spring. Then turn knob
clockwise and adjust regulator to desired downstream pressure. This
permits pressure to build up slowly in the downstream line.
5. To decrease regulated pressure settings, always reset from a pressure
lower than the final setting required. 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).
6. When desired secondary pressure settings have been reached, push the
knob down to lock this pressure setting.
Service
Caution: Disconnect or shut off air supply and exhaust the primary
and secondary pressures before servicing unit. Turning the
adjusting knob counterclockwise does not vent downstream
pressure on non-relieving regulators. Downstream pressure must
be vented before servicing regulator.
Note: 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.
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.
With Polycarbonate Bowl
kPa PSIG bar
Operating Pressure Maximum 1000 150 10.3
Operating Temperature Maximum 52°C (125°F)
Operating Temperature Minimum 0°C (32°F)
With Metal Bowl
kPa PSIG bar
Operating Pressure Maximum 1700 250 17.0
Operating Temperature Maximum 80°C (175°F)
Operating Temperature Minimum 0°C (32°F)
05/15 Series with Metal Bowl and Auto Drain
kPa PSIG bar
Operating Pressure Maximum 1000 150 10.3
Operating Temperature Maximum 80°C (175°F)
Operating Temperature Minimum 0°C (32°F)
Note: The maximum recommended pressure drop for a particulate filter is
70 kPa (10 PSIG, 0.7 bar)
Symbols
Filter / Regulator Filter / Regulator 12E
05E, 06E, 07E & 27E (Coalescing Element)
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.
!
WARNING
Product rupture can cause serious injury.
Do not connect regulator to bottled gas.
Do not exceed maximum primary pressure rating.
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.
Pneumatic Division
Richland, Michigan 49083
269-629-5000
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➚
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➚
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Retainer
O-rings
Threaded Ro
d
Coalescing
Element
Bowl
(Metal Only)
End Cap
Drain Nut
Twist Drain
Adapter
(Reverse Flow)
Collar
(Bottom)
Lip Seal
Body
Collar (Bottom)
Deflector
Baffle
Bowl Assembly
Twist Drain
Drain Nut
Bowl Guard
Element
O-ring
⁄
Spring Guide /
Adjusting
Screw Assy
Control Spring
Thrust Washer
Knob
O-ring
(Upper Insert)
Seal
(Upper Balancing
)
Poppet
Assembly
Retainer
Filter Stem
Insert Assembly
(Includes Upper
Balancing Seal)
Collar (Top)
Spring
(Poppet Return)
Seal
(Lower Balancing)
(Not Used On 27E)
O-ring
(Lower Insert)
Vent Seal
(Relieving Only)
(Not Used On 27E) Diaphragm
Assembly
05E, 06E, 07E, 12E & 27E Filter / Regulator Series 2FR100G
Figure 1: 05E, 06E, 07E & 27E Figure 2: 12E
Servicing Filter Element -
A. 05E, 06E, 07E & 27E Units (Refer to Figure 1.)
1. Unscrew the bottom threaded collar and remove bowl.
2. Unscrew the baffle and then remove element.
3. Clean all internal parts and bowl before reassembling. See polycarbonate
bowl cleaning section. IMPORTANT: The 05E, 06E, 07E & 27E Filter /
Regulator will not operate properly if the deflector (or rubber spacer if using
an 06E adsorber) is not installed properly. The deflector (or rubber spacer)
must be installed between the filter stem and the filter body.
4. Install new element.
5. Attach baffle and finger tighten firmly.
6. Replace bowl seal. Lightly lubricate new seal to assist with retaining it in
position.
7. Install bowl into body and tighten collar; hand tight, plus 1/4 turn.
B. 12E Units (Refer to Figure 2.)
1. Hold bowl collar stationary while unscrewing and removing bowl.
2. Unscrew end cap and then remove element. (Do not remove threaded rod.)
3. Clean all internal parts and bowl before reassembling.
4. Install new element.
5. Attach end cap and finger tighten firmly.
6. Replace bowl seal. Lightly lubricate new seal to assist with retaining it
in position.
7. Thread bowl into collar; hand tighten until bowl stops against collar.
Servicing Regulator -
A. 05E, 06E, 07E & 27E Units - (Refer to Figure 1.)
1. Disengage the adjusting knob by pulling upward. Turn adjusting knob
counterclockwise until the compression is released from the pressure
control spring.
2. Remove the bonnet and bowl assemblies by unscrewing the two
threaded collars.
3. Remove diaphragm assembly from bonnet assembly.
4. Remove filter stem, filter element, poppet assembly, poppet return spring,
(seat) insert and its o-rings.
5. Clean and carefully inspect parts for wear or damage. If replacement is
necessary, use parts from service kits. Clean bowl. See polycarbonate bowl
cleaning section.
6. Lubricate o-ring and vee packing seals with grease found in service kits.
7. Install poppet return spring, poppet assembly, (seat) insert and its o-rings,
and filter stem. IMPORTANT: The 05E, 06E, 07E & 27E Filter / Regulator
will not operate properly if the deflector (or rubber spacer if using an 06E
adsorber) is not installed properly. The deflector (or rubber spacer) must be
installed between the filter stem and filter body.
8. Install filter element and firmly tighten baffle onto the filter stem.
9.
Install diaphragm assembly into bonnet assembly. Assemble bonnet assembly
to body and tighten threaded collar from 5.4 to 5.9 Nm (48 to 52 in-lbs).
10. Install bowl into body and tighten collar; hand tight, plus 1/4 turn.
B. 12E Units - (Refer to Figure 2.)
1. Disengage the adjusting knob by pulling upward. Turn adjusting knob
counterclockwise until the compression is released from the pressure
control spring.
2. Remove the bonnet assembly by unscrewing its threaded collar.
3. Remove the bottom collar and bowl as an integral unit. Note: The reverse
flow adapter and element assembly should remain in proper alignment with
the collar; they are held in place by the o-ring between the adapter and
the collar.
4. Remove diaphragm assembly from bonnet assembly.
5. Remove poppet assembly, poppet return spring, (seat) insert and its
o-rings.
(06E Shown)
Safety: Polycarbonate 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 subjected
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 occur.
!
WARNING
To avoid polycarbonate bowl rupture that can cause personal injury or
property damage, do not exceed bowl pressure of temperature ratings.
Polycarbonate bowls have a 150 PSIG (1030 kPa) pressure rating and a
maximum temperature rating of 52°C (125°F).
MAINTENANCE 05E 06E 07E 12E 27E
SERVICE KITS
Element Kits
5 Micron PS902 PS702 PS802 N/A PS902
40 Micron PS901 PS701 PS801 N/A PS901
Grade 6 N/A N/A N/A PS884 N/A
Grade 10 N/A N/A N/A PS885 N/A
Relieving Regulator
Repair Kit PS908 PS710 PS810 PS886 PS907
Non-Relieving
Regulator Repair Kit PS909 PS711 PS811 PS887 N/A
6. Clean and carefully inspect parts for wear or damage. If replacement is
necessary, use parts from service kits.
7. Lubricate o-ring and vee packing seals with grease found in service kits.
8. Install poppet return spring, poppet assembly, (seat) insert and its
o-rings.
9. Install diaphragm assembly into bonnet assembly. Assemble bonnet
assembly to body and tighten threaded collar from 5.4 to 5.9 Nm
(48 to 52 in-lbs).
10. Install bottom collar and bowl subassembly into body. Tighten collar
hand tight, plus 1/4 turn.