Norgren 11-042 Series Installation Instructions - Manual

11-042
Installation & Maintenance
Instructions
4. Install a pressure gauge in a gauge port on the 11-042, or
to the application point downstream of the 11-042. Do not
connect the gauge to the pilot pressure line, as this
pressure is not the same as the 11-042 outlet pressure.
Locate the gauge next to the pilot regulator. Plug unused
gauge ports.
5. Install a general purpose filter upstream of the regulator.
6. Install a Norgren muffler (see Replacement Parts) in the
exhaust port of the 11-042 regulator. Installation of a
muffler will reduce work area noise and protect 11-042
internal parts from contamination.
Warning
Do not plug exhaust port. Relief feature will fail if
exhaust port is plugged.
ADJUSTMENT
1. Before applying inlet pressure to regulators, turn pilot
regulator adjustment counterclockwise to remove all
force on regulating spring.
2. Apply inlet pressure, then turn pilot regulator adjustment
clockwise to increase and counterclockwise to decrease
pressure setting.
3. Always approach the desired pressure from a lower
pressure. When reducing from a higher to a lower
setting, first reduce to some pressure less than that
desired, then bring up to the desired pressure.
DISASSEMBLY
1. Regulator can be disassembled without removal from air
line.
2. Shut off inlet pressure to pilot regulator and to the 11-
042. Reduce pressure in inlet and outlet lines to zero.
3. Turn pilot regulator adjustment counterclockwise to
remove all force on regulating spring.
4. Disassemble the 11-042 in general accordance with the
item numbers on exploded view.
CLEANING
1. Clean parts with warm water and soap
2. Rinse and dry parts. Blow out internal passages in body
(8) with clean, dry compressed air.
3. Inspect parts. Replace those found to be damaged.
ASSEMBLY
1. Lubricate o-rings and surfaces in contact with o-rings
with a light coat of good quality o-ring grease.
2. Assemble the unit as shown on the exploded view. Apply
increasing torque to the bonnet screws (1) in a
crisscross pattern. Apply final torque of 5,6 to 7,9 Nm
(50 to 70 inch-pounds). Tighten bottom plug (9) hand
tight.
WARNING
These products are intended for use in industrial
compressed air systems only. Do not use these products
where pressures and temperatures can exceed those listed
under Technical Data.
If outlet pressure in excess of the regulator pressure
setting could cause downstream equipment to rupture or
malfunction, install a pressure relief device downstream of
the regulator. The relief pressure and flow capacity of the
relief device must satisfy system requirements.
The accuracy of the indication of pressure gauges can
change, both during shipment (despite care in packaging)
and during the service life. If a pressure gauge is to be
used with these products and if inaccurate indications may
be hazardous to personnel or property, the gauge should be
calibrated before initial installation and at regular intervals
during use.
Before using these products with fluids other than air,
for non industrial applications, or for life-support systems
consult Norgren.
TECHNICAL DATA
Fluid: Compressed air
Inlet pressure range: 0,7 bar to 27,6 bar (10 to
400 psig). For best performance, inlet pressure
should be at least 0,7 bar (10 psig) greater than the
desired regulated pressure, but must not exceed the
specified maximum.
Operating temperature: -20° to +80°C (0° to +175°F)
Air supply must be dry enough to avoid ice
formation at temperatures below +2°C (+35°F).
Typical flow with a conventional pilot regulator at 6,9
bar (100 psig) inlet pressure, 6,3 bar (90 psig) set
pressure, and a droop of 0,35 bar (5 psig) from
set:
1/2" ports: 57 dm 3 /s (120 scfm)
1" ports: 142 dm 3 /s (300 scfm)
Port sizes:
Main Gauge Pilot Exhaust
1/4" 1/4" 1/4" 3/4"
3/8" 3/8" 1/4" 3/4"
1/2", 3/4", 1", 1-1/4" 1/2" 1/4" 3/4"
Thread type:
Main and gauge ports: PTF, ISO G, or ISO Rc
Pilot port: PTF with PTF main ports, ISO G with
ISO G and ISO Rc main ports
Exhaust port: PTF with PTF main ports, ISO G
with ISO G and ISO Rc main ports
Materials:
Body: Zinc
Bonnet: Aluminum
Bottom plug: Acetal
Valve: Brass
Elastomers: Nitrile
REPLACEMENT ITEMS
Repair kit - items 3, 4, 5, 7, 10, 12, 13, 14, 15
1/4", 3/8" 1/2" regulators......................................4158-01
3/4", 1", 1-1/4" regulators .....................................4158-02
Elastomer kit - items 3, 5, 7, 10, 13, 14, 15
1/4", 3/8" 1/2" regulators.......................................4158-03
3/4", 1", 1-1/4" regulators .....................................4158-04
Exhaust muffler, 3/4 PTF .........................................MB006A
INSTALLATION
1. Shut off air pressure. Install regulators in air line -
● upstream of lubricators and cycling valves.
● at any angle.
● install the 11-042 pilot operated regulator as close as
possible to the device being serviced.
● install the pilot regulator at any convenient, accessible
location.
2. Use pipe thread sealant on male threads only when
making the following pipe connections. Do not allow
sealant to enter interior of regulator.
● Connect inlet and outlet air lines to 11-042 main ports.
Inlet port is marked IN.
● Connect inlet and outlet air lines to pilot regulator main
ports. The inlet port of the R40 and R41 is marked IN,
and the outlet port is marked OUT. The direction of air
flow thru the 11-104 pilot is indicated by an arrow on
the bottom of the body.
● Connect the outlet of the pilot regulator to the pilot port
in the side of the 11-042 bonnet. This is the pilot
pressure line.
3. Special Instructions for a Feedback Pilot:
Connect one end of the feedback line to the feedback
port on the pilot regulator. The feedback port on the R41
is marked FDBK. The 11-104 has two 1/8" PTF feedback
ports. Plug the unused feedback port. Connect the other
end of the feedback line to a gauge port on the 11-042
or, if maximum precision pressure regulation is desired,
to the application point downstream of the 11-042. Keep
the feedback line as short as possible and unrestricted.
Use 1/4" or 3/8 " OD copper tube for the feedback line.
Plug unused gauge ports.
Warning - Feedback Pilot Regulators
Norgren manufacturers two feedback pilot
regulator types (the R41 and the 11-104). Use the
R41, the 11-104-002, or the 11-104-003 feedback
pilot regulator to control outlet pressures greater than
100 psig (7 bar). Use the Norgren 11-104-001
feedback pilot regulator to control outlet pressures at
or less than 100 psig (7 bar).
The feedback line must sense 11-042 outlet
pressure and must be connected before turning on air
pressure. If the feedback line is not connected, 11-042
outlet pressure will rapidly increase to inlet pressure
when the feedback pilot adjusting knob is turned
clockwise.
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a subsidiary of IMI plc
IM-422.245 (7/01)
Pilot Operated Regulator
11-042 PILOT
OPERATED
REGULATOR
Feedback
Line
R41 FEEDBACK
PILOT REGULATOR
Inlet Air
Outlet
Air
Pilot
Pressure
Line
Inlet Air
11-104 FEEDBACK
PILOT REGULATOR
Feedback
Line
Pilot Pressure Line
Inlet
Air
© Norgren 2001 Figure 1. Conventional Pilot Installation Figure 2. Feedback Pilot Installation
11-042 PILOT
OPERATED
REGULATOR
R40 CONVENTIONAL
PILOT REGULATOR
Pilot
Pressure
Line
Inlet Air
Inlet Air
Outlet
Air