Wilkerson Dial-Air Regulator - Manual

You
have selected a quality product, and
we appreciate it… To be assured of maximum
performance and satisfaction please read these
instructions before installing this product.
IMPoRTANT INSTALLATIoN INSTRuCTIoNS
FoR DIAL-AIR™ REGuLAToRS
1.
Do NoT install the unit until you have read
this entire product information sheet.
2. EXCEPT as otherwise specified by
manufacturer, this product is specifically
designed for compressed air service, and
use with any other fluid (liquid or gas) is a
misapplication. For example, use with or
injection of certain hazardous liquids or gases
in the system (such as alcohol or liquid
petroleum gas) could be harmful to unit or
result in a combustible condition or hazardous
external leakage. Manufacturer’s warranties
are void in the event of misapplication and
manufacturer assumes no responsibility for
any resulting loss. Maximum pressure rating
is 300 psig (21 bar). Temperature range is
32°F to 150°F (0°C to 65.5°C).
3. INSTALL upstream of and as close as
possible to where regulated air is needed.
4. INSTALL with air flow in direction of arrow on
casting.
5. Do NoT restrict the air flow with undersize
piping or fittings, unless maximum air flow is
not needed.
6. INSTALL regulator in any rotational position.
7. GAuGE PoRTS may be used for installing
gauge or they may be used as additional
regulated air outlet ports. Plug all unused ports.
8. PANEL MouNTING requires a 2 11/16" (69
mm) diameter hole, and 4 7/32" (5.5 mm)
screw holes. Unit can be mounted on material
up to 1 1/4" (32 mm) thick.
9. INSTALLATIoN of a 5-micron rated filter
upstream of regulator is recommended.
10. To REGuLATE AIR turn adjustment knob
clockwise to raise the regulated air pressure
and counterclockwise to lower the regulated
air pressure.
IMPoRTANT MAINTENANCE INSTRuCTIoNS
FoR DIAL-AIR™ REGuLAToRS
1.
BEFoRE SERVICING THIS uNIT, READ
THIS ENTIRE PRoDuCT INFoRMATIoN
SHEET AND TuRN oFF AIR SuPPLY AND
VENT BoTH SIDES oF REGuLAToR.
LuBRICATIoN oF DIAL-AIR™ REGuLAToRS
1.
FoR TRouBLE-FREE oPERATIoN, proper
lubrication of the Dial-Air™ regulator is
essential.
2. WHEN ANY of the following symptoms
occur, lubricate regulator with CHRISTO-
LUBE
® MCG 111. (See note) If CHRISTO-
LUBE ® MCG 111 is not available, use
MAGNALUBE ® -G , Lubriplate, or Molykote ® .
NoTE: Never use oil as a lubricant.
A. Excessive relief venting.
B. Inability to attain high secondary pressure.
C. Erratic secondary pressures.
D. Excessive hysteresis (a retardation of
desired effect: in this case because of the
lack of lubrication).
3. Refer to “Figure A” for steps 1 thru 10.
1. Remove bottom plug (1), main valve
spring (2), main valve (3), pilot valve
spring (4), and pilot valve (5).
2. Clean main valve molded rubber seat (Do
not lubricate).
3. Clean and lubricate bottom plug seal,
main valve seal and pilot valve seal.
4. Reassemble unit.
5. If problem is not remedied, lubricate
remaining seals. (See steps 6 thru 10)
6. Remove retaining ring (6) and pull bonnet
assembly (7) from unit.
7. Remove upper piston (8), upper piston
cup (9), lower piston (10), needle valve
(11), and needle valve spring (12).
8. Clean and lightly lubricate inside of body.
9. Clean and lubricate upper piston seal,
upper piston cup seal, lower piston seal,
needle valve seal and main valve slide
seal (13).
10. Reassemble unit. If symptoms still exist,
contact manufacturer.
RECALIBRATIoN oF DIAL-AIR™
REGuLAToRS
1.
Do NoT ATTEMPT To CALIBRATE uNIT
uNTIL ALL EIGHT SEALS HAVE BEEN
PRoPERLY LuBRICATED.
2. To RECALIBRATE Dial-Air™ REGuLAToR:
A.
INSTALL regulator on air line with at least
110 psig (7,5 bar) air pressure at the inlet
port.
B. INSTALL an air pressure gauge to one
of the gauge ports. Plug remaining gauge
port with plug (supplied).
C. REMoVE lock button (Figure A, Item 14)
from unit.
D. TuRN adjusting knob to 100 psi (7 bar)
setting.
E. CHECK the gauge for 100 psig (7 bar)
reading. If gauge reads other than 100
psig (7 bar) adjust screw “A” (Fig. B) with
a screwdriver while holding adjusting knob
on 100 psi (7 bar) setting. If more than
one-half turn of screw “A” is required to
achieve 100 psig (7 bar), see “G” below.
F. To CHECK CALIBRATIoN ADJuSTMENT:
when dial and gauge are reading the
same (100 psig ± 2 psig; 7 bar ± 0,14
bar), turn adjusting knob to 20 psi (1,4
bar). Unit is calibrated when gauge reads
20 psig ± 5 psig (1,4 bar ± 0,34). (The ± 2
psig and ± 5 psig are accepted tolerances
of the most commonly used gauges.)
G. Do NoT adjust screw “A” more than one-
half turn when calibrating unit. If unit has
been properly lubricated and more than
one-half turn is required to calibrate it,
additional problems with unit are involved
and unit should be returned to the vendor.
ENGLISH
WARNING ! !
Product rupture can cause serious injury.
Do not connect regulator to bottled gas.
Do not exceed maximum primary pressure rating.
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 ! !
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.
Safety Guide
For more complete information on recommended
application guidelines, see the Safety Guide
section of Pneumatic Division catalogs or you can
download the
Pneumatic Division Safety Guide
at: www.wilkersoncorp.com
Installation & Service Instructions
83-528-000
Dial-Air™ Regulators
ISSuED: May, 2012
Supersedes: March, 2011
Doc. #83528000, EN# 120233, Rev. 6
Richland, MI 49083 Tel: (269) 629-5000