PRESSURE REGULATOR SERIES R 4100 R 2100 R 5100 VIRTUAL CATALOGUE FAIL TO OPEN REGULATOR BALANCED VALVE HIGH FLOW COEFFICIENT

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1 VIRTUAL CATALOGUE FAIL TO OPEN REGULATOR BALANCED VALVE HIGH FLOW COEFFICIENT PRESSURE REGULATOR WIDE PRESSURE-REGULATION RANGE CAN BE SUPPLIED WITH MINIMUM / MAXIMUM PRESSURE SLAM-SHUT VALVE R 4100 POSSIBILITY OF ESCAPE VALVE HIGH PRECISION REGULATION SIMPLE MAINTENANCE; NO NEED TO REMOVE FROM GAS LINE R 2100 SHLAM SHUT VALVE CAN BE INCORPORATED WITHOUT DISSEMBLING FROM GAS LINE R2100 CONNECTIONS 1" y DN25 R4100 CONNECTIONS 1.1/2" y DN40 R5100 CONNECTIONS 2" y DN50 R 5100 SERIES

2 Use Due to their characteristics, the regulators of series R2100 / R4100 / 5100 are used with optimum results in industrial facilities where a fast response is required for quick changes in flow. They can work with natural or manufactured gas, propane, air and other gases that do not contain a high percentage of benzol. Construction characteristics The regulators of series R2100 / R4100 are direct acting, with regulation by spring and balanced valve. This series of regulators has been designed with easy, practical maintenance in mind and any element can be substituted without having to remove the regulator from the gas line. The products are equipped with an anti-pump device in order to slow up the flow and backflow of gas and air in the regulation head. Control operations Movement in the membrane or diaphragm (d) via the lever (p) and shaft (e) is transmitted to the balanced valve (o). The outlet pressure from the internal port is transfered to the chamber (c) and increases the force on the membrane (d); this is countered by the decreasing force exercised by the calibration spring (m). The increase in outlet gas pressure in the chamber (c) pushes the membrane (d) and gradually closes off the flow of gas by means of the plug (o). The force exercised by the calibration spring (m) gradually opens the gas flow. The balance between these two forces results in the different flows having a constant exit pressure. Each variation in flow will tend to increase or decrease the pressure at the outlet, so that the moving system will look for a new balanced position in order to keep the gas pressure at the pre-established setting. Thanks to its balanced valve, a constant outlet pressure can be obtained in spite of variations in entry pressure, provided these variations are within the outlet margins of the regulator. Versions Entry Exit Shlam-shut Valve R2100 1" 1" no R2100/S 1" 1" yes R /2" 1.1/2" no R4100/S 1.1/2" 1.1/2" yes R5000 2" 2" R5100/S 2" 2" Exit Pressure Range Ps (mbar) R R R5100 Setting up the regulator c r m d p e o To set up the regulator, create a small consumption by slightly opening the exit valve or a purge valve. Then slowly open the entry valve until it is fully open. Check that the regulator stabilises itself and then slowly open the exit valve until it's fully open. To ensure the regulator operates effectively and has a long service life, the gas reaching the regulator should be perfectly filtered and dry. If the regulator has an incorporated safety shut-off valve: Open the entry valve fully but carefully. Slightly turn the lever connected to the release shaft to open the safety valve's internal by-pass. Check that the exit pressure increases then stabilises at a level close to that of the regulation level, then you will notice that the resistance in the release shaft lever disappears and you can continue turning until it is totally reset. Then slowly open the exit valve until it is fully open.

3 Adjusting the regulator To increase outlet pressure, the dial (r) should be turned clockwise, compressing the calibration spring (m) until the desired pressure is reached, which should be checked by means of a manometer installed at the outlet zone. To decrease the pressure, the above-mentioned dial (r) should be turned anti-clockwise. APQ supplies the regulator with the settings requested by the client and these values are indicated on both the regulator label and the quality certificate. Safety valve The regulators of the series R2100 / R4100 / R5100 can be supplied with a minimum and/or maximum pressure safety valve, in this case being known as R2100/S, R4100/S or R5100/S. The function of this valve is to cut off the gas flow when the regulator exit pressure doesn't reach or exceeds the pre-adjusted minimum or maximum pressure values. It contains a by-pass for resetting the safety valve without effort, even in the case of high entry pressure. The safety valve acts totally independently of the regulation parts and can be actuated at minimum pressure, maximum pressure or both. Safety valve operations o 1 The outlet pressure from the external port arrives at the chamber (c1) and exercises a force on the membrane or diaphragm (d1), gradually moving it. This membrane also undergoes a counterforce exercised by the minimum (m1) and maximum (m2) calibration springs. Under these balanced conditions, the spheres (e1) hold the shaft (f1) with the lock-up plug (o1) mounted at one end. An increase or decrease in exit pressure exceeding the value tolerated by the moving parts makes the spheres move (e1), releasing the shaft (f1) and blocking the flow of gas by means of the plug (o1). The safety valve external port must be 5 diameters from the threaded outlet connection. Safety adjustment limits Actuation pressure in mbar By minimum By maximum S-BP S-MP S-AP c 1 r 2 r 1 e 1 d1 m 2 m 1 f 1 Reset of the safety valve t 1 To reset the safety valve, the lock lever must be turned slowly; then verify that the gas is passing through the regulator and check that the exit pressure slowly increases and then reaches the regulation pressure, after stabilising. Continue turning the lever until it stops and locks. Setting the safety valve The safety valve is adjusted at the factory at the value indicated on the label of the valve itself and on the quality certificate. Should you wish to modify the value of the safety maximum or minimum, proceed as described below: Remove the plastic protective cover (t1) - if the safety valve has a minimum setting, you should always start with this setting. Turn the minimum dial (r1) clockwise to increase the minimum value and anti-clockwise to reduce it. If you wish to cancel the minimum, simply remove the minimum spring. To set the safety maximum, turn the dial (r2) clockwise to increase the value and anti-clockwise to reduce it. To cancel the safety maximum, turn the dial (r2) clockwise to a value where actuation would be illogical. Replace the plastic protective cover (t1).

4 TECHNICAL CHARACTERISTICS Body design pressure 20 bar Servo. design pressure 8 bar Maximum entry pressure 6 bar Maximum exit pressure 300 mbar Minimum exit pressure 10 mbar Regulation accuracy RG 5 Closure overpressure SG 10 Connections R2100 1" / 1" Connections R /2" / 1.1/2" Connections R5100 2" / 2" Operational temperature -10º 50 ºC MATERIALS Regulator body Servomotor body Balanced valve Valve seat Membranes Joints Regulation shaft Block valve cover Shaft Spheroid cast iron Injected aluminium Vulcanised brass Brass Woven nitrile Nitrile Steel Injected aluminium Steel R R 4100 R 2100/S - R 4100/S R R 4100 con bridas R 5100 R 5100/S con bridas DIMENSIONS Regulator Connection Entry/Exit R 5100/S A B C D E F G I J K L Seat Ø Ø Ø Ø Weight R " BSP /4"G ,0 kg R 2100/S 1"BSP /4"G ,2 kg R /2" BSP /4"G ,2 kg R 4100/S 1.1/2" BSP /4"G ,0 kg R " BSP ,7 kg R 5100/S 2" BSP ,2 kg The measurements are in mm C = Distance required from pipe axis to change regulation springs E = Distance required from pipe axis to change safety springs Flow conversion For other gases, the flow must be converted to natural gas, in accordance with the following formula: Nm 3 /h natural gas = Nm 3 /h gas to be converted / factor f of gas to be converted Conversion factor f Butane 0.55 Methane 1.08 Propane 0.64 City gas 1.23 Bio gas 0.85 Oxygen 0.76 Air 0.80 Nitrogen 0.81 Carbon Monoxide 0.81 Hydrogen 3.04 Choice of regulator The regulator must be chosen in accordance with the flow required, taking into account the desired flow, the necessary exit pressure and the entry pressure. For regulators used in on-off installations, it is good practice to calculate the regulator with an extra margin of 10%. To maintain the RG 5, do not exceed 85% of the value of the maximum flow calculated.

5 INSTALLATION a) Install in a gas line that is sufficiently strong to bear the weight of the regulation unit. b) Ensure that there is a cut-off valve, a manometer with the suitable range and filter at the entry point. c) Ensure that there is a manometer with the suitable range, a 1/4" port and cut-off valve at the exit point. d) Install the regulator following the flow indicated on the regulator body. e) Verify that the safety valve port is at least 5 diameters from the threaded outlet connection. f) Verify that the gas entry speed and especially exit speed do not exceed that requested or recommended by the gas company. In no case should the speed exceed 40 m/sec. g) In fast switch-off installations with on-off electro valves, the exit lung capacity must be the correct size and at least 0.2% of the flow in Nm 3 /h. h) Ensure that the pipe has been cleaned of earth, sand, solder remains, etc. 5xDNs 5xDNs DNe DNs DNe DNs PORTS GOOD GOOD BAD The data contained in this catalogue may be modified without prior notice to ensure the ongoing improvement of the product. Ctra. de Ripollet 51, Polígono Foinvasa Montcada i Reixac (Barcelona) Spain Tel: Fax: apq@apq.cc -