AirCom R120 Operating instructions

R120 Pressure regulator made of brass

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Operating Manual

1. Intended Use

Line or outlet pressure regulators- /reducer for Air, gases and liquids which is designed to effect reduction to a

downstream pressure independent of the flow rate. Not for use as a flow controller or as a shut-off valve. The

regulators from series R120 are self-contained, spring loaded pressure reducing regulators.

The general function of pressure regulators is shown in the movie link!

Movie pressure regulators

2. Information on Instructions for use

Any use of the device requires full understanding and strict observation of these instructions. The device is only to

be used for purposes specified here.

2.1. Symoble

This symbol points to special data and/or rules and prohibitions concerning damage precaution.

These instructions are important for working safety!

This symbol identifies important instructions/regulations or in case of property damage danger.

3 Safety

3.1 Safety Instructions

Do not endanger yourself and other people. Please read the following safety instructions before

performing installation, operation and maintenance of fittings. They enable to avoid dangers to

people and units. Handling of technical gases – especially flammable or toxic gases – requires

knowledge of the subject, observation of instructions for use and special safety measures. In addition, regulations

and rules must be followed as applicable. (see 3.2)

Use these units only as intended (see section “Intended Use”). The same is valid for the used gas: improper use can

cause damage of the unit or injury and even death of persons.

Use gas detection devices, if you work with dangerous gases. These products detect leakage and warn the

personnel.

Wear gas mask, protection glasses and protection gloves, if you work with toxic gases and provide good ventilation.

Make sure that venting openings are not clogged and toxic gases will be discharged in use with pressure reducer

and plants equipped with relief valves.

Some gases can cause suffocation, because they displace oxygen from air. Ensure good ventilation, if you work with

these gases. It is recommended to install detectors which give an alarm if there is a lack of oxygen at the working

place.

Oil and grease must never be used at gas control units. Oil and grease ignite easily and can intensely react with

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R120 Pressure regulator made of brass

some gases under pressure. In special cases greases can be used, which are specified for the corresponding

application.

The use of AirCom regulator for oxygen applications is permitted only with signed units.

Special safety instructions for pressure reducers.

If devices are connected with the pressure reducer ensure via separate protection equipment that no dangerous

pressure will be built up in them. The relief valve of the pressure reducer (if available) is not applicable for these

devices as protection means.

When using cylinder pressure reducers the pressure reducer connector must directly mate with the cylinder valve

connection. The use of adaptors is not permitted.

When changing the gas type the pressure reducer must be sufficiently purged with inert gas.

3.2 Regulations and Rules

The national rules and regulations concerning the handling of:

- compressed gases

- toxic gases

- flammable gases

are to be observed.

4 Installation

4.1 Transport and Packing

Please check directly after delivery the pressure reducer for any transport damages and deficiencies

The port openings of the pressure reducer are often closed via hole plugs to prevent contamination with dirty

particles. Remove plugs just before the assembly.

In case of further disassembly close the port openings again before storing or transporting. Temporarily it can be

done using a strip of adhesive tape by sticking it to the opening.

The pressure reducer (e. g. dispatch to customer service) may only be transported in an appropriate, stable packing.

4.2 Preparation

• Turn hand knob of pressure reducer counter clockwise until the range spring is complete released.

• Attach pressure reducer - make sure that connections threads are matching.

• To ensure that the regulator works properly, all lines have to be purged prior to installing the regulator. Deposits

and other foreign objects can damage the valve seat and influence the regulator’s behaviour.

Do not use any lubricants since this would contaminate the pressure reducer and, in the case that oxygen or nitrous

oxide is used, there is danger of combustion.

The regulator has to be installed in the line in such a way that the air flows in the direction of the arrows on the

housing (IN to OUT).

An internal filter is provided only to stop random contamination resulting from the installation of the regulator; an

Dok-Nr.: BA-R120 Page 2 of 4

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R120 Pressure regulator made of brass

auxiliary upstream filter is recommended for use in all but the cleanest of media. Gaseous media should be free of

excessive moisture to prevent icing of the regulator at high flow rates.

4.3 Operation

Controlled outlet pressure settings are obtained by adjusting the control knob. Rotating the knob clockwise raises the

outlet pressure while a counterclockwise rotation coupled with venting of the downstream side of the regulator

plumbing lowers the outlet pressure. Final adjustment should be made in the direction of increasing pressure to

obtain the most accurate set points. These regulators will operate with any liquid or gaseous media compatible with

the wetted materials.

Pressure regulators Series 231; 232; 233; 239 and R13 are factory setted. The range can’t be changed and range

spring can’t released.

The general function of pressure regulators is shown in the movie link!

Movie pressure regulators

Final adjustment should be made in the direction of increasing pressure to obtain the most accurate set points.

These regulators will operate with any liquid or gaseous media compatible with the wetted materials.

Satisfy yourself that the pressure reducers will only be used within their admissible limiting value (see technicla

data). Operating outside the nominal temperature range could destroy the sealings.

Warning:

By placing and locking the handknob at a corresponding position on the adjusting screw or by placing and locking

the adjusting screw at a corresponding position against the bonnet, the maximum output pressure of some regulator

types can be increased to a value considerably higher than the maximum output pressure signed on the unit. Using

a regulator with a output pressure considerably higher than the output pressure specific by the manufacturer may

have the following consequences:

• a load spring compressed nearly to solid height has a different characteristic than an elongated spring, this may

negatively affect the regulator's controlling function (the harshly compressed loadspring may prevent a

complete shutoff of the main valve, the regulator would show creep). - At the risk of their permanent

deformation

• internal regulator parts are exposed to stresses beyond their design. Damages caused by excessive back

pressure setting are excluded from warranty.

4.4 Shut-Down Actions

• Close inlet valve.

• Use up the remaining gas or drain completely.

• Turn hand knob counterclockwise until the spring is completely uncharged

5 Maintenance

Do not carry out any maintenances / repairs if the pressure reducer will be under pressure.

The maintenance and repair may only be performed by trained experts! The inspection is recommended

every 6 months if a system has a normal duty cycle. The device is checked for outside damages and function. More

frequent maintenance may be necessary when the system is used under extreme conditions.

5.2 Trouble Shooting

When performing necessary corrective action in the following operations, refer to the "Maintenance" section for the

Dok-Nr.: BA-R120 Page 3 of 4

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R120 Pressure regulator made of brass

necessary procedure.

1. Problem:

The regulated pressure continues to increase after lock up without a change in control knob position.

Possible cause: Valve seat needs replacement

2. Problem:

Leakage through or around edge of bonnet

Possible cause:

1. Torque on bonnet is insufficient. Retorque bonnet.

2. Inspect for nicks and scratches on piston / diaphragm

Replace diaphragm and/or piston (repairkit)

5.3 Spare Parts

Only original spare parts must be used for repair or overhaul. Replacement only by trained personnel!

You find the repairkits under www.aircom.net

5.4 Repairs

Faulty / damaged units can be send back to AirCom Pneumatic GmbH. After checking the unit we will send you a

cost estimate with a first diagnostic. Regulators wich were not in use with air or neutral gases have to be cleaned

before you send them back for repair. Furthermore please note the used medium and a short error discription on the

delivery note.

Dok-Nr.: BA-R120 Page 4 of 4

Created on 2018-10-30

High

pressure

4

Produktgruppe

Dimensions Regul. system K

v

- Flow Connection P

1

Pressure Order Preis

A B C D: diaphragm value rate thread max. range number

mm mm mm P: piston (m

3

/h) m

3

/h*

1

l/min*

1

G bar bar €

B

G

1

⁄8

up to G4

0.1 … 1.5 / 50 bar

Order example:

R120-01A

*

1

at max. supply pressure and max. outlet pressure

40 88 18 D 0.20 8 130 G

1

⁄8 30 0.1 … 1.5 R120-01A 89,00

D 10 160 30 0.2 … 3.0 R120-01B 89,00

D 15 250 30 0.5 … 8.0 R120-01C 89,00

D 20 330 30 1,5 … 15 R120-01E 89,00

40 88 18 D 0.20 8 130 G¼ 30 0.1 …1.5 R120-A2A 89,00

D 10 160 30 0.2 … 3.0 R120-A2B 89,00

D 15 250 30 0.5 … 8.0 R120-A2C 89,00

D 20 330 30 1,5 … 15 R120-A2E 89,00

63 140 34 D 0.35 16 260 G¼ 30 0.1 … 1.5 R120-02A 144,00

D 20 320 30 0.2 …3.0 R120-02B 144,00

D 30 500 30 0.5 …8.0 R120-02C 144,00

D 40 660 50 1,5 … 15 R120-02E 144,00

63 141 34 P 50 840 50 2,5 … 30 R120-02F 185,00

63 156 34 P 60 1 000 50 3,5 … 50 R120-02G 185,00

63 140 34 D 0.35 16 260 G

3

⁄8 30 0.1 … 1.5 R120-03A 144,00

D 20 320 30 0.2 …3.0 R120-03B 144,00

D 30 500 30 0.5 …8.0 R120-03C 144,00

D 40 660 50 1,5 … 15 R120-03E 144,00

63 141 34 P 50 840 50 2,5 … 30 R120-03F 185,00

63 156 34 P 60 1 000 50 3,5 … 50 R120-03G 185,00

Brass pressure regulator R120

for compressed air, supply pressure max. 30 / 50 bar,

relieving, without pressure gauge

Brass Pressure Regulator up to 50 bar R120

Gauges: see chapter for measuring devices

Special options and Accessories, see separate page

R120-01/-A2 R120-02/-03

R120-01/-A2

accessory: gauge

R120-02/-03

accessory: gauge

4.04

Description Pressure regulator of solid design. Made of brass or bronze. Series R120-0.A to -0.E and

R120-16 and -32 are equipped with diaphragms, all other are piston-operated.

Media

compressed air, non-corrosive gases or liquids

Supply pressure

see chart, max. 50 bar, for liquids Δpmax. = 25 bar

Adjustment R120-01/-A2: with adjusting screw, at R120-02 with black knob

R120-04 to -B6: with T-handle R120-16: with hexangonal spindel (spanner size 24 mm)

R120-16/-24/-32: by pilot pressure regulator

Relieving function R120-B6: relieving R120-16/-24/-32: non-relieving

Gauge port R120-01/-A2:

G

1

⁄8

on both sides of the body, all others G¼ on both sides of the body,

one screw plug supplied Mounting position any

Temperature range

0 °C bis 80 °C / 32 °F to 176 °F, for appropriately conditioned compressed air down to -20 °C / -4 °F

or low temperature version down to -40 °C / -40 °F, optionally high temperature version up to 130 °C / 266 °F

Material Body: brass at R120-02 to -04, bronze at R120-06 to -16, aluminium at R120-24/-32

O-ring: FKM, optionally EPDM

Spring cage: brass at R120-01 to -04, aluminum at R120-06 to -32

Inner valve: brass

Diaphragm: NBR/Buna-N with PTFE coating

High

pressure

4

Produktgruppe

B

Order example:

R120-04A

*

1

at max. supply pressure and max. outlet pressure

Brass Pressure Regulator up to 50 bar R120

Gauges: see chapter for measuring devices

78 163 37 D 1.0 27 450 G½ 30 0.1 …1.5 R120-04A 185,00

D 30 600 30 0.2 …3.0 R120-04B 185,00

D 40 830 30 0.5 …8.0 R120-04C 185,00

D 60 1 250 50 1,5 … 15 R120-04E 185,00

78 159 37 P 100 2 080 50 2,5 … 30 R120-04F 255,00

P 120 2 500 50 3,5 … 50 R120-04G 255,00

118 291 66 D 5.5 75 1 250 G¾ 30 0.1 … 1.5 R120-06A 440,00

D 98 1 600 30 0.2 … 3.0 R120-06B 440,00

D 170 2 800 30 0.5 … 8.0 R120-06C 440,00

D 280 4 600 50 1,5 … 15 R120-06E 440,00

118 316 66 P 400 6 600 50 2,5 … 30 R120-06F 660,00

P 500 8 300 50 3,5 … 50 R120-06G 660,00

118 291 66 D 5.5 75 1 250 G1 30 0.1 … 1.5 R120-08A 440,00

D 98 1 600 30 0.2 … 3.0 R120-08B 440,00

D 170 2 800 30 0.5 … 8.0 R120-08C 440,00

D 280 4 600 50 1,5 …

15 R120-08E 440,00

118 316 66 P 400 6 600 50 2,5 … 30 R120-08F 660,00

P 500 8 300 50 3,5 … 50 R120-08G 660,00

R120-06/-08

R120-08

accessory: gauge

Special options and Accessories, see separate page

R120-04

accessory: gauge

R120-04

4.05

Description Pressure regulator of solid design. Made of brass or bronze. Series R120-0.A to -0.E and

R120-16 and -32 are equipped with diaphragms, all other are piston-operated.

Media

compressed air, non-corrosive gases or liquids

Supply pressure

see chart, max. 50 bar, for liquids Δpmax. = 25 bar

Adjustment R120-01/-A2: with adjusting screw, at R120-02 with black knob

R120-04 to -B6: with T-handle R120-16: with hexangonal spindel (spanner size 24 mm)

R120-16/-24/-32: by pilot pressure regulator

Relieving function R120-B6: relieving R120-16/-24/-32: non-relieving

Gauge port R120-01/-A2:

G

1

⁄8

on both sides of the body, all others G¼ on both sides of the body,

one screw plug supplied Mounting position any

Temperature range

0 °C bis 80 °C / 32 °F to 176 °F, for appropriately conditioned compressed air down to -20 °C / -4 °F

or low temperature version down to -40 °C / -40 °F, optionally high temperature version up to 130 °C / 266 °F

Material Body: brass at R120-02 to -04, bronze at R120-06 to -16, aluminium at R120-24/-32

O-ring: FKM, optionally EPDM

Spring cage: brass at R120-01 to -04, aluminum at R120-06 to -32

Inner valve: brass

Diaphragm: NBR/Buna-N with PTFE coating

G

1

⁄8

up to G4

0.1 … 1.5 / 50 bar

Dimensions Regul. system K

v

- Flow Connection P

1

Pressure Order Preis

A B C D: diaphragm value rate thread max. range number

mm mm mm P: piston (m

3

/h) m

3

/h*

1

l/min*

1

G bar bar €

B

Brass pressure regulator R120

for compressed air, supply pressure max. 30 / 50 bar,

relieving, without pressure gauge

High

pressure

4

Produktgruppe

B

Order example:

R120-12A

*

1

at max. supply pressure and max. outlet pressure

Brass Pressure Regulator up to 50 bar R120

Gauges: see chapter for measuring devices

180 387 128 P 12.6 400 6 600 G1½ 30 0.1 … 1.5 R120-12A 1.550,00

P 670 11 000 30 0.2 … 3.0 R120-12B 1.550,00

P 1 000 16 600 30 0.5 … 8.0 R120-12C 1.550,00

P 1 500 25 000 50 1,3 … 15 R120-12E 1.550,00

180 402 128 P 1 600 27 000 50 2,3 … 30 R120-12F 1.850,00

P 2 000 33 000 50 3,3 … 50 R120-12G 1.850,00

180 387 128 P 12.6 400 6 600 G2 30 0.1 … 1.5 R120-B6A 1.550,00

P 670 11 000 30 0.2 … 3.0 R120-B6B 1.550,00

P 1 000 16 600 30 0.5 … 8.0 R120-B6C 1.550,00

P 1 500 25 000 50 1,3 … 15 R120-B6E 1.550,00

180 402 128 P 1 600 27 000 50 2,3 … 30 R120-B6F 1.850,00

P 2 000 33 000 50 3,3 … 50 R120-B6G 1.850,00

180 425 128 D 26 1 800 30 000 G2 30 0.1 … 1.5 R120-16AK 2.730,00

D 2 500 40 000 30 0.3 … 6.0 R120-16CK 2.730,00

180 379 128 D 3 500 50 000 30 1,3 … 15 R120-16DK 2.730,00

389 463 118 D 70 2 400 40 000 flange 30 0.1 … 1.5

R120-24AKF

6.500,00

D 5 000 83 000 DN80 30 0.3 … 6.0

R120-24CKF

6.500,00

D 6 000 99 000 30 1,3 … 15

R120-24DKF

6.500,00

389 463 118 D 70 2 400 40 000 flange 30 0.1 … 1.5

R120-32AKF

6.500,00

D 5 000 83 000 DN100 30 0.3 … 6.0

R120-32CKF

6.500,00

D 6 000 99 000 30 1,3 … 15

R120-32DKF

6.500,00

R120-12/-B6 R120-16

R120-12/-B6

accessory: gauge

R120-16

accessory: gauge

R120-24/-32

Special options and Accessories, see separate page

4.06

Description Pressure regulator of solid design. Made of brass or bronze. Series R120-0.A to -0.E and

R120-16 and -32 are equipped with diaphragms, all other are piston-operated.

Media

compressed air, non-corrosive gases or liquids

Supply pressure

see chart, max. 50 bar, for liquids Δpmax. = 25 bar

Adjustment R120-01/-A2: with adjusting screw, at R120-02 with black knob

R120-04 to -B6: with T-handle R120-16: with hexangonal spindel (spanner size 24 mm)

R120-16/-24/-32: by pilot pressure regulator

Relieving function R120-B6: relieving R120-16/-24/-32: non-relieving

Gauge port R120-01/-A2:

G

1

⁄8

on both sides of the body, all others G¼ on both sides of the body,

one screw plug supplied Mounting position any

Temperature range

0 °C bis 80 °C / 32 °F to 176 °F, for appropriately conditioned compressed air down to -20 °C / -4 °F

or low temperature version down to -40 °C / -40 °F, optionally high temperature version up to 130 °C / 266 °F

Material Body: brass at R120-02 to -04, bronze at R120-06 to -16, aluminium at R120-24/-32

O-ring: FKM, optionally EPDM

Spring cage: brass at R120-01 to -04, aluminum at R120-06 to -32

Inner valve: brass

Diaphragm: NBR/Buna-N with PTFE coating

G

1

⁄8

up to G4

0.1 … 1.5 / 50 bar

Dimensions Regul. system K

v

- Flow Connection P

1

Pressure Order Preis

A B C D: diaphragm value rate thread max. range number

mm mm mm P: piston (m

3

/h) m

3

/h*

1

l/min*

1

G bar bar €

B

Brass pressure regulator R120

for compressed air, supply pressure max. 30 / 50 bar,

relieving, without pressure gauge

High

pressure

4

Produktgruppe

B

Gauges: see chapter for measuring devices

Order example:

MA4001-02

Brass Pressure Regulator up to 50 bar R120

NPT connection thread R120-. . . N +10,00

non-relieving

withour relieving function up to R120-B6 R120- . . . K + 5%

down to - 40 °C low temperature version up to R120-04 R120-. . .

X51

+ 30%

up to 130 °C high temperature version up to R120-04 R120-. . .

X54

+ 30%

EPDM o-ring PTFE diaphragm R120- . . . E + 10%

T-handle instead of plastic knob for R120-02 R120-02 . T +10,00

PWIS-free for painting plants R120- . . . LA

auf Anfr.

carbon dioxide

CO

2

R120- . . . K03+ 15%

argon

Ar

R120- . . . K05+ 15%

nitrogen

N

2

R120- . . . K07+ 5%

helium

He

R120- . . . K09+ 15%

hydrogen

H

2

R120- . . . K11+ 15%

methane

CH

4

R120- . . . K13

+ 15%

natural gas

*

3

R120- . . . K14

+ 15%

oxygen

O

2

R120- . . . K15

+ 15%

propane

C

3

H

6

R120- . . . K16

+ 15%

nitrous oxide

N

2

O

R120- . . . K17

+ 15%

water

H

2

O

R120- . . . K

W

+ 15%

flange connection

standard for R120-32, otherwise see chapter SST devices /flanges

R120- . . . F.

s. Kap.15

Special options, add the appropriate letter

*

1

at max. supply pressure and max. outlet pressure

*

2

02 = 0…2.5 bar, 04 = 0…4 bar, 06 = 0…6 bar, 10 = 0…10 bar, 16 = 0…16 bar

*

3

without DVGW approval

BW35-01S

43

53

9

6

16

BW50-01S

43

53

16

9

6

BW00-43

92

38

7

86

8

BW00-42

104

7

73

31

R4,5

4.07

pressure gauge Ø 40 mm, 0 …*

2

bar, G

1

⁄8 for G

1

⁄8 and G¼ (A2) MA4001- . . *

2

9,50

Ø 50 mm, 0 …*

2

bar, G¼ for G¼ (02) and G½ MA5002- . . *

2

9,50

Ø 50 mm, 0 …60 bar, G¼ for G¼ and

G½ MA5002-60 20,00

Ø 63 mm, 0 …*

2

bar, G¼ for G¾ up to

G4 MA6302- . . *

2

10,50

Ø 63 mm, 0 …60 bar, G¼ for G¾ up to

G4 MA6302-60 20,00

gauge up to 130 °C Ø 63 mm, 0 …*

2

bar, G¼ , stainless steel MS6302-..*

2

89,00

mounting bracket made of stainless steel for G¼ BW35-01S 30,00

mounting nut made of stainless steel for G¼ M35x1,5S 27,00

mounting bracket made of stainless steel for G½ BW50-01S 37,00

mounting nut made of stainless steel for G½ M50x1,5S 30,00

mounting bracket made of steel for G¾ and

G1 BW00-42 20,00

for G1½

and

G2 (B6) BW00-43 55,00

Accessories

C

Description Pressure regulator of solid design. Made of brass or bronze. Series R120-0.A to -0.E and

R120-16 and -32 are equipped with diaphragms, all other are piston-operated.

Media

compressed air, non-corrosive gases or liquids

Supply pressure

see chart, max. 50 bar, for liquids Δpmax. = 25 bar

Adjustment R120-01/-A2: with adjusting screw, at R120-02 with black knob

R120-04 to -B6: with T-handle R120-16: with hexangonal spindel (spanner size 24 mm)

R120-16/-24/-32: by pilot pressure regulator

Relieving function R120-B6: relieving R120-16/-24/-32: non-relieving

Gauge port R120-01/-A2:

G

1

⁄8

on both sides of the body, all others G¼ on both sides of the body,

one screw plug supplied Mounting position any

Temperature range

0 °C bis 80 °C / 32 °F to 176 °F, for appropriately conditioned compressed air down to -20 °C / -4 °F

or low temperature version down to -40 °C / -40 °F, optionally high temperature version up to 130 °C / 266 °F

Material Body: brass at R120-02 to -04, bronze at R120-06 to -16, aluminium at R120-24/-32

O-ring: FKM, optionally EPDM

Spring cage: brass at R120-01 to -04, aluminum at R120-06 to -32

Inner valve: brass

Diaphragm: NBR/Buna-N with PTFE coating

G

1

⁄8

up to G4

0.1 … 1.5 / 50 bar

Dimensions Regul. system K

v

- Flow Connection P

1

Pressure Order Preis

A B C D: diaphragm value rate thread max. range number

mm mm mm P: piston (m

3

/h) m

3

/h*

1

l/min*

1

G bar bar €

B

AirCom R120 Operating instructions

AirCom R120 Operating instructions

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