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Elster J125, Commissioning Instructions, Page: 18 / 24

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Elster J125 Commissioning Instructions Download Page 18

 

18 

J125B: Maintenance Instructions 

Regulator Body 

Drawing Reference:  Figs. 14, 15 & 16 

 

NOTE:  Numbers in brackets identify items on drawings  

 

 

Regulator Dismantling Procedure. 

1.

 

Check external surfaces for excessive corrosion. 

2.

 

Disconnect diaphragm case assembly from regulator body (38) by removing the three grub screws (16), 
gently pull out the case from the regulator body (38). 

3.

 

Disconnect the safety shut-off unit assembly, or blanking plate (42), from the regulator body (38) by removing 
the four cap screws (43) or (48). 

4.

 

Remove valve seat (39) assembly from the regulator body (38). 

5.

 

Remove bonded seal (94) or gasket (45) from valve seat (39) assembly. Note: the old design valve seat 
assembly with gasket (45) was glued into body (38). 

6.

 

Wipe clean the valve seat (39) assembly, check for any damage and take note of whether bonded seal (94) 
or aluminium gasket (45) is fitted to the valve seat. 

7.

 

Check that the impulse tube (40) is clear. DO NOT REMOVE TUBE FROM BODY. 

 

Regulator Rebuilding Procedure

. 

 

NOTE: Inspect all sealing "O" rings, and replace where necessary 

 

(a soft spares kit is available for this purpose, see page 17). 

 

The use of Molykote 111 "O" ring lubricant is recommended during the rebuild- unless for use with oxygen 
when no lubricant should be used. 

1.

 

If, when the valve seat (39) assembly was dismantled, the bonded seal (94) was fitted, then replace with a 
new bonded seal (94). DO NOT USE ALUMINIUM GASKET (45). 

2.

 

If, when the valve seat (39) assembly was dismantled, the aluminium gasket (45) was fitted, then replace 
with new aluminium gasket (45). DO NOT USE WITH BONDED SEAL (94).  

Note: The bonded seal (94) and 

aluminium gasket (94) CANNOT be interchanged with each other, due to valve seat (39) being a different 
length and this may affect unit performance and safety.  

3.

 

Refit valve seat (39) assembly into regulator body (38) by screwing it in until metal contact is made. 

4.

 

Fit new "O" ring (46) onto diaphragm case assembly and apply "O" ring lubricant. 

5.

 

Insert diaphragm case assembly into regulator body (38) being careful not to damage the "O" ring, secure in 
place with three grub screws (16). 

6.

 

Replace "O" rings (41) and (44) into regulator (38) making sure the contact surfaces are clean and the "O" 
rings are lubricated. 

7.

 

Locate and secure the safety shut-off assembly, or blanking plate (42), in place using four cap screws (43) or 
(48). 

8.

 

Test unit for gas tightness.

 

9.

 

Commission unit as described on pages 2 - 6.

 

Summary of Contents for J125

Page 1: ...J125B Service Regulator Inlet Pressure up to 8 6 bar Commissioning Instructions General Arrangements Parts Lists Maintenance Instructions For J125 MKII Regulator with balanced valve 1 2 and 50mm size ...

Page 2: ...cap screws evenly See Fig 2 9 For units with no OPSS fitted it is advised that a slam shut device is fitted to protect downstream equipment INSTALLATION OF VENT LINE 1 Remove clip and vent screen from regulator top cover 2 Connect the vent line 2 using a jointing compound approved to national standards and lead to atmosphere in accordance with national standards Ensure that no water can penetrate ...

Page 3: ...fitted insert a pozidriv screw driver No 2 point into UPSS adjusting screw in bottom spring holder See Fig 8 9 Turn anticlockwise to reduce loading on UPSS spring making sure screw head does not protrude from the bottom spring holder 10 Slowly open inlet valve s 11 If safety device fitted re cock by unscrewing reset spindle end cap and pulling firmly Hold in this position until the outlet pipework...

Page 4: ...w clockwise until UPSS device trips off See Fig 8 24 Slowly open inlet valve to regain inlet pressure up to approximately 140mbar 2 PSI then close inlet valve 25 Re cock UPSS device by unscrewing reset spindle end cap and firmly pull Hold in this position until the outlet pipework is fully pressurised then release reset spindle end cap gently Re screw reset spindle end cap into body See Fig 9 26 S...

Page 5: ... FITTED A OPSS spring 38 Remove top cap from the safety shut off device cover 39 Choose an OPSS spring from the catalogue or page 17 that will give the required pressure range 40 Fully unscrew and remove top spring holder See Fig 12 41 Remove spring and replace with new one See Fig 10 42 Screw spring holder back in place ensuring that castellated spigot is uppermost in chimney See Fig 12 43 Adjust...

Page 6: ...n bottom of cover ensuring not to disturb UPSS spring and UPSS spring holder 53 Replace OPSS spring or spacer tube if UPSS only 54 Screw top spring holder back in place ensuring that castellated spigot is uppermost in chimney See Fig 11 If UPSS only ensure that spacer tube is firmly clamped 55 Adjust the trip off pressure as described previously 56 Replace the top cap seal if necessary NOTE UPSS p...

Page 7: ...B General Arrangement S1 S2 S3 Assembly Fig 14 S1 VERSION NO RELIEF VALVE S3 VERSION LIMITED RELIEF VALVE DIAPHRAGM CASE ASSEMBLY SEE FIG 17 S2 VERSION FULL CAPACITY RELIEF VALVE 41 38 39 40 42 44 46 16 94 43 ...

Page 8: ...nt S4 S5 S10 Assembly Fig 15 DIAPHRAGM CASE ASSEMBLY SEE FIG 17 S4 VERSION FULL CAPACITY RELIEF VALVE 41 38 39 40 44 46 16 94 S10 VERSION NO RELIEF VALVE S5 VERSION LIMITED RELIEF VALVE OPSS SAFETY SHUT OFF ASSEMBLY SEE FIG 18 ...

Page 9: ... Fig 16 DIAPHRAGM CASE ASSEMBLY SEE FIG 17 S8 VERSION FULL CAPACITY RELIEF VALVE 41 38 39 40 44 46 16 94 S11 S12 VERSION NO RELIEF VALVE S7 S9 VERSION LIMITED RELIEF VALVE OPSS UPSS SAFETY SHUT OFF ASSEMBLY SEE FIG 19 S6 S7 S11 VERSIONS UPSS ONLY SEE FIG 20 ...

Page 10: ...y Fig 17 S1 S10 S11 S12 VERSIONS NO RELIEF VALVE S3 S5 S7 S9 VERSIONS LIMITED RELIEF VALVE 33 34 35 36 11 95 35 36 37 S2 S4 S6 S8 VERSIONS FULL RELIEF VALVE 13 97 10 96 15 12 14 45 7 8 9 95 6 5 4 3 2 1 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 16 17 ...

Page 11: ...t Off Assembly Fig 18 83 82 81 80 79 65 50 87 86 85 78 84 47 61 62 63 64 65 66 67 68 69 71 77 72 76 75 74 65 73 72 70 88 49 89 90 91 TOP COVER TO BODY FIXING OPSS BODY TO ADAPTOR PLATE FIXING ENLARGED VIEW OF VALVE DISC 52 53 54 55 57 58 92 60 48 ...

Page 12: ... Off Assembly Fig 19 83 82 81 80 79 65 50 87 86 85 78 84 47 61 62 63 64 65 66 67 68 69 71 77 72 76 75 74 65 73 72 70 88 49 89 90 91 TOP COVER TO BODY FIXING OPSS BODY TO ADAPTOR PLATE FIXING ENLARGED VIEW OF VALVE DISC 51 52 53 54 55 56 57 58 59 60 48 ...

Page 13: ...ff Assembly Fig 20 83 82 81 80 79 65 50 87 86 85 78 84 47 61 62 63 64 65 66 67 68 69 71 77 72 76 75 74 65 73 72 70 88 49 89 90 91 TOP COVER TO BODY FIXING OPSS BODY TO ADAPTOR PLATE FIXING ENLARGED VIEW OF VALVE DISC 48 51 52 53 54 55 56 93 58 59 60 ...

Page 14: ...2509 121 Ï 1 16 SOCKET GRUB SCREW JSA1012S0NSS 3 17 REGULATOR DIAPHRAGM CASE J12509 123 if tapped 1 18 PLUG C Sunk Recess BSP Galvanised JMFP2G04 if fitted 1 PLUG C Sunk Recess NPT Galvanised I11970P031 if fitted 1 19 LEVER ASSEMBLY I72626G001 1 20 DIAPHRAGM STEM I72629P005 1 21 HEXAGON NUT JNA8FZD 12 22 SCREW HEX HEAD JSA825HHNZG 12 23 DIAPHRAGM Full Relief J12509 116 Ï 1 24 DIAPHRAGM PLATE Full ...

Page 15: ... JOBS338 Ï 1 47 ADAPTOR PLATE USSA J12509 082Z02 1 48 SCREW Adaptor Plate Regulator Body JSA620SANSS 4 49 SCREW OPSS Body Adaptor Plate JSA516SANSS 4 50 SCREW Shut off Diaphragm JSA412XPTZ 1 51 UPSS SPRING SEE TABLE 1 52 SAFETY SHUT OFF SPRING HOLDER J12506 248 1 53 O RING Safety Shut Off Top Cap JORM0251 16D Ï 1 54 BOTTOM SPRING HOLDER J12506 250 1 55 SAFETY SHUT OFF TOP CAP J12506 142 1 56 SCREW...

Page 16: ...CAP J12506 254 1 79 COVER Spindle End Cap J12506 255 1 80 INDICATOR CAP Safety Shut Off JCLOSEMC4 1 81 WASHER REAR circlip protection J12506 292 1 82 REAR O RING RETAINING WASHER J12506 253 Ï 1 83 TRIP OFF LATCH J12506 241 1 84 LOWER DIAPHRAGM PLATE J12506 247 1 85 SAFETY SHUT OFF DIAPHRAGM J12506 246 Ï 1 86 VENT SCREEN J12506 277 1 87 TOP DIAPHRAGM PLATE J12506 245 1 88 SCREW Top Cover Body JSA51...

Page 17: ...NUMBER COLOUR 18 60 7 5 24 J12506 281 BLACK 50 80 20 32 J12506 282 ORANGE 60 110 24 44 J12506 283 RED 100 210 40 84 J12506 284 DARK GREEN 200 350 3 5 PSI J12506 287 YELLOW 280 500 4 7 PSI J12506 288 WHITE UNDER PRESSURE SLAM SHUT SPRINGS mbar w g PART NUMBER COLOUR 8 16 3 6 J12506 285 LIGHT BLUE 16 60 6 24 J12506 286 BROWN 60 150 24 60 J12506 289 PURPLE NOTE A minimum differential of 30mb must be ...

Page 18: ...pose see page 17 The use of Molykote 111 O ring lubricant is recommended during the rebuild unless for use with oxygen when no lubricant should be used 1 If when the valve seat 39 assembly was dismantled the bonded seal 94 was fitted then replace with a new bonded seal 94 DO NOT USE ALUMINIUM GASKET 45 2 If when the valve seat 39 assembly was dismantled the aluminium gasket 45 was fitted then repl...

Page 19: ...embly from the diaphragm case 17 8 Unscrew spring adjusting nut 6 from diaphragm assembly 23 or 35 to allow dismantling 9 Lift lever assembly 19 to disengage with BVO piston 13 10 Withdraw BVO valve assembly 10 12 13 14 15 45 96 97 from the diaphragm case 17 11 Take BVO piston 13 and BVO loading spring 96 from BVO piston holder 14 and remove O rings 10 45 97 12 Unscrew BVO sensing screw 12 and che...

Page 20: ...if necessary replace with a new assembly 16 Insert BVO sensing screw into BVO piston and tighten 17 Fit O rings 10 45 onto BVO Piston 13 and with BVO loading spring 97 in place insert into BVO piston holder 14 18 Replace O ring 97 to outside of BVO piston holder 14 19 Carefully push BVO piston assembly 10 12 13 14 15 45 96 97 through hole in the diaphragm case 17 and engage grooves into teeth in l...

Page 21: ...dy 70 and remove circlip 65 Valve spring cup 67 and valve spring 64 can now be withdrawn 10 Remove four screws 49 securing USSA body 70 to adaptor plate 47 11 Remove O rings 63 and 68 from USSA body 70 12 Unscrew reset spindle end cap 78 and pull out until it comes to a stop 13 Within body prise visible circlip 65 from valve spindle 73 to release trip off bush 75 14 Slide trip off bush 75 forward ...

Page 22: ...new circlip 65 to groove on valve spindle 73 which clamps trip off bush 75 to valve spindle 73 7 Fit new O ring 72 into front O ring groove in body 70 and apply O ring lubricant replace front O ring retaining washer 71 and secure firmly with new circlip 69 8 Replace valve spring 64 into front face of body 70 9 Locate valve spring cup 67 over spindle 73 and into valve spring 64 10 Push valve spring...

Page 23: ...ey of top cover 60 ensuring that castellated spigot is uppermost If UPSS spacer tube 93 is fitted screw top spring holder 52 down firmly 22 If fitted locate UPSS spring 51 into recess in top diaphragm plate 87 refit UPSS spring holder 59 ensuring that spigot locates in UPSS spring 51 23 Replace top cover assembly 60 and secure with four screws 88 ensuring UPSS spring arrangement 51 and 59 if fitte...

Page 24: ...vons gb elster com info elster instromet com M125B2EN04 A13 05 2010 Subject to change without prior notice All rights reserved Subject to change without prior notice All rights reserved Elster Jeavons is committed to a programme of continuous quality enhancement All equipment designed by Elster Jeavons and manufactured within the Elster Instromet Group benefits from the groups quality assurance st...

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