687 Technology Way
Napa, CA 94558
Phone: (707) 259-0102
FAX: (707) 259-0117
www.aptech-online.com
Operation Manual
Piston Sensed Gas Pressure Regulators
(Models KT10, Welded KT10, KT12)
Table of Cont ents:
A. General information ...................................................................................................................... 1
B. System Design/Product Selection ................................................................................................. 1
C. Installation..................................................................................................................................... 1
D. Manually Adjustable, Non-relieving (non-venting) Regulator Operation .................................... 4
E. Manually Adjustable, Self-relieving (self-venting) Regulator Operation .................................... 5
F. Preset Regulator Operation ........................................................................................................... 6
G. Pneumatically Actuated, Non-relieving (non-venting) Regulator Operation ............................... 7
A. General information
AP Tech pressure regulators are used in gas delivery systems to reduce the source pressure to a
lower delivery (outlet) pressure. This operation manual is applicable to gas pressure regulators that
use a piston to sense the delivery pressure.
Refer to the appropriate catalog data sheet for specific product information. For special options that
are not shown in the data sheet, contact the factory or your local representative for questions on
proper operation.
B. System Design/Product Selection
1. AP Tech piston sensed gas pressure regulators are not safety accessories per EU Pressure
Equipment Directive 97/23/EC or safety related devices per EU ATEX Directive 94/9/EC. The
EU Pressure Equipment Directive requires the system designer to install a safety accessory (for
example, safety relief valve or burst disc) where the design pressure of the downstream system is
lower than the upstream pressure.
2. When selecting the pressure regulator model and configuration, verify the following information. a. Verify the materials of construction are compatible with the intended process gas. b. Verify the pressure and temperature ratings are acceptable for the intended application. c. If the regulator is to be equipped with either a supply or delivery pressure gauge, verify that
the pressure gauge range is suitable for the application.
d. Verify that the flow capability of the regulator is appropriate for the application.
3. KT10, Welded KT10, and KT12 regulators must be ordered with the non-relieving (non-venting)
option if the process gas they are to be used with is hazardous (flammable, toxic, etc.). The
self-relieving (venting) option on these models vents process gas through the regulator cap
directly into the atmosphere surrounding the regulator, which is undesireable with a hazardous
gas.
4. Pressure regulators can be used under a large variety of operation conditions. The system
designers shall decide product selection based upon their own analysis and testing to verify
acceptable operation with specific equipment.
C. Installation
1. Verify the pressure rating is acceptable for the intended application.
2. If the regulator is equipped with either a supply or delivery pressure gauge, verify that the
pressure gauge range is suitable for the application.
Page 1 of 9 Manual 15000011 Rev. 5
Operation Manual Piston Sensed Pressure Regulators
3. Inspect the regulator to determine the flow path through the regulator and how the regulator will
need to be installed in the system.
a. The high pressure (inlet/supply) port(s) is labeled with an “HP” marked on the body near the
port. Arrows are sometimes used next to the HP characters to point toward a high pressure
port.
b. The low pressure (outlet/delivery) port(s) is labeled with an “LP” marked on the body near
the port. Arrows are sometimes used next to the LP characters to point toward a low pressure
port.
c. Always connect the gas source to the high pressure port. Never connect the gas source to the
low pressure port as the regulator can be damaged and leakage can result.
Caution: If a regulator was installed incorrectly and a low pressure port was pressurized above the
rated outlet pressure, then the regulator must be returned to the factory for repair prior to use.
4. Install the regulator using the appropriate method described below. For assembly of other type
connections, consult connector manufacturer or contact the factory.
a. For NPT connections, apply PTFE (e.g. Teflon) tape to connector threads and install
connector in regulator body wrench tight.
b. For straight thread o-ring connections (such as MS33649 porting), verify the proper mating
fittings and o-rings are being used and install the fittings in the regulator. Tighten according
to fitting manufacturer specification.
c. For metal face seal connectors (Welded KT10), assemble connections per standard practice
described by fitting supplier (typically 1/8 turn past fingertight).
5. For pneumatically actuated KT10 and KT12 regulators, a separate line will need to be plumbed
to provide the pneumatic actuator control pressure. Pressurized inert gas, typically nitrogen gas,
or air may be used for actuation. The maximum allowable actuation control pressure is 100 psig.
The actuation port is 1/8th inch NPT and is located on the top center of the actuator. A pilot
regulator with an outlet pressure vent is recommended to control the actuation pressure.
6. If appropriate for the application, secure the regulator body using one of the below methods. a. For KT10 and KT12 regulators with NPT or straight thread connections, use the panel mount
clamp option to secure the regulator. It may be necessary to remove the regulator wheel to
install the regulator through the panel. Refer to Figure 1 to remove closure, retaining ring,
wheel, and thrust washer. Refer to Figure 2 for panel mount clamp installation. Loosen the
10-32 screws on the clamp using a 5/32 inch hex wrench. Position the clamp on the regulator
body so the 1/4-20 UNC threaded holes line up with the panel cutout, then retighten the 1032 screws leaving the same gap between each half of the panel mount clamp. Install and
tighten 1/4-20 UNC screws (customer supplied) to secure regulator to panel. Reinstall the
thrust washer, wheel, retaining ring, and closure.
b. For Welded KT10 regulators with metal face seal connections, use the mounting holes in the
bottom of the body to secure the regulator with 10-32 UNF screws.
7. After installation, perform a leak test. A pressure decay leak test is recommended to check for
leak integrity of the regulator internal parts and external fitting connections. A bubble leak test
may be performed to check for leaks at external fitting connections. A helium leak test is
recommended for Welded KT10 regulators with face seal connections per standard industry
practice (reference SEMI standard F1).
Page 2 of 9 Manual 15000011 Rev. 5
Operation Manual Piston Sensed Pressure Regulators
Figure 1. KT Adjustable and Preset Regulator
______________________________________________________________________________________________________________________
Figure 2. KT Panel Mount Clamp Detail
Page 3 of 9 Manual 15000011 Rev. 5
Operation Manual Piston Sensed Pressure Regulators
Figure 3. Pneumatically actuated KT10 and KT12 regulator dimensions.
Page 4 of 9 Manual 15000011 Rev. 5
Operation Manual Piston Sensed Pressure Regulators
D. Manually Adjustable, Non-relieving (non-venting) Regulato r Operation
Note: A pressure regulator should not be used as a positive shut-off device.
Caution: Do not pressurize the regulator low pressure port, except by rotating the adjustment wheel
clockwise (increasing the set point), as damage to the regulator internal parts or leakage may result.
1. Perform the following to increase the regulator delivery pressure set point. a. Before opening the source valve, verify that the regulator adjustment wheel is turned fully
counterclockwise (fully decreased position).
b. Slowly open the source valve to pressurize the regulator high pressure port.
c. Rotate the regulator wheel clockwise to increase the delivery pressure to the desired pressure.
Note: The delivery pressure will decrease as the flow rate is increased. It may be
advantageous to compensate by adjusting the regulator to the desired delivery pressure while
operating at the desired flow conditions. Be aware the delivery pressure will rise if the flow
is shut-off or decreased downstream.
2. Perform the following to decrease the regulator delivery pressure set point for non-relieving
(non-venting) regulators.
a. Open a downstream valve to initiate a flowing condition.
b. Rotate the regulator wheel counterclockwise to reduce the delivery pressure below the
desired pressure.
c. Close the downstream valve to stop flow.
d. Rotate the regulator wheel clockwise to increase the delivery pressure to the desired pressure.
Note: The delivery pressure will decrease as the flow rate is increased. It may be
advantageous to compensate by adjusting the regulator to the desired delivery pressure while
operating at the desired flow conditions. Be aware the delivery pressure will rise if the flow
is shut-off or decreased downstream.
3. Perform the following to fully decrease the regulator delivery pressure. a. Close the source valve. b. Vent outlet to atmospheric pressure. c. Rotate the regulator wheel fully counterclockwise.
E. Manually Adjustabl e, Self-relieving (self-ven ting) Regulator Operation
Note: A pressure regulator should not be used as a positive shut-off device.
Caution: Do not pressurize the regulator low pressure port, except by rotating the adjustment wheel
clockwise (increasing the set point), as damage to the regulator internal parts or leakage may result.
Caution: Self-relieving KT10 and KT12 regulators have a built in vent mechanism that vents the
delivery pressure through the cap into the atmosphere if the delivery pressure exceeds the set point.
Self-relieving KT10 and KT12 regulators should only be used with gases that can be safely released
in the area where the regulator is being used. The self-relieving mechanism incorporated into
AP Tech piston sensed regulators will come from the factory preset and should not need adjustment.
If any of the below conditions occur, then adjust the vent valve setting per section E.4.
The regulator does not relieve its delivery pressure after several counterclockwise rotations
of the adjustment wheel.
Audible venting is detected inside the regulator bonnet without rotating the adjustment
wheel.
Note: This condition may indicate a leak across the seat of the regulator. If adjusting the vent
valve according to section E.4 results in a steadily increasing outlet pressure or excessive
creep, then it is likely the regulator is leaking across the seat and needs to be repaired.
Page 5 of 9 Manual 15000011 Rev. 5
Operation Manual Piston Sensed Pressure Regulators
Audible venting is detected inside the regulator bonnet while increasing the delivery pressure
of the regulator by rotating the adjustment wheel clockwise.
1. Perform the following to increase the regulator delivery pressure set point. a. Before opening the source valve, verify that the regulator adjustment wheel is turned fully
counterclockwise (fully decreased position).
b. Slowly open the source valve to pressurize the regulator high pressure port.
c. Rotate the regulator wheel clockwise to increase the delivery pressure to the desired pressure.
Note: The delivery pressure will decrease as the flow rate is increased. It may be
advantageous to compensate by adjusting the regulator to the desired delivery pressure while
operating at the desired flow conditions. Be aware the delivery pressure will rise if the flow
is shut-off or decreased downstream.
2. Perform the following to decrease the regulator delivery pressure set point for self-relieving
(self-venting) regulators.
a. Slowly rotate the regulator wheel counterclockwise to reduce the delivery pressure below the
desired pressure. The self-relieving feature will vent the delivery pressure through the
regulator bonnet to atmosphere.
b. Rotate the regulator wheel clockwise to increase the delivery pressure to the desired pressure.
Note: The delivery pressure will decrease as the flow rate is increased. It may be
advantageous to compensate by adjusting the regulator to the desired delivery pressure while
operating at the desired flow conditions. Be aware the delivery pressure will rise if the flow
is shut-off or decreased downstream.
3. Perform the following to fully decrease the regulator delivery pressure. a. Close the source valve. b. Vent outlet to atmospheric pressure. c. Rotate the regulator wheel fully counterclockwise.
4. When necessary perform the following to adjust the vent valve. Refer to Figure 1. a. Remove the closure (6) on the top of the regulator adjustment wheel (4). b. Rotate the adjustment wheel clockwise to set the delivery pressure to approximately 10% of
regulator’s rated maximum outlet pressure or 200 psig whichever is greater, with all valves
downstream of the regulator closed.
c. Use a flat tip screwdriver to turn the vent screw (9) clockwise until gas can be heard venting
through the bonnet of the regulator.
d. Once venting is heard, turn the vent screw counterclockwise until audible gas flow stops plus
one half additional turn.
e. Replace the closure on the top of the adjustment wheel.
F. Preset Regulator Operati on
Note: Preset regulators are adjusted at the factory to customer specified conditions. Generally, no
readjustment will be required.
1. Perform the following to readjust the regulator delivery pressure set point. Refer to Figure 1 a. Close the source valve. b. Vent outlet to atmospheric pressure. This should vent both source and delivery pressures to
atmospheric pressure since the regulator is preset to some set point.
c. Remove acorn nut (8) from top of stem (2).
d. Loosen jam nut (7).
e. Place a 3/8 inch open end wrench on stem flats and rotate stem fully counterclockwise (fully
decreased position).
f. Slowly open the source valve to pressurize the regulator high pressure port to the desired
inlet pressure.
Page 6 of 9 Manual 15000011 Rev. 5
Operation Manual Piston Sensed Pressure Regulators
g. Using 3/8 inch wrench on stem flats, turn stem clockwise to increase the delivery pressure to
the desired pressure.
Note: The delivery pressure will decrease as the flow rate is increased. It may be
advantageous to compensate by adjusting the regulator to the desired delivery pressure while
operating at the desired flow conditions. Be aware the delivery pressure will rise if the flow
is shut-off or decreased downstream.
h. Reinstall jam nut and tighten to 100 in-lb against regulator bonnet.
i. Reinstall acorn nut and tighten to 40 in-lb against jam nut.
G. Pneumatically Actuated, Non-relieving (non-venting) Regulator O peration
Note: A pressure regulator should not be used as a positive shut-off device.
Caution: Do not reduce the actuation control pressure under no flow conditions as damage to the
regulator internal parts or leakage may result.
Caution: Do not pressurize the regulator low pressure side except by slowly increasing the actuation
control pressure, as damage to the regulator internal parts or leakage may result.
1. Perform the following to increase the regulator delivery pressure set point. a. Before opening the source valve, verify that the actuation control pressure is at atmospheric
pressure.
b. Slowly open the source valve to pressurize the regulator high pressure port.
c. Slowly increase the actuation control pressure to increase the delivery pressure to the desired
pressure. See Figure 4 and Figure 5 for delivery pressure versus actuation control pressure
charts for the pneumatically actuated KT10 and KT12 models.
Note: The delivery pressure will decrease as the flow rate is increased. It may be
advantageous to compensate by adjusting the regulator to the desired delivery pressure while
operating at the desired flow conditions. Be aware the delivery pressure will rise if the flow
is shut-off or decreased downstream.
2. Perform the following to decrease the regulator delivery pressure set point for non-relieving
(non-venting) regulators.
a. Open a downstream valve to initiate a flowing condition.
b. Reduce the actuation control pressure to reduce the delivery pressure below the desired
pressure.
c. Increase the actuation control pressure to obtain the desired delivery pressure.
Note: The delivery pressure will decrease as the flow rate is increased. It may be
advantageous to compensate by adjusting the regulator to the desired delivery pressure while
operating at the desired flow conditions. Be aware the delivery pressure will rise if the flow
is shut-off or decreased downstream.
3. Perform the following to fully decrease the regulator. a. Close the source valve. b. Vent outlet pressure to atmospheric pressure while applying actuation control pressure to
allow both sides of the pressure regulator to vent to atmospheric pressure.
c. Vent or otherwise reduce the actuation control pressure to atmospheric pressure.
Please contact the factory or your local representative to answer questions or for further
information
Page 7 of 9 Manual 15000011 Rev. 5
Operation Manual Piston Sensed Pressure Regulators
Supply Pressure Effect
decrease in source pressure)
Standard KT10:
KT10F
0.7 psi
KT10H
0.7 psi
KT10J
1.3 psi
KT10L
2.9 psi
KT10N
2.9 psi
KT10P
5.1 psi
KT10R
5.1 psi
High Flow KT10:
KT10F HF
1.2 psi
KT10H HF
1.2 psi
KT10J HF
2.1 psi
KT10L HF
4.8 psi
KT10N HF
4.8 psi
KT10P HF
8.6 psi
Standard KT12:
KT12E
0.3 psi
KT12G
0.3 psi
KT12I
0.9 psi
KT12J
0.9 psi
KT12L
1.3 psi
High Flow KT12:
KT12E HF
0.9 psi
KT12G HF
0.9 psi
KT12I HF
2.7 psi
KT12J HF
2.7 psi
KT12L HF
3.9 psi
Table 1. AP Tech piston regulator supply pressure effect values.
Model
(Increase in delivery pressure for every 100 psi
Page 8 of 9 Manual 15000011 Rev. 5
Operation Manual Piston Sensed Pressure Regulators
0
500
1000
1500
2000
2500
3000
3500
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0
Actuation Co nt rol Press ur e (psig)
Delivery Pressu re (psig)
0
34
69
103
138
172
207
241
0.00
0.69 1.38 2.07 2.76 3.45 4.14
4.83 5.52
Actuation Co nt rol Press ur e (bar)
Delivery Pressu e ( bar)
KT12L
KT12J
KT12G
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
0.0
10.0 20.0 30.0
40.0 50.0
60.0 70.0 80.0
Actuation Co nt rol Press ur e (psig)
Delivery Pressu re ( psig)
0
69
138
207
276
345
414
483
552
621
690
0.00
0.69 1.38
2.07 2.76
3.45
4.14 4.83
5.52
Actuation Co nt rol Press ur e (bar)
Delivery Pressu e ( ba r)
KT10R *
KT10N
KT10J
KT10H
Figure 4. Pneumatically actuated KT10 delivery pressure vs. actuation control pressure.
* Note: KT10R not available on welded body KT10’s.
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Page 9 of 9 Manual 15000011 Rev. 5
Figure 5. Pneumatically actuated KT12 delivery pressure vs. actuation control pressure.
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