GAS PRESSURE REGULATORS

WITH RELIEF VALVE

Serie IR5 ... DN 32 ÷ 100

DESCRIPTION
Direct-operated gas pressure regulator with compensated obturator.

Pmax = 0,5 ÷ 5 bar

This devices are equipped with the following safety devices and
accessories:

• relief valve:
it vents outside small quantity of gas in case there are downstream
regulator overpressure.That exhaust it is convoyed outside in case of
installation in environment with bad ventilation

• outlet over pressure shut-off device (OPSO): it stops the gas flow when
the regulator outlet pressure goes up the device setting value

• outlet under pressure shut-off device (UPSO): it stops the gas flow
when the regulator outlet pressure goes down the device setting value.
It closes even if there is no inlet pressure.

• outlet pressure test point.

- EC certified according to EN 88-2 and EN 334

- In conformity with the 2009/142/EC Directive (Gas Directive)
- In conformity with the 97/23/EC Directive (PED Directive)
- In conformity with the 94/9/EC Directive (ATEX Directive)

IDENTIFICATION

IR N 5 02N M88 A B

Single stage gas pressure regulator

B = biogas
with relief valve series IR...

Versions
Types = without relief valve
N = STANDARD version A = with relief valve
O1 = with OPSO, UPSO and relief valve

Pmax
5 = Pmax 0,5 ÷ 5 bar

Connections

Threaded Flanged Settings: see next page

Code Code ANSI M88 = setting spring (mbar)
Code GAS NPT Code PN 16 (P2+diff. relief valve range)
NPT ANSI PN 16
M66 = setting spring (mbar)
05 DN 32 (G 1”1/4) 05N DN 32 (NPT 1”1/4) 32 DN 32 32A DN 32 ANSI
(P2+OPSO+UPSO+diff. relief valve range)
06 DN 40 (G 1”1/2) 06N DN 40 (NPT 1”1/2) 40 DN 40 40A DN 40 ANSI .....
07 DN 50 (G 2”) 07N DN 50 (NPT 2”) 50 DN 50 50A DN 50 ANSI
08 DN 65 08A DN 65 ANSI
09 DN 80 09A DN 80 ANSI
NOTE: not all combinations are possible
10 DN 100 10A DN 100 ANSI
Please contact the technical department.

81
 SETTINGS

P2 OPSO UPSO Differential Code

Connections (mbar) (mbar) (mbar) relief valve P. max 0,5 ÷ 5 bar
range (mbar)

10 ÷ 22 30 ÷ 90 7 ÷ 20 10 ÷ 20 M66
15 ÷ 33 30 ÷ 90 7 ÷ 20 15 ÷ 40 M67
32 ÷ 60 30 ÷ 90 10 ÷ 30 15 ÷ 40 M68
50 ÷ 95 70 ÷ 140 10 ÷ 30 40 ÷ 80 M69
85 ÷ 180 90 ÷ 260 30 ÷ 50 40 ÷ 80 M70
150 ÷ 350* 200 ÷ 550 50 ÷ 110 50 ÷ 120 M71
DN 32 - 40 - 50

300 ÷ 500* 500 ÷ 1000 50 ÷ 110 50 ÷ 120 M72

500 ÷ 800* 500 ÷ 1000 50 ÷ 110 50 ÷ 120 M77
10 ÷ 22 - - 10 ÷ 20 M88
15 ÷ 33 - - 15 ÷ 40 M89
32 ÷ 60 - - 15 ÷ 40 M90
50 ÷ 95 - - 40 ÷ 80 M91
85 ÷ 180 - - 40 ÷ 80 M92
150 ÷ 350* - - 50 ÷ 120 M93
300 ÷ 500* - - 50 ÷ 120 M94
500 ÷ 800* - - 50 ÷ 120 M78

13 ÷ 27 40 ÷ 110 7 ÷ 15 15 ÷ 50 M73
22 ÷ 58 40 ÷ 110 15 ÷ 25 15 ÷ 50 M74
50 ÷ 130 90 ÷ 210 25 ÷ 70 15 ÷ 50 M75
110 ÷ 200 180 ÷ 350 70 ÷ 110 20 ÷ 100 M76
13 ÷ 27 - - 15 ÷ 50 M95
DN 65 - 80

22 ÷ 58 - - 15 ÷ 50 M96
50 ÷ 130 - - 15 ÷ 50 M97
110 ÷ 200 - - 20 ÷ 100 M98
PILOTED REGULATOR
170 ÷ 400 - - 40 ÷ 200 M85
300 ÷ 530 - - 40 ÷ 200 M86
530 ÷ 1300 - - 40 ÷ 200 M87
800 ÷ 1500 - - 40 ÷ 200 M99

15 ÷ 27 40 ÷ 110 7 ÷ 15 15 ÷ 50 M73
27 ÷ 55 40 ÷ 110 15 ÷ 25 15 ÷ 50 M74
55 ÷ 130 90 ÷ 210 25 ÷ 70 15 ÷ 50 M75
130 ÷ 200 180 ÷ 350 70 ÷ 110 20 ÷ 100 M76
15 ÷ 27 - - 15 ÷ 50 M95
27 ÷ 55 - - 15 ÷ 50 M96
DN 100

55 ÷ 130 - - 15 ÷ 50 M97
130 ÷ 200 - - 20 ÷ 100 M98
PILOTED REGULATOR
170 ÷ 400 - - 40 ÷ 200 M85
300 ÷ 530 - - 40 ÷ 200 M86
530 ÷ 1300 - - 40 ÷ 200 M87
800 ÷ 1500 - - 40 ÷ 200 M99

* = stregthen diaphragm

82
 GENERAL DATA
TECHNICAL DATA MATERIALS

• Use: not aggressive gases of the 3 families (dry gases) • Die-cast aluminium (UNI EN 1706)
• Threaded connections Rp: (DN 32 ÷ DN 50) according to EN 10226 • OT-58 brass (UNI EN 12164)
• Flanged connections PN 16: (DN 32 ÷ DN 100) according to ISO 7005 • 11S aluminium (UNI 9002-5)
• On request ANSI 150 flanged connections • Stainless steel (UNI EN 10088)
• Max. working pressure: 5 bar • NBR rubber (UNI 7702)
• Environment temperature: -20 ÷ +60 °C • Nylon 30% glass fibre (UNI EN ISO 11667)
• Max superficial temperature: 60 °C
• P2 accuracy class (AC): 10
• Overpressure lockout accuracy group (AG): 10
• Closing pressure class (SG): 30
• Trip pressure range: see springs table
• Shut-off closure time: < 1 s
• Relief valve: tested according to EN 334
• Vent connection: G 1/4”
• Mechanical strength: Group 2 (according to EN 13611:2007)
• Safety factor: f=4 (5*4 = 20 bar) according to EN 88-2 point 7.2

DIMENSIONS

DN 32 - DN 40 -DN 50 DN 65 - DN 80 - DN 100

Connections A B C Connections A B

DN 32 ÷ 50 threaded 160 245 225 DN 65 290 471

DN 32 ÷ 50 flanged 230 285 225 DN 80 310 478

DN 100 350 504

IR ... O

DN 65 290 528

DN 80 310 535

DN 100 350 561

PILOTED REGULATOR

DN 65 290 518

DN 80 310 525

DN 100 350 551

Connections A B C

DN 32 ÷ 50 threaded 160 297 225

DN 32 ÷ 50 flanged 230 330 225

83
 COMPONENTS

DN 32 - DN 40 -DN 50

LEGEND

1. Closing cap
2. Outlet pressure calibration
3. P2 regulation spring
4. Relief valve calibration
5. Compensation diaphragm
6. Body
7. Bottom fixing screws
8. Seal O-Ring
9. Bottom
10. Fixing nut
11. Closure member
12. Central pin
13. Sensor tube
14. Outlet pressure test nipple
15. G 1/8” connection
16. Diaphragm disc
17. Working diaphragm
18. Relief valve spring
19. Antidust cap
20. Funnel
21. Maximum shut-off spring
22. Closing cap (shut-off)
23. Calibration of maximum pressure
shut-off
24. Reset of shut-off device
25. Calibration of minimum pressure
shut-off
26. Minimum shut-off spring
27. Closure member of shut-off
28. Special Key

DN 65 - DN 80 - DN 100

LEGEND
1. Closing cap
2. Outlet pressure calibration
3. P2 regulation spring
4. External sensing line connection
5. Body
6. Closure member
7. Bottom fixing screws
8. Seal O-Ring
9. Bottom
10. Fixing nut
11. Seal seat
12. Outlet pressure test nipple
13. Central pin/Closure member
14. Compensation diaphragm
15. Diaphragm disc
16. Working diaphragm
17. Relief valve spring
18. Antidust cap/relief valve discharge
19. Relief valve calibration
20. Funnel
21. Tap
22. OPSO spring
23. Closing cap (shut-off)
24. OPSO calibration
25. Reset of shut-off device
26. UPSO calibration
27. UPSO spring
28. By-pass button
29. Special key
30. Safety diaphragm
(no on piloted version)

29
29

84
 SETTINGS SPRINGS

P2 Code and Code and Code and Differential Code and

dimensions OPSO dimensions UPSO dimensions relief valve dimensions
Connections (mbar) range
(d x De x Lo x it) (mbar) (d x De x Lo x it) (mbar) (d x De x Lo x it) (d x De x Lo x it)
* = stregthen (mm) (mm) (mm) (mbar) (mm)
diaphragm

M08 M51 M40 M33

10 ÷ 22 30 ÷ 90 7 ÷ 20 10 ÷ 20
(2x29x140x16) (2x35x20x4) (0,8x17x40x6) (1,3x17x40x6)

M09 M51 M40 M34

15 ÷ 33 30 ÷ 90 7 ÷ 20 15 ÷ 40
(2,2x29x140x18) (2x35x20x4) (0,8x17x40x6) (1,8x18,4x45x8,5)
DN 32 - DN 40 - DN 50

M06 M53 M41 M34

32 ÷ 60 70 ÷ 140 10 ÷ 30 15 ÷ 40
(2,5x29x155x16) (2X35X37X4) (0,9x17x45x7) (1,8x18,4x45x8,5)

M10 M53 M41 M35

50 ÷ 95 70 ÷ 140 10 ÷ 30 40 ÷ 80
(3x29x140x18) (2X35X37X4) (0,9x17x45x7) ( 2x17x54x9)

M11 M54 M44 M35

85 ÷ 180 90 ÷ 260 30 ÷ 50 40 ÷ 80
(3,5X29X125X14) 2X35,5X27X3) (1x17x52x7) ( 2x17x54x9)

M12 M55 M43 M36

150 ÷ 350* 200 ÷ 550 50 ÷ 110 50 ÷ 120
(4X29X98X8) (2,5x35x27x2,25) (1,2x15x36x5) (18x2,5x50x8)

M29 M56 M43 M36

300 ÷ 500* 500 ÷ 1000 50 ÷ 110 50 ÷ 120
(4,6x29,4x95x9) (3x35x33,5x3,5) (1,2x15x36x5) (18x2,5x50x8)

M29 M56 M43 M36

500 ÷ 800* 500 ÷ 1000 50 ÷ 110 50 ÷ 120
(4,6x29,4x95x9) (3x35x33,5x3,5) (1,2x15x36x5) (18x2,5x50x8)

M14 M54 M41 M22

13 ÷ 27 40 ÷ 110 7 ÷ 15 15 ÷ 50
(4,5x70x200x14,5) (2X35,5X27X3) (0,9x17x45x7) (3,5x29,8x64x9)
DN 65 - DN 80

M15 M54 M42 M22

22 ÷ 58 40 ÷ 110 15 ÷ 25 15 ÷ 50
(5x70x200x13,5) (2X35,5X27X3) (1x17x40x6) (3,5x29,8x64x9)

M16 M55 M46 M22

50 ÷ 130 90 ÷ 210 25 ÷ 70 15 ÷ 50
(6x70x200x10,5) (2,5x35x27x2,25) (1,3X17X40X6) (3,5x29,8x64x9)

M80 (M16+M17)
M47 M12
110 ÷ 200 (6x70x200x10,5 + 180 ÷ 350 M57 70 ÷ 110 20 ÷ 100
(1,8x18,4x45x8,5) (4X29X98X8)
5,5x54,5x195x12,5)

M14 M54 M41 M22

15 ÷ 27 40 ÷ 110 7 ÷ 15 15 ÷ 50
(4,5x70x200x14,5) (2X35,5X27X3) (0,9x17x45x7) (3,5x29,8x64x9)

M15 M54 M42 M22

27 ÷ 55 40 ÷ 110 15 ÷ 25 15 ÷ 50
DN 100

(5x70x200x13,5) (2X35,5X27X3) (1x17x40x6) (3,5x29,8x64x9)

M16 M55 M46 M22

55 ÷ 130 90 ÷ 210 25 ÷ 70 15 ÷ 50
(6x70x200x10,5) (2,5x35x27x2,25) (1,3X17X40X6) (3,5x29,8x64x9)

M80 (M16+M17)
M47 M12
130 ÷ 200 (6x70x200x10,5 + 180 ÷ 350 M57 70 ÷ 110 20 ÷ 100
(1,8x18,4x45x8,5) (4X29X98X8)
5,5x54,5x195x12,5)

PILOTED REGULATOR

M22 M32
170 ÷ 400 - - - - 40 ÷ 200
(3,5X29,8X64X9) (2x17x29x6)
DN 65 - 80 - 100

M07 M32
300 ÷ 530 - - - - 40 ÷ 200
(3,5x29,8x98x11,5) (2x17x29x6)

M12 M32
530 ÷ 1300 - - - - 40 ÷ 200
(4X29X98X8) (2x17x29x6)

M29 M32
800 ÷ 1500 - - - - 40 ÷ 200
(4,6x29,4x95x9) (2x17x29x6)

Dimension Legend
d=diameter
De = external diameter
Lo= length
it = total number of turns

85
 PRESSURE CAPACITIES
Air = 0,806
Natural Gas =1
3
(Nm /h) Natural Gas Town gas = 1.177
LPG = 0.62

Inlet Pressure
Connections
P2 (mbar)
0,5 bar 1 bar 2 bar 3 bar 4 bar 5 bar

20 185 350 470 470 470 470

30 185 370 495 495 495 495

50 198 370 540 740 740 740

DN 32
100 150 290 520 815 850 850

200 100 220 495 790 960 960

300 110 250 495 890 1100 1100

20 220 400 740 960 990 990

30 220 400 740 1090 1140 1140

50 220 400 740 1090 1240 1240

DN 40
100 200 370 790 1090 1190 1190

200 135 250 580 890 1340 1390

300 135 290 590 940 1190 1200

20 248 446 850 1230 1500 1500

30 248 446 818 1280 1440 1500

50 300 446 818 1230 1500 1500

DN 50
100 290 440 818 1240 1500 1500

200 245 372 740 1140 1480 1490

300 186 320 645 1100 1480 1480

20 300 450 990 1290 1500 1500

30 370 465 990 1350 1500 1500

DN 50
50 325 470 850 1265 1500 1500

Outlet pipe DN 80 100 300 470 850 1265 1500 1500

200 300 420 900 1380 1500 1500

300 250 400 740 1100 1500 1500

Data obtained using the external sensor tube

Inlet Pressure
Connections P2 (mbar)
0,5 bar 1 bar 2 bar 3 bar 4 bar 5 bar

20 904 1480 2100 2900 2900 2900

DN 65 - DN 80
100 1000 1600 2900 4400 4400 4400
Inlet pipe DN 80 - Outlet pipe DN 80 for 10 diameters then DN 100 pipe

20 1200 1800 2900 3400 3400 3400

DN 100
100 800 2200 3300 4000 4000 4000
Inlet pipe DN 100 - Outlet pipe DN 100 for 10 diameters then DN 150 pipe

86
PRESSURE DROP DIAGRAM

NATURAL GAS

AIR

TOWN GAS

LPG

NATURAL GAS

AIR

TOWN GAS

LPG
87
 INSTALLATION
The regulator is in conformity with the Directive 94/9/CE (said Directive ATEX 100 a) as device of group II, category 2G and as device of group II, category
2D; for this reason it is suitable to be installed in the zones 1 and 21 (besides in the zones 2 and 22) as classified in the attachment I to the Directive 99/92/EC.

The regulator is not suitable to be used in zones 0 and 20 as classified in the already said Directive 99/92/EC.

To determine the qualification and the extension of the dangerous zones, see the norm EN 60079-10.

The device, if installed and serviced respecting all the conditions and the technical instructions of this document, is not source of specific dangers: in particular,
during the normal working, is forecast, by the regulator, the emission in the atmosphere of inflammable substance only occasionally.

The regulator can be dangerous as regards to the presence close to it of other devices when the integrated relief valve vents or in case of damage of the working
diaphragm (16/17) and safety one (30). Only in this last case the regulator is a source of emission of the continue degree explosive atmosphere and, so, it can
originate dangerous areas 0 as defined in the 99/92/EC Directive.

In conditions of particularly critic installation (places not protected, lack of servicing, lacking availability of ventilation) and, especially in presence, close to
the regulator, of potential sources of primer and/or dangerous devices during the normal working because susceptible to origine electric arcs or sparks, it is
necessary to value before the compatibility between the regulator and these devices.

In any case it is necessary to take any useful precaution to avoid that the regulator could be origin of areas 0: for example yearly periodical inspection of regular
working, possibility to change the emission degree of the source or to attend on the exhaust outside the explosive material canalizing outside, for example, the
relief valve discharge.

Installation must be in compliance with local law in force!

WARNING: Read carefully the instruction sheet of each product before installing.
Installation and maintenance must be carried out by qualified personnel.

• The gas supply must be shut-off before installation.

• Check that the line pressure DOES NOT EXCEED the maximum pressure stated on the product label.
• The regulator is normally installed before the user. It must be installed with the arrow on the body (6/5) towards the user.
• It can be installed in any position but it is preferable the installation with the spring in vertical position. Outside the regulator and downstream of it there is a
checking pressure-tap (14) for the control of the regulation pressure.
• Connect the G1/8” connection pulse tap (15/4) to downstream regulator pipe. On versions IR..O connect togheter with the impulse grip the tap outlet (21).
• Canalize outside the relief valve discharge. Please see installation examples.
• If the device is threaded check that the pipeline thread is not too long; overlong threads may damage the body of the device when screwed into place.
• If the device is flanged check that the inlet and outlet counterflanges are perfectly parallel to avoid unnecessary mechanical stresses on the body of the device.
Also calculate the space needed to fit the seal. If the gap left after the seal is fitted is too wide, do not try to close it by over-tightening the device’s bolts.
• During installation take care not to allow debris or scraps of metal to enter the device.
• Do not use the spring casing for leverage when screwing into place; use the appropriate tool.
• Always check that the system is gas-tight after installation.

EXAMPLE OF INSTALLATION
1. high pressure manometer
2. regulator IR
3. low pressure manometer
4. ball valve downstream

1 2 3 4

88
MANUAL RESET (versions IR...O)

DN 32-40-50
1. Close the tap or ball valve downstream the regulator.
2. Unscrew the tap (22)
3. Slowly push the reset pin (24), wait a few moments to get the pressure balanced and then push till the end the reset pin (24).
4. Keeping pushed the reset pin (24), slowly open the tap upstream the regulator.
5. Subsequently screw again the cap (22) on its original position.

DN 65-80-100
In order to reset the shut-off device, you need to follow the instructions:
1. Close ball valve downstream of the regulator.
2. Close the shut-off tap (21)
3. Push the by-pass button (28).
4. Reset pushing the pin (25). a. If RESETED, slowly open the ball valve downstreamthe regulator and open the shut-off tap (21).
b. If NOT RESETED, open the shut-off tap (21) and reset pushing the pin (25).
b1. If RESETED, slowly open the ball valve downstream of regulator.
b2. If NOT RESETED: - open the ball valve downstream of regulator
- close the shut-off tap (21)
- close the ball valve downstream of regulator
- push the by-pass button (28)
- reset pushing the pin (25)
- once rearmed, slowly open the ball valve downstream of regulator
- open the shut-off tap (21)
When the reset operation is completed, to avoid any contact with the internal reset pin, slowly pull down the reset pin (25).

CALIBRATION P2

Before starting the system, pay attention that the standard regulation spring is suitable with the needed regulation pressure.
Get a proper pressure gauge to check the regulator pressure.
On versions with relief valve, you must act directly on the adjustment regulation screw (2), on versions without relief valve you have to unscrew the cap (1).
When the regulator is set, rescrew the cap (1) in the original position.

SETTING

DN 32-40-50
Normally the devices are presetted according to the customer specification, where it is needed to set it, with the plant giving flow, you need:
• Get a spanner (hex with a pipe of 8 mm and a max. external Ø not over 12 mm) and a proper pressure gauge to check the regulator pressure.
• Unscrew the caps (1) and (22)
• In order to change the setting value of the out let pressure P2, act on the regulation screw (2).
• Screw till the end the setting screws (4) and (23) and place at minimum, unscrewing it, the regulation screw (25).
• To modify the setting value of the minimum pressure shut-off tripping, act with the supplied key (28) on the regulation screw (25).
• To modify the setting value of overpressure shut-off tripping, act with the supplied screw (28) on the regulation screw (23).
• To modify the setting of the relief valve, act with a 8 mm spanner (not supplied) on the regulation screw (4).

DN 65-80-100
Where it is needed to set the devices, with the plant giving flow, you need:
• On versions with relief valve use an hex with a pipe type of 10 mm and a maximum external Ø not over than 15 mm.
• On versions of piloted regulator with relief valve use an hex with a pipe type of 8 mm and a maximum external Ø not over than 12 mm.
• Unscrew the cap (23).
• Unscrew and remove the final part of the pin (25).
• By the special key (29) screw completely the regulation screw (24) and put at minimum the regulation screw (26).
• In order to change the setting value of the out let pressure P2, act on the regulation screw (2).
• Screw till the end the setting screws (4) and (23) and place at minimum, unscrewing it, the regulation screw (25).
• To modify the setting value of the minimum pressure shut-off tripping, act with the supplied key (29) on the regulation screw (26).
• To modify the setting value of overpressure shut-off tripping, act with the supplied screw (29) on the regulation screw (24).
• To modify the setting of the relief valve, act with a commercial spanner (not supplied) on the regulation screw (19).

FOR FURTHER INFORMATION PLEASE CONTACT OUR TECHNICAL OFFICE.

89