Spirax-Sarco IR1 compressed air regulator Installation and Maintenance Instructions

0582156/2
IM-P058-05
CH Issue 2
IR1 Spirax-Monnier
International Compressed Air Regulator
Installation and Maintenance Instructions
1
3
4
7
6
5
9
2
How does the IR1 work
With adjustment knob (1) rotated fully anticlockwise, the valve return spring (9) will keep
the main valve (2) shut. Clockwise rotation of the adjustment knob will compress the main
pressure control spring (3), deflect the diaphragm (4) downwards, opening the main valve (2).
As air flows to the downstream (5) side of the regulator, the secondary pressure increases.
The secondary pressure is sensed by the aspirator (6) and transmitted to the underside
of the diaphragm. As the controlled pressure varies, so does the force on the underside
of the diaphragm. When this force (proportional to the secondary pressure) equals the
compression in the main control spring, the main valve will shut. Any fall in the secondary
pressure will cause the main valve to open sufficiently to meet the air flow requirements and
accurately maintain the set secondary pressure.
On self-relieving models any appreciable rise in the secondary pressure from its set value
will cause the diaphragm and the push rod (7) to lift. This will allow air to escape through
the centre of the push rod to atmosphere. When excess pressure has been vented the orifice
in the push rod will reseat on the main valve.
Printed in the UK
© Copyright 2001
General safety, installation and maintenance guidelines
WARNING
As with all pressurised systems, do not attempt any installation or maintenance
function if there is any pressure in the product or connected system.
Spirax-Monnier
Spirax-Monnier compressed air products are of well proven and simple design, with high natural
levels of designed safety built-in. However, used or installed incorrectly, their performance and
that of the system they are protecting or controlling, may suffer. The information given in this
document indicates the product limiting conditions, maintenance and installation requirements
and any specific component disposal needs (see Table opposite).
Note
Customers are reminded that under UK and EC Health, Safety and Environmental Law,
when returning products to Spirax Sarco they must provide information on any hazards
and the precautions to be taken due to contamination residues or mechanical damage
which may present a health, safety or environmental risk. This information must be
provided in writing including Health and Safety data sheets relating to any substances
identified as hazardous.
Installation and operation
1. Filters, filter / regulators, lubricators, flowmeters, separators and drain traps should be
fitted in horizontal pipelines, with the bowls vertically downwards.
2. Regulators and ball valves can be installed in any position.
3. On pressure regulators and combined filter / regulators, a pressure gauge can be connected
to one of the 1/ 8" ports. The gauge should be selected to cover the maximum pressure range
of the main control spring. The gauge will indicate the downstream or controlled pressure.
4. Ensure that the control spring range for regulators and filter / regulators fully meets the
pressure requirements of the system.
5. There are maximum operating pressures, and maximum operating and environmental
temperatures for each product. These are shown in the Table opposite.
6. Adequate space should be provided around any product to allow easy access for routine
servicing requirements.
7. Products fitted with a bowl (polycarbonate or metal ) should be adequately drained - manually
or automatically - to reduce the potentially harmful effects of water carryover.
8. WARNING Polycarbonate bowls and sight domes, and sight levels fitted to metal bowls,
may be attacked by phosphate ester based fluids, solvents, chemical cleaners, carbon
tetrachloride, etc. These and other similar substances should never be allowed to come into
contact with these product components. Certain compressor lubricating oils also contain
additives harmful to these components. Where there is any doubt, we recommend, in the
interests of safety, that bowl guards or metal bowls are fitted.
9. Local regulations may restrict the use of this product below the conditions quoted.
10. For more detailed information on any individual product, please ask for the appropriate
Technical Information Sheet listed in the Table opposite.
2
IM-P058-05 CH Issue 2
Maximum pressures / temperatures
Polycarbonate bowl
Filters
bar
10
10
10
10
-
MF2
IF2/D/A
IC3/4/DA
IXI
SF3/A
°C
50
50
50
50
-
Metal bowl
bar
17
17
17
17
°C
80
80
70
80
*
Technical
Metal bowl with
Disposal Information
sight level
Sheet
bar
°C
Class
TI1 and 3
P050-05
17
70
1 and 2
P500-01
17
70
1 and 2
P501-01
17
70
1 and 2
P057-01
17
70
1 and 3
P050-03
Regulators
MR1/2/3
IR1
SR2
SR3
21
20
21
21
bar @ 70°C : Control ranges : 0.2 - 2, 0.3 - 4, 0.7 - 9 bar
bar @ 70°C : Control ranges : 0.2 - 3.5, 0.5 - 10 bar
bar @ 70°C : Control ranges : 1.3 - 17.0 bar
bar @ 70°C : Control ranges : 0.2 - 4, 0.3 - 9 bar
1 and 3
1 and 2
1 and 3
1 and 3
P051-01
P058-01
P570-01
P570-03
70
1 and 2
P510-01
-
1 and 3
P054-01
-
1 and 3
P054-04
Filter regulators
IP2 / A / D
MP2
MPC2
10
50
17
80
17
Ranges : 0.2 - 3.5, 0.5 - 10 bar
10
50
Ranges : 0.2 - 2.0, 0.3 - 4.0, 0.7 - 9.0 bar
10
50
Ranges : 0.2 - 2.0, 0.3 - 4.0, 0.7 - 9.0 bar
Lubricators
ML3
IL1
SL3
10
10
-
50
50
-
17
17
80
80
17
17
70
70
1 and 3
1 and 2
1 and 3
P052-07
P059-01
P052-04
50
-
17
70
-
-
1 and 2
1 and 3
P580-01
P050-17
1 and 4
P560-01
1 and 3
P050-07
Other products
IFM2
S.M.S.
10
-
All ball
valves
All to 15 bar and 45°C
(see performance graph on TI for full details)
Dri-line
-
-
16
80
-
*
IM-P058-05 CH Issue 2
-
Disposal classes
1. Some plastic and / or rubber components
2. Main body zinc - epoxy coated
3. Main body aluminium - epoxy coated
4. Brass and steel
5. Electronic components
3
Commissioning
How to adjust the IR1:
- Lift the adjustment knob (1) to unlock.
- Turn the adjustment knob clockwise to
increase secondary pressure, or
anticlockwise to decrease.
- Push down to relock.
- It is recommended that adjustments are
made under flow conditions - there may be
a slight increase in set pressure when flow
stops.
F
1
X
Spare parts
The spare parts available are detailed below.
No other parts are available as spares.
Available spares
Pressure control spring set
O, E, F
(state pressure range)
Valve and diaphragm
G, H, J, K, L, M, N
assembly
How to order spares
Always order spares by using the description
given in the column headed 'Available spares'
and state the size and type of unit.
Example: 1 off Pressure control spring set
(0.5 - 10 bar) for ¼" Spirax-Monnier IR1
International compressed air regulator.
Y
O
E
J
G
K
How to service the IR1
How to remove or replace the pressure
control spring assembly:
Shut off the main air supply. Lift the adjustment
knob to unlock. Rotate the adjustment knob
fully anticlockwise until the stop is felt,
continue rotating until the knob is free.
Remove the adjuster nut (X) from inside the
adjustment knob. Remove the control spring
(E) and spring plate (O). Replace with a new
control spring (E), spring plate (O) and
screw in the adjuster nut (X), making sure
the recess is facing upwards, until flush with
the regulator body. Snap on the adjustment
knob, being careful to line up the four driving
lugs on the locking ring with the corresponding
slots on the adjustment knob. Change the
pressure indicator (F) to reflect the new
pressure range, if required.
How to replace the valve and diaphragm
assembly:
Isolate the regulator from the main supply.
Rotate the adjustment knob fully
anticlockwise until the stop is felt. Release
mounting ring (Y), unscrew the bonnet
assembly complete from the main body.
Remove the diaphragm assembly and
replace using new 'O' rings. Diaphragm
sealing ring (J) fits on the top of the diaphragm.
4
P
H
L
N
M
Replace complete bonnet assembly and
retorque to 25 Nm, using a 42 mm spanner.
How to replace the valve and return spring:
Isolate the regulator from the main air supply.
Vent by rotating the adjustment knob fully
anticlockwise. Unscrew the end cap and
replace the components using new 'O' rings
(L) and (N). Retighten to good hand
tightness.
IM-P058-05 CH Issue 2