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Pressure regulator

Pressure regulators from FESTO – for stable processes with a system

In pneumatic systems, pressure control determines efficiency, safety, and reliability. Fluctuating pressure can lead to malfunctions, strain components, and impair the quality of your products. FESTO pressure regulators create stable conditions – precisely, consistently, and reliably. They regulate the output pressure independently of the input pressure or air consumption. This protects your systems, reduces energy consumption, and extends the service life of your components. Consistent pressure is essential, especially in sensitive areas such as medical technology or food processing.

MS-BASIC

MS-BASIC

Compact pressure regulator for standard applications with reliable basic features.

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MS

MS

Modular pressure regulator for flexible combinations in compressed air treatment.

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D Polymer

D Polymer

Lightweight plastic pressure regulator for simple applications with limited space requirements.

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Individual devices

Individual devices

Robust controllers as stand-alone solutions for individual installations.

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VRPA

VRPA

Electronically controlled proportional regulator for dynamic and precise pressure control.

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LRL/LRLL

LRL/LRLL

Micro pressure regulator for very low pressures in sensitive applications.

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What is a pressure regulator?

What is a pressure regulator?

A pressure regulator ensures that air or gas is available in the system at a constant pressure. It reduces the inlet pressure to a specified value and keeps it stable. Even with fluctuating inlet pressure or varying air consumption, the outlet pressure remains reliably at the desired level. Pressure regulation is achieved by a combination of a spring, diaphragm, and valve. When the pressure in the system rises, the regulator reduces the air flow. When the pressure drops, the valve opens again. This automatically adjusts the working pressure and keeps it constant.

The regulator plays an important role in compressed air treatment. It follows the filter and dryer and ensures that the treated air is delivered to the application at the correct pressure. Neither too much nor too little, but exactly as required by the process. A well-adjusted pressure regulator saves energy, reduces wear and tear, and improves process reliability. FESTO offers suitable solutions for a wide range of requirements in industry and automation.

Which pressure regulator for which application?

FESTO offers the right regulator for every pneumatic application. This is because the requirements for pressure control vary depending on the area of application, medium, or control requirements. Choosing the right model ensures stable processes, saves energy, and extends the service life of the system. In the following, we present the most important types of regulators in simple language.

Standard pressure regulators

Standard pressure regulators

Standard pressure regulators are the right choice for many industrial applications. They maintain the outlet pressure at a fixed set value. The setting is made manually, usually via a rotary knob. Even if the inlet pressure fluctuates or the air consumption changes, the outlet pressure remains stable. These regulators are robust and versatile, for example in machines, systems, or compressed air tools.

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Precision pressure regulators

Precision pressure regulators

Precision pressure regulators are used when pressure needs to be controlled with particular accuracy. They maintain a stable supply even at very low pressures. This is important in sensitive areas such as medical technology, testing systems, and laboratory equipment. Precision regulators enable fine adjustment and protect sensitive components from overpressure or underpressure.

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Proportional pressure regulators

Proportional pressure regulators

Proportional pressure regulators respond to electrical control signals and adjust the pressure flexibly. They operate continuously and in real time. This makes them suitable for automated processes where the pressure must be adjusted continuously. Typical areas of application are production lines, robotics, or test benches where different pressure levels must be available quickly.

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Digital pressure controllers

Digital pressure controllers

Digital pressure controllers can be connected to control systems via interfaces and programmed with precision. They collect data, offer diagnostic functions, and simplify maintenance. This makes them ideal for networked systems that place high demands on transparency, control accuracy, and system integration.

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Pressure regulators with check valve function

Pressure regulators with check valve function

Pressure regulators with check valve function ensure that the set pressure is maintained even if the air supply is briefly interrupted. An integrated check valve prevents air from flowing back or the pressure from dropping uncontrollably. This design increases safety during load changes or system shutdowns.

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Micro pressure regulators

Micro pressure regulators

Micro pressure regulators regulate very low pressures, usually below one bar. They are used wherever small amounts of air need to be controlled with particular precision. This is the case, for example, in analytics, medical technology, and miniature valves.

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What to look for when choosing a pressure regulator

Not every pressure regulator is suitable for every application. For a system to operate reliably and economically, the regulator must be technically tailored to the requirements. Several factors play a role here. Below are the most important selection criteria, each with a brief explanation of why they are relevant.

Pressure range

A pressure regulator limits the inlet pressure to a specified outlet value. To ensure reliable operation, the regulator must be designed for the actual operating pressure in the system. Pay attention to both the maximum permissible inlet pressure and the control range for the outlet pressure. In systems with pressure peaks or fluctuating supply, the regulator should have a certain safety reserve.

Flow rate

The amount of air flowing through the system has a significant influence on the choice of regulator. If the flow rate is too high for the selected model, the outlet pressure cannot be kept constant. If the regulator is oversized, this can lead to unnecessary energy consumption or imprecise control. Manufacturers specify the maximum flow rate of a regulator in liters per minute or cubic meters per hour.

Medium

In most cases, compressed air is used. However, some applications also use other gases such as nitrogen, oxygen, or CO₂. In these cases, it must be ensured that the regulator is approved for the corresponding medium. The resistance of the materials to moisture, oil, or chemical residues should also be taken into account.

Environment and temperature

The conditions at the installation site also influence the choice of controller. Special designs are required for high or low temperatures, humid or dusty environments, or contact with chemicals. Models with corrosion-resistant housings, suitable seals, and appropriate protection classes (e.g., IP65) ensure reliable operation even under difficult conditions.

Design and connection

The regulator must be able to be integrated into the existing system – both mechanically and pneumatically. This includes suitable connection sizes (e.g., G1/4 or G1/2), the correct installation position, and sufficient space for operation or maintenance. The question of whether the regulator is part of a modular system or a stand-alone device can also be decisive for the selection.

Control function and application objective

Not every application has the same control requirements. If you simply want to maintain a constant pressure, a standard regulator will suffice. For sensitive processes or very low pressures, a precision regulator is recommended. If the pressure needs to be controlled flexibly, for example in automated systems or with changing loads, proportional or digital pressure regulators are the right choice.

Installation and maintenance of pressure regulators

A correctly installed pressure regulator forms the basis for stable processes and a consistent pressure supply. To ensure that everything runs smoothly, the following steps should be observed during installation and commissioning.

Preparation

Before installing the regulator, check the requirements of your application. These include the required pressure range, maximum flow rate, medium (e.g., air or gas), and ambient conditions. Also ensure that the connection sizes match the existing system (e.g., G1/4 or G1/2). If necessary, plan for additional components such as filters or water separators.

Take safety precautions

Before you start installation, the pneumatic system must be completely depressurized. Wear suitable protective equipment when working with compressed air, especially gloves and eye protection.

Installing the pressure regulator

Choose an easily accessible location that is not exposed to excessive heat, moisture, or dirt. Install the regulator in the direction of flow—i.e., with the inlet facing the pressure source and the outlet facing the application. The direction of flow is usually marked by an arrow on the housing. Screw the connections together carefully and tightly. Use sealing material such as Teflon tape and observe the torque recommended by the manufacturer to avoid damage.

Adjusting the pressure

Slowly turn the adjustment screw until the desired outlet pressure is reached. For sensitive applications or when using precision regulators, additional fine adjustment using a pressure gauge is recommended.

System check and commissioning

Start the system and observe the outlet pressure. It should remain constant. Check all connections for possible leaks. If air escapes, carefully tighten the connections and check the seals.

Documentation

Record the most important installation data, including the pressure setting, installation date, and any special features. This information will be helpful for future maintenance or replacement.

Maintenance intervals and tips for extending service life

Customized solutions

A pressure regulator will work reliably if it is serviced regularly. Even simple measures such as an annual visual inspection help to detect possible leaks, corrosion, or pressure deviations at an early stage.
In addition to visual inspection, the following measures contribute to operational safety and longevity:

  • Calibration
    For precision applications, the pressure regulator should be calibrated every 12 to 24 months. This applies in particular to digital and precision regulators.
  • Filter replacement
    If the regulator has an integrated filter, it should be replaced every six to twelve months. Otherwise, dirt and moisture can impair its function.
  • Seals and diaphragms
    These components wear out over time. Regular inspection and timely replacement prevent leaks and loss of performance.
  • Ensure air quality
    Oil, water, and dirt particles can damage the regulator. The use of filters and water separators provides lasting protection for the system.
  • Careful handling
    Adjustment wheels and screws should always be operated carefully and only as far as they will go. Careless adjustments can damage the mechanics.
  • Use suitable materials
    In damp or chemically contaminated environments, the use of corrosion-resistant materials is recommended. Seals should also be checked regularly.

FAQ zu Druckreglern

What does a pressure regulator do?

A pressure regulator ensures that the pressure in a compressed air system remains constant. It reduces the inlet pressure to a specified outlet value and keeps it stable even if the consumption or inlet pressure changes. This ensures reliable operation and prevents the connected components from being subjected to pressure fluctuations.

How does a pressure regulator work in detail?

Inside, there is a mechanical system consisting of a spring, diaphragm, and valve. The spring sets the desired outlet pressure. When the pressure in the system rises, the diaphragm presses against the valve and throttles the air flow. When the pressure drops, the valve opens again. In this way, the regulator automatically compensates for changes without the need for external control.

How do I install a pressure regulator correctly?

The regulator is installed in the intended flow direction. This is usually indicated by an arrow on the housing. Before installation, the system should be vented and all connection sizes checked. After installation, the desired pressure is set using the adjustment wheel. Finally, it is recommended to perform a leak test with a pressure gauge to confirm that it is working properly.

What does pressure regulator maintenance involve?

Pressure regulators require little maintenance, but should be checked regularly. This includes visual inspections for leaks, corrosion, or wear. Filter inserts and seals should be replaced as necessary. In systems with high accuracy requirements, regular calibration is recommended, for example every 12 to 24 months.

How can I tell if a pressure regulator is no longer working properly?

If the outlet pressure fluctuates significantly, air can be heard escaping, or the pressure can no longer be adjusted precisely, this may indicate a defect. A stiff adjustment screw or visible deposits and corrosion are also warning signs. In such cases, the regulator should be checked or replaced.

What happens when a pressure regulator fails?

A malfunctioning regulator can no longer control the pressure. This can lead to overpressure, which damages machines. Conversely, too low a pressure can slow down or completely stop processes. Energy losses are also possible. In critical areas such as medical technology or food production, a failure can compromise safety or product quality.

Contact and consultation – take advantage of our expertise

Do you have questions or need help choosing the right pressure regulator? Are you planning a project or looking for a suitable solution for your control task? Our team is available by phone, email, or via the contact form. Together, we will find the best solution for your application.

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