controlair 3500 Manual

Installation, Operation and
Maintenance Instructions
TYPE-3500/3600
High Pressure Regulator
INTRODUCTION
Scope
This manual provides instructions for the installation, adjustment, maintenance, and parts ordering of
all Type-3500 brass and Type-3600 316 Stainless Steel high-pressure regulators.
Description
The Type-3500/3600 regulators are self-operated, high-pressure regulators which can be designed to
be used in applications requiring high-pressure reducing regulators for various gases. Type
3500/3600 regulators can also be used where high-pressure gas must be reduced for use as pilot
supply pressure in pilot-operated regulators.
SPECIFICATIONS
Connections: Flow Capacities (SCFH of 0.6 SG Gas)
1/4” NPT (one inlet and two outlet connections)
Operating Temp.:
Type-3500: -70to 225°F (-57 to 107°C)
Type-3600: -40to 225°F (-40 to 107°C)
Max Inlet Pressure:
6000 psig
Outlet Ranges:
0 – 125 psi
0 – 150 psi
0 – 225 psi
Materials of Construction:
See Parts List
INSTALLATION
WARNING: Over-pressuring a regulator or associated equipment may cause leakage, part
damage, or personal injury due to bursting of pressure-containing parts or explosion of
accumulated gas. Do not install a regulator where service conditions can exceed the specifications
listed in this manual or the specifications of any applicable local, state, or Federal codes and
regulations.
Use qualified personnel when installing, operating, and maintaining these regulators. Make sure that
there is not damage to or foreign material in the regulator and that all tubing and piping are clean and
unobstructed. The regulator may be installed in any position. Apply pipe compound to the pipeline
threads. Connect inlet piping or tubing to the 1/4” NPT screwed connection marked “IN” and outlet piping
or tubing to one of the 1/4” NPT screwed connections marked “OUT”. Install a pressure gauge or pipe
plug in the unused outlet connection.
Inlet
Pressure Outlet Pressure
Outlet Range
0-120
psig 0-150 psig 0-225 psig
250
20 700 1300 -
40 120 400 -
50 60 190 1300
60 - 90 850
80 - - 400
100 - - 125
115 - - 40
2000
50 3200 7800 -
60 - 1300 -
85 - - 10000
100 - - 2800
115 - - 500

TYPE-3500/3600
Installation, Operation, and Maintenance Instructions
2
If continuous operation of the system is required during inspection or maintenance, install a three-valve
bypass around the regulator.
WARNING: A regulator may vent some gas to the atmosphere. In hazardous gas service, vented
ay accumulate, causing personal injury or equipment damage due to fire or explosion. Vent a
regulator in hazardous gas service to a remote, safe location.
The Type 3600 regulator is supplied with a 1/4” NPT female connection on the spring case for
remote venting (tapped exhaust). To remotely vent the spring case, remove the screen, if present, and
connect 1/4” piping or tubing to the spring case connection. The piping or tubing should (a) vent the
spring case to a safe location, (b) have as few bends as possible, and (c) have a screened vent on its
exhaust end.
STARTUP
With installation completed and downstream equipment adjusted, slowly open the upstream and
downstream block valves while using pressure gauges to monitor pressure. To adjust, remove the
adjusting screw cap and turn the adjusting screw clockwise to increase the set pressure or
counterclockwise to decrease the set pressure. Monitor pressure with gauges during adjustment. When
adjustment is complete, replace the adjusting screw cap. If the desired outlet pressure is not within the
range of the regulator spring, install a spring with the desired range according to the “Maintenance”
section.
SHUTDOWN
First, close the upstream shutoff valve, and then, close the downstream shutoff valve. Next, open the
vent valve between the regulator and the downstream shutoff valve and open the vent valve between the
regulator and the upstream shutoff valve. If vent valves are not installed, safely bleed off both inlet and
outlet pressures and check that the regulator contains no pressure.
MAINTENANCE
Regulator parts are subject to normal wear and must be inspected and replaced as necessary. The
frequency of inspection and parts replacement depends on the severity of service conditions and the
requirements of local, state, and federal rules and regulations.
Instructions are given below for disassembly and assembly of parts.
WARNING: To avoid personal injury or equipment damage from sudden release of pressure or
explosion of accumulated gas, do not attempt any maintenance or disassembly without first
isolating the regulator from system pressure and relieving all internal pressure from the regulator.

TYPE-3500/3600
Installation, Operation, and Maintenance Instructions
3
DISASSEMBLY
The following procedure describes how to completely disassemble the regulator. When part replacement
or inspection is required, complete only those steps necessary to accomplish the job.
1. Remove the adjusting screw cap.
2. Turn the adjusting screw counterclockwise to remove spring compression.
3. Remove the bottom housing, bottom housing seal, and tension spring.
4. Unscrew the seat block screw from the yoke.
5. Remove the seat housing and seat body.
6. Remove the bonnet screws and separate the bonnet from the body.
7. Remove the upper spring retainer and spring.
8. Unscrew the diaphragm locknut, and remove the diaphragm plate, the diaphragm, the
diaphragm gasket, and the diaphragm washer.
9. Remove the yoke from the body.
10. Unscrew the supply nozzle. Examine seating edge of supply nozzle. Replace with a new part if
worn or nicked.
ASSEMBLY
The procedure assumes that the regulator was completely disassembled. It not, start these instructions
at the appropriate step.
1. Screw the supply nozzle into the regulator.
2. Insert the yoke into the regulator. The seat block has four valve discs, one on each side. Inspect
the valve discs and select the one to be used. Insert the seat block and seat housing into the
regulator and fasten to the yoke with the seat block screw.
3. Place the bottom housing seal in the seal pocket of the regulator body. Place the tension spring
in the bottom housing, and thread it into the regulator.
4. Put the diaphragm gasket on the regulator body.
5. Place the diaphragm washer, the diaphragm, and the diaphragm plate on the yoke. Make sure
the diaphragm convolutions are toward the spring and secure the parts by threading the
diaphragm locknut onto the yoke.
6. Place the spring and upper spring retainer on the diaphragm plate.
7. Position the bonnet over the spring and on the regulator body. Orient the bonnet vent or vents
as necessary. Insert the cap screws and tighten them only finger-tight.
8. Thread the adjusting screw into the bonnet just far enough to slightly compress the spring.
Securely tighten the cap screws and refer to the “Startup” section for adjustment procedures.
LIMITED WARRANTY & DISCLAIMER
ControlAir, Inc. products are warranted to be free from defects in materials and workmanship for a
period of 18 months from the date of manufacture, provided said products are used according to
ControlAir, Inc. recommended usages. ControlAir, Inc.’s liability is limited to repair of, refund of purchase
price paid for, or replacement in kind of, at ControlAir, Inc.’s sole option, any products proved defective.
ControlAir, Inc. reserves the right to discontinue manufacture of any products or change product
materials, design or specifications without notice.

TYPE-3500/3600
Installation, Operation, and Maintenance Instructions
8 Columbia Drive, Amherst, New Hampshire 03031 U.S.A.
Tel: [phone] Fax: [phone]
441-622-083 07/31/18 www.controlair.com 4
Parts List
*INCLUDEDINREPAIRKIT
DESCRIPTIONPARTNO.Type‐3500PARTNO.Type‐3600
RepairKit449‐871‐084449‐871‐142
3
9
13
14
7
1
12 4
11
13
8
5
6
18
10
15
16
17
2
21
20
22
19
NOT SHOWN
REPLACES
ITEMS 20 &21
ITEMDESCRIPTIONMATERIAL–Type‐3500MATERIAL–Type‐3600QTY.
1BodyBrass316StainlessSteel1
2BonnetBrass316StainlessSteel1
3BottomHousingBrass316StainlessSteel1
4DiaphragmPlateSteelSteel1
*5Diaphragm302StainlessSteelMonel4001
*6DiaphragmGasketNitrileFluorocarbon1
7SupplyNozzle316StainlessSteel316StainlessSteel1
8SpringRetainer316StainlessSteelSteel1
9
Spring–0‐125
17‐4StainlessSteelStainlessSteel1Spring–0‐150
Spring–0‐225
*10SealBottomHousingPTFEPTFE1
11TensionSpringZincPlatedWireSteel1
12HexCapScrew.250‐20UNFX.625StainlessSteelStainlessSteel6
13YokeBrass316StainlessSteel1
14SeatHousingBrass316StainlessSteel1
15SeatBlockScrew316StainlessSteel316StainlessSteel1
*16SeatBlockBrass/Nylon316StainlessSteel/PTFE1
*17DiaphragmWasherPTFEPTFE1
*18HexNut.375‐24UNFSteel–ZincPlatedStainlessSteel1
19InletScreenStainlessSteelStainlessSteel1
20CapBrass316StainlessSteel1
21SlotHeadAdjustingScrewStainlessSteelStainlessSteel1
22TeeHandleAdjustingScrewBrassStainlessSteel1