GE Masoneilan 78 User manual

GE Oil & Gas
Masoneilan*
78 Model
Air Filter Regulator
Instruction Manual [Rev. D]
GE Data Classication : Public

© 2017 General Electric Company. All rights reserved.2 | GE Oil & Gas
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE INFORMATION
IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION
AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES
NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE
TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS FOR
SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE,
THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS
APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY
POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER
INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE
CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD BE REFERRED TO GE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE
EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS
OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING,
OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE
OR IN PART WITHOUT THE WRITTEN APPROVAL OF GE.

© 2017 General Electric Company. All rights reserved. Masoneilan Model 78 Series Air Filter Regulator Instructions Manual | 3
Safety Information
Important - Please Read Before Installation
The model 78 Series air filter regulator instructions contain
DANGER, WARNING, and CAUTION labels where necessary, to
alert you to safety related or other important information. Read the
instructions carefully before installing and maintaining your control
valve. DANGER and WARNING hazards are related to personal
injury. CAUTION hazards involve equipment or property damage.
Operation of damaged equipment can, under certain operational
conditions, result in degraded process system performance that
can lead to injury or death. Total compliance with all DANGER,
WARNING, and CAUTION notices is required for safe operation.
CAUTION
CAUTION
WARNING
DANGER
This is the safety alert symbol. It alerts you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not avoided, could
result in serious injury.
CAUTION
CAUTION
WARNING
DANGER
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
CAUTION
WARNING
DANGER
When used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, could result in
property damage.
Note: Indicates important facts and conditions.
About this Manual
• The information in this manual is subject to change without prior
notice.
• The information contained in this manual, in whole or part, shall
not be transcribed or copied without GE’s written permission.
• Please report any errors orquestions about the information in this
manual to your local supplier.
• These instructions are written specifically for the model 78 air filter
regulator, and do not apply for other instrument outside of this
product line.
Warranty
Items sold by General Electric are warranted to be free from
defects in materials and workmanship for a period of one year
from the date of shipment provided said items are used according
to GE recommended usages. GE reserves the right to discontinue
manufacture of any product or change product materials, design or
specifications without notice.
Note: Prior to installation
• The instrument must be installed, put into service and maintained
by qualified and competent professionals who have undergone
suitable training.
• All surrounding pipe lines must be thoroughly flushed to ensure
all entrained debris has been removed from the system.
• Under certain operating conditions, the use of damaged
equipment could cause a degradation of the performance of
the system which may lead to personal injury or death.
• Changes to specifications, structure, and components used may
not lead to the revision of this manual unless such changes
affect the function and performance of the product.

© 2017 General Electric Company. All rights reserved.4 | GE Oil & Gas
Model 78 Air Filter Regulators
Product Description
The Model 78 Series pressure regulators are compact, lightweight,
high-performance pressure reducing instruments. They are used
primarily for supplying a stable source of air to process control
equipment such as current to pneumatic transducers and control
valve positioners.
Numbering System
Model No. Pressure Range Description
78-4 5-40 psi (35-280
kPa), (0.35-2.8 bar)
Air Loading with
Relief and Filter
78-40 5-100 psi (35-700
kPa), (0.35-7 bar)
Air Loading with
Relief and Filter
Specications
Inlet Pressure Rating 210 psi (1.5 MPa, 15 bar)
maximum
Pressure Set Range
5-40 psi (35-280 kPa, 0.35-2.8
bar)5-100 psi (35-700 kPa, 0.35-7
bar)
Connection 1/4 NPT
Rated Cv 0.25
Filter Element Sintered Porous Polyethylene (5μ)
Ambient Temperature
Range -40° to +83°C (-40° to +182°F)
Air Consumption 0.004 scfm (100 sccm)
Weight 14 oz. (0.4 kg)
Materials of
Construction See table next page
CAUTION
CAUTION
WARNING
DANGER
Do not install this Regulator in air lines which exceed 210 psi
(1.5 MPa, 15 bar) pressure.
Installation
Clean the lines thoroughly to remove all dirt, scale or other foreign
matter before installing the regulator. Install with ow in direction
of ow arrows on regulator body. The airset should be installed
with the drain cock facing down. Regulator should be installed
as close as possible to device utilizing the reduced pressure to
minimize pressure drop. Do not use piping or tubing smaller than
the regulator connections since this will restrict ow and reduce
capacity.
It is recommended that pressure gauges be installed on the inlet
and outlet sides of the regulator as an aid in adjusting the pressure
and in monitoring of working pressures.
Operation
Prior to applying supply pressure, loosen knob lock screw and turn
pressure set knob counterclockwise. Turn on supply pressure.
Output pressure should be zero. Slowly rotate set knob clockwise
until desired pressure is reached. Tighten knob locking screw to
ensure that pressure remains set at desired value. When changing
output from a higher to lower pres¬sure, initially go to lower than
desired pressure, then increase to desired pressure. Re-tighten
knob lock-screw.
Maintenance
It is recommended that the drain cock be opened at regular
intervals to drain any uid that may have collected in the dripwell.
The interval between draining will have to be determined based on
the actual rate of accumulation of uid.
It is recommended that pressure gauges be installed on the inlet
and outlet sides of the regulator as an aid in adjusting the pressure
and in monitoring of working pressures.
CAUTION
CAUTION
WARNING
DANGER
The relief valve feature should not be confused with any
auxiliary safety valve which might be needed for complete
protection of air operated equipment. It is intended only
to provide more uniform controlled pressure and to permit
adjusting the outlet pressure downward without venting the
line.
CAUTION
CAUTION
WARNING
DANGER
Prior to performing maintenance on the regulator, shut off the
inlet and outlet pressures and remove the spring compression
by turning the setting knob fully counterclockwise. Open
the drain cock carefully to relieve any retained pressure and
drain the dripwell. It is recommended that the regulator be
removed from the line for repairs.
CAUTION
CAUTION
WARNING
DANGER
When draining the dripwell, open the drain cock slowly and
collect the fluid in a suitable container for safe disposal.
Note:
• Considering the high labor costs involved in replacing internal
parts, it may be more economical to stock complete units.
• Care must be taken to avoid damage to the plug and stem
assembly.

© 2017 General Electric Company. All rights reserved. Masoneilan Model 78 Series Air Filter Regulator Instructions Manual | 5
Troubleshooting
If at any time the regulator fails to function properly it is
recommended to replace rather than repair the device.
Parts List and Materials of Construction
No. Part Standard Material
1Body Aluminum Die Casting
2Spring Casing Aluminum Die Casting
3Bottom Cap Aluminum Die Casting
4Knob VALOX 420
5Lock Screw Stainless Steel
6Adjusting Screw Stainless Steel
7Spacer VALOX 420
8Spring Button Zn-Cr Plated Carbon Steel
9Spring Coated Spring Steel
101Diaphragm NBR
15 Plug Guide VALOX 420
161Plug Neoprene/416 Stainless Steel
171Filter Sintered Polyethylene
181Port Spring Stainless Steel
191“O”-Ring NBR
-
21 Drain Cock Stainless Steel
22 Screw Stainless Steel
23 Pipe Plug Zinc Plated Carbon Steel
24 Aspirator VALOX 420
25 Nameplate Aluminum
1 Recommended Spare Parts
5
4
22
7
6
8
9
25
2
10
23
22
3
21
15
16
18
17
19
1
23
24

© 2017 General Electric Company. All rights reserved.6 | GE Oil & Gas
Lock Screw
Setting Knob
Diaphragm
Aspirator
OUTLET
Supply Valv
e
Bottom Cap
Drain Cock
Relief Valve
Spring
Spring Button
Adjust Screw
Spring Case
Diaphragm Plate
Body
INLET
Plug
Filter
Port Spring
Top View
Threaded Holes for Mounting Bracket (M5)
52 mm
(2.05 in.)
81 mm
(3.19 in.)
60 mm
(2.36 in.)
55 mm (2.17 in.)
141 mm
(5.55 in.)
Dimensions
Cut-Away View of 78 Series Pressure Regulator

© 2017 General Electric Company. All rights reserved. Masoneilan Model 78 Series Air Filter Regulator Instructions Manual | 7

GEA31190D 03/2017
*Denotes a trademark of General Electric Company.
Other company names and product names used in this doc-
ument are the registered trademarks or trademarks of their
respective owners.
© 2017 General Electric Company. All rights reserved.
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