Sensus 441-57S User manual

Models 441-57S
Regulator
RM-1360 R9
Installation and
Maintenance Instructions

2
The Model 441-57S Regulator is an excellent general purpose gas pressure regulator for larger loads.
Use it for natural gas, air, dry CO2, propane, butane, and other gases.
Regulator Maximum
Body Type Body Materials Inlet Pressure
2" Screwed Cast Iron 250 psi
Flanged ANSI 125 Cast Iron 175 psi*
Flanged ANSI 250 Ductile Iron 575 psi*
Flanged ANSI 300 Cast Steel 720 psi *
Flanged ANSI 600 Cast Steel 1000 psi*
*Carefully note the following exceptions to the above, based on valve size:
Maximum Inlet Pressures
Maximum
Body Size Valve Inlet Pressure
6" 4-1/4" 150 psi
6" 3" reduced 300 psi
4" 3"
6" 2-1/8" reduced
4" 2-1/8" reduced 500 psi
3" 2-1/8"
Valve material selection is limited by inlet pressure and differential.
Valve Maximum Maximum
Material Inlet Pressure Pressure Differential
Buna-N 575 psi 250 psi
Poly-U Red 720 psi 400 psi
Poly-U Tan 1200 psi 600 psi
Installation and Start-Up
1. Thoroughly purge inlet piping to remove dirt and debris
that could damage the regulator or impair its operation.
If this cannot be done, a filter or strainer should be installed
ahead of the regulator (see Catalog RDS 1498, Regulator
Pressure Ratings). Make certain that inside of regulator and
piping are free of dirt, foreign matter, and other debris.
2.Install the regulator. Make certain flow through the regulator
is in the correct direction. High pressure connects to
the inlet side. Be sure that shipping screens or covers,
if used, are removed.
On flanges, tighten bolts evenly. On screwed connections,
apply pipe dope to male threads only.
Where required, the regulator may be inverted.
CAUTION
It is the user’s responsibility to assure that all regulator
vents and/or vent lines exhaust to a non-hazardous location
away from ANY POTENTIAL sources of ignition.
Where vent lines are used, it is the user’s responsibility
to assure that each regulator is individually vented and
that common vent lines ARE NOT used.
3. The vent connection is an escape path for flammable gas and
it must be located and/or piped so that potential discharge
occurs in a safe area away from buildings, open flames,
collection areas, arcing devices, etc.
Regulators that are installed indoors or in a non-vented area
must be vented to the outside. Simply run vent piping from
the regulator vent connection to a non-hazardous location
on the outside away from any potential sources of ignition.
The vent piping must be connection size or larger and piped
to a safe area.
The outlet of the vent piping must allow for the free and
unobstructed passage of air and gas and must be protected
against the potentials listed in the instructions.
4. For outdoor installations, it is recommended that the
regulator be installed so that the regulator vent faces
downward to avoid the potential for water or other foreign
matter entering the regulator and interfering with proper
operation of the regulator.
5. Install the control line. Run it from the Union shown at 60
on the regulator to the control connection in the outlet piping.
The control line should be no less than 1/2” in size. It should
be sturdy with adequate protection against breakage
(regulators go wide open if the control line is broken). Pitch it
to drain away from the regulator, free of moisture pockets.
The regulator will work to deliver the pressure (for which it
is adjusted) at that point in the piping where the control
connection is located.
In general, the control connection should be at least eight
pipe diameters downstream from the regulator and should
be in as straight a run of pipe as possible where turbulence
is at a minimum. Keep clear of elbows, valves, and other
causes of excessive turbulence.
The control connection should be clean and smooth inside
the pipe to minimize turbulence. It should be free of rough
edges, welding “icicles”, etc. It should be located on the top
or side of the pipe, not on the bottom. Where outlet piping
increases in size near the regulator, it is generally preferable
to locate the connection to the larger size piping.
The Union 60 contains a small orifice (approximately
1/16” diameter). This orifice should not be removed.
Also, make certain it is open and free of foreign material.
6Check all connections for leaks.
Installation and Maintenance Instructions
Model 441-57S Regulator

3
Servicing and Adjustment
General Notes (See illustration on pages 5 – 7)
1. Make sure the regulator is entirely depressurized before
servicing.
2. A quick visual inspection of the valve can be made by
removing inspection plates 38 from the sides of the body.
These also provide greatly improved access to the valve
when servicing or adjusting.
3. Carefully note location and position of disassembled parts
to be certain reassembly is correct. Inspect each one
carefully and replace those that are worn or damaged or
otherwise unsatisfactory.
4.The diaphragm 20, the springs 14, and all other parts
from the diaphragm up (except the 24 stem) are fully
interchangeable with the Model 461-57S Regulator.
Valve and body parts are interchangeable with other
441 Regulators (441-S, 441-X57, 441-VPC.).
CAUTION
Turn gas on very slowly. If an outlet stop valve is used,
it should be opened first. Do not overload the diaphragm with
a sudden surge of inlet pressure. Monitor the outlet pressure
during start-up to prevent an outlet pressure overload.
7. Put the regulator into operation as follows:
a. Slowly open downstream control line valve (A).
b. Slowly open downstream block valve (B).
c. Very slowly open upstream block valve (C).
8. Set adjusting screw 10 for the required outlet pressure. Turn
it clockwise to increase the pressure and counterclockwise
to decrease it. Only make this adjustment when gas is
actually flowing through the regulator. After adjustment
is complete, locknut 11 should be tightened firmly and seal
cap 1replaced.
9. To shut down, carefully close valves (C), (B), and
(A) in that order.
CAUTION
1. Keep pipe dope and all other foreign substances out of
the control line.
2. Never install any type of automatic shut-off device,
which closes completely, between the regulator outlet
and the downstream control line connections.
3. The vent must be positioned to protect against flooding,
drain water, ice formation, traffic, tampering, etc.
The vent must be protected against nest building animals,
bees, insects, etc. to prevent vent blockage and minimize
the chances for foreign material from collecting in the
vent side of the regulator diaphragm.
5.Use lubricants sparingly and with care to avoid exposing
tacky surfaces to the gas stream. Such surfaces could
cause dirt accumulation on close clearance parts.
Use moly or silicone type lubricants.
Avoid the use of petroleum base types.
Lubricate the stem 24, the guide 50h and stem O-ring 23
with dry silicone lubricant to help assure free movement
and a tight seal.
An application of silicone base lubricant to the other O-rings
and the tetraseals in the regulator will also help assure
their tightness.
6.There is one screwed connection that must be loose.
Carefully note which one it is. All other connections must
be firm and tight.
On 2" and 3” regulators, the loose connection is between
parts 50e and 24.
On 4” and 6” regulators, the loose connection is between
parts 50i and 24.
This loose connection should be screwed together until
it bottoms, then be backed off 1/2 to 1 full turn.
7.When replacing orifices, tighten cap screws 26 evenly and
carefully to avoid stripping female threads in body casting.
8.When changing to different size valve in 4” and 6”
regulators, be sure to use the correct travel stop (Ill. No. 54).
For identification, last digit of part number is recessed into
one end of travel stop.
CAUTION
Regulators are pressure control devices with numerous moving
parts subject to wear which is dependent upon particular
operating conditions. To assure continuous satisfactory
operation, a periodic inspection schedule must be adhered to
with the frequency of inspection determined by the severity
of service and applicable laws and regulations.
To Remove Valves
1.Remove seal cap 1, back off adjusting screw 10,
remove housing cover 5and spring 14 (also, 14a
and 14b if used).
2.Remove bottom plate 33, and side plates 38.
3.Insert an Allen wrench through side inspection opening and
loosen Allen screw 50g.
4.Unscrew lower valve assembly and remove through bottom
opening. (50h unscrews from 50e).
5.Unscrew upper valve assembly and remove through side
opening. (50e or 50i unscrews from 24).
Installation and Maintenance Instructions
Model 441-57S Regulator

4
Note:
a. If upper valve assembly is too large to remove through
side opening, then remove it through bottom opening by
also removing outlet orifice 29, (remove cap screws 26
to remove orifice, and if tight, jack out using cap screws in
jacking holes).
b. Entire valve assembly may be removed intact through
bottom opening by also removing orifice 29. This method
leaves the lock-up adjustment undisturbed.
c. Use care with orifice O-ring 27.
6.To disassemble upper and/or lower valve assembly,
remove nuts 50a.
To Replace and Adjust Valves
1. Assemble upper valve assembly
(parts 50a, 50b, 50c, 50d, 50e, 50f, 50g, 50i), and lower
valve assembly (parts 50a, 50b, 50c, 50d, 50h).
Firmly tighten nuts 50a. Also, 50i should be firmly
tightened against 50a.
2.Insert upper valve assembly and screw into place.
Screw 50e or 50i into 24 until it bottoms.
Then back off 1/2 to 1 turn - this is important.
3.If orifice 29 was removed, reinstall it.
4.Insert lower valve assembly and screw into place by a few
turns (50h screws into 50e).
5.Turn upper valve assembly so Allen screw 50g is accessible
through side inspection opening.
6.Make the valve lock-up adjustment as follows:
a. Hold upper valve against its seat. This can be done by
hand, reaching through side inspection opening.
b. While holding the upper valve against its seat, screw lower
valve assembly upwards until the lower valve also touches
its seat. When both upper and lower valves are touching
their seats, they are correctly adjusted for tight lock-up.
c. Firmly tighten Allen screw 50g. This locks the adjustment
by evenly and tightly locking 50h and 50e together.
Note: If the entire valve assembly was removed intact and
Allen screw 50g has not been loosened, the assembly may
be reinstalled without making the lock-up adjustment.
7.Screw entire valve assembly up (50e or 50i screws into
24 until it bottoms). Then back off 1/2 to 1 turn –
this is important.
8.Replace side plates 38.
9.Replace bottom plate 33. Match bottom end of 50h
into 31 and/or 32, then turn bottom plate either way to
first matching bolt hole position.
To Remove Orifices
1.Remove orifice 29 per applicable steps 1 through 5 under
section “To Remove Valves”.
2.Remove inlet orifice 28 as follows:
a. Remove seal cap 1, back off adjusting screw 10,
remove housing cover 5, and remove spring.
b. Remove bottom plate 33 and then unscrew valve
assembly by grasping 50h and turning. (50e or 50i
unscrews from 24).
c. Remove diaphragm case assembly by first opening union
60 and removing cap screws 34.
d. Remove cap screws 26 and remove inlet orifice 28.
If orifice is tight, jack out cap screws in jacking holes.
Use care with O-ring 27.
e. When replacing diaphragm assembly, the threaded
connection between 24 and 50e or 50i should be
screwed together until it bottoms.
Then backed off 1/2 to 1 turn - this is important.
To Change Spring
1.Remove seal cap 1, back off adjusting screw 10,
remove housing cover 5, and remove spring.
2.Insert the new spring. Be sure it nests correctly into part 19
and travel indicator bracket 45k is in place. Also, make a
visual inspection of diaphragm 20 before inserting the spring
to be sure the roll-out is uniform and in place.
(Use a flashlight if necessary).
3.Complete steps 7, 8, and 9 under “To Assemble 441-57S”.
To Service Diaphragm
1.Remove seal cap 1, back off adjusting screw 10,
remove housing cover 5, and remove spring 14.
If used, also remove spring 14a and 14b.
2. Remove bolts 42. Then carefully remove upper
diaphragm case 8.
3.Turn diaphragm assembly counterclockwise until 24
unscrews from 50e or 50i, then remove assembly and
inspect diaphragm.
4.If a new diaphragm 20 is required, remove nut 16
and disassemble.
5.When reassembling, be sure that fabric side of diaphragm
20 will be toward the vent side of the regulator and the
rubber side of diaphragm toward the pressure side.
The gasket is always placed on the spring side of
the diaphragm.
6.Screw diaphragm assembly back into place
(24 screws into 50e or 50i until it bottoms).
Then back off 1/2 to 1 turn – this is important.
7.Fold roll into roll-out diaphragm and then carefully reinstall
upper diaphragm case 8. Diaphragm must not be pinched
between upper and lower cases 8and 40 or 40a. Also,
roll-out loop must be uniformly full and even. It should be
in place as shown on the cross-section drawing.
Tighten bolts 42 evenly.
8.Replace spring, etc., per steps 6 thru 9 under
“To Assemble 441-57S”.
Installation and Maintenance Instructions
Model 441-57S Regulator

Side Inspection Plate
39
38
26
27 29
26
27 28
25
24
23
22a
22 20
19
17 16
45
13 12
11
10
32
33
34
35
1
1a
4
6
5
7
8
14
42
41
36a
40a
40
36
60
40
36 34
35 37a
37
ab
c
d
e
a
b
d
c
g
h
50
See General
Note 6, p.3
5
To Assemble 441-57S
1. Install orifice 28 through top opening.
2.Install valve assembly and orifice 29 per applicable steps
1 through 6 under “To Replace and Adjust Valves”
(except that 50e or 50i does not yet screw into 24).
3.Install centerpiece and lower diaphragm case 36 and
40 or 40a.
4.Install diaphragm assembly and case per steps 5 through 7
under “To Service Diaphragm”.
5.Replace bottom plate 33. Match bottom end of 50h into
31 and/or 32, then rotate bottom plate either way to
the first matching bolt hole position.
6.Inset the spring. Be sure it nests correctly onto part 19
and travel indicator bracket 45k is in place. Also, make
a visual inspection of diaphragm 20 before inserting the
spring to be sure the roll-out is uniform and in place
(use a flashlight if necessary).
7.Insert top spring button 12. Be sure it is nested correctly
on the spring. Also, make sure that ball 13 is in place.
8.Install housing cover 5. Be sure the lower end of adjusting
screw 10 fits into the hole in button 12.
9.Set adjusting screw 10 for desired outlet pressure.
Firmly tighten nut 11 and replace seal cap 1.
Over Pressurization Protection
Protection must be provided for the downstream piping system
and the regulator’s low pressure chambers to assure against
the potential over pressurization due to a regulator malfunction
or a failure of the regulator to lock-up. The allowable over
pressurization is the lowest of the maximum pressures permitted
by federal codes, state codes, Sensus bulletin RDS-1498, or other
applicable standards. The Method of providing over
pressure protection could be a relief valve, a monitor regulator,
a shut-off device or any similar device.
Temperature Limits
The Model 441-57S Regulator can be used for
flowing temperatures from -20°F to 150°F.
Buried Service
The 441-57S Regulators ARE NOT recommended
for buried service.
Model 441-57S
General Assembly 2" and 3" Models
Installation and Maintenance Instructions
Model 441-57S Regulator

Side Inspection Plate
39
38
31
54
26
27 29
26
27
28
25 24
23
22a
22 20
19
17 16
45
13 12
11
10
32 33
34
35
1
1a
4
6
5
7
8
14
42
41
36a
60
40
34 36
35
37a
i
b
cd
e
a
b
d
c
g
h
50
See General
Note 6, p.3
14a
14b
37
a
d
6
Typical Arrangements and Dimensions Model
(Indoor or Outdoor Installation)
1
(Minimum Service Space)
10
11
Set
Adjustment
Screw
for Desired
Outlet Pressure
Inlet
Remove Vent
(If Required)
441-57S
60 Downstream
Control Line
A
Control
Connection
Outlet
N
F
D
E
C B
Vent
M(Minimum Service Space)
Regulator F (Face to Face, in.)
Body Type 2" Pipe 3" Pipe 4" Pipe 6" Pipe
Screwed 10 – – –
Flanged
ANSI 125 10 11 3⁄413 7⁄817 3⁄4
Flanged
ANSI 250 10 1⁄212 1⁄2141⁄218 5⁄8
Flanged
ANSI 300 10 1⁄212 1⁄2141⁄218 5⁄8
Flanged
ANSI 600 11 1⁄413 1⁄415 1⁄220
Model 441-57S
General Assembly 4" Model
Installation and Maintenance Instructions
Model 441-57S Regulator

26
28
25
45
13 12
11
10
32
34
See General
Note 6, p.3
1
1a
4
6
5
7
8
14
42
41 40
34
36
35
37a
i
bc
d
14a
14b
37
a
33 34
31
30
27
29
27
26
24
23
22a
22
20 19
17 16
32
e
f
g
ab
cd
h
36a
60
Side Inspection Plate
39
38
7
Model 441-57S
General Assembly 6" Model
DE MN
2" Pipe 6 24 5 7
3" Pipe 6 24 5 7
4" Pipe 9 1⁄225 5 8
6" Pipe 12 28 1⁄2514
Outlet Nominal
Pressure Spring Diaphragm
Min. to Max Color Size (I.D.)
3 to 6 psi Yellow
5 to 9 psi Gray
7-1/2 to 15 psi Blue
12-1/2 to 30 psi Red 5" all ranges
25 to 55 psi Brown
50 to 75 psi Black
70 to 100 psi Brown plus White*
* White colored spring is nested within brown
Spring RangesDimensions in Inches
Installation and Maintenance Instructions
Model 441-57S Regulator

2" and 3" Models
Illustration Part
Number Description Number
32 Guide Bushing with Pin, brass 090-16-385-01
Guide Bushing with Pin, 090-16-385-03
stainless steel
34 Hex Cap Screw, 1/2" – 910106
13 x 1-1/4"
35 Tetraseal (or O-Ring), 904085
4-3/8" x 4-5/8"
36 Tetraseal (or O-Ring), 904084
3" x 3-1/4"
37 Centerpiece Stem Bushing 090-16-373-00
37a Aluminum Seal Ring 090-26-178-00
39 Tetraseal (or O-Ring), 904078
3-1/4" x 3-1/2"
8
Model 441-57S Condensed Parts List
2", 3", 4", and 6" Models
Illustration Part
Number Description Number
1a Tetraseal (or O-Ring), 1-3/4" x 2" 904092
4Hex Cap Screw, 5/16" – 18 x 1", 910030
120,000 tensile, 8 used
6 Housing Cover Gasket 091-00-066-30
7 Vent Cap, 1/4 NPT 137-02-505-02
10 Spring Adjustment Screw 090-16-007-02
11 Hex Steel Jam Nut, 5/8" – 11 921407
13 Thrust Bearing, 3/8" dia. 930510
stainless steel ball
Spring, Yellow 3 to 6 psi 091-00-021-05
Spring, Gray 5 to 9 psi 091-00-021-04
Spring, Blue 7-1/2 to 15 psi 091-00-021-03
Spring, Red 12-1/2 to 30 psi 091-00-021-02
14 Spring, Brown 25 to 55 psi 091-00-021-01
Spring, Black 50 to 75 psi 091-00-021-00
Spring, Brown plus White
70 to 100 psi
Brown outer spring 091-00-021-01
White inner spring 091-00-021-08
16 Hex Steel Nut 5/8" 905993
17 Split Lockwasher 5/8" 932531
19 Diaphragm Plate, upper 091-00-010-00
20 Diaphragm, 5" Roll-Out 091-00-350-00
41 Hex Steel Nut, 3/8" – 920853
16, 8 used
42 Hex Steel Bolt, 3/8" – 910058
16 x 1-3/4" Lg., 8 used
Travel Indicator Assembly
5/8" scale
45 (1-1/2", 1-3/4", 2-1/8" valves) 091-00-365-75
1" scale (3" valves) 091-00-365-77
1-1/4" scale (4-1/4" valves) 091-00-365-79
60 1/2" NPT Nipple, Orifice Plug 090-16-361-01
and Steel Union Assembly
90 Nameplate 090-00-086-05
91 Nameplate, round 090-16-086-00
92 Rd. Hd. Type U Drive Screw, 903004
#4 x 3/16" Lg.
93 Rd. Hd. Machine Screw, 914402
6-32 x 1/4" Lg.
2" and 3" Models
Illustration Part
Number Description Number
22 Lower Diaphragm Plate 091-00-022-00
22a O-Ring, 5/8" x 3/4" 902922
23 O-Ring, 11/16" x 7/8" 934013
24 Diaphragm Connecting Screw, 090-16-058-00
stainless steel
2" Models
Illustration Part
Number Description Number
26 Hex Cap Screw, 1/4" – 910001
20 x 1/2" Lg., 120,00 tensile
27 O-Ring for Orifices 904832
1-3/4" Inlet Orifice, plated steel 090-16-028-00
28 1-3/4" Inlet Orifice, stainless steel 090-16-028-50
1-1/2 Inlet Orifice, plated steel 090-16-028-01
1-1/2" Inlet Orifice, stainless steel 090-16-028-51
1-3/4" Outlet Orifice, plated steel 090-16-029-00
26 1-3/4" Outlet Orifice, stainless steel 090-16-029-50
1-3/4" Outlet Orifice, plated steel 090-16-029-01
1-3/4" Outlet Orifice, stainless steel 090-16-029-51
3" Models
Illustration Part
Number Description Number
26 Hex Cap Screw, 1/4" – 910001
20 x 1/2" Lg., 120,00 tensile
27 O-Ring for Orifices 950818
2-1/8" Inlet Orifice, plated steel 090-20-028-00
2-1/8" Inlet Orifice, stainless steel 090-20-028-50
28 1-3/4" Inlet Orifice, plated steel 090-20-028-02
1-3/4" Inlet Orifice, stainless steel 090-20-028-52
1-1/2" Inlet Orifice, plated steel 090-20-028-03
1-1/2" Inlet Orifice, stainless steel 090-20-028-53
2-1/8" Outlet Orifice, plated steel 090-20-029-00
2-1/8" Outlet Orifice, stainless steel 090-20-029-50
29 1-3/4" Outlet Orifice, plated steel 090-20-029-02
1-3/4" Outlet Orifice, stainless steel 090-20-029-52
1-1/2" Outlet Orifice, plated steel 090-20-029-03
1-1/2" Outlet Orifice, stainless steel 090-20-029-53
Installation and Maintenance Instructions
Model 441-57S Regulator

9
4" Models
Illustration Part
Number Description Number
22 Lower Diaphragm Plate 091-00-022-01
22a O-Ring, 5/8" x 3/4" 902922
23 O-Ring, 11/16" x 7/8" 934013
24 Diaphragm Connecting Screw, 090-16-058-00
stainless steel
26 Hex Cap Screw, 3/8" – 16 x 3/4" Lg., 910053
120,000 tensile
27 O-Ring for Orifices 905583
3" Inlet Orifice, plated steel 090-22-028-00
3" Inlet Orifice, stainless steel 090-22-028-50
28 2-1/8" Inlet Orifice, plated steel 090-22-028-02
2-1/8" Inlet Orifice, stainless steel 090-22-028-52
1-3/4" Inlet Orifice, plated steel 090-22-028-01
1-3/4" Inlet Orifice, stainless steel 090-22-028-51
3" Outlet Orifice, plated steel 090-22-029-00
3" Outlet Orifice, stainless steel 090-22-029-50
29 2-1/8" Outlet Orifice, plated steel 090-22-029-02
2-1/8" Outlet Orifice, stainless steel 090-22-029-52
1-3/4" Outlet Orifice, plated steel 090-22-029-01
1-3/4" Outlet Orifice, stainless steel 090-22-029-51
30 Hex Cap Screw, 3/8" – 16 x 1" Lg. 910055
31 Spin Stop Plate 090-22-040-01
32 Guide Bushing, brass 090-22-074-00
Guide Bushing, stainless steel 090-22-074-01
Hex Cap Screw, 5/8" – 11 x 1-1/2" 910157
34 Hex Cap Screw, 5/8" – 11 x 1-3/4" 910158
for ductile bottom plate
35 Tetraseal (or O-Ring), 904080
6-1/4" x 6-1/2"
36a Tetraseal (or O-Ring), 904084
4" x 4-1/4"
37 Centerpiece Stem Bushing 090-16-373-00
37a Aluminum Seal Ring 090-26-178-00
39 Tetraseal (or O-Ring), 904083
4-1/4" x 4-1/2"
2" and 3" Models
Illustration Part
Number Description Number
Valve Assembly, 1-3/4",
brass trim, Polyurethane 090-16-515-32
(Red, 65-75 Duro)
Valve Assembly, 1-3/4",
stainless steel trim, 090-16-515-52
50 Polyurethane (Red, 65-75 Duro)
Valve Assembly, 1-1/2",
brass trim, Polyurethane 090-16-515-33
(Red, 65-75 Duro)
Valve Assembly, 1-1/2"
stainless steel trim, 090-16-515-53
Polyurethane (Red, 65-75 Duro)
6" Models
Illustration Part
Number Description Number
22 Lower Diaphragm Plate 091-00-022-02
22a O-Ring, 5/8" x 3/4" 902922
23 O-Ring, 11/16" x 7/8" 934013
24 Diaphragm Connecting Stem, 090-22-058-00
stainless steel
26 Hex Cap Screw, 3/8" – 16 x 1" Lg., 910055
120,000 tensile
27 O-Ring for Orifice 906301
4-1/4 Inlet Orifice, plated steel 090-24-028-00
4-1/4" Inlet Orifice, stainless steel 090-24-028-02
28 3" Inlet Orifice, plated steel 090-24-028-10
3" Inlet Orifice, stainless steel 090-24-028-12
2-1/8" Inlet Orifice, plated steel 090-24-028-22
2-1/8" Inlet Orifice, stainless steel 090-24-028-24
4-1/4" Outlet Orifice, plated steel 090-24-029-00
4-14" Outlet Orifice, stainless steel 090-24-029-02
29 3" Outlet Orifice, plated steel 090-24-029-10
3" Outlet Orifice, stainless steel 090-24-029-12
2-1/8" Outlet Orifice, plated steel 090-24-029-22
2-1/8" Outlet Orifice, stainless steel 090-24-029-24
30 Hex Cap Screw, 3/8" –16 x 1" Lg. 910055
31 Spin Stop Plate 090-24-040-01
32 Guide Bushing, stainless steel 090-24-074-01
34 Hex Cap Screw, 5/8" – 11 x 2" 910159
35 Tetraseal (or O-Ring), 7-3/4" x 8" 904088
36 Tetraseal (or O-Ring), 4" x 4-1/4" 904084
37 Centerpiece Stem Bushing 090-16-373-02
37a Aluminum Seal Ring 090-26-178-00
39 Tetraseal (or O-Ring), 6" x 6-1/4" 904089
Installation and Maintenance Instructions
Model 441-57S Regulator

10
3" Models
Illustration Part
Number Description Number
Valve Assembly, 2-1/8",
brass trim, Polyurethane 090-20-515-40
50 (Red, 65-75 Duro)
Valve Assembly, 2-1/8",
stainless steel trim, Polyurethane 090-20-515-60
(Red, 65-75 Duro)
Valve Retainer, standard, stainless
50b steel, 2-1/8" 090-20-018-30
Valve Retainer, v-port wings,
stainless steel, 2-1/8" 090-20-012-51
Molded Valve, 2-1/8", Buna-N
(Black, 50-55 Duro) all trim 090-20-315-00
50d Molded Valve, 2-1/8", Polyurethane
(Red, 65-76 Duro) all trim 090-20-315-02
Molded Valve, 2-1/8", Polyurethane
(Tan 85-95 Duro) all trim 090-20-315-03
Model 441-57S Condensed Parts List
2" and 3" Models
Illustration Part
Number Description Number
50a Valve Lock Nut, 5/8" – 18 090-16-034-00
Valve Retainer, standard,
steel, 1-3/4" 090-16-018-00
Valve Retainer, standard,
stainless steel, 1-3/4" 090-16-018-30
Valve Retainer, v-port wings,
stainless steel, 1-3/4" 090-16-012-53
50b Valve Retainer, standard,
steel, 1-1/2" 090-16-018-01
Valve Retainer, standard,
stainless steel, 1-1/2" 090-16-018-31
Valve Retainer, v-port wings,
steel, 1-1/2" 090-16-012-52
Valve Retainer, v-port wings,
stainless steel, 1-1/2" 090-16-012-55
50c O-Ring, 5/8" x 13/16" 934012
Molded Valve, 1-3/4", Buna-N
(Black, 50-55 Duro) all trim 090-16-315-00
Molded Valve, 1-1/2", Buna-N
(Black, 50-55 Duro) all trim 090-16-315-01
Molded Valve, 1-3/4", Polyurethane
50d (Red, 65-75 Duro) all trim 090-16-315-02
Molded Valve, 1-1/2", Polyurethane
(Red, 65-75 Duro) all trim 090-16-315-03
Molded Valve, 1-3/4", Polyurethane
(Tan, 85-95 Duro) 090-16-315-05
Molded Valve, 1-1/2", Polyurethane
(Tan, 85-95 Duro) all trim 090-16-315-04
50e Female Valve Stem, brass 090-16-116-00
Female Valve Stem, stainless steel 090-16-116-01
Adjustment Clamp Screw,
50g Soc. Hd. Screw, 10 – 24 x 1/2" Lg. 903486
Adjustment Clamp Screw,
for 1-1/2" valve only 090-16-046-01
50h Male Valve Stem, brass 090-16-016-01
Male Valve Stem, stainless steel 090-16-016-02
4" Models
Illustration Part
Number Description Number
Valve Assembly, 3", brass trim
Polyurethane (Red, 65-75 Duro) 090-22-515-40
Valve Assembly, 3", stainless steel
trim, Polyurethane 090-22-515-60
(Red, 65-75 Duro)
Valve Assembly, 2-1/8", brass trim,
50 Polyurethane (Red, 65-75 Duro) 090-22-515-41
Valve Assembly, 2-1/8", stainless
steel trim, Polyurethane 090-22-515-61
(Red, 65-75 Duro)
Valve Assembly, 1-3/4", brass trim,
Polyurethane (Red, 65-75 Duro) 090-22-515-42
Valve Assembly, 1-3/4", stainless
steel trim, Polyurethane 090-22-515-62
(Red, 65-75 Duro)
50a Valve Lock Nut, 3/4" – 16 090-22-034-00
Valve Retainer, standard, iron, 3" 090-22-018-03
Valve Retainer, standard,
stainless steel, 3" 090-22-018-00
Valve Retainer, v-port wings,
iron, 3" 090-22-012-20
Valve Retainer, v-port wings,
stainless steel, 3" 090-22-012-40
Valve Retainer, standard,
50b iron, 2-1/8" 090-22-018-01
Valve Retainer, standard,
stainless steel, 2-1/8" 090-22-018-31
Valve Retainer, v-port wings,
iron, 2-1/8" 090-22-012-50
Valve Retainer, v-port wings,
stainless steel, 2-1/8" 090-22-012-51
Valve Retainer, standard,
stainless steel, 1-3/4" 090-22-018-34
50c O-Ring, 13/16" x 1" 904173
Molded Valve, 3", Buna-N
(Black, 50-55 Duro) all trim 090-22-315-00
Molded Valve, 2-1/8", Buna-N
(Black, 50-55 Duro) all trim 090-22-315-01
Molded Valve, 1-3/4", Buna-N
(Black, 50-55 Duro) all trim 090-22-315-04
Molded Valve, 3", Polyurethane
(Red, 65-75 Duro) all trim 090-22-315-02
50d Molded Valve, 2-1/8", Polyurethane
(Red, 65-75 Duro) all trim 090-22-315-03
Molded Valve, 1-3/4", Polyurethane
(Red, 65-75 Duro) all trim 090-22-315-05
Molded Valve, 3", Polyurethane
(Tan, 85-95 Duro) all trim 090-22-315-08
Molded Valve, 2-1/8", Polyurethane
(Tan, 85-95 Duro) all trim 090-22-315-07
Molded Valve, 1-3/4", Polyurethane
(Tan, 85-95 Duro) all trim 090-22-315-06
Installation and Maintenance Instructions
Model 441-57S Regulator

11
4" Models (continued)
Illustration Part
Number Description Number
50e Female Valve Stem, brass 090-22-016-40
Female Valve Stem, stainless steel 090-22-016-41
Adjustment Clamp Ring, brass 090-22-043-00
50f Adjustment Clamp, Ring,
stainless steel 090-22-043-02
50g Adjustment Clamp Screw,
Soc. Hd. Screw, 1/4" – 20 x 3/4" Lg. 903494
50h Male Valve Stem, stainless steel 090-22-116-01
50i Stem Extension, stainless 090-22-058-40
Travel Stop, for 3" valves 090-22-040-51
54 Travel Stop, for 2-1/8" and
1-3/4" valves 090-22-040-55
6" Models (continued)
Illustration Part
Number Description Number
Molded Valve, 4-1/4", Buna-N
(Black, 50-55 Duro) all trim 090-24-315-00
Molded Valve, 3", Buna-N
(Black, 50-55 Duro) all trim 090-24-315-01
Molded Valve, 2-1/8", Buna-N
(Black, 50-55 Duro) all trim 090-20-315-00
Molded Valve, 4-1/4", Polyurethane
(Red, 65-75 Duro) all trim 090-24-315-02
50d Molded Valve, 3", Polyurethane
(Red, 65-75 Duro) all trim 090-24-315-03
Molded Valve, 2-1/8", Polyurethane
(Red 65-75 Duro) all trim 090-20-315-02
Molded Valve, 4-1/4", Polyurethane
(Tan, 85-95 Duro) all trim 090-24-315-05
Molded Valve, 3", Polyurethane
(Tan, 85-95 Duro) all trim 090-24-315-04
Molded Valve, 2-1/8", Polyurethane
(Tan, 85-95 Duro) all trim
Female Valve Stem, stainless steel 090-24-016-01
50e Female Valve Stem, stainless steel
for 2-1/8" reduced valve only 090-24-016-11
Adjustment Clamp Ring,
stainless steel 090-24-043-02
50f Adjustment Clamp Ring,
stainless steel for 2-1/8" 090-16-043-03
reduced valve only
Adjustment Clamp Screw,
50g Soc. Hd. Screw, 5/16" – 18 x 1" Lg. 903498
Adjustment Clamp Screw, for
2-1/8" reduced valve only 903494
Male Valve Stem, stainless steel 090-24-116-01
50h Male Valve Stem, brass for 2-1/8"
reduced valve only 090-24-116-10
Stem Extension, stainless 090-24-062-04
50i Valve Stem Hex Extension, stainless,
for 2-1/8" reduced valve only 090-16-062-11
Travel Stop, for 4-1/4" valves 090-22-040-50
54 Travel Stop, for 3" valves 090-22-040-52
Travel Stop, for 2-1/8" valves 090-22-040-56
6" Models
Illustration Part
Number Description Number
Valve Assembly, 4-1/4",
brass trim, Polyurethane 090-24-515-40
(Red, 65-75 Duro)
Valve Assembly, 4-1/4",
stainless steel trim, Polyurethane 090-24-515-60
(Red, 65-75 Duro)
Valve Assembly, 3", brass trim,
50 Polyurethane (Red, 65-75 Duro) 090-24-515-41
Valve Assembly, 2-1/8", brass trim,
Polyurethane (Red 65-75 Duro) 090-24-515-42
Valve Assembly, 2-1/8", stainless
steel trim, Polyurethane 090-24-515-62
(Red, 65-75 Duro)
Valve Lock Nut 015-31-034-70
50a Valve Lock Nut, 5/8" – 18,
for 2-1/8" reduced valve only 090-16-034-00
Valve Retainer, standard, iron, 4-1/4" 090-24-018-00
Valve Retainer, standard,
stainless steel, 4-1/4" 090-24-018-02
Valve Retainer, v-port wings,
50b stainless steel, 4-1/4" 090-24-012-40
Valve Retainer, standard, iron, 3" 090-24-018-21
Valve Retainer, standard,
stainless steel, 3" 090-24-018-22
Valve Retainer, standard,
stainless steel, 2-1/8" 090-20-018-30
Valve Retainer, v-port wings,
stainless steel, 2-1/8" 090-20-012-51
O-Ring, 1-3/16" x 1-3/8" 904174
50c O-Ring, 5/8" x 13/16" for
2-1/8" reduced valve only 934012
Installation and Maintenance Instructions
Model 441-57S Regulator

Type of Gas Correction Factor
Air (specific gravity 1.0) 0.77
Propane (specific gravity 1.53) 0.63
1350 BTU Propane-Air Mixture
(specific gravity 1.20) 0.71
Nitrogen (specific gravity 0.97) 0.79
Dry CO2(specific gravity 1.52) 0.63
For other non-corrosive gases use the following formula:
0.60
Correction Factor = Specific gravity of the gas
For use with gases not listed above, please contact your Sensus
representative or Industrial Distributor for recommendations.
Monitoring
The Model 441-57S Regulator makes an excellent monitor.
It can act as a standby regulator installed in series which
assumes control if a failure in the operating regulator
permits the outlet pressure to exceed the set-point. It can
be located in either the upstream or the downstream position.
When a Model 441-57S Regulator is used to monitor a
regulator with an identical inner valve (another 441-57S
Regulator), the total maximum capacity through both
regulators can be figured at 70% of the capacity of one
regulator alone. This applies with the monitor located either
upstream or downstream.
Models 441-57S Regulator
Installation and Maintenance Instructions
Limited Warranty
Seller warrants the Goods to be free from defects in materials manufactured by Seller and in Seller’s workmanship for a period of one (1) year after tender of delivery (the “Warranty Period"). THIS LIMITED WARRANTY
(a) IS IN LIEU OF, AND SELLER DISCLAIMS AND EXCLUDES ALL OTHER WARRANTIES, STATUTORY, EXPRESS OR IMPLIED, INCLUDING, WITH LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, OR OF CONFORMITY TO MODELS OR SAMPLES; (b) does not apply to any Goods which have been (I) repaired, altered or improperly installed; (ii) subjected to improper use or storage,
(iii) used or incorporated with other materials or equipment, after buyer or anyone using the Goods has, or reasonably should have, knowledge of any defect or nonconformance of the Goods; or (iv) manufactured,
fabricated or assembled by anyone other than Seller, (c) shall not be effective unless buyer notifies Seller in writing of any purported defect or nonconformance with (thirty days) after Buyer discovers or should have
reasonably discovered such purported defect or nonconformance; and (d) shall only extend to Buyer and not to any subsequent buyers or users of the Goods. Buyer shall provide Seller access to the Goods as to which
Buyer claims a purported defect or nonconformance, upon request by Seller, buyer shall, at its own risk and expense, promptly return the Goods in question to Seller’s Plant.
© Sensus 2009 Made in USA 12/09
Maximum Emergency Pressure
The Maximum emergency pressure that the inlet side of the
Model 441-57S Regulator may be subjected to under abnormal
conditions without causing damage to the regulator is:
Cast Iron Body Maximum Inlet Pressure + 25 psi
Ductile Iron Body Maximum Inlet Pressure + 60 psi
Cast Steel Body Maximum Inlet Pressure + 100 psi
If pressure exceeds the above values the regulator must be
removed from service and inspected. Damaged or otherwise
unsatisfactory parts must be repaired or replaced before return-
ing the regulator to service.
The maximum pressure which the diaphragm may be subjected
to under abnormal conditions without causing internal damage is
the set-point + 25 psi. If the pressure on the diaphragm exceeds
set-point by more than + 25 psi, the regulator must be removed
from service and inspected. Damaged or otherwise unsatisfactory
parts must be repaired or replaced before returning the regulator
to service. The set-point is the outlet pressure the regulator is
adjusted to deliver.
The maximum pressure that can be safely contained by the
diaphragm case is 175 psi. Safely contained means no leakage as
well as no bursting.
Before using any of the above data, make sure this entire section
is clearly understood.
Other Gases
The Model 441-57S Regulator is mainly used on natural gas serv-
ices; however, this regulator will perform equally as well on other
gases. When using the Model 441-57S Regulator on other gases,
the regulator capacities must be adjusted using the following cor-
rection factors:
Authorized Distributor:
805 Liberty Boulevard
DuBois, PA 15801
800-375-8875
Fax: [phone]
www.sensus.com/gas