GE Oil & Gas

Masoneilan*
78 Model
Air Filter Regulator
Instruction Manual [Rev. D]

GE Data Classification : Public

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.

2 | GE Oil & Gas © 2017 General Electric Company. All rights reserved.
 Safety Information About this Manual
CAUTION
Important - Please Read Before Installation
The model 78 Series air filter regulator instructions contain
• The information in this manual is subject to change without prior
notice.
DANGER, WARNING, and CAUTION labels where necessary, to • The information contained in this manual, in whole or part, shall
alert you to safety related or other important information. Read the not be transcribed or copied without GE’s written permission.
instructions carefully before installing and maintaining your control • Please report any errors or questions about the information in this

CAUTION
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
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
conditions, result in degraded process system performance that product line.
can lead to injury or death. Total compliance with all DANGER,
WARNING, and CAUTION notices is required for safe operation. Warranty
Items sold by General Electric are warranted to be free from

WARNING
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
This is the safety alert symbol. It alerts you to potential manufacture of any product or change product materials, design or
personal injury hazards. Obey all safety messages that specifications without notice.
follow this symbol to avoid possible injury or death. Note: Prior to installation

WARNING
DANGER
• The instrument must be installed, put into service and maintained
by qualified and competent professionals who have undergone

CAUTION
suitable training.
Indicates a potentially hazardous situation which, if not avoided, could • All surrounding pipe lines must be thoroughly flushed to ensure
result in death or serious injury. all entrained debris has been removed from the system.

CAUTION
• Under certain operating conditions, the use of damaged
WARNING equipment could cause a degradation of the performance of
the system which may lead to personal injury or death.
Indicates a potentially hazardous situation which, if not avoided, could
• Changes to specifications, structure, and components used may

CAUTION
result in serious injury.
not lead to the revision of this manual unless such changes

WARNING
affect the function and performance of the product.

CAUTION
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.

CAUTION
CAUTION
When used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, could result in
property damage.

CAUTION
Note: Indicates important facts and conditions.

DANGER

DANGER
DANGER

DANGER

© 2017 General Electric Company. All rights reserved. Masoneilan Model 78 Series Air Filter Regulator Instructions Manual | 3
Model 78 Air Filter Regulators
Product Description Operation
The Model 78 Series pressure regulators are compact, lightweight, Prior to applying supply pressure, loosen knob lock screw and turn
high-performance pressure reducing instruments. They are used pressure set knob counterclockwise. Turn on supply pressure.
primarily for supplying a stable source of air to process control Output pressure should be zero. Slowly rotate set knob clockwise
equipment such as current to pneumatic transducers and control until desired pressure is reached. Tighten knob locking screw to
valve positioners. 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
Numbering System knob lock-screw.
Model No. Pressure Range Description
5-40 psi (35-280 Air Loading with Maintenance
78-4
kPa), (0.35-2.8 bar) Relief and Filter It is recommended that the drain cock be opened at regular
5-100 psi (35-700 Air Loading with intervals to drain any fluid that may have collected in the dripwell.
78-40 The interval between draining will have to be determined based on
kPa), (0.35-7 bar) Relief and Filter
the actual rate of accumulation of fluid.

Specifications It is recommended that pressure gauges be installed on the inlet

and outlet sides of the regulator as an aid in adjusting the pressure
210 psi (1.5 MPa, 15 bar) and in monitoring of working pressures.
Inlet Pressure Rating
maximum
5-40 psi (35-280 kPa, 0.35-2.8
Pressure Set Range bar)5-100 psi (35-700 kPa, 0.35-7
bar)
WARNING
Connection 1/4 NPT The relief valve feature should not be confused with any
auxiliary safety valve which might be needed for complete
Rated Cv 0.25
protection of air operated equipment. It is intended only
Filter Element Sintered Porous Polyethylene (5μ) to provide more uniform controlled pressure and to permit
Ambient Temperature
Range
-40° to +83°C (-40° to +182°F) CAUTION
WARNING
adjusting the outlet pressure downward without venting the
line.
Air Consumption 0.004 scfm (100 sccm)
Weight
Materials of
14 oz. (0.4 kg)
WARNING
CAUTION
See table next page
Construction Prior to performing maintenance on the regulator, shut off the

CAUTION
inlet and outlet pressures and remove the spring compression
by turning the setting knob fully counterclockwise. Open

WARNING the drain cock carefully to relieve any retained pressure and
CAUTION
drain the dripwell. It is recommended that the regulator be
Do not install this Regulator in air lines which exceed 210 psi removed from the line for repairs.
(1.5 MPa, 15 bar) pressure.

Installation
CAUTION
CAUTION
Clean the lines thoroughly to remove all dirt, scale or other foreign
matter before installing the regulator. Install with flow in direction
CAUTION
When draining the dripwell, open the drain cock slowly and
collect the fluid in a suitable container for safe disposal.
of flow arrows on regulator body. The airset should be installed Note:
with the drain cock facing down. Regulator should be installed • Considering the high labor costs involved in replacing internal
parts, it may be more economical to stock complete units.
as close as possible to device utilizing the reduced pressure to

CAUTION
minimize pressure drop. Do not use piping or tubing smaller than
the regulator connections since this will restrict flow and reduce
assembly. DANGER
• Care must be taken to avoid damage to the plug and stem

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.

DANGER
DANGER
4 | GE Oil & Gas © 2017 General Electric Company. All rights reserved.
Troubleshooting
If at any time the regulator fails to function properly it is
recommended to replace rather than repair the device.
5

Parts List and Materials of Construction

4
No. Part Standard Material
1 Body Aluminum Die Casting 25
22
2 Spring Casing Aluminum Die Casting
3 Bottom Cap Aluminum Die Casting 2
4 Knob VALOX 420
5 Lock Screw Stainless Steel 24
7
6 Adjusting Screw Stainless Steel
6 15
7 Spacer VALOX 420
23
8 Spring Button Zn-Cr Plated Carbon Steel
8
9 Spring Coated Spring Steel
1
101 Diaphragm NBR 9
23
15 Plug Guide VALOX 420
16 1
Plug Neoprene/416 Stainless Steel
171 Filter Sintered Polyethylene 10 16
18 1
Port Spring Stainless Steel 18
191 “O”-Ring NBR 17
-
3 19
21 Drain Cock Stainless Steel
22 Screw Stainless Steel
23 Pipe Plug Zinc Plated Carbon Steel
24 Aspirator VALOX 420 21 22
25 Nameplate Aluminum
1
Recommended Spare Parts

© 2017 General Electric Company. All rights reserved. Masoneilan Model 78 Series Air Filter Regulator Instructions Manual | 5
Dimensions

Threaded Holes for Mounting Bracket (M5)

81 mm
(3.19 in.)
Top View

141 mm
(5.55 in.)
52 mm
(2.05 in.)

60 mm
(2.36 in.)

55 mm (2.17 in.)

Cut-Away View of 78 Series Pressure Regulator

Lock Screw
Setting Knob
Spring Button

Adjust Screw
Spring
Spring Case Relief Valve
Diaphragm
Diaphragm Plate

Body Aspirator

INLET OUTLET
Plug

Filter
Supply Valve
Port Spring

Bottom Cap

Drain Cock

6 | GE Oil & Gas © 2017 General Electric Company. All rights reserved.
© 2017 General Electric Company. All rights reserved. Masoneilan Model 78 Series Air Filter Regulator Instructions Manual | 7
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*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.

GEA31190D 03/2017