535H,536H,535H-50536H-50 Instruction.pdf

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These installation, operation, adjustment and mainte- local Masoneilan Representative or Spare Parts rJ
nance instructions, apply to the Masoneilan Models Department. When ordering parts, always include Model "-
535HI 536H Reducing and Back Pressure Regulators and Serial Numbers shown on serial plate.
and Models 535H-501 536H-50 Differential Pressure
Regulators. They include a parts reference list including After sales Department
recommended spara parts (see page 5). Masoneilan has a highly skilled After Sales Department
Refer to Instructions No 176420 E far connecting, available far star1-Up, maintenance and repair of our
adjustment and maintenance of the 10900 Series regulators and components parts. Contact the nearest
Actuators equipping the 500 Series regulators. Masoneilan Sales Office or Representative or, directly
Description-Operation h
Nos 535H/536H Regulators Nos 535H-50/536H-50 Regulators
The 535H direct operated regulators are designed to Masoneilan 535H-501 536H.50 Series Differential
regulate the discharge pressure of steam driven pumps Pressure Regulators ara designed far maintaining one
and to maintain a uniform reduced pressure on such pressure in excess of another (reference) pressure by
industriai equipment as gas distribution systems, fluids
heat exchangers, reboilers, fractionning columns and on
fuellines to gas-fired boilers, topping units and preheaan
adjustable amount.
.. .. . .
TYPICaI appllCatlOn~ Include regulatlng the del~very presterso
AIso supplied far back-pressure service Is' the 536 sure of a steam-dnven pump at a predetermlned va!ue
H Model. Bodies of regulators ara offered in single seat abo~e a refe~ence pressure; and f.or compressor bearlng
type . seallng
maintained
servlce,
at a desired
where
value
the seallng
above casing
pressure
pressure.
must be
Operatlon Operatlon .
The adjustable spring cf actuator is set far the desired . controlled pressure. In No 535H regulators thls sprlng
holds the regulator open; In No 536H regulators the
spring holds the regulator closed. An Increase in control-
Th ad. stabl . f ct t is t f th d . e Ju e sprlng o a ua or se or e esIred
d.ff I Gran t. la 1pressure. In No 535H- 50 regu Ia tors th.s I
. h Id th I t .. N 536H 50 I -
spnng o ~ e regu a or open, In o : regu ~
.
led pressure above the set point causes No 535H regu- to:rs the ~pnng holds the reg.ulator closed. An Increase In
lators to cIose or No 536H r ulators to o n.
eg pe
differentlal above the set polnt causes No 535H.50 regu-
lators to close or No 536H-50 regulators' to open.
Variations In the controlled pressure thus cause the .. . .
necessary regulator movement to resto re the controlled Variatlons In the differenti al pressure thus cause the
U t t . t necessary regulator movement to restare the controlled
press re o se poln. .
pressure to set polnt.
Installation
Before Installing, blow out line thoroughly to remove ali diaphragm chamber down so that the diaphragm will be
foreign matter which might foul thé regulator. protected by a water seal. " installed otherwise, an ade- )'~_;é :;
Placa the regula.tor vorticaJJy in. a horizontal run of pipo
quale water seal or seals must be provided. fi:f1:~~'
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so that the rontrolled fluid will fk>w through the body in
the dlrection Indicated by the arrow on the body or the
A three valve by-pass around the regulators permits
removing the regulator tram the li ne without shutting off
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words -IN & our marked on the connections. On the flow. "éj)f!ii,';:;~
steam servk:e, the regulat.or soould be installed with the ,.',~(~'-,
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On Nos 535H/ 536H Regulators Pipe the hlgher pressure fluid from a convenient point to
the 1/2 wNPT connection in the upper diaphragm case
Pipe
line
the
6-10
controlled
teet (1,8
pressure
ta 3m)
from
trom
a
the
convenient
regulator
point
(or
in the
(i.e..
spring).
to diaphragm
Pipe the
chamber
lower
where
pressure
pressure
fluid
will
to the
oppose
dia-
..Ie discharg,e line 6-10 feet tram the pump on pump phragm chamber.
pressure applications.) to the 1/2w NPT connection in Install a needle valve and gauge in each of these contrai
the diaphragm case. lines, sufficiently near each other so that both valves can
Install a gauge and a needle valve in the controlled pres- be reached simuftaneously.
sure li ne, to protect diaphragm case against any over- Needle valves permit shutting off both controllines and
pressure.
" ,
Needle valve permlts shuttmg off the contrai Iine and
may be used as adjustable chokes to prevent cycling of
the regulator as a resuft of pump pulsations. By adjustin
y accl '
g both valves simultaneousl
I d ' bl h k l ' f ' dent a I
overpressua,so
serves as an a Justa e c o e to prevent cyc Ing o ring either side of the diaphragm can be 'd d
the regulator, which may result tram the pulsation of a avo I e .
~ .
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NEE[x'E V AL VE
No 535H Reduclng Regulator No 536H Back Pressure Regulator
Figure 1 - Typlcallnstallatlon
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M a I n te n a n ce i':Jr\,(,j:I.~it.~,,~;,;4?~'\iJ,t,;,.-r:ì\!è
lOW ~~
NEEDlE V Al VE
EQUAUZJNG
VAlVE
No 535H-SO or 536H-SO -
Dlfferentlal
Pressure Regulator
If there is excessive leakag~ throughthe regulatorwhen 2- Normal wear of seatting ~urfaces: disassemble and
it is shutQff, the cause may be: replace plug and/or seat rmg.
1- Foreig~ matter holding regulator off seat: disas- 3- Seat ~ing gasket (23) damaging (on/y on quid< chansemble
and clean. g8 tnm regulators): replace gasket.
3

Body SIA disassembly . Remove plug (3) and plug stem (4) tram the bonnet (6).
: ~:d "(ì
Nos 535H and 535H 50 Regulators service damage. After determining the maintenance
required, praceed to the appropriata section ot this ins-
Threaded Trlm (Figure 2) truction book.
. Disconned the controlline(s) at the diaphragm case. Nos 536H and 536H 50 Regulators I
o Remove body stud nuts (15).
. .
o Fasten the aduator to a holstlng gear and, very slowly,
Qulck-Change Trlm (Figure 4)
pull out aduator, bonnet (6), plug (3) and plug stem . Disconnect the contraI line(s) at the diaphragm case
tram the body.
Note: "a new body gasket (16) is not available, care
and conned a temporary supply air line.
o Apply on the diaphragm sufficient pressure to open the .
must be taken to preserve the old gasket for re-use. plug about 1 mm.
SpiraI wound
an
flexitallic gaskets are standard in the
- eslgn a IS recommen .
535H d 535H 50 d . nd n. . ded o Loosen stem locknuts (13), turn them down plug stem
th t k t J tal"ed h ti. th la, and Iod< them together. With wrench applled aver Iock-
a a new gas e Utt is disassembled. InS , eac me e regu ,or
nuts, !urn plug stem out ot actuator sterno
o Loosen stem Iod

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4
. 17
L"C
21
7
1
10
2
1
9
6 8 3
16 5 2
Figure 3
3
Qulck Change Trlm
2 Model 535H or 535H-50
Regulator
1 (Detall>
13
14
15
Figure 2 13
4
Threaded Trlm
Model 535H or 535H-50 7
Regulator 1 10
Figure 4
Qulck Change Trlm
Model 536H or 536H-SO
Regulator 1
1
6
1
1
3
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PARTS REFERENCE"'-'
1 Body 9 Packing Flange Plug Guide Bushing (Incl. w/ref.. 6)
2 Seat Ring 10 Packing Flange Nut Seria! Plate (Not Shown)
3 Plug . 11 Packing Drive Sa'ew (Not Shown)
4 Plug Stem 12 Packing Spaoor Packing Range Stud
5 Plug Pin 13 Plug Stem Nut Cage.
6 Bonnet 14 8ody Stud Seat Ring Gasket .
7 Drive Nut 15 8ody Stud Nut
8 Paoong Follower - . 16 Body Ga&ket
. Rerommended spare parta
. 0nIy OrI Q.lid< Change Trim Regulator
,,' 5
2
.
9

~
Cautlon: When uslng heatlng devlces, Insure that o Insert two or three pieces of packing (11) into the pacpro
per safety practlces ara observed. Such Items as king box to assist in guiding the stem and plug during
the flammabl/lty and toxlclty of the controlled subtaken
stance must ba consldered and proper precautlons
. ,
lapping.
S d 'Il d d t d d 'ìth T h di
o crew a rl e an appe ro w a - an e on to
the plug stem and secure with a /ocknut. (See figure 5).
r, "'.
.
Bushing Remaval Note: A5 an alternative, drill a hole through a tlat I
The bushing (17) is a press fit into the bonnet and does pi9Ce ot 5teel and fasten to the plug stem u5ing two
not normally raquire replacement. It may be pulled or locknuts.
machined out. When machlning the bushing out, care be
taken to maintain proper dimensions and tolerances.
o Applying a slight pressure on the stem, rotate the stem
in short oscillating strokes, 8 to 10 times,
These will be fumlshed upon request.
Lapping Seats
Note: The plug 5hould be lifted and tumed 90° betore
repeating pr9Ceding step. This intermittent lifting is
. . . ,
Lappl~g IS t,he process.of worklng the plug ag~lnst the
required to keep the plug and seat ring concentric
during lapping. .
seat nng, wìth an abrasIVe, to produce a close filo When
regulator leakage becomes excessive, lapping becomes o After completion of the lapping operation the seat ring
necessary, The plug and seat ring seating surfaces and plug must be cleaned of alliapping compound in
should be free of large scratches or dents and the preparation for reassembly.
contact surfaces of the seats should be as narrow as
possible. This may require dressing both parts in a lathe. aulck-Change Trlm
The seat ~urf~ce of the plug is 28 degrees an? that.cf
the seat nng IS 30 degrees, both tram centerllne axlS.
O
n
Nos 535H and 535H-50 Regulat r
o S
For the lapping operation, a good grade of fine grinding (Flgures 2& 3)
compound is required. The compound should be mixed o Clean body gasket surface areas.
with a small quantity of lubricant such as graphite. This '"
will slow the cutting rate and prevent tearing of the sea- o Inst,a" a new seat rmg gasket (23) and Insert seat rlng
ting surfaces. The amount of lapping required depends (2) In the body.
on the materials, condition of seating surfaces and accu- Note: Gasket (23) Is temporarl/y placed to hold the
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~
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. Piace bonnet (6) on the body. . Insert two ~r ~hree.P!eces of packing into the packing
C ti . 1 th t th t I (2) (22)
- au on. nsure a e sea r ng , cage,
( and bonnat (6) are properly allgned.
. Uslng
.
4 OOdy , stud nuts (15), spaced equally apart, fas-
ten the bonnet to the body usmg " only sllght pressure
box to asslst m guldlng the stem and plug during lapin
p g.
. Screw a drilled and tapped !Od with a T -handle on to the
pI st and ith 1 J,- ug em securew a~1 ut.(See ti ~ure5)
.
and tighten evenly. Note: As an alternative, dri// a ho/e through a f/at
Ca ti Do t ti ht t t t Ifl
tlons,
u on
at
:
thls tlrne.
no
The
9 en
bonnet
nu s
Is
o
used
orque
ten:lporarlly
spec capiece
of stee/ and fasten to the p/ug stem using two
bcknuts.
far guldlng purposes.
I rt tw th ' f cki , . nse o or ree pleces o pa ng m
t
o
th
e pac
ki
ng
. While to exert a lightly pulling on the stem, rotate it in
short oscillating strokes 8 to 10 times,
box to assist in guiding the stem and plug during lap- Note: The p/ug should be pu//ed out and turned 90°
ping.
. Screwa dn '1'-..1and t,,~
~ ,.,
rodw itha T' " andle to th
"Il on e
before repeating preceding step. This intermittent pu/-
/ing is required to keep the pIug and seat tr' d . lap'
ring concen-
plug stem and secure with a bd

~ ~---~ ,
. Unscrew the plug from the sterno (Counterclockwise.) Addlng Packlngs
. Cut off the stem directly above the pin hole (Figure 6). To add a ring of packing, depressurize the regulator,
. Re-thread the stem the originai amount. back off packing flange nuts (10) ali the way, lift the pac- ~ n
king flange and follower and insert one ring of packing. "-"'
Note: The apea of the plug siero marked 13 mm in TIghten nuts (10) finger tight plus one full turno
figure 6 se/Ves as a guide and musi be checked to
insure a close fit in the regulator plug. Body SIA Reassembly
. Screw the stem solldly into the plug.
. Piace the plug guide on a V-block and using a 3,5 mm After completion of the required maintenance the regulasize
drill bit, drill the stem using the hole in the plug as tor should be re-assembled using the following proce- .
a guide. dures:
. Remove any burrs from the plug guide by making a Note: If any of the following steps were completed .
slight counterbore. during maintenance, proceed to the next step.
. Select the correct size pin, apply a small amount of
grease on it, and press into the hole.
On 535 H and 535H-50 Regulators
Note: The pin musi be recessed approximate/y 1116"
(1,5mm) belo w the plug guide surface.
. After the plug has been pinned, it should be placed in
Threaded Trim (Figure 2)
. Clean ali gasketed surfaces.
. Apply a small amount of sealant to the seat ring
a lathe to insure it is running "true". If it is not, strike threads and sealing shoulder and installo
the plug with a soft faced mallet to straighten.
N A l h J h C PI ' L d AI
ore: sea ani suc as o n rane ast/C ea IYO.
Note: The siero should be placed in a co//et with the 2 is recommended or a sealant compatible with the
plug guide against it and the plug should be struck. processo
P k. B (F . 2 & 4) . Using seat ring wrench fabricated far removal, tighten ")
ac Ing OX Igures seat ring only enough to insure a seal.
Packlng Replacement Cautlon: Do not overtighten. Do not strlke seat
rlng lugs. Thls could dlstort the seat rlng resultlng
Packing box maintenance is one of the principle chores In unwarranted seat leakage.
of routine se:vicing. 1ight~ess of the pac~ing. is m~intai- Note: Regulator should be lapped before final assemned
by packlng compresslon. Compresslon IS achleved
by evenly tightening the packing flange nuts (10) against
bl S "L' t- Th aded tr.m-
r. ee applng sea re I.
the packing flange (9). . Carefully install plug and stem assembly.
Care must be taken not to aver tighten as this could prev~nt
.smooth operation of the regulator. If ali com.pre~ston
.IS used ,up and the regulator leaks, new packlng IS
. Install body gasket (16).
. Install bonnet (6) and screw body stud nuts (15).
Bonnet must be positioned so the packing flange
requlred. studs afe at a right angle 70 the flow center fine.
Cautlon: Regulator must be lsolated an the pressure TIghten nuts (15). .
vented before performlng packlng box malntenance. Cautlon: Refer to figure 7 far proper bolt torque
Proceed as follows :
. Loosen and remove packing flange nuts (10).
. Raise pad

- . .
..' . i
" -
. Install packing flange stud nuts (1 O). . Insert four packing rings (11). then packing spacer (12)
- Cautlon: Do noI overtlghten (See paragraph
and two rings.
:--MPacklng Box"). . Install packing follower (8) and packing flange (9).
. Proceed lo the be~w paragraph instructions far actua- . Install packing flange stud nuts (10).
tor to body assembly and plug stem adjustment.
C au t I on: D o no t aver ti g ht en (S ee paragrap
h
"Packlng Box").
Qulck-Change Trlm (Flgures 2 & 3) . Proceed to the below paragraph Instructions far adua-
. Clean ali gasketed surfaces.
. Install seat ring gasket (23) and seat ring (2).
tor to body assembly and plug stem adjustment.
.Install cage (22). Actuator to Body Assembly and
, . Carefully install plug and stem assembly. Plug Stem Adjustment
Note: Regulator should be lapped before fina! assem-
. bfy. 5ee -Lapping seat-Quick-Change trim-.
'Install body gasket (16). On 535 H and 535H-50 Regulat~rs
. Install bonnet (6) and screw body stud nuts (15). . Hold actuator above body SIA. Before that actuator
BQnnet musi be positioned so the packing flange stem contact the plug stem, screw the two nuts (13) lo
studs are at a righi angle to the flow center llne. the threaded end of plug stem and piace the drive nut
lighten nuts (15). (7) on the actuator yoke.
Cautlon: Care musI be taken to assure that the . While holding the plug in -Open- position, slowly pull
cage, seat and bonnet are properly allgned In the down the actuator and screw the plug stem into the
body. Refer to figure 7 far proper bolt torque and actuator stem.
tlghtenlng sequence speclflcatlons. '
Note: Thls operatlon wlll be facliltated tumlng the
.Insert four packing rings (11), then packing spacer (12) plug stem by means of a wrench applled on the
and two rings. nuts (13) tlghtened one agalnst the other.
. Install packing follower (8) and packing flange (9). Carefully avold that seatlng surface of the plug
. Install packing flange stud nuts (10). contact the seat rlng durlng the plug screwlng.
C ti D t ti ht (S h - Pulling down motlon of the actuator and plug stem
..:uck~n:B o,,~o aver g en ee paragrap screwlng musi be slmultaneously performed:
a ng ox . carry on untll the lower parI of actuator yoke
. Proceed to the belowparagraph instructions far actua- contact the bonnet (6).
Ior to body assembly and plug stem adjustment. . PI ace th e a d ua t or . In th e corre d pos 'n ° IOn. Screw and
On 536 H and 536H-SO Regulators Ig. 4
. . Clean body gasket surface areas.
(Fi )
tighten the drive nut (7).
. Turn plug stem into actuator stem as far as it will goo
. Connect the controlled pressure line(s) to diaphragm
. . Apply slightly more pressure to diaphragm actuator
. Insert the stem and plug assembly Into the body and than spring is set foro
.. put it on the bottom.
. Turn plug stem out of aduator stem until plug is sea-
. Install a new seat ring gasket (23) and insert seat ring ledo
(2) in the body.
case.
. . Relieve diaphragm pressure and turn plug stem out of
Note: Regulato.r should be.lapped befor.e fina! assem- aduator stem one fuI! turn more.
bfy. 5ee -Lapplng seat-Qulck-Change t"m-.
I Il bod k (16) . Lod< stems with Iocknuts (13).
. nsta y gas et .
. Placo back in service and tighten the packing flange
. Insert the cage (22) iAto the body. nuts (10) only as much as is necessary to stop any
. Slide the bonnet (6) on the plug stem, then piace it on leakage.
1.he cage and the body.
Cautlon: Insure that the seat rlng (2), cage (22),
and bonnet (6) are properly allgned. ,".'
. Screw body stud nuts (15). Bonnet musi be positioned On 536 H and 536H-50 Regulators
so the packing flange studs are al a righi angle lo the . Hold actuator above body SIA. Before that actuator
flow center Une. Tighten nuts (15). stem contact the plug stem, screw the two nuts (13) to
Cautlon: Refer to figure 7 for pro per bolt torque the threaded end of plug stem and piace the drive nut ~",
and tlghtenlng sequence speclflcatlons. (7). on the actuator yoke. .
,..
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.. .-. l''''
"
. ~Iowly pull down the actuator and screw the plug stern . Connect a pressure line to upper diaphragrn case
Into the actuator sterno .
Note: Thls operatlon wlll be facllltated turnlng the . Apply sufficient pressure to upper diaphragrn case to ~
plug stem by means of a wrench applled on the rnove plug off seat. ,
nuts (13) tlghtened one agalnst the other. "-'-
Carefully avold that seatlng surface of the plug . Turn plug stern one full turn into actuator sterno
contact the seat rlng durlng the plug screwlng. . .
-Pulling down motlon of the actuator and plug stem . Screw and tlghten nuts (13) agalnst the actuator sterno
screwlng musI be slmultaneously performed:
carry on unIti the lower parI of actuator yoke
contact the bonnet (6).
. Piace the actuator in the correct position. Screw and
tighten the drive nut (7). . . Scre~ the plug stern mto the actuator stern until the
Lock by rneans of a wrench applied on the nuts.
. Connect the controlled pressure line(s) to diaphragrn
case.
. Piace back . In servlce . and tlghten . the packing flan e
nuts (10) only as much as is necessary to stop a~y
plug IS seated. leakage. "
Masoneilan ITALY I Masoneilan~~ii ~ é
- f;;,
Headquarters Via Cassa no 77, 80020 Casavatore (Napoli) . Tel. 7892111 h
Works & Atter sale service Telex: 710084 - Facsimile: (081) 7382922 - Cable: Masonica - Casavatore ";
,iO,
Sales office C.so Garibaldi 113, 20121 Milano - Tel. (02) 29.005.650 - Telex: 314231 :
North Italy Facsimile: (02) 29.005.660
Ooc. Ted\niq.. MN - Condé - DESK1OP PUBLISHING. . ~j:':r i Janu.y 1991
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