PARTS, SERVICE & REPAIR BULLETINbillswelderrepair.com/files/edge_regulator.pdf · Service and repair of VICTOR apparatus should only be performed by a Qualified Repair Technician

PARTS, SERVICE& REPAIR BULLETIN

Issue Date: March 2011Revision: D Form No.: 0056-1966

ESS3ESS4ESS7EST4ESL4ELC4

Pressure Regulators

INDEXSection Models Page

1

2

3

4

5

ESS3 & ESS4

ESS7, EST4, ESL4 & ELC4

Future EDGE Models

Future EDGE Models

Future EDGE Models

- i -

01

15

--

--

--

ESS3/ESS4 - 1 - SECTION 1

SECTION 1

SERVICE & REPAIR INSTRUCTIONS ESS3 & ESS4 Single Stage EDGE™ Series Regulators

� WARNING! � Apparatus improperly operated, maintained or repaired can be dangerous!

Service and repair of VICTOR apparatus should only be performed by a Qualified Repair Technician. The term “Qualified Repair Technician” refers to repair personnel capable of servicing apparatus in strict accordance with all applicable Victor “Parts & Service Bulletins” and literature. Improper service or repair, or modification of the product, could result in damage to the product or injury to the operator. Protect your investment! Some parts and accessories manufactured by others may fit VICTOR apparatus, but not conform to VICTOR’s exacting standards for quality, fit and function. For your own protection and the protection of your investment, specify and use only VICTOR genuine parts and accessories. It’s the only way to guarantee the level of performance, safety and reliability that you expect from VICTOR.

GLOSSARY – COMMONLY USED TERMS

OUTLET PRESSURE: The pressure measured at the Regulator’s outlet port.

INLET PRESSURE: The pressure measured immediately at the Regulator’s entry.

DROP: A change in outlet pressure from a no-flow to flowing condition while the inlet pressure remains constant.

RISE: An increase in outlet pressure as the inlet pressure decreases.

CREEP: A gradual increase in outlet pressure. RECOMMENDED TOOLS & SUPPLIES FOR REPAIR PROCEDURES

• Inlet Swivel Assembly Plug • 1/2”, 5/8”, 9/16”, 11/16” and 3/4” Sockets • Socket Wrench • Torque Wrench • 7/16”, 3/4” and 13/16” Open End Wrenches • 1/8”, 9/64”, 3/16” and 1/4” Hex Keys • Bench Vise • Repair Tool RT-180 (8” Leverage Bar with 1/4-18 NPT [M] End) • Oxygen-compatible Teflon® Tape • Loctite® #222 Threadlocker • CHRISTO-LUBE® #129 Lubricant.

KNOB

DEC

AL

6SC

REW 7

WAS

HER

8

KNOB 9

BONN

ET S

CREW

S

10

(a)

BONN

ET 2

O-RI

NG

17NO

ZZLE

16

DIAP

HRAG

M A

SSM

.

4

ADJU

STIN

G SP

RING

15

SCRE

W 7W

ASHE

R

14GU

IDE

BUSH

ING

13DR

IVE

SCRE

W

12TH

RUST

WAS

HER

11FR

ICTI

ON D

AMPE

R

21GL

AND

20

VALV

E SP

RING

19SE

AT A

SSM

.

18

BODY 1

INEL

T NU

T

23

FILT

ER

24A

INLE

T SW

IVEL

24

PIPE

PLU

G

25

OUTL

ET

26

RELI

EF V

ALVE

27

(b)

L.P.

GAUG

E

28H.P.

GAUG

E

29

GAUG

E GU

ARD

3

SCRE

W 5

SCRE

W 5

BONN

ET D

ECAL

(GAS

)

30

REAR

BOD

Y DE

CAL

(GAS

I.D.

)

31

SEAT

GUI

DE

22

(See

Det

ail A

)

BACK

-UP

RING

4A

(c)

Diap

hrag

mAs

sem

bly

Body

Bonn

et

Back

-Up

Ring

Orie

ntat

ion

In

Ass

embl

y (c)

EXPL

ODED

VIE

W -

ESS

3 AN

D ES

S4 M

ODEL

S

LOCK

WAS

HER

8A

BODY

27A

SEAT

RET

.

27C

DISC

27E

SEAT

27B

UPPE

R SE

AT

27D

SPRI

NG

27F

CAP

27G

DETA

IL A

- R

elie

f Val

ve (b

)

(a) E

SS3

mod

els

use

five

Scre

ws

for B

onne

t, ES

S4 m

odel

s us

e si

x Sc

rew

s.(b

) Pip

e Pl

ug re

plac

es R

elie

f Val

ve o

n fu

el g

as m

odel

s (5

10, 3

00, 9

93).

(c) U

sed

on E

SS4

“E”

Rang

e (2

00 P

SIG

Deliv

ery)

mod

els

only

.

SPRI

NG B

UTTO

N

27I

VENT

ED C

AP

27H

ADJ.

SCR

EW

27J

CAP

NUT

27K

Vent

ed

Non-

Vent

ed

- 2 -ESS3/ESS4 SECTION 1

ESS3

ESS4

Desc

riptio

nPa

rt N

o.Pa

rt N

o.Qt

y.1

Body

0701

-070

507

01-0

706

12

Bonn

et07

20-0

343

0720

-034

21

3Ga

uge

Guar

d14

29-0

071

1429

-007

01

4Di

aphr

agm

Ass

embl

y07

30-0

024

TABL

E 1

14A

Back

-Up

Ring

---

TABL

E 1

15

Scre

w (G

auge

Gua

rd)

1400

-024

814

00-0

239

26

Deca

l, Kn

ob14

15-0

788

1415

-079

11

7Sc

rew

28

Was

her

1

9Kn

ob1

10So

cket

Hea

d Ca

p Sc

rew

(b)

11Th

rust

Was

her

112

Driv

e Sc

rew

113

Guid

e Bu

shin

g As

sm.

114

Was

her,

Spec

ial

115

Adju

stin

g Sp

ring

116

Nozz

le1

17O-

Ring

(Noz

zle

Body

)1

18Se

at A

ssem

bly

119

Valv

e Sp

ring

120

Glan

d1

21Fr

ictio

n Da

mpe

r1

22Bo

ttom

Gui

de1

23In

let N

ut1

24In

let S

wiv

el w

/Filt

er1

24A

Inle

t Filt

er1

25Pi

pe P

lug

126

Outle

t Con

nect

ion

127

Relie

f Val

ve1

28Ga

uge,

Low

Pre

ssur

e1

29Ga

uge,

Hig

h Pr

essu

re1

30De

cal,

Bonn

et G

as I.

D.1

31De

cal,

Rear

Bod

y Ga

s In

fo.

1(a

) Cyl

inde

r mod

els

only

.(b

) ESS

3 us

es fi

ve (5

) scr

ews,

ESS

4 us

es s

ix (6

) scr

ews.TA

BLE

2TA

BLE

2

TABL

E 2

TABL

E 3

TABL

E 1

TABL

E 1

TABL

E 2

TABL

E 2

0717

-000

3 (a

)11

05-0

014

0708

-001

814

08-0

033

0708

-000

307

62-0

006

TABL

E 1

TABL

E 2

1407

-028

2TA

BLE

2

1406

-022

0

1406

-000

607

50-0

201

0750

-020

3

1400

-023

914

06-0

050

TABL

E 2

1400

-024

6

Ref.

No.

It

ems

mos

t com

mon

ly re

quire

d fo

r reg

ulat

or re

pair

and

reco

mm

ende

d fo

r sto

ck.

PART

S LI

ST -

ESS

3 an

d ES

S4 M

odel

Reg

ulat

ors

8ALo

ck W

ashe

r1

1406

-021

5

ESS3

Mod

el(E

SS3-

125-

540

Show

n)

ESS4

Mod

el(E

SS4-

125-

540

Show

n)

5.69

2.18

5.88

2.55

3.23

3.82

INLE

T

OUTL

ET

RELI

EF

INLE

T

OUTL

ET

RELI

EF


TABL

E 3

- Re

lief V

alve

Desc

riptio

n40

psi

Del

iver

y12

5 ps

i Del

iver

y20

0 ps

i Del

iver

y15

psi

Del

iver

y40

psi

Del

iver

y12

5 ps

i Del

iver

y20

0 ps

i Del

iver

y

6020

040

030

6020

040

0

27Re

lief V

alve

Com

plet

e As

sem

bly

or P

ipe

Plug

27A

Body

0601

-000

606

01-0

006

0601

-000

606

01-0

004

0601

-000

406

01-0

004

0601

-000

6

27B

Seat

0608

-000

606

08-0

006

0608

-000

906

08-0

006

0608

-000

606

08-0

006

0608

-000

9

27C

Seat

Ret

aine

r06

09-0

006

0609

-000

606

09-0

006

0609

-000

306

09-0

003

0609

-000

306

09-0

006

27D

Uppe

r Sea

t06

08-0

023

0608

-002

306

08-0

021

0608

-001

806

08-0

018

0608

-001

806

08-0

023

27E

Disc

1406

-001

714

06-0

017

1406

-001

714

06-0

016

1406

-001

614

06-0

016

1406

-001

7

27F

Sprin

g06

10-0

016

0610

-001

606

10-0

014

0610

-000

406

10-0

005

0610

-000

806

10-0

013

27G

Cap

---

---

---

0614

-000

406

14-0

004

0614

-000

406

14-0

006

27H

Cap

(Ven

ted)

0614

-001

606

14-0

016

0614

-001

6--

---

---

---

-

27I

Sprin

g Bu

tton

0606

-000

506

06-0

005

0606

-000

5--

---

---

---

-

27J

Adju

stin

g Sc

rew

1401

-000

714

01-0

008

1401

-000

8--

---

---

---

-

27K

Cap

Nut

1403

-002

414

03-0

024

1403

-002

4--

---

---

---

-

0600

-000

506

00-0

014

0600

-001

8

Acet

ylen

eAl

l Mod

els

---

---

---

---

---

---

---

---

---

---

---

---

Pipe

Plu

g11

05-0

014

0600

-006

006

00-0

066

0600

-007

106

00-0

003

All O

ther

Mod

els

Hydr

ogen

(Ven

ted

Relie

f Val

ve)

Relie

f Val

ve N

omin

al S

et P

ress

ure

Ref.

No.

LP G

asAl

l Mod

els

---

---

---

---

---

---

---

---

---

---

---

---

Pipe

Plu

g11

05-0

014

TABL

E 2

- In

let &

Out

let,

Seat

Ass

embl

y &

Noz

zle,

Col

or C

oded

Item

s

Gas

Inle

t Typ

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. Col

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S3ES

S4ES

S3ES

S4ES

S3ES

S4

Oxyg

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A 54

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0790

-020

907

90-0

200

0702

-008

507

02-0

068

0740

-015

807

40-0

131

0967

-004

409

67-0

032

0950

-006

814

15-0

790

1415

-079

2

Oxyg

en99

2GR

EEN

0790

-020

907

90-0

200

0702

-008

507

02-0

068

0740

-015

807

40-0

131

0992

-000

309

70-0

015

0950

-006

814

15-0

790

1415

-079

2

Argo

n/He

lium

/Nitr

ogen

CGA

580

BLAC

K07

90-0

214

0790

-020

807

02-0

085

0702

-006

807

40-0

158

0740

-013

109

73-0

003

0970

-001

509

50-0

017

(e)

1415

-079

914

15-0

798

Air (

Indu

stria

l)CG

A 59

0BL

ACK

0790

-021

407

90-0

208

0702

-008

507

02-0

068

0740

-015

807

40-0

131

0974

-000

309

70-0

015

0960

-001

414

15-0

805

1415

-080

4

Air (

Brea

thin

g)CG

A 34

6YE

LLOW

0790

-021

907

90-0

216

0702

-008

507

02-0

068

0740

-015

807

40-0

131

0972

-001

509

72-0

009

0960

-001

414

15-0

807

1415

-080

6

Carb

on D

ioxi

deCG

A 32

0 (d

)GR

EY07

90-0

212

0790

-020

607

02-0

085

0702

-006

807

40-0

158

0740

-013

109

85-0

030

0985

-005

8 (d

)09

50-0

017

(e)

1415

-080

114

15-0

800

Nitro

us O

xide

CGA

326

BLUE

0790

-021

107

90-0

205

0702

-008

507

02-0

068

0740

-015

807

40-0

131

0963

-001

509

63-0

009

0950

-008

014

15-0

803

1415

-080

2

Hydr

ogen

& M

etha

neCG

A 35

0RE

D07

90-0

210

0790

-020

407

02-0

085

0702

-006

807

40-0

158

0740

-013

109

83-0

003

0983

-000

509

60-0

029

1415

-080

914

15-0

808

Acet

ylen

eCG

A 51

0RE

D07

90-0

210

0790

-020

409

70-0

003

0970

-001

509

60-0

029

1415

-078

914

15-0

793

Acet

ylen

eCG

A 30

0RE

D07

90-0

210

0790

-020

409

68-0

003

0968

-000

509

60-0

029

1415

-078

914

15-0

793

Acet

ylen

e99

3RE

D07

90-0

210

0790

-020

409

93-0

003

0970

-001

509

60-0

029

1415

-078

914

15-0

793

LP G

ases

CGA

510

ORAN

GE07

90-0

213

0790

-020

709

70-0

003

0970

-001

509

60-0

029

1415

-079

714

15-0

796

(f) T

o re

plac

e Le

ns o

nly

- Re

plac

emen

t Len

s Pa

rt No

. 142

9-00

29.

(d) C

GA 3

20 in

let r

equi

res

inle

t was

her p

art n

umbe

r 140

8-00

65.

(e) F

low

Gau

ge (F

G) m

odel

s m

ust u

se O

utle

t Con

nect

ion

with

orifi

ce -

Par

t No.

095

0-01

20.

0740

-010

1

16 Nozz

le

Inle

t Nut

Inle

t Sw

ivel

(w

/Filt

er)

0740

-010

1

0740

-010

1

0740

-010

1

Outle

tCo

nnec

tion

Deca

l, Re

arBo

dy G

as In

fo.

9Ad

just

ing

Knob

(w/D

ecal

)De

cal,

Bonn

etGa

s I.D

.

18Se

at A

ssem

bly

0702

-006

8

0702

-006

8

0702

-006

8

0702

-006

8

2324

2630

31Re

f. No

.

TABL

E 1

- Di

aphr

agm

, Adj

ustin

g Sp

ring

& G

auge

s

ESS3

-FG-

580

Desc

riptio

nES

S3-F

G-32

0ES

S3-4

0-ES

S4-4

0-ES

S3-1

25-

ESS4

-125

-ES

S3-2

00-

ESS4

-200

-

4Di

aphr

agm

Ass

embl

y07

30-0

024

0730

-006

307

30-0

024

0730

-006

307

30-0

063

0730

-002

407

30-0

024

0730

-006

307

30-0

024

0730

-006

307

30-0

024

0730

-006

8

4ABa

ck-U

p Ri

ng--

---

---

-07

36-0

002

15Ad

just

ing

Sprin

g07

61-0

107

0761

-008

907

61-0

060

0761

-009

307

61-0

098

0761

-006

007

61-0

060

0761

-009

307

61-0

080

0761

-009

8

28Ga

uge,

Low

Pre

ssur

e (f)

1424

=05

1214

24=

0516

29Ga

uge,

Hig

h Pr

essu

re (f

)14

24=

0513

1424

=05

11

All O

ther

Mod

els

Flow

Gau

ge M

odel

s

1424

=05

13

1424

=05

11

0761

-009

8

1424

=05

15

1424

=05

11

---

--- 14

24=

0512

1424

=05

11

LP G

asES

S3-4

0-51

0LP

ESS4

-40-

510L

PES

S4-1

25-5

10LP

LP G

as

---

1424

=05

15

1424

=05

13

ESS3

-15-

510

ESS4

-15-

510

Ref.

No.

Acet

ylen

e

1424

=05

14

1424

=05

13

---

---

---

---

---



SERVICE & REPAIR PROCEDURES ESS3 & ESS4 Single Stage EDGE™ Series Regulators

DISASSEMBLY PROCEDURES Refer to the exploded view for reference numbers [Shown in brackets]

1. Mount the Inlet Swivel Assembly Plug in the Bench Vise and firmly attach the Regulator.

2. Remove the Knob Decal [6], and remove the #10-32 Screw [7], Lock Washer [8A] and Washer [8] located inside the Knob [9]. The Knob can now be removed.

3. Remove the 5 (for ESS3) or 6 (for ESS4) Socket Head Cap Screws [10]. The Bonnet [2] can now be removed.

TIP: Be careful when removing the Bonnet, as the Diaphragm Assembly can sometimes stick to it when disassembling.

4. Remove the Drive Screw [12], Guide Bushing [13], and Thrust Washer [11]. The Guide Bushing can be separated from the Drive Screw by removing the #10-32 Screw [7] and Washer [14] installed in the bottom of the Drive Screw.

TIP: Make sure you’ve got the Thrust Washer. If it’s not sitting on top of the Drive Screw, it may still be up inside the Bonnet.

5. Remove the Adjusting Spring [15], Diaphragm Assembly [4], and Back-Up Ring [4A] (if so equipped), and then remove the Nozzle [16] from the Body.

6. Remove the Seat Assembly [18], Valve Spring [19], Gland [20], Friction Damper [21] and Bottom Guide [22] from the Body.

7. Remove the Relief Valve or Pipe Plug [27], Outlet Connection [26] and Pipe Plug [25] (if necessary) from the Body.

8. Screw the Leverage Bar Tool RT-180 into the outlet port of the Body (lightly hand tight), and use the bar to unscrew the Body off the Inlet Swivel [24].

TIP: Watch the Inlet Swivel while trying to turn the Body. If the Swivel is turning with the Body, then you need to tighten the Inlet Nut tighter on the Inlet Swivel Assembly Plug.

9. Holding the Body by hand, or lightly in the Bench Vise (with the top surface of the body protected from damage), remove the Gauge Guard [3] (held on by two screws [5]) and then remove the Gauges [28, 29].

TIP: Step 9 can be done before Step 8 if desired, but it’s usually easier to remove the Gauge Guard and Gauges with the Inlet Swivel Assembly Plug out of the way. NOTE ON ESS4 MODELS: The lower Gauge Guard Screw cannot be accessed until the Relief Valve has been removed (if so equipped). Subsequently, the Gauge Guard (and Gauges) must be installed into the Body prior to installing the Relief Valve.

10. If necessary, disassemble the Relief Valve as shown in DETAIL A. � CAUTION! Discard the used Nozzle O-Ring, Inlet Filter, Diaphragm Assembly, Seat Assembly and Friction Damper. Replace them with new parts each time you assemble a Regulator.


All of these recommended components are available together in convenient repair kits for your ESS3 or ESS4 model Regulator:

Repair Kit Part No. Description RK-ESS3-HP 0790-0162 ESS3 Repair Kit for Oxygen, Inert Gases, Air, CO2,

N2O, Hydrogen.

RK-ESS4-HP 0790-0163 ESS4 Repair Kit for Oxygen, Inert Gases, Air, CO2, N2O, Hydrogen.

RK-ESS4-HP200 0790-0164 ESS4 Repair Kit - 200 PSIG Delivery Models Only - for Oxygen, Inert Gases, Air, CO2, N2O, Hydrogen.

RK-ESS3-F 0790-0165 ESS3 Repair Kit for Acetylene, LP Gas.

RK-ESS4-F 0790-0166 ESS4 Repair Kit for Acetylene, LP Gas.

CLEANING PARTS It is recommended to clean all metal parts for oxygen service, regardless of Regulator Model being repaired. There are several ways to clean components for oxygen service; the following standards are recommended reading for more detailed information on methods and processes:

• CGA G-4.1 “Cleaning Equipment for Oxygen Service”

• ASTM G-93 “Standard Practice for Cleaning Methods and Cleanliness Levels for Material and Equipment Used in Oxygen-Enriched Environments”

• ASTM G-127 “Standard Guide for the Selection of Cleaning Agents for Oxygen Systems”

For metal parts, Victor brand suggests using CCI Envirospray Liquid, used per the manufacturer's instructions, followed by a hot water rinse and thorough drying. Additional information can be found at http://www.ccichemical.com.

DO NOT allow non-metal parts to come in contact with cleaning solvents. Cleaning solvents can cause non-metal parts to swell and/or crack. To clean these parts, use a non-petroleum based mild soap solution, followed by a thorough rinsing in water. Dry parts completely prior to reassembling. ASSEMBLY PROCEDURES

Refer to the exploded view for reference numbers [Shown in brackets]

� IMPORTANT NOTES ABOUT SEALING PIPE THREADS: • When using Teflon® tape where noted: Apply two to three layers around the

threads, leaving the first thread clean. Insure your Teflon® tape is oxygen-compatible.

• When using Loctite® #222 Threadlocker where noted: Apply two to three drops to the second and third thread, leaving the first thread clean.

http://www.ccichemical.com/


1. Wrap the Low and High Pressure Gauges [28, 29] with Teflon® tape.

2. Holding the Body [1] by hand, or lightly in the Bench Vise (with the top surface of the Body protected from damage), install the Gauges into the Body and torque each to 10 ft-lbs minimum. Then install the Gauge Guard [3] using the two mounting Screws [5], tightening them until snug (the Gauge Guard firmly held in position).

TIP: If you cannot get a torque wrench on the Gauges, some simple rules will help insure adequate tightness: When the Gauges are tight, nearly all of the 1/8-27 NPT Gauge threads will disappear into the Body. You should only see one to two turns of complete thread remaining. Additionally, when the Gauge Guard is in position, the face of each Gauge should be at least 1/32” away from the underside of the Gauge Guard. If the Gauges are closer to the Gauge Guard than that, tighten the Gauges tighter as needed (one full revolution of the 1/8-27 NPT Gauge thread will move the Gauge closer to the Body by approximately 1/32”). Be sure to note the orientation of the Gauge face – always go tighter to line up Gauge dial artwork.

3. Install the new Filter [24A] into the Inlet Swivel [24], and apply either Teflon® tape or Loctite® #222 to the Inlet Swivel threads.

4. If not already in place, mount the Inlet Swivel Assembly Plug back in the Bench Vise. Firmly attach the Inlet Swivel and Inlet Nut [23] onto the Inlet Swivel Assembly Plug.

5. Screw the Body onto the Inlet Swivel, screw the Leverage Bar Tool RT-180 into the outlet port of the Body (light hand tight), and then use the Leverage Bar to tighten the Body onto the Inlet Connection. At this point, tighten enough so that the body cannot be turned by hand without the assistance of the Leverage Bar. Final torque for the Inlet Connection will occur in upcoming STEP 10.

6. Apply either Teflon® tape or Loctite® #222 to the Pipe Plug [25] threads. Install the Pipe Plug into the rear Body high pressure port, and torque to 15 ft-lbs.

7. Preassemble the Relief Valve (if so equipped): Assemble (or reassemble) the Relief Valve [27] as shown in DETAIL A. Use no lubricants or sealants. If your Regulator model has a Pipe Plug instead of a Relief Valve, or if your Relief Valve is already assembled and tested, you can skip to STEP 10.

8. To ensure proper Relief Valve performance, perform the following test procedures before assembling the Relief Valve in the Regulator. a. Attach the Relief Valve to a 450 PSIG source of oil-free air or dry nitrogen. b. Slowly pressurize the Relief Valve, increasing to the recommended blow-off pressure

listed below. Note that VICTOR Relief Valves are stamped with their nominal set pressure, in case you’re unsure which Relief Valve you have. Non-Vented Relief Valves: If the Relief Valve vents before the minimum blow-off pressure is reached, then a second Disc [27E] may be added. If it still vents, then the Spring [27F] must be replaced. Vented Relief Valves: If the Vented Relief Valve fails to vent within the recommended blow-off pressure, reset the Adjusting Screw [27J] as necessary and perform this step again. Make sure you fully bleed off all pressure each time you test for blow-off pressure.


Regulator Max. Delivery Pressure

Mating Relief Valve (Nominal)

Recommended Blow-off Pressure

15 PSIG 30 PSIG 27 to 33 PSIG 40 PSIG 60 PSIG 55 to 66 PSIG 125 PSIG 200 PSIG 180 to 220 PSIG 200 PSIG 400 PSIG 360 to 440 PSIG

9. When all testing is completed, bleed pressure off the Relief Valve. Install the Cap Nut

[27K] on the Vented Relief Valve.

10. Apply either Teflon® tape or Loctite® #222 to the Relief Valve (or Pipe Plug) [27] threads. Install the Relief Valve (or Pipe Plug) into the Body and torque to 15 ft-lbs.

11. Apply only Loctite® #222 threadlocker to the Outlet Connection [26] threads. Install the Outlet Connection into the Body and torque to 15 ft-lbs.

12. At this point, thoroughly blow out the Body assembly with pressurized oil-free air or dry nitrogen to insure it is completely free of chips and debris.

13. Install the Bottom Guide [22] into the Body – it should slip in freely. Note its orientation when installing – the cupped end with the hex on it should face up.

14. Preassemble the seat components: Push the Friction Damper [21] into the Gland [20], and then slip the Valve Spring [19], Gland and Friction Damper onto the shaft of the Seat Assembly [18].

TIP: The Friction Damper should have enough tension to hold the Gland and the Valve Spring in position on the shaft of the Seat Assembly. If there appears to be no tension (if the parts just seem to want to fall off), then there may be a problem with your Friction Damper, or the Friction Damper may not be firmly pushed up in place inside the Gland.

Then install the preassembled seat components into the Regulator Body – with the Friction Damper and Gland fitting down into the cup shape of the Bottom Guide.

15. Install the new O-Ring [17] onto the Nozzle [16], taking care to guide it carefully over the Nozzle threads to avoid nicks or tears. DO NOT use lubricant on the O-Ring. Install the Nozzle/O-Ring into the Regulator Body and torque to 15 ft-lbs. Note that 15 ft-lbs is the same recommended torque for the Inlet Connection Swivel, so as you torque down the Nozzle, you’re also finish-tightening the Inlet Swivel to the correct torque value.

TIP: Watch the Inlet Swivel while you torque down the Nozzle. If the Swivel is turning with the Body, then you need to tighten the Inlet Nut tighter on the Inlet Swivel Assembly Plug. You want to be sure that the 15 ft-lbs torque is being applied to both the Nozzle threads and the Inlet Swivel threads.

16. Preassemble the Adjusting Mechanism: Apply CHRISTO-LUBE® #129 Lubricant to the entire length of the threads of the Drive Screw [12], and screw the Guide Bushing [13] onto the Drive Screw (by hand) all the way up until it stops (do not over tighten!). Note that this is a left hand thread. Next, apply only Loctite® #222 to the threads of the #10-32 Screw [7], and install the Screw and Washer [14] into the Drive Screw – tightening until snug.

TIP: Make sure you’ve got the Drive Screw oriented correctly – the Screw and Washer you just installed should be in the end that’s opposite the square flats.

17. Install the Diaphragm Assembly [4], Adjusting Spring [15], preassembled Adjusting Mechanism and Thrust Washer [11] onto the Regulator Body. Note that the Diaphragm


centers itself in a recessed pocket in the top of the Body. Don’t forget the Thrust Washer! Regulator function will be impaired without it.

18. Install the Bonnet [2] onto the Body. Take care while slipping the Bonnet down over the internal components – the ribs inside the Bonnet must slide into the scallops of the Guide Bushing.

TIP: If your Bonnet still has the Gas I.D. decal on it, make sure you get the Bonnet oriented correctly with the Gas I.D. decal facing front.

19. Install the five (for ESS3) or six (for ESS4) Socket Head Cap Screws [10] into the Bonnet. Tighten all bolts until snug, then torque each to 12-15 ft-lbs in the sequence shown in FIGURE 1.

FIGURE 1 - Torque Sequence for Bonnet Screws

20. Apply a small amount of CHRISTO-LUBE® #129 to the top surface of the Bonnet (the surface around the square of the Drive Screw), then slip the Knob [9] into position – with the square hole inside the knob mating to the square shaft of the Drive Screw.

21. Install the #10-32 Screw [7], Lock Washer [8A] and Washer [8] to hold the Knob on. Torque this Screw a minimum of 30 in-lbs.

22. Apply new Knob or Gas I.D. decals [6, 30, 31] as needed to insure the Regulator maintains clear visual identification.

TIP: If you’re replacing the rear Body Gas I.D. decal, make sure you don’t cover up the model number stamped on the Body. The Gas I.D. decal should be positioned right next to the stamping, with the arrow on the decal pointing to the stamped model number.

23. Disconnect the Regulator from the Inlet Swivel Assembly Plug. The Regulator is now ready to test.

RECOMMENDED TOOLS AND SUPPLIES FOR TEST PROCEDURES • Test Gun (quick opening on/off valve) with #52 (.0635”) restricting orifice • Source of oil-free air or dry nitrogen


TEST PROCEDURES

� WARNING! � For your safety, and the safety of others:

• Always test with oil-free air or dry nitrogen only. • Always wear eye protection while testing a Regulator. • Always perform all of the following test procedures after reassembling a Regulator.

1. Adjust the Test Manifold to the proper pressure shown in TABLE 4. Gas Service Manifold Pressure for Testing Acetylene & LP Gas 250±20 PSIG CO2 & N2O 100±100 PSIG Air, Argon, Hydrogen, Helium, Nitrogen, Oxygen 2000±100 PSIG

TABLE 4 – Edge™ Regulator Test Pressures

2. Attach the Regulator to the Manifold connection or test adapter. Start the nut by hand (do not force), and tighten securely with a wrench to create a seal.

3. Turn the Regulator Adjusting Knob clockwise two or three times until you feel slight tension being applied to the Adjusting Spring.

4. Slowly open and close the Manifold Valve two or three times to remove contamination that may cause malfunctions. Leave the Manifold Valve closed. a. If no flow comes through the Regulator, determine the cause – refer to the

TROUBLESHOOTING CHART at the end of this section.

5. Turn the Adjusting Knob counterclockwise until it stops, and attach the Test Gun (with a #52 restricting orifice) to the outlet of the Regulator.

6. Open the Test Manifold Valve and close the Test Gun. a. Manifold working pressure will appear on the High Pressure Gauge. b. If the Low Pressure Gauge begins to show pressure building, turn the Test Manifold

off and refer to the TROUBLESHOOTING CHART.

7. Use the values in the following TABLE 5 for all subsequent tests:

Edge™ Model

A Pressure Set for Leak Test

B Pressure Set for Creep/Drop Test

C Drop

Allowance

D Initial Shut-off

Allowance ESS3-15- ESS4-15- 15 PSIG 5 PSIG 3 PSIG 1 PSIG

ESS3-40- ESS4-40- 40 PSIG 10 PSIG 3 PSIG 1 PSIG



TABLE 5 – Edge™ Regulator Test Values


8. LEAK TEST a. With the Test Gun closed and the Manifold Valve open, adjust the Regulator to

deliver A PSIG. b. Close the Manifold Valve and turn the Adjusting Knob one turn counterclockwise. c. Observe the Low Pressure and High Pressure Gauges for five (5) minutes:

1. If the High Pressure Gauge reading drops, there is a leak in the Cylinder Valve, Inlet Connection, High Pressure Gauge or the rear plugged high pressure port.

2. If the Low Pressure Gauge reading drops, there is a leak in the downstream equipment, Low Pressure Gauge, Outlet Connection or Relief Valve port.

3. If the High Pressure Gauge reading drops at the same time the Low Pressure Gauge reading increases, there is a leak in the Regulator Seat.

d. If any leaks are found, isolate if possible using a liquid leak detector, disassemble and repair or replace parts as needed, and start the test over again. Refer to TROUBLESHOOTING CHART for more detailed cause and possible corrective action information.

9. DROP TEST a. With the Test Gun closed and the Manifold Valve open, adjust the Regulator to

deliver B PSIG. b. Open the Test Gun and note the new indicated delivery pressure. Drop (indicated

pressure static minus indicated pressure flowing) must not exceed C PSIG.

10. CREEP TEST / SLOW SHUT-OFF TEST a. With the Test Gun closed and the Manifold Valve open, adjust the Regulator to

deliver B PSIG. b. Open and close the Test Gun several times to stabilize the Regulator. Leave the test

gun closed. c. Observe the Low Pressure Gauge for five (5) minutes:

1. During the first minute, an initial shut-off increase of D PSIG is permissible. 2. During the next 4 minutes, no further increase (creep) is allowed.

11. Close the Manifold Valve and release all pressure from the Regulator by opening the Test Gun. Turn the Adjusting Knob counterclockwise until it stops.

12. Remove the Test Gun from the Regulator.

13. Remove the Regulator from the Test Manifold. The Regulator is now ready to use.


TROUBLESHOOTING

CAUSES POSSIBLE CORRECTIVE ACTIONS

1. No gas flows through the Regulator and the High Pressure Gauge does not indicate pressure.

a. Inlet or Inlet Filter is plugged. Blow 40-45 PSIG of air through the Filter in reverse direction of the normal gas flow.

b. Empty Supply Cylinder. Replace the Cylinder.

2. No gas flows through the Regulator and the High Pressure Gauge does indicate pressure.

a. Damaged Adjusting Mechanism or missing components.

Check the Drive Screw, Guide Bushing and Thrust Washer – insure they are installed correctly and moving freely in the Bonnet.

b. Adjusting Knob not installed correctly.

Make sure the square of the Drive Screw is properly mated into the square in the Adjusting Knob.

c. Outlet Connection plugged. Inspect and clear the Outlet Connection of any debris.

d. Broken Adjusting Spring. Replace the Adjusting Spring. e. Broken Seat Stem. Replace the Seat Assembly.

3. Gauges do not indicate pressure but gas flows through the Regulator.

a. Defective Gauge(s). Replace Gauge(s).

4. Regulator does not deliver in its designed delivery pressure range.

a. Incorrect Adjusting Spring used during repair.

Replace with correct Adjusting Spring.

b. Damaged Adjusting Mechanism or missing components.


5. Regulator hums or clatters while flowing.

a. Missing Friction Damper. Install a Friction Damper. b. Missing Bottom Guide. Install the Bottom Guide. c. Flow exceeds Regulator capacity. Reduce flow to below the maximum rating of

the Regulator. d. Restriction upstream of the

Regulator. Inspect system and remove restriction.



6. Regulator experiences excessive drop.

a. Friction Damper too tight. Replace the Friction Damper and/or Gland. b. Wrong size orifice in Test Gun. Insure the correct orifice is installed in the

Test Gun - size #52 (.0635”). c. Partially plugged Inlet Filter. Clean or replace the Inlet Filter. d. Incorrect Adjusting Spring used

during repair. Replace with correct Adjusting Spring.

e. Low Cylinder pressure or Manifold test pressure.

Check Cylinder and Manifold pressure and adjust/replace as needed.

f. Flow exceeds Regulator capacity. Reduce flow to below the maximum rating of the Regulator.

7. Increase in the low pressure gauge reading (creep).

a. Loose Nozzle. Tighten Nozzle to 20 ft-lbs torque. b. Missing or damaged Nozzle O-Ring. Inspect and install or replace O-Ring as

necessary. c. Accumulation of foreign particles on

Seat Assembly or seating surfaces. Clean seating surfaces and/or replace Seat Assembly.

8. With the cylinder valve closed, the High Pressure Gauge indicator drops, and there is no immediate increase in pressure indicated on the Low Pressure Gauge.

a. Loose connection – Regulator to Test Manifold.

Insure Regulator is securely tightened to the Manifold.

b. Loose connection – Inlet Swivel to Regulator Body.

Tighten the Swivel using 20 ft-lbs torque.

c. Loose connection – High Pressure Gauge to Regulator Body.

Tighten the High Pressure Gauge using 10 ft-lbs torque minimum (See STEP 2 of the Assembly Procedure).

d. Loose connection – Rear Pipe Plug. Tighten Pipe Plug using 15 ft-lbs torque minimum.

e. Leaking Gauge. Replace the Gauge.

9. Low Pressure Gauge indicator slowly drops, and there is no decrease in pressure on the High Pressure gauge when the Manifold Valve is closed.

a. Test Gun is not attached securely. Tighten the Test Gun. b. Loose connections at the Regulator

Body – Outlet Connection, L.P. Gauge or Relief Valve/Plug

Tighten connections using 15 ft-lbs torque minimum.

c. Loose connection – Bonnet to Body. Tighten Bonnet Screws using 12-15 ft-lbs. Follow the sequence shown in STEP 19 FIGURE 1 of the Assembly Procedure.

d. Damaged Diaphragm. Replace Diaphragm Assembly.



10. Rapid pressure drop on both High and Low Pressure Gauges.

a. Loose connection – Bonnet to Body.

Tighten Bonnet Screws using 12-15 ft-lbs. Follow the sequence shown in STEP 19 FIGURE 1 of the Assembly Procedure.

b. Loose connection – Regulator to Test Manifold.


11. Rapid increase in Low Pressure Gauge reading.

a. Damaged or loose Nozzle. Replace and/or tighten the Nozzle to 20 ft-lbs torque.

b. Heavy accumulation of foreign particles on Seat Assembly or seating surfaces.

Clean seating surfaces and/or replace Seat Assembly.

c. Missing or damaged Nozzle O-Ring.

Inspect and install or replace O-Ring as necessary.

d. Improper Adjusting Spring (spring too long).

Replace Adjusting Spring.

12. Relief Valve opens at a greater or less than marked pressure (outside a pressure tolerance of ±15% of the marked pressure).

a. Incorrect Spring used. Replace with correct Spring. b. Relief Valve not set properly. Repeat Relief Valve assembly/test procedure

STEP 8.

ESS7/EST4/ESL4/ELC4 - 15 - SECTION 3

SECTION 3

SERVICE & REPAIR INSTRUCTIONS ESS7, EST4, ESL4 & ELC4 Single Stage EDGE™ Series Regulators

� WARNING! � Apparatus improperly operated, maintained or repaired can be dangerous!

Service and repair of VICTOR apparatus should only be performed by a Qualified Repair Technician. The term “Qualified Repair Technician” refers to repair personnel capable of servicing apparatus in strict accordance with all applicable Victor “Parts & Service Bulletins” and literature. Improper service or repair, or modification of the product, could result in damage to the product or injury to the operator. Protect your investment! Some parts and accessories manufactured by others may fit VICTOR apparatus, but not conform to VICTOR’s exacting standards for quality, fit and function. For your own protection and the protection of your investment, specify and use only VICTOR genuine parts and accessories. It’s the only way to guarantee the level of performance, safety and reliability that you expect from VICTOR.

GLOSSARY – COMMONLY USED TERMS

OUTLET PRESSURE: The pressure measured at the Regulator’s outlet port.

INLET PRESSURE: The pressure measured immediately at the Regulator’s entry.

DROP: A change in outlet pressure from a no-flow to flowing condition while the inlet pressure remains constant.

RISE: An increase in outlet pressure as the inlet pressure decreases.

CREEP: A gradual increase in outlet pressure.

RECOMMENDED TOOLS & SUPPLIES FOR REPAIR PROCEDURES

• Inlet Swivel Assembly Plug • 1/2”, 5/8”, 9/16”, 11/16” and 7/8” Sockets and Socket Wrench • Torque Wrench • 9/16” and 1” Open End Wrenches • 1/8”, 3/16” and 1/4” Hex Keys/Drivers • Flat Bottom Punch Set • Small, Long Shank Screwdriver • Bench Vise • Repair Tool RT-180 (8” Leverage Bar with 1/4-18 NPT [M] End) • Oxygen-compatible Teflon® Tape • Loctite® #222 Threadlocker • CHRISTO-LUBE® #129 Lubricant.

BODY28A

SEAT RET.28C

DISC28E

SEAT28B

UPPER SEAT28D

SPRING28F

CAP28G

VENTED CAP28H

SPRING BUTTON28I

ADJ. SCREW28J

CAP NUT28K

VentedNon-Vented

DETAIL A - Relief Valve (a)

DECAL19

SCREW10

WASHER17 KNOB

23

BONNET SCREWS16

BONNET15

O-RING8

NOZZLE9

DIAPHRAGM ASSM.2

ADJUSTING SPRING22

SCREW10

WASHER11

GUIDE BUSHING12

DRIVE SCREW13

THRUST WASHER14

FRICTION DAMPER5

GLAND6

VALVE SPRING7

SEAT ASSM.21

BODY1

INLET NUT24 INLET FILTER

3

INLET SWIVEL26PLUG

20OUTLET27

RELIEF VALVE 28 (a)

L.P. GAUGE29 H.P. GAUGE

30

RETAINING RING25

INFO DECAL31

SEAT GUIDE4

(See DETAIL A)

BACKUP RING 2A (b)

DiaphragmAssembly

Body

Bonnet

Back-Up RingOrientation

In Assembly (b)

EXPLODED VIEW - ESS7 HIGH-FLOW

200 P

SIG DELIVER

Y ONLY

LOCK WASHER18

(a) Pipe Plug replaces Relief Valve on fuel gas models (510, 300, 993).(b) Used on “E” Range (200 PSIG Delivery) models only.

- 16 - SECTION 3

EST4-R

ELC4

ESL4

EST4EST4-RELC4 EST4

ESL4

EST4ELC4EST4-R

EST4

EST4-R

ESL4

ELC4

EST4

EST4-RELC4

DECAL

19 SCREW

10

WASHER

17

KNOB

23

BONNET SCREWS

16BONNET

15

O-RING

8

NOZZLE

9

DIAPHRAGM ASSM.

2

ADJUSTING SPRING

22

SCREW

10WASHER

11

GUIDE BUSHING

12

DRIVE SCREW

13

THRUST WASHER

14

FRICTION DAMPER

5

GLAND

6

VALVE SPRING

7

SEAT ASSM.

21

BODY

1

INLET NUT

24RETAINING RING

25

INLET SWIVEL

26

PLUG

20

PLUG

20OUTLET

27

L.P. GAUGE

29

INLET FILTER

3INFO DECAL

31

SEAT GUIDE

4

DIAPHRAGM SHIM

2B

EXPLODED VIEW - ESL4 / EST4 / ELC4

DIAPHRAGM ASSM.(STAINLESS STEEL)

2C

O-RING

2D

PLUG

20

INLET NUT

24INLET SWIVEL

26

INLET FILTER

3

LOCK WASHER

18 - 17 - SECTION 3

Mod

el N

umbe

rSt

ampi

ng L

ocat

ion

(All

Mod

els)

E XX

X –

XXX

– X

XX

E =

EDG

E Se

ries

Type

:SS

= S

ingl

e St

age,

St

anda

rd In

let

SL =

Lin

e Re

gula

tor

ST =

Sta

tion

Regu

lato

rLC

= L

iqui

d Cy

linde

r

Regu

lato

r

Size

:4

= H

igh

Capa

city

(Lar

ge)

7 =

Ultr

a-Hi

gh C

apac

ity (H

igh

Flow

)

Deliv

ery

Pres

sure

:(1

5, 4

0, 1

25, e

tc.)

Inle

t Con

nect

ion:

• CG

A 54

0, 5

10, 0

24, e

tc.

• 25

0 =

1/4

NPT

(F) I

nlet

/Out

let

• 25

0A =

1/4

NPT

(F) I

nlet

/Out

let

fo

r Ace

tyle

ne•

250F

= 1

/4 N

PT (F

) Inl

et/O

utle

t

for H

.P. F

uel G

ases

• 25

0X =

1/4

NPT

(F) I

nlet

/Out

let

fo

r Oxy

gen

1Bo

dy07

01-0

697

0701

-069

707

01-0

696

0701

-069

61

2Di

aphr

agm

Ass

embl

y07

30-0

063

0730

-006

807

30-0

063

---

12A

Back

up R

ing

---

0736

-000

2--

---

-1

2BDi

aphr

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m--

---

---

-07

36-0

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12C

Diap

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---

---

---

0730

-009

61

2DDi

aphr

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---

---

---

1407

-021

51

3Fi

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0717

-000

307

17-0

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0717

-000

707

17-0

007

1

Ref.

No.

Desc

riptio

nES

S7ES

S7-2

00

EST4

EST4

-RES

L4EL

C4Qt

y.

Part

Num

bers

4Se

at G

uide

107

08-0

019

5Fr

ictio

n Da

mpe

r1

1408

-003

36

Glan

d1

0708

-000

3

(Com

mon

Par

ts)

7Va

lve

Sprin

g1

0762

-000

68

O-Ri

ng (N

ozzl

e)1

1407

-035

19

Nozz

le1

0702

-008

8

21Se

at A

ssem

bly

1SE

E TA

BLE

1(C

onfig

urat

ion-

Spec

ific

Part

s)

19De

cal,

Knob

114

15-0

791

20Pi

pe P

lug

A/R

1105

-001

4

22Ad

just

ing

Sprin

g1

SEE

TABL

E 1

23Kn

ob1

SEE

TABL

E 1

24In

let N

ut1

SEE

TABL

E 1

25Re

tain

ing

Ring

1SE

E TA

BLE

126

Inle

t Sw

ivel

1SE

E TA

BLE

127

Outle

t Con

nect

ion

1SE

E TA

BLE

128

Relie

f Val

ve1

SEE

TABL

E 2

29Ga

uge,

Low

Pre

ssur

e1

SEE

TABL

E 1

30Ga

uge,

Hig

h Pr

essu

re1

SEE

TABL

E 1

31De

cal,

Gas

Info

rmat

ion

1SE

E TA

BLE

1

10Sc

rew

(#10

-32)

214

00-0

239

11W

ashe

r (Sp

ecia

l)1

1406

-000

612

Guid

e Bu

shin

g1

0750

-020

113

Driv

e Sc

rew

107

50-0

203

14Th

rust

Was

her

114

06-0

220

15Bo

nnet

107

20-0

342

16Sc

rew

(1/4

-20)

614

00-0

246

17W

ashe

r1

1406

-005

018

Lock

Was

her

114

06-0

215

It

ems

mos

t com

mon

ly re

quire

d fo

r reg

ulat

or re

pair

and

reco

mm

ende

d fo

r sto

ck.

PART

S LI

ST -

ESS

7, E

ST4,

ESL

4 an

d EL

C4 M

odel

Reg

ulat

ors

ESS7

EST4

ESL4

ELC4

Mod

el N

umbe

ring

Sch

eme

- 18 -ESS7/EST4/ESL4/ELC4 SECTION 3

TABL

E 2

- Re

lief V

alve

400

200

400

0601

-000

6

0601

-000

406

01-0

006

0608

-000

9

0608

-000

606

08-0

009

0609

-000

6

0609

-000

306

09-0

006

0608

-002

1

0608

-001

806

08-0

023

1406

-001

7

1406

-001

614

06-0

017

0610

-001

4

0610

-000

806

10-0

013

---

0614

-000

406

14-0

006

0614

-001

6

---

---

0606

-000

5

---

---

1401

-000

8

---

---

1403

-002

4

---

---

0600

-001

406

00-0

018

0600

-007

1

2828

A28

B28

C28

D28

E28

F28

G28

H28

IEd

ge M

odel

Nom

inal

Set P

ress

ure

Com

plet

eAs

sem

bly

Body

Seat

Seat

Reta

iner

Uppe

rSe

atDi

scSp

ring

Cap

Vent

edCa

pSp

ring

Butt

on

Ref.

No.

28J

28K

Adju

stin

gSc

rew

Cap

Nut

TABL

E 1

- Di

aphr

agm

, Adj

ustin

g Sp

ring

& G

auge

s

GREE

N

(Sor

ted

by M

odel

/Pre

ssur

e/Co

nnec

tion)

2122

2324

2526

2729

3031

Edge

Mod

elGa

s Se

rvic

eKn

obCo

lor

Seat

Asse

mbl

yAd

just

ing

Sprin

gKn

ob(w

/Dec

al)

Inle

tNu

tRe

tain

ing

Ring

In

let

Swiv

elOu

tlet

Conn

ectio

nGa

uge,

Low

Pres

sure

(c)

Gaug

e, H

igh

Pres

sure

(c)

Deca

l, Ga

sIn

form

atio

nES

S7-1

5-51

0Ac

etyl

ene

RED

350

0740

-007

107

61-0

089

0790

-020

409

70-0

003

---

0970

-000

5 (e

)09

60-0

017

1424

=052

514

24=0

529

0707

-142

6ES

S7-1

25-5

10LP

LP G

asOR

ANGE

350

0740

-007

107

61-0

098

0790

-020

709

70-0

003

---

0970

-000

5 (e

)09

60-0

017

1424

=052

814

24=0

529

0707

-143

1ES

S7-1

25-5

40Ox

ygen

GREE

N30

0007

40-0

070

0761

-009

807

90-0

200

0967

-004

414

06-0

130

0967

-003

4 (e

)09

50-0

024

1424

=052

814

24=0

532

0707

-142

4ES

S7-1

25-5

80In

ert G

asBL

ACK

3000

0740

-007

007

61-0

098

0790

-020

809

73-0

003

---

0970

-000

5 (e

)09

50-0

024

1424

=052

814

24=0

532

0707

-142

8ES

S7-2

00-3

46Ai

rYE

LLOW

3000

0740

-007

007

61-0

098

0790

-021

609

72-0

015

---

0972

-001

0 (e

)09

50-0

024

1424

=052

914

24=0

532

0707

-142

9ES

S7-2

00-3

50Hy

drog

en, M

etha

ne30

0007

40-0

070

0761

-009

807

90-0

204

0983

-000

3--

-09

83-0

008

(e)

0960

-001

714

24=0

529

1424

=053

207

07-1

430

ESS7

-200

-540

Oxyg

en30

0007

40-0

070

0761

-009

807

90-0

200

0967

-004

414

06-0

130

0967

-003

4 (e

)09

50-0

024

1424

=052

914

24=0

532

0707

-142

4ES

S7-2

00-5

80In

ert G

as30

0007

40-0

070

0761

-009

807

90-0

208

0973

-000

3--

-09

70-0

005

(e)

0950

-002

414

24=0

529

1424

=053

207

07-1

428

ESS7

-200

-992

Oxyg

en30

0007

40-0

070

0761

-009

807

90-0

200

0992

-000

3--

-09

70-0

005

(e)

0950

-002

414

24=0

529

1424

=053

207

07-1

424

EST4

-15-

025

Acet

ylen

e20

007

40-0

071

0761

-008

907

90-0

204

0966

-000

3--

-09

52-0

001

0960

-002

914

24=0

525

---

0707

-142

7ES

T4-1

5-02

5RAc

etyl

ene

200

0740

-007

107

61-0

089

0790

-020

409

66-0

003

---

0952

-000

009

60-0

029

1424

=052

5--

-07

07-1

427

EST4

-40-

024

Oxyg

en20

007

40-0

070

0761

-009

307

90-0

200

0965

-000

5--

-09

52-0

001

0950

-006

814

24=0

526

---

0707

-142

5ES

T4-4

0-02

4ROx

ygen

200

0740

-007

007

61-0

093

0790

-020

009

65-0

005

---

0952

-000

009

50-0

068

1424

=052

6--

-07

07-1

425

EST4

-80-

024

Oxyg

en20

007

40-0

070

0761

-008

007

90-0

200

0965

-000

5--

-09

52-0

001

0950

-006

814

24=0

527

---

0707

-142

5ES

T4-8

0-02

4ROx

ygen

200

0740

-007

007

61-0

080

0790

-020

009

65-0

005

---

0952

-000

009

50-0

068

1424

=052

7--

-07

07-1

425

EST4

-80-

025

Hyd

roge

n, M

etha

ne,

Nat

ural

Gas

& L

P G

as20

007

40-0

071

0761

-008

007

90-0

204

0966

-000

3--

-09

52-0

001

0960

-002

914

24=0

527

---

0707

-143

5ES

T4-8

0-02

5RHy

d, M

eth,

LP

Gas

200

0740

-007

107

61-0

080

0790

-020

409

66-0

003

---

0952

-000

009

60-0

029

1424

=052

7--

-07

07-1

435

EST4

-125

-024

Oxyg

en20

007

40-0

070

0761

-009

807

90-0

200

0965

-000

5--

-09

52-0

001

0950

-006

814

24=0

528

---

0707

-142

5ES

T4-1

25-0

24R

Oxyg

en20

007

40-0

070

0761

-009

807

90-0

200

0965

-000

5--

-09

52-0

000

0950

-006

814

24=0

528

---

0707

-142

5ES

T4-1

25-0

25H

ydro

gen,

Met

hane

, N

atur

al G

as &

LP

Gas

200

0740

-007

107

61-0

098

0790

-020

409

66-0

003

---

0952

-000

109

60-0

029

1424

=052

8--

-07

07-1

435

EST4

-125

-025

RHy

d, M

eth,

LP

Gas

200

0740

-007

107

61-0

098

0790

-020

409

66-0

003

---

0952

-000

009

60-0

029

1424

=052

8--

-07

07-1

435

EST4

-125

-034

Iner

t Gas

200

0740

-007

007

61-0

098

0790

-020

809

56-0

000

---

0952

-000

109

50-0

017

1424

=052

8--

-07

07-1

434

EST4

-125

-034

RIn

ert G

as20

007

40-0

070

0761

-009

807

90-0

208

0956

-000

0--

-09

52-0

001

0950

-001

714

24=0

528

---

0707

-143

4ES

L4-1

5-25

0AAc

etyl

ene

350

0740

-007

107

61-0

089

0790

-020

4--

---

---

---

-14

24=0

525

---

0707

-142

6ES

L4-8

0-25

0FHy

d, M

eth,

LP

Gas

350

0740

-007

107

61-0

080

0790

-020

4--

---

---

---

-14

24=0

527

---

0707

-143

6

ESL4

-125

-250

XOx

ygen

3000

0740

-007

007

61-0

098

0790

-020

0--

---

---

---

-14

24=0

528

---

0707

-142

4ES

L4-1

25-2

50F

Hyd,

Met

h, L

P Ga

s35

007

40-0

071

0761

-009

807

90-0

204

---

---

---

---

1424

=052

8--

-07

07-1

436

ELC4

-125

-320

Carb

on D

ioxi

deGR

EY30

0007

40-0

070

0761

-009

807

90-0

206

0985

-003

0--

-09

85-0

003

(d)

0950

-001

714

24=0

528

---

0707

-143

3EL

C4-1

25-5

40Ox

ygen

3000

0740

-007

007

61-0

098

0790

-020

009

67-0

044

1406

-013

009

67-0

005

0950

-006

814

24=0

528

---

0707

-142

4EL

C4-1

25-5

80In

ert G

as30

0007

40-0

070

0761

-009

807

90-0

208

0973

-000

3--

-09

70-0

004

0950

-001

714

24=0

528

---

0707

-142

8EL

C4-3

25-5

80In

ert G

as30

0007

40-0

070

0799

-080

907

90-0

208

0973

-000

3--

-09

70-0

004

0950

-001

714

24=0

529

---

0707

-142

8

(c) T

o re

plac

e Le

ns o

nly,

use

Repl

acem

ent L

ens

Part

No. 1

429-

0028

.(d

) CGA

320

Inle

t Con

nect

ion

requ

ires

Inle

t Sea

l Was

her P

art N

o. 1

408-

0065

.(e

) Sw

ivel

s in

clud

e Fi

lter 0

717-

0003

pre

-inst

alle

d.

Max

Inle

t

RED

RED

RED

RED

RED

RED

RED

RED

RED

RED

GREE

N

GREE

N

GREE

NGR

EEN

GREE

NGR

EEN

GREE

NGR

EEN

GREE

N

BLAC

K

BLAC

KBL

ACK

BLAC

K

BLAC

KBL

ACK

Ref.

No.

ESS7

-125

ESS7

-200

ESS7

-200

-350

(VEN

TED)

ESL4

-125

-250

Air,

Oxy

gen,

CO

2,

N2O

& In

ert G

as30

0007

40-0

070

0761

-009

807

90-0

208

---

---

---

---

1424

=052

8--

-07

07-1

432

Repa

ir Ki

tPa

rt N

o.07

90-0

169

0790

-016

907

90-0

167

0790

-016

707

90-0

168

0790

-016

807

90-0

168

0790

-016

807

90-0

168

0790

-017

107

90-0

171

0790

-017

007

90-0

170

0790

-017

007

90-0

170

0790

-017

107

90-0

171

0790

-017

007

90-0

170

0790

-017

107

90-0

171

0790

-017

007

90-0

170

0790

-017

107

90-0

171

0790

-017

007

90-0

171

0790

-017

207

90-0

172

0790

-017

207

90-0

172

0790

-017

0

- 19 -ESS7/EST4/ESL4/ELC4 SECTION 3


SERVICE & REPAIR PROCEDURES ESS7, EST4, ESL4 & ELC4 Single Stage EDGE™ Series Regulators

DISASSEMBLY PROCEDURES Refer to the exploded views for reference numbers [Shown in brackets]

1. Mount the Inlet Swivel Assembly Plug (hereafter called “Inlet Plug”) in the Bench Vise and firmly attach the Regulator. If you do not have or do not wish to use an Inlet Plug, you may also clamp the Regulator in the Bench Vise by the hex on the back of the Body.

2. Remove the Knob Decal [19], and remove the #10-32 Screw [10], Lock Washer [18] and Washer [17] located inside the Knob [23]. The Knob can now be removed.

3. Remove the 6 Socket Head Cap Screws [16]. The Bonnet [15] can now be removed. TIP: Be careful when removing the Bonnet, as the Diaphragm Assembly can sometimes stick to it when disassembling.

4. Remove the Drive Screw [13], Guide Bushing [12], and Thrust Washer [14]. The Guide Bushing can be separated from the Drive Screw by removing the #10-32 Screw [10] and Washer [11] installed in the bottom of the Drive Screw.

TIP: Make sure you’ve got the Thrust Washer. If it’s not sitting on top of the Drive Screw, it may still be up inside the Bonnet.

5. Remove the Adjusting Spring [22], Diaphragm Assembly [2] (including the Back-Up Ring [2A] on 200 psig delivery models), or Diaphragm Assembly, Shim & O-Ring [2B, 2C & 2D] on ELC4 models. Then remove the Nozzle [9] from the Body.

6. Remove the Seat Assembly [21], Valve Spring [7], Gland [6], Friction Damper [5] and Seat Guide [4] from the Body.

TIP: The easiest way to get the Seat Guide out is to simply flip the Body over.

7. Remove the Gauge(s) [29 & 30], Outlet Connection [27] and Relief Valve and/or Pipe Plugs [20 & 28] (if necessary) from the Body.

8. Screw the Leverage Bar Tool RT-180 into one of the Body ports (lightly hand tight), and use the bar to unscrew the Body off the Inlet Swivel [26].

TIP: Watch the Inlet Swivel while trying to turn the Body. If the Swivel is turning with the Body, then you need to tighten the Inlet Nut tighter on the Inlet Swivel Assembly Plug.

It is also acceptable to use a Wrench and Socket on the hex of the Inlet Swivel, but take caution not to damage the hex in any way.

9. Remove the Inlet Filter: EST4, ESL4 and ELC4 models: The Inlet Filter [3] is a mesh screen with a tubular ring surrounding it. It is installed into the body with the tubular ring flattened to secure it into the port. Remove the Filter by prying it out, or by pushing it out from the inside of the Body, with a Screwdriver or Punch. ESS7 models: The Inlet Filter [3] is a sintered cone shape that is pressed into the end of the Inlet Swivel [26]. It can be removed by lightly tapping at it from the inside with a flat bottom Punch.

10. If necessary, disassemble the Relief Valve as shown in Page 1, DETAIL A.


� CAUTION! Discard the used Nozzle O-Ring, Inlet Filter, Diaphragm Assembly, Seat Assembly and Friction Damper. Replace them with new parts each time you assemble a Regulator. All of these recommended components are available together in convenient repair kits for your ESS7, EST4, ESL4 or ELC4 model Regulator. See TABLE 1 on Page 3 for your specific application.

Repair Kit Part No. Description RK-ESS7-X 0790-0167 ESS7 Repair Kit for Oxygen, Inert Gases, Air, CO2,

N2O, Hydrogen. RK-ESS7-X200 0790-0168 ESS7 Repair Kit - 200 PSIG Delivery Models Only -

for Oxygen, Inert Gases, Air, CO2, N2O, Hydrogen. RK-ESS7-F 0790-0169 ESS7 Repair Kit for Acetylene, LP Gas. RK-STSL-X 0790-0170 EST4/ESL4 Repair Kit for Oxygen, Inert Gases, Air,

CO2, N2O. RK-STSL-F 0790-0171 EST4/ESL4 Repair Kit for Acetylene, LP Gas,

Hydrogen. RK-ELC4-X 0790-0172 ELC4 Repair Kit for Oxygen, Inert Gases, Air, CO2

CLEANING PARTS It is recommended to clean all metal parts for oxygen service, regardless of Regulator Model being repaired. There are several ways to clean components for oxygen service; the following standards are recommended reading for more detailed information on methods and processes:

• CGA G-4.1 “Cleaning Equipment for Oxygen Service”

• ASTM G-93 “Standard Practice for Cleaning Methods and Cleanliness Levels for Material and Equipment Used in Oxygen-Enriched Environments”

• ASTM G-127 “Standard Guide for the Selection of Cleaning Agents for Oxygen Systems”

For metal parts, Victor brand suggests using CCI Envirospray Liquid, used per the manufacturer's instructions, followed by a hot water rinse and thorough drying. Additional information can be found at http://www.ccichemical.com.

DO NOT allow non-metal parts to come in contact with cleaning solvents. Cleaning solvents can cause non-metal parts to swell and/or crack. To clean these parts, use a non-petroleum based mild soap solution, followed by a thorough rinsing in water. Dry parts completely prior to reassembling.

ASSEMBLY PROCEDURES Refer to the exploded views for reference numbers [Shown in brackets]

� IMPORTANT NOTES ABOUT SEALING PIPE THREADS: • When using Teflon® tape where noted: Apply two to three layers around the

threads, leaving the first thread clean. Insure your Teflon® tape is oxygen-compatible.

• When using Loctite® #222 Threadlocker where noted: Apply two to three drops to the second and third thread, leaving the first thread clean.

http://www.ccichemical.com/


1. Filter Installation: EST4, ESL4 and ELC4 Models: Install the new Inlet Filter screen [3] into the appropriate inlet port in the Body. To retain the Inlet Filter in the Body, flatten the Filter’s tubular ring with a flat bottom Punch. ESS7 Models: Install the new Filter [3] into the Inlet Swivel [26] by pressing in a Vise.

2. Install the Inlet Nut [24] onto the Inlet Swivel, and apply either Teflon® tape or Loctite® #222 to the Inlet Swivel threads.

3. If not already in place, mount the Inlet Plug (if one is being used) back in the Bench Vise. Firmly attach the Inlet Swivel and Inlet Nut onto the Inlet Plug. If not using an Inlet Plug, simply clamp the Body itself into the Vise using the hex on the back of the Body.

4. Either screw the Body onto the Inlet Swivel using the Leverage Bar Tool RT-180, or tighten the Inlet Swivel into the Body using a Wrench and Socket, taking care not to damage the Inlet Swivel hex. Torque the Inlet Swivel 20-25 ft-lbs.

5. Apply either Teflon® tape or Loctite® #222 to the Gauge(s) [29, 30] and any Pipe Plugs [20], and install into the Body using a minimum of 10 ft-lbs. torque.

6. Preassemble the Relief Valve (if so equipped): Assemble (or reassemble) the Relief Valve [28] as shown in DETAIL A. Use no lubricants or sealants. If your Regulator model has a Pipe Plug instead of a Relief Valve, or if your Relief Valve is already assembled and tested, you can skip to STEP 10.

7. To ensure proper Relief Valve performance, perform the following test procedures before assembling the Relief Valve in the Regulator. a. Attach the Relief Valve to a 450 PSIG source of oil-free air or dry nitrogen. b. Slowly pressurize the Relief Valve, increasing to the recommended blow-off pressure

listed below. Note that VICTOR Relief Valves are stamped with their nominal set pressure, in case you’re unsure which Relief Valve you have. Non-Vented Relief Valves: If the Relief Valve vents before the minimum blow-off pressure is reached, then a second Disc [28E] may be added. If it still vents, then the Spring [28F] must be replaced. Vented Relief Valves: If the Vented Relief Valve fails to vent within the recommended blow-off pressure, reset the Adjusting Screw [28J] as necessary and perform this step again. Make sure you fully bleed off all pressure each time you test for blow-off pressure.

Regulator Max. Delivery Pressure

Mating Relief Valve (Nominal)

Recommended Blow-off Pressure

15 PSIG 30 PSIG 27 to 33 PSIG 40 PSIG 60 PSIG 55 to 66 PSIG 125 PSIG 200 PSIG 180 to 220 PSIG 200 PSIG 400 PSIG 360 to 440 PSIG

8. When all testing is completed, bleed pressure off the Relief Valve. Install the Cap Nut

[28K] on the Vented Relief Valve.

9. Apply either Teflon® tape or Loctite® #222 to the Relief Valve threads. Install the Relief Valve into the Body and torque to a minimum of 10 ft-lbs.


10. Apply only Loctite® #222 threadlocker to the Outlet Connection [27] threads. Install the Outlet Connection into the Body and torque to 15 ft-lbs.

11. At this point, thoroughly blow out the Body assembly with pressurized oil-free air or dry nitrogen to insure it is completely free of chips and debris.

12. Install the Seat Guide [4] into the Body – it should slip in freely. Note its orientation when installing – the angled end faces down, into the Body.

TIP: Make sure the Seat Guide is installed straight. It should appear flat and level in the body (not tilted at an angle). To ease installation, use a small Screwdriver or Punch that can fit through the center hole of the Seat Guide. Slip the Seat Guide onto the Screwdriver, then, while holding the Seat Guide up on the shank, position the end of the Screwdriver approximately centered down inside the body (below the assembly location of the Seat Guide). Then, simply drop the Seat Guide, letting it slide down the Screwdriver and fall into position.

13. Preassemble the seat components: Push the Friction Damper [5] into the Gland [6], and then slip the Valve Spring [7], Gland and Friction Damper onto the shaft of the Seat Assembly [21].

TIP: The Friction Damper should have enough tension to hold the Gland and the Valve Spring in position on the shaft of the Seat Assembly. If there appears to be no tension (if the parts just seem to want to fall off), then there may be a problem with your Friction Damper, or the Friction Damper may not be firmly pushed up in place inside the Gland.

Then install the preassembled seat components into the Regulator Body – with the Friction Damper and Gland fitting down into the cup shape of the Seat Guide.

14. Install the new O-Ring [8] onto the Nozzle [9], fitting it in place over the small ridge on the bottom of the Nozzle. DO NOT use lubricant on the O-Ring. Install the Nozzle/O-Ring into the Regulator Body and torque to 20 ft-lbs.

15. Preassemble the Adjusting Mechanism: Apply CHRISTO-LUBE® #129 Lubricant to the entire length of the threads of the Drive Screw [13], and screw the Guide Bushing [12] onto the Drive Screw (by hand) all the way up until it stops (do not over-tighten!). Note that this is a left hand thread. Next, apply only Loctite® #222 to the threads of the #10-32 Screw [10], and install the Screw and Washer [11] into the Drive Screw – tightening until snug.

TIP: Make sure you’ve got the Drive Screw oriented correctly – the Screw and Washer you just installed should be in the end that’s opposite the square flats.

16. Diaphragm Assembly: EST4, ESL4 and ESS7 models: Install the Diaphragm Assembly [2] into the Body. Note that the Diaphragm centers itself in a recessed pocket in the top of the Body. ESS7 200 PSIG Delivery models: Install the Diaphragm Assembly [2] into the Body. Note that the Diaphragm centers itself in a recessed pocket in the top of the Body. Then install the Backup Ring [2A] over the Diaphragm Assembly. Insure it is oriented as shown in the Exploded View detail on Page 1. ELC4 Models: Apply a very light coat of CHRISTO-LUBE® #129 Lubricant to the Diaphragm O-Ring [2D] and install it into the groove in the top of the Body. Next, place the Diaphragm Assembly [2C] on top of it. Note that the Diaphragm centers itself in a recessed pocket in the top of the Body. Lastly, install the Diaphragm Shim [2B] on top of the Diaphragm Assembly. It sits loosely on top of the Diaphragm Assembly, centered on the Body.


17. Install the Adjusting Spring [22], preassembled Adjusting Mechanism and Thrust Washer [14] onto the Regulator Body. Don’t forget the Thrust Washer! Regulator function will be impaired without it.

18. Install the Bonnet [15] onto the Body. Take care while slipping the Bonnet down over the internal components – the ribs inside the Bonnet must slide into the scallops of the Guide Bushing.

19. Install the six Socket Head Cap Screws [16] into the Bonnet. Tighten all bolts until snug, then torque each to 12-15 ft-lbs in the sequence shown in FIGURE 1.

FIGURE 1 - Torque Sequence for Bonnet Screws

20. Apply a small amount of CHRISTO-LUBE® #129 to the top surface of the Bonnet (the surface around the square of the Drive Screw), then slip the Knob [23] into position – with the square hole inside the knob mating to the square shaft of the Drive Screw.

21. Install the #10-32 Screw [10], Lock Washer [18] and Washer [17] to hold the Knob on. Torque this Screw a minimum of 30 in-lbs.

22. Apply new Knob or Gas Information decals [19, 31] as needed to insure the Regulator maintains clear visual identification.

23. Remove the Regulator from the Inlet Plug or Bench Vise. It is now ready to test.

RECOMMENDED TOOLS AND SUPPLIES FOR TEST PROCEDURES • Test Gun (quick opening on/off valve) with #52 (.0635”) restricting orifice • Source of oil-free air or dry nitrogen


TEST PROCEDURES

� WARNING! � For your safety, and the safety of others:

• Always test with oil-free air or dry nitrogen only. • Always wear eye protection while testing a Regulator. • Always perform all of the following test procedures after reassembling a Regulator.

1. Adjust the Test Manifold to the proper pressure shown in TABLE 4. Regulator Model Gas Service Manifold Pressure for Testing

Acetylene 30±5 PSIG EST4, ESL4, ELC4 All Other Gases 200±20 PSIG

ELC4-325-580 Nitrogen 350±20 PSIG Acetylene & LP Gas 250±20 PSIG CO2 & N2O 1000±100 PSIG ESS7 Air, Argon, Hydrogen, Helium, Nitrogen, Oxygen 2000±100 PSIG

TABLE 4 – Regulator Test Pressures

2. Attach the Regulator to the Manifold connection or test adapter. Start the nut by hand (do not force), and tighten securely with a wrench to create a seal.

3. Turn the Regulator Adjusting Knob clockwise two or three times until you feel slight tension being applied to the Adjusting Spring.

4. Slowly open and close the Manifold Valve two or three times to remove contamination that may cause malfunctions. Leave the Manifold Valve closed. a. If no flow comes through the Regulator, determine the cause – refer to the

TROUBLESHOOTING CHART at the end of this section. 5. Turn the Adjusting Knob counterclockwise until it stops, and attach the Test Gun (with a

#52 restricting orifice) to the outlet of the Regulator.

6. Open the Test Manifold Valve and close the Test Gun. a. Manifold working pressure will appear on the High Pressure Gauge. b. If the Low Pressure Gauge begins to show pressure building, turn the Test Manifold

off and refer to the TROUBLESHOOTING CHART. 7. Use the values in the following TABLE 5 for all subsequent tests:

Nominal Delivery Pressure

A Pressure Set for Leak Test

B Pressure Set for Creep/Drop Test

C Drop

Allowance

D Initial Shut-off

Allowance 15 15 PSIG 10 PSIG 4 PSIG 2 PSIG 40 40 PSIG 10 PSIG 4 PSIG 2 PSIG 80 80 PSIG 10 PSIG 4 PSIG 2 PSIG 125 125 PSIG 20 PSIG 5 PSIG 2.5 PSIG 200 200 PSIG 20 PSIG 5 PSIG 3 PSIG 325 200 PSIG 20 PSIG 5 PSIG 5 PSIG

TABLE 5 –Regulator Test Values


8. ESS7 LEAK TEST (When HP/LP Gauges are present): a. With the Test Gun closed and the Manifold Valve open, adjust the Regulator to

deliver A PSIG. b. Close the Manifold Valve and turn the Adjusting Knob one turn counterclockwise. c. Observe the Low Pressure and High Pressure Gauges for five (5) minutes:

1. If the High Pressure Gauge reading drops, there is a leak in the Cylinder Valve, Inlet Connection, High Pressure Gauge or the rear plugged high pressure port.

2. If the Low Pressure Gauge reading drops, there is a leak in the downstream equipment, Low Pressure Gauge, Outlet Connection or Relief Valve port.

3. If the High Pressure Gauge reading drops at the same time the Low Pressure Gauge reading increases, there is a leak in the Regulator Seat.

d. If any leaks are found, isolate if possible using a liquid leak detector, disassemble and repair or replace parts as needed, and start the test over again. Refer to TROUBLESHOOTING CHART for more detailed cause and possible corrective action information.

9. EST4, ESL4, ELC4 LEAK TEST (When only LP Gauge is present): a. With the Regulator set at A PSIG, use a liquid leak detector to check for external

leaks around all ports, caps, vents, etc. No visible leaks allowed.

10. DROP TEST a. With the Test Gun closed and the Manifold Valve open, adjust the Regulator to

deliver B PSIG. b. Open the Test Gun and note the new indicated delivery pressure. Drop (indicated

pressure static minus indicated pressure flowing) must not exceed C PSIG.

11. CREEP TEST / SLOW SHUT-OFF TEST a. With the Test Gun closed and the Manifold Valve open, adjust the Regulator to

deliver B PSIG. b. Open and close the Test Gun several times to stabilize the Regulator. Leave the test

gun closed. c. Observe the Low Pressure Gauge for five (5) minutes:

1. During the first minute, an initial shut-off increase of D PSIG is permissible. 2. During the next 4 minutes, no further increase (creep) is allowed.

12. Close the Manifold Valve and release all pressure from the Regulator by opening the Test Gun. Turn the Adjusting Knob counterclockwise until it stops.

13. Remove the Test Gun from the Regulator.

14. Remove the Regulator from the Test Manifold. The Regulator is now ready to use.


TROUBLESHOOTING


1. No gas flows through the Regulator and the High Pressure Gauge does not indicate pressure (or if no High Pressure Gauge is present).

a. Inlet or Inlet Filter is plugged. Blow 40-45 PSIG of air through the Filter in reverse direction of the normal gas flow.

b. Empty Supply Cylinder. Replace the Cylinder.

2. No gas flows through the Regulator and the High Pressure Gauge does indicate pressure (or if no High Pressure Gauge is present).

a. Damaged Adjusting Mechanism or missing components.


b. Adjusting Knob not installed correctly.

Make sure the square of the Drive Screw is properly mated into the square in the Adjusting Knob.

c. Outlet Connection plugged. Inspect and clear the Outlet Connection of any debris.

d. Broken Adjusting Spring. Replace the Adjusting Spring. e. Broken Seat Stem. Replace the Seat Assembly.

3. Gauge(s) do not indicate pressure but gas flows through the Regulator.

a. Defective Gauge(s). Replace Gauge(s).

4. Regulator does not deliver in its designed delivery pressure range.

a. Incorrect Adjusting Spring used during repair.

Replace with correct Adjusting Spring.

b. Damaged Adjusting Mechanism or missing components.


5. Regulator hums or clatters while flowing.

a. Missing Friction Damper. Install a Friction Damper. b. Missing Bottom Guide. Install the Bottom Guide. c. Flow exceeds Regulator capacity. Reduce flow to below the maximum rating of

the Regulator. d. Restriction upstream of the

Regulator. Inspect system and remove restriction.



6. Regulator experiences excessive drop.

a. Friction Damper too tight. Replace the Friction Damper and/or Gland. b. Wrong size orifice in Test Gun. Insure the correct orifice is installed in the

Test Gun - size #52 (.0635”). c. Partially plugged Inlet Filter. Clean or replace the Inlet Filter. d. Incorrect Adjusting Spring used

during repair. Replace with correct Adjusting Spring.

e. Low Cylinder pressure or Manifold test pressure.

Check Cylinder and Manifold pressure and adjust/replace as needed.

f. Flow exceeds Regulator capacity. Reduce flow to below the maximum rating of the Regulator.

7. Increase in the Low Pressure Gauge reading (creep).

a. Loose Nozzle. Tighten Nozzle to 20 ft-lbs torque. b. Missing or damaged Nozzle O-

Ring. Inspect and install or replace O-Ring as necessary.

c. Accumulation of foreign particles on Seat Assembly or seating surfaces.


8. With the cylinder valve closed, the High Pressure Gauge indicator drops, and there is no immediate increase in pressure indicated on the Low Pressure Gauge.

a. Loose connection – Regulator to Test Manifold.


b. Loose connection – Inlet Swivel to Regulator Body.

Tighten the Swivel using 20 ft-lbs torque.

c. Loose connection – High Pressure Gauge to Regulator Body.

Tighten the High Pressure Gauge using 10 ft-lbs torque minimum.

d. Leaking Gauge. Replace the Gauge.

9. Low Pressure Gauge indicator slowly drops, and there is no decrease in pressure on the High Pressure Gauge when the Manifold Valve is closed.

a. Test Gun is not attached securely. Tighten the Test Gun. b. Loose connections at the Regulator

Body – Outlet Connection, L.P. Gauge or Relief Valve/Plugs

Tighten connections using 15 ft-lbs torque minimum.

c. Loose connection – Bonnet to Body.


d. Damaged Diaphragm. Replace Diaphragm Assembly.

- 29 -


10. Rapid pressure drop on both High and Low Pressure Gauges.

a. Loose connection – Bonnet to Body.


b. Loose connection – Regulator to Test Manifold.


11. Rapid increase in Low Pressure Gauge reading.

a. Damaged or loose Nozzle. Replace and/or tighten the Nozzle to 20 ft-lbs torque.

b. Heavy accumulation of foreign particles on Seat Assembly or seating surfaces.


c. Missing or damaged Nozzle O-Ring.

Inspect and install or replace O-Ring as necessary.

d. Improper Adjusting Spring (spring too long).

Replace Adjusting Spring.

12. Relief Valve opens at a greater or less than marked pressure (outside a pressure tolerance of ±15% of the marked pressure).

a. Incorrect Spring used. Replace with correct Spring. b. Relief Valve not set properly. Repeat Relief Valve assembly/test

procedure STEP 6.

Form No. 0056-1966Revision: D

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