VICTOR SGS 500 Series Stainless Steel Regulators Troubleshooting instruction

PARTS & SERVICE BULLETIN

SGS 500 Series

Stainless Steel Regulators

FORM NO. 0056-1316 EFFECTIVE December 1996

VICTOR High Purity regulators were helium leak tested at the factory to an inboard rate of
1 x 10

-9

scc/sec. Always leak test with helium after servicing the regulators. DO NOT ser­vice the regulators if you do not have access to helium leak testing facilities. Take the
regulators to a qualified repair technician with helium leak testing equipment.

Apparatus improperly operated, maintained or repaired can be dangerous. Some parts
and accessories manufactured by others may fit VICTOR apparatus but not conform to
VICTOR’s exacting standards. For your own protection, specify and use ONLY VICTOR­made parts and accessories with your VICTOR apparatus.

Service or repair of VICTOR apparatus should be performed only by a qualified techni­cian. Improper service, repair or modification of the the product could result in damage to
the product or injury to the operator.

2

CHART 1

SGS 500-15

0761-0109
1424-0312
1424-0311

SGS 500-40

0761-0110
1424-0313
1424-0311

SGS 500-80

0761-0111
1424-0314
1424-0311

SGS 500-125

0761-0112
1424-0315
1424-0311

CHART 2

CGA NO.

240
330
350
540
580
590
660
705

INLET SWIVEL

0998-0003
0985-0006
0983-0014
0967-0022
0970-0051
0970-0051
0995-0017
0998-0011

INLET NUT

0998-0006
0986-0007
0983-0013
0967-0052
0973-0004
0974-0010
0995-0007
0998-0012

INLET WASHER

1408-0018
1408-0023

N/A
N/A
N/A

N/A
1408-0024
1408-0032

ITEM NO.

NO. DESCRIPTION PART NO. REQ’D

1 HOLE PLUG 0919-0028 1
2 ADJUSTING KNOB 0750-0111 1
3 LOCKNUT 1409-0079 1
4 LOCKWASHER 1406-0110 2
5 ADJ. SCREW ASSY. 0750-0143 1
6 HOUSING CAP 0720-0221 1
7 ADJUSTING SPRING See Chart 1 1
8

9 DIAPHRAGM PLATE 0735-0047 1
10 DIAPHRAGM 0731-0021 1
11 CARTRIDGE ASSY. 0739-0024 1
12 BODY 0701-0233 1
13 CARTRIDGE GASKET 1408-0114 1
14
15
16
17 L.P. GAUGE See Chart 1 1
18 H.P. GAUGE See Chart 1 1
19 DIFF. RES. VALVE 0660-0519 1
20 BUSHING 0910-0081 1
21 INLET SWIVEL See Chart 2 1
22 INLET NUT See Chart 2 1
23 WASHER See Chart 2 1
24 PIPE PLUG 1105-0021 1

ITEM NO.

NO. DESCRIPTION PART NO. REQ’D

A BODY 0658-0011 1
B POPPET GUIDE 0783-0014 1
C SPRING 0762-0040 1
D SEAT ASSEMBLY 0740-0142 1
E DIAPHRAGM (copper) 0731-0053 1
F DIAPHRAGM (SST) 0731-0054 2
G NOSE, ADJ.SCREW 0751-0088 1
H ADJUSTING SCREW 0667-0039 1
J CAP 0659-0004 1
K GASKET 1408-0100 1
L LOCK NUT 1409-0003 2
M LOCKWASHER 1406-0110 1
N ADJUSTING KNOB 0750-0107 1
P HOLE PLUG 0919-0028 1

SGS 500 REGULATOR

DRK VALVE

SGS 500-200

0761-0113
1424-0316
1424-0311

Description

Adjusting Spring
L. P. Gauge
H. P. Gauge

SERVICE PROCEDURES

Recommended Tools and Supplies:

Bench Vise
Inlet Swivel Ass’y Plug RT-2 (CGA 350) (1420-0009)
Inlet Swivel Ass’y Plug RT-4 (CGA 540) (1420-0014)
Inlet Swivel Ass’y Plug RT-85 (CGA 580) (1420-0134)
Inlet Swivel Ass’y Plug RT-86 (CGA 590) (1420-0135)
9/16” Open-End Wrench
5/8”, 1

3

/

16

” and 1

7

/

8

” Hex Sockets

Torque Wrench
Lubricant (0034-0020)
TEFLON® Tape (0028-0028)

For additional information, refer to Apparatus Service
and Testing Procedures (Form No.0056-0886) and Repair Tools
Manual (Form No. 0056-0121).

Disassembly Procedure

1. Secure the Holding Fixture in the Bench Vise. Place the Regulator
in the Holding Fixture with the Gauges face up.

2. Remove the Nameplate from the Adjusting Knob.

3. Remove the Adjusting Knob from the Regulator. Remove the
Housing Cap.

4. Remove the Spring Button, Adjusting Spring, Slip Ring and
Diaphragm from the Body. Discard the Slip Ring.

5. Remove the Cartridge and Cartridge Gasket from the Body.
Discard the Cartridge Gasket.

6. Remove the Gauges from the Body.

DO NOT attempt to repair the Gauges.

7. Remove the Relief Valve or Pipe Plug from the Body.

8. While holding the Bushing, remove the DRK Valve from the
Bushing.

If the DRK Valve requires repair, refer to the

DRK Valve Parts and Service Bulletin (Form No. 0056-1083).

9. Remove the Bushing from the Body.

10. Clamp the appropriate Inlet Swivel Assembly Plug in the Bench
Vise. Attach the Regulator to it.

11. Remove the Inlet Swivel from the Body. DO NOT damage the
Inlet Swivel seating surfaces. Remove the Inlet Nut from the Inlet
Swivel.

12. Remove the Filter from the Inlet Swivel. Discard the Filter.

Discard the Slip Ring, Cartridge Gasket and

Filter. Replace them each time you reassemble a Regulator.

Cleaning Regulator Parts

Clean all metal parts with a cleaner that is safe for use with oxygen.
Contact a chemical/cleaning supply distributor for recommended clean­ers for use with oxygen. Always use cleaning solvents in accordance
with the manufacturer’s instructions.

DO NOT allow nonmetal parts to come in contact with

any cleaning solvent! Cleaning solvents cause elastomeric and plastic
parts to swell and stress crack. If these parts require cleaning, use a
mild soap solution, followed by thorough rinsing in water. Dry these
parts completely before installing in the Regulator. REPLACE NON­METAL PARTS THAT HAVE COME IN CONTACT WITH OIL,
GREASE OR ANY OTHER PETROLEUM BASED SUBSTANCE!

Assembly Procedures

1. Install the Body in the Body Wrench.

2. Install a new Filter in the Inlet Swivel. Install the Inlet Nut on the
Inlet Swivel.

3. Clamp the appropriate Inlet Swivel Assembly Plug in the Bench
Vise. Screw the Inlet Nut onto the Plug and tighten firmly.

4. Wrap two or three layers of TEFLON® tape around the second
and third threads of the Inlet Swivel. Install the Inlet Swivel in the
Body. Tighten to a torque of 20-25 ft.lbs.

5. Wrap two or three layers of TEFLON® tape around the second
and third threads on both ends of the Bushing. Install the Bushing
in the Body. Tighten to a torque of 14-18 ft.lbs.

6. Install the DRK Valve on the Bushing. Tighten to a torque of 10
ft.lbs. minimum.

7. Wrap two or three layers of TEFLON® tape around the second
and third threads of the L.P. and H.P. Gauges. Install the Gauges
in the Body. Tighten to a torque of 10 ft.lbs. minimum.

8. Wrap two or three layers of TEFLON® tape around the second
and third threads of the Relief Valve or Pipe Plug. Install the Pipe
Plug in the Body. Tighten to a torque of 14-18 ft.-lbs.

9. Remove the Regulator from the Body Wrench. Secure the Holding
Fixture in the Bench Vise. Place the Body in the Holding Fixture
with the Gauges face up.

10. Remove any contaminants that may otherwise cause the
Regulator to malfunction by connecting the Regulator to a source
of oil-free air. Slowly open and close the Manifold Valve two or
three times. Blow out the inside of the Body with pressurized
oil-free air.

Always wear eye protection when cleaning the

Regulator Body with pressurized air.

11. Place the new Cartridge Gasket in the Body.

12. Install the Cartridge in the Body. Tighten the Cartridge to a torque
of 60 ft.lbs maximum.

13. Place the new Diaphragm and new Slip Ring on the Body.

14. Place the Adjusting Spring over the Diaphragm.

15. Apply a small amount of lubricant (0034-0020) to the O-ring
around the Spring Button.

16. Carefully place the Housing Cap over the Adjusting Spring.
Screw the Housing Cap onto the Body. Tighten the Housing Cap
to a torque of 100 ft.lbs maximum.

Test Procedure

Recommended Tools and Supplies:

High Pressure Test Gun (quick-opening on/off valve) with

#70 (0.0280) Orifice

2000+/-100 PSIG Source of Oil-Free Air or Dry Nitrogen

(SGS 500)

Always perform the following test procedure after

assembling a Regulator. Test with oil-free air or dry nitrogen ONLY!
Always wear eye protection when testing a Regulator. NEVER stand
directly in front of or behind a Regulator when opening the Cylinder
Valve or Test Manifold. Always stand so that the Cylinder Valve or
Test Manifold is between you and the Regulator.

1. BEFORE attaching the Regulator to the oil-free air or dry nitro-

gen, slowly open and close the Cylinder Valve several times. This
dislodges any particles which may otherwise enter the Regulator.
Leave the Valve closed.

2. Connect the Regulator to the Test Cylinder or Manifold. Back out
the Adjusting Screw until no pressure is on the Adjusting Spring.

3. Attach the Test Gun (with #70 orifice) to the Regulator or Valve
Outlet. Open the DRK Valve, if applicable.

4. Adjust the Test Manifold to deliver 2000 PSIG of pressure.

5. Setting the Adjusting Screw:

a. Open the Test Manifold.
b. Adjust the Adjusting Set Screw until the Regulator delivers the

appropriate pressure listed below:

15 Range - 30 PSIG Max. No Flow

15 PSIG Min. Flowing

40 Range - 60 PSIG Max. No Flow

40 PSIG Min. Flowing

3

80 Range - 100 PSIG Max. No Flow

80 PSIG Min. Flowing

125 Range - 200 PSIG Max. No Flow

125 PSIG Min. Flowing

200 Range - 400 PSIG Max. No Flow

200 PSIG Min. Flowing

c. Without moving the adjusting screw and with the test gun

turned off, run the lock nut in a clockwise direction until it is
flush (not tight) against the gaskets above the packing nut.
Make sure the lockwasher is placed on the adjusting screw
between the stop nut and the knob. Slip the knob down onto the
adjusting screw. Install the top lockwasher and nut loosely.
Hold the knob position firmly with one hand and tighten the
nut to 8-10 ft.lbs. of torque. Adjust the control knob in a coun­terclockwise (decrease) direction until the knob stops turning.
Bleed pressure from the test gun. Readjust the regulator clock­wise (increase) to assure that the regulator is set to the desired
rated pressure. If the setting is not correct, repeat Step C. After
the setting is correct, snap the nameplate plug into the recess of
the knob.

6. CREEP TEST/SLOW SHUT-OFF TEST:

a. Close the Test Gun.
b. Adjust the Regulator to deliver the appropriate pressure listed

below:

15 Range - 5 PSIG
40 Range - 10 PSIG
80 Range - 10 PSIG
125 Range - 20 PSIG
200 Range - 20 PSIG

c. Observe the L.P. Gauge for five (5) minutes. During the first

two (2) minutes, slow shut-off (delivery rise due to the Seat
closing slowly) should not exceed 2 PSIG. During the next
three (3) minutes, no creep (0 PSIG) is allowed. Creep is indi­cated by an increase in the L.P. Gauge reading.

7. DROP TEST:

a. Close the Test Gun.
b. Adjust the Regulator to deliver the appropriate pressure listed

below.

15 Range - 5 PSIG
40 Range - 10 PSIG
80 Range - 10 PSIG
125 Range - 20 PSIG
200 Range - 20 PSIG

c. Open the Test Gun. Observe the L.P. Gauge. Drop (difference

in delivery from no-flow to flow) should not exceed the appro­priate pressure listed below.

15 Range - 2 PSIG
40 Range - 3 PSIG
80 Range - 3 PSIG
125 Range - 4 PSIG
200 Range - 10 PSIG

8. LEAK TEST:
a. Close the Test Gun.
b. Adjust the Regulator to deliver the appropriate pressure listed

below.

15 Range - 15 PSIG
40 Range - 40 PSIG
80 Range - 80 PSIG
125 Range - 125 PSIG

200 Range - 200 PSIG
c. Close the Test Manifold Valve.
d. Turn the Adjusting Knob counterclockwise one turn. Observe

the Gauges for five (5) minutes. If the Gauge readings change,
a leak exists. Disassemble the Regulator. Clean the compo­nents as described under Cleaning Regulator Parts. Replace
any damaged parts. Reassemble and retest the Regulator.

9. Open the Test Gun to release pressure from the Regulator. Turn
the Adjusting Knob counterclockwise until there is no pressure on
the Adjusting Spring. Close the Valve.

10. Remove the Test Gun from the Regulator.

11. Remove the Regulator from the Test Manifold.

12. HELIUM LEAK TEST:

Helium leak test (mass spectrometer) these regulators to an
inboard rate of 1 x 10

-9

scc/sec or better. If you do not have heli­um leak testing facilities, take the Regulator to a qualified repair
technician with proper facilities.

If the Regulator does not perform properly during testing, refer to the
Troubleshooting Chart in the Apparatus Service and Testing Procedures
(Form No. 0056-0886).

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U.S. CUSTOMER SERVICE: P. O. Box 1007 • Denton, TX 76202-1007

800-426-1888 • FAX [phone]

International Offices

®

Form No. 0056-1316 (6/00) © Victor Equipment Co., 1996 www.victorequip.com Printed in U.S.A.

WORLD HEADQUARTERS: 101 S. Hanley Road • St. Louis, MO 63105 • 314-721-5573 • FAX [phone]