VICTOR Single Stage Regulator Troubleshooting instruction

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PARTS, SERVICE & REPAIR BULLETIN

ESS2 ESS4

Single Stage Regulators

Issue Date: Aug 2009Revision: A Form No.: 0056-1966

3.23

ESS2 Model

(ESS2-125-540 Shown)

2.18

OUTLET

RELIEF

3.82

ESS4 Model

(ESS4-125-540 Shown)

OUTLET

RELIEF

2.55

5.69

INLET

TABLE 1

TABLE 2

1400-0239

1406-0050

1406-0220

1400-0246

1406-0006

0750-0201

0750-0203

TABLE 2

0762-0006

1407-0214

0708-0018

1408-0033

0708-0003

5.88

INLET

TABLE 2

TABLE 3

TABLE 2

1105-0014

0717-0003 (a)

TABLE 1

TABLE 2

TABLE 1

ESS2 ESS4

Description Part No. Part No. Qty.1Body 0701-0705 0701-0706 12Bonnet 0720-0343 0720-0342 13Gauge Guard 1429-0071 1429-0070 14Diaphragm Assembly 0730-0024 TABLE 1 14ABack-Up Ring --- TABLE 1 15Screw (Gauge Guard) 1400-0248 1400-0239 26Decal, Knob 1415-0788 1415-0791 17Screw 28Washer 19Knob 110Socket Head Cap Screw (b)11Thrust Washer 112Drive Screw 113Guide Bushing Assm. 114Washer, Special 115Adjusting Spring 116Nozzle 117O-Ring (Nozzle Body) 118Seat Assembly 119Valve Spring 120Gland 121Friction Damper 122Bottom Guide 123Inlet Nut 124Inlet Swivel w/Filter 1

Ref.

PARTS LIST - ESS2 and ESS4 Model Regulators

No.



- 1 -

Inlet Filter 125Pipe Plug 126Outlet Connection 127Relief Valve 128Gauge, Low Pressure 129Gauge, High Pressure 130Decal, Bonnet Gas I.D. 131Decal, Rear Body Gas Info. 1

24A



 Items most commonly required for regulator repair and recommended for stock.

(a) Cylinder models only.

(b) ESS2 uses ﬁve (5) screws, ESS4 uses six (6) screws.

(c)

Orientation

Back-Up Ring

Diaphragm

(c)

Bonnet

In Assembly

Body

Assembly

(a)

27I

27H

27F

27D

27B

27J

Vented

27E

27C

27A

27K

(b)

Non-Vented

27G

DETAIL A - Relief Valve

(b)

(See Detail A)

EXPLODED VIEW - ESS2 AND ESS4 MODELS

24A

- 2 -

(a) ESS2 models use ﬁve Screws for Bonnet, ESS4 models use six Screws.

(b) Pipe Plug replaces Relief Valve on fuel gas models (510, 300, 993).

All Other ModelsFlow Gauge Models

Decal,

Gas Info.

Rear Body

1424-0513

1424-0511

0761-0098

Decal,

Bonnet

Gas I.D.[ 16 ]

Outlet

Connection

1424-0512

1424-0511

All Other ModelsHydrogen (Vented Relief Valve)

ESS2-FG-580

LP Gas

(w/Filter)

Inlet Swivel

--- ---

1424-0515

1424-0511

--- --- --- 0736-0002

Inlet Nut

Seat Assembly

Nozzle

0974-0003 0970-0015 0960-0014 1415-0805 1415-0804

0992-0003 0970-0015 0950-0068 1415-0790 1415-0792

0973-0003 0970-0015 0950-0017 (e) 1415-0799 1415-0798

0972-0015 0972-0009 0950-0068 1415-0807 1415-0806

0985-0030 0985-0058 (d) 0950-0017 (e) 1415-0801 1415-0800

0963-0015 0963-0009 0950-0080 1415-0803 1415-0802

0983-0003 0983-0005 0960-0029 1415-0809 1415-0808

0740-0131

0740-0101

0702-0068

0740-0101

0702-0068

0600-0005 0600-0014 0600-0018

--- --- --- ---

60 200 400 30 60 200 400

0601-0006 0601-0006 0601-0006 0601-0004 0601-0004 0601-0004 0601-0006

0600-0060 0600-0066 0600-0071 0600-0003

0606-0005 0606-0005 0606-0005 --- --- --- ---

LP Gas

ESS2-40-510LP ESS4-40-510LP ESS4-125-510LP

Acetylene

ESS2-15-510 ESS4-15-510

Description ESS2-FG-320 ESS2-40- ESS4-40- ESS2-125- ESS4-125- ESS2-200- ESS4-200-4Diaphragm Assembly 0730-0024 0730-0063 0730-0024 0730-0063 0730-0063 0730-0024 0730-0024 0730-0063 0730-0024 0730-0063 0730-0024 0730-00684ABack-Up Ring

Ref.

TABLE 1 - Diaphragm, Adjusting Spring & Gauges

No.

1424-0515

---

1424-0514

--- --- --- --- ---

Adjusting Spring 0761-0107 0761-0089 0761-0060 0761-0093 0761-0098 0761-0060 0761-0060 0761-0093 0761-0080 0761-009828Gauge, Low Pressure 1424-0512 1424-0516

1424-0513

[ 9 ] [ 18 ]

0790-0214 0790-0208 0702-0085 0702-0068 0740-0158

Adjusting Knob (w/Decal)

1424-0513

Gauge, High Pressure 1424-0513 1424-0511

TABLE 2 - Inlet & Outlet, Seat Assembly & Nozzle, Color Coded Items

Gas Inlet Type I.D. Color ESS2 ESS4 ESS2 ESS4 ESS2 ESS4 [ 23 ] [ 24 ] [ 26 ] [ 30 ] [ 31 ]

Oxygen CGA 540 (c) GREEN 0790-0209 0790-0200 0702-0085 0702-0068 0740-0158 0740-0131 0967-0044 0967-0032 (c) 0950-0068 1415-0790 1415-0792

Oxygen 992 GREEN 0790-0209 0790-0200 0702-0085 0702-0068 0740-0158

0790-0214 0790-0208 0702-0085 0702-0068 0740-0158

BLACK

Argon/Helium/Nitrogen CGA 580

Air (Industrial) CGA 590

Air (Breathing) CGA 346

Carbon Dioxide CGA 320 (d) GREY 0790-0212 0790-0206 0702-0085 0702-0068 0740-0158

Nitrous Oxide CGA 326 BLUE 0790-0211 0790-0205 0702-0085 0702-0068 0740-0158

Hydrogen & Methane CGA 350 RED 0790-0210 0790-0204 0702-0085 0702-0068 0740-0158

Acetylene CGA 510 RED 0790-0210 0790-0204 0970-0003 0970-0015 0960-0029 1415-0789 1415-0793

Acetylene CGA 300 RED 0790-0210 0790-0204 0968-0003 0968-0005 0960-0029 1415-0789 1415-0793

Acetylene 993 RED 0790-0210 0790-0204 0993-0003 0970-0015 0960-0029 1415-0789 1415-0793

LP Gases CGA 510 ORANGE 0790-0213 0790-0207 0970-0003 0970-0015 0960-0029 1415-0797 1415-0796

TABLE 3 - Relief Valve

(d) CGA 320 inlet requires inlet washer part number 1408-0065.

(e) Flow Gauge (FG) models must use Outlet Connection with oriﬁce - Part No. 0950-0120.

LP Gas

All Models

Acetylene

All Models

Description 40 psi Delivery 125 psi Delivery 200 psi Delivery 15 psi Delivery 40 psi Delivery 125 psi Delivery 200 psi Delivery

Ref.

No.

---

Relief Valve Nominal Set Pressure >

Pipe Plug

Relief Valve Complete Assembly

---

1105-0014

---

1105-0014

or Pipe Plug

Body

Seat 0608-0006 0608-0006 0608-0009 0608-0006 0608-0006 0608-0006 0608-0009

Seat Retainer 0609-0006 0609-0006 0609-0006 0609-0003 0609-0003 0609-0003 0609-0006

Upper Seat 0608-0023 0608-0023 0608-0021 0608-0018 0608-0018 0608-0018 0608-0023

Disc 1406-0017 1406-0017 1406-0017 1406-0016 1406-0016 1406-0016 1406-0017

Spring 0610-0016 0610-0016 0610-0014 0610-0004 0610-0005 0610-0008 0610-0013

Cap --- --- --- 0614-0004 0614-0004 0614-0004 0614-0006

Cap (Vented) 0614-0016 0614-0016 0614-0016 --- --- --- ---

Spring Button

Adjusting Screw 1401-0007 1401-0008 1401-0008

Cap Nut 1403-0024 1403-0024 1403-0024

27A

27B

27C

27D

27E

27F

27G

27H

27I

27J

27K



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SERVICE & REPAIR INSTRUCTIONS

ESS2 and ESS4 Single Stage Edge™ Series Regulators

 WARNING! 

Apparatus improperly operated, maintained or repaired can be dangerous!

Service and repair of technician. 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 level of performance, safety and reliability that you expect from

VICTOR genuine parts and accessories. It’s the only way to guarantee the

GLOSSARY – COMMONLY USED TERMS

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

VICTOR apparatus should only be performed by a qualified

VICTOR.

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

•

/2”, 5/8”, 9/16”, 11/16” and 3/4” Sockets

• Socket Wrench

• Torque Wrench

/16”, 3/4” and 13/16” Open End Wrenches

•

/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.

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] and Washer [8] located inside the Knob [9]. The Knob can now be removed.

- 4 -

3. Remove the 5 (for ESS2) 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], Guid e 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 ESS2 or ESS4 model Regulator:

Repair Kit Part No. Description

RK-ESS2-HP 0790-0162 ESS2 Repair Kit for Oxygen, Inert Gases, Air, CO

O, Hydrogen.

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

O, Hydrogen.

RK-ESS4-HP200 0790-0164 ESS4 Repair Kit - 200 PSIG Delivery Models Only -

for Oxygen, Inert Gases, Air, CO

, N2O, Hydrogen.

RK-ESS2-F 0790-0165 ESS2 Repair Kit for Acetylene, LP Gas. RK-ESS4-F 0790-0166 ESS4 Repair Kit for Acetylene, LP Gas.

- 5 -

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”

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 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 oxygencompatible.

• When using Loctite® #222 Threadlocker where noted: Apply two to three drops

to the second and third thread, leaving the first thread clean.

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 ftlbs 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

/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 Guard. If the Gauges are closer to the Gauge Guard than that, tighten the Gauges tighter as needed (one full revolution of the Gauge closer to the Body by approximately

/32” away from the underside of the Gauge

/8-27 NPT Gauge thread will move the

/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 -

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 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.

VICTOR Relief Valves are stamped with their nominal set

Regulator Max. Delivery 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.

Mating Relief Valve (Nominal)

Recommended Blow-off Pressure

- 7 -

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] on to 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 ESS2) 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

- 8 -

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. Apply only Loctite® #222 to the #10-32 Screw [7] and install the Screw and Washer [8] to hold the Knob on. Torque this Screw 16-18 in-lb. Note that if the mating surfaces of the Bonnet and Knob are not in factory new condition, this torque may result in the Knob becoming too tight and difficult to turn. If this occurs, simply loosen the Screw slightly until the desire rotation tension is achieved.

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

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.

2000±100 PSIG

- 9 -

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 ESS2-15-

ESS4-15ESS2-40-

ESS4-40ESS2-125-

ESS4-125ESS2-200-

ESS4-200-

Pressure Set

for Leak Test

15 PSIG 5 PSIG 3 PSIG 1 PSIG

40 PSIG 10 PSIG 3 PSIG 1 PSIG

125 PSIG 20 PSIG 4 PSIG 1 PSIG

200 PSIG 50 PSIG 5 PSIG 1 PSIG

Pressure Set for Creep/Drop Test

Drop

Allowance

Initial Shut-off

Allowance

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.

- 10 -

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.

b. Adjusting Knob not installed

correctly.

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

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

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

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

any debris.

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.

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

d. Restriction upstream of the

Regulator.

Replace with correct Adjusting Spring.

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

the Regulator. Inspect system and remove restriction.

- 11 -

CAUSES POSSIBLE CORRECTIVE ACTIONS

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.

e. Low Cylinder pressure or Manifold

test pressure.

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

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

c. Accumulation of foreign particles on

Seat Assembly or seating surfaces.

Replace with correct Adjusting Spring.

Check Cylinder and Manifold pressure and

adjust/replace as needed.

the Regulator.

necessary.

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.

b. Loose connection – Inlet Swivel to

Regulator Body.

c. Loose connection – High Pressure

Gauge to Regulator Body.

d. Loose connection – Rear Pipe

Plug.

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

c. Loose connection – Bonnet to

Body.

d. Damaged Diaphragm. Replace Diaphragm Assembly.

Insure Regulator is securely tightened to the Manifold.

Tighten the Swivel using 20 ft-lbs torque.

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

Tighten Pipe Plug using 15 ft-lbs torque minimum.

Tighten connections using 15 ft-lbs torque minimum.

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

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CAUSES POSSIBLE CORRECTIVE ACTIONS

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

a. Loose connection – Bonnet to

Body.

b. Loose connection – Regulator to

Test Manifold.

c. Cracked Body. Replace the Regulator Body.

11. Rapid increase in Low Pressure Gauge reading.

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

b. Heavy accumulation of foreign

particles on Seat Assembly or seating surfaces.

c. Internal crack on the high pressure

side of the Body.

d. Missing or damaged Nozzle O-

Ring.

e. Improper Adjusting Spring (spring

too long).

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

Insure Regulator is securely tightened to the Manifold.

torque. Clean seating surfaces and/or replace Seat

Assembly.

Replace the Body.

Inspect and install or replace O-Ring as necessary.

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

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FAX

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VICTOR Single Stage Regulator Troubleshooting instruction

Specifications and Main Features

Frequently Asked Questions

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