PARTS, SERVICE & REPAIR BULLETIN ESS3 ESS4 ESS7 EST4 ESL4 ELC4 Pressure Regulators Revision: D Issue Date: March 20 Form No.: 0056-966
INDEX Section Models Page ESS3 & ESS4 0 2 3 Future EDGE Models ESS7, EST4, ESL4 & ELC4 -- 5 4 5 Future EDGE Models Future EDGE Models -- -- - i -
SECTION 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 /2, 5 /8, 9 /6, /6 and 3 /4 Sockets Socket Wrench Torque Wrench 7 /6, 3 /4 and 3 /6 Open End Wrenches /8, 9 /64, 3 /6 and /4 Hex Keys Bench Vise Repair Tool RT-80 (8 Leverage Bar with /4-8 NPT [M] End) Oxygen-compatible Teflon Tape Loctite #222 Threadlocker CHRISTO-LUBE #29 Lubricant. ESS3/ESS4 - - SECTION
KNOB 9 ESS3/ESS4-2 - SECTION EXPLODED VIEW - ESS3 AND ESS4 MODELS H.P. GAUGE 29 L.P. GAUGE 28 FILTER 24A SCREW 5 SCREW 5 GAUGE GUARD 3 INLET SWIVEL 24 INELT NUT 23 SEAT GUIDE 22 FRICTION DAMPER 2 REAR BODY DECAL (GAS I.D.) 3 RELIEF VALVE VALVE SPRING SEAT ASSM. 9 8 GLAND 20 27 (b) (See Detail A) OUTLET 26 BODY BONNET DECAL (GAS) 30 O-RING 7 NOZZLE 6 PIPE PLUG 25 (a) ESS3 models use five Screws for Bonnet, ESS4 models use six Screws. (b) Pipe Plug replaces Relief Valve on fuel gas models (50, 300, 993). (c) Used on ESS4 E Range (200 PSIG Delivery) models only. DIAPHRAGM ASSM. 4 BACK-UP RING 4A (c) BODY 27A BONNET 2 SEAT 27B ADJUSTING SPRING 5 SEAT RET. 27C DISC Diaphragm Assembly SCREW 7 WASHER 4 Body Bonnet BONNET SCREWS 0 (a) UPPER SEAT 27D SPRING 27F Vented GUIDE BUSHING 3 DRIVE SCREW 2 WASHER 8 LOCK WASHER 8A SPRING BUTTON 27I 27E CAP 27G Non-Vented DETAIL A - Relief Valve (b) THRUST WASHER KNOB DECAL SCREW 6 7 Back-Up Ring Orientation In Assembly (c) VENTED CAP 27H ADJ. SCREW 27J CAP NUT 27K
2.8 2.55 ESS3 Model (ESS3-25-540 Shown) RELIEF ESS4 Model (ESS4-25-540 Shown) RELIEF 3.23 OUTLET 3.82 OUTLET ESS3/ESS4-3 - SECTION PARTS LIST - ESS3 and ESS4 Model Regulators Ref. ESS3 ESS4 No. Description Part No. Part No. Qty. Body 070-0705 070-0706 2 Bonnet 0720-0343 0720-0342 3 Gauge Guard 429-007 429-0070 4 Diaphragm Assembly 0730-0024 TABLE 4A Back-Up Ring TABLE 5 Screw (Gauge Guard) 400-0248 400-0239 2 6 Decal, Knob 45-0788 45-079 7 Screw 400-0239 2 8 Washer 406-0050 8A Lock Washer 406-025 9 Knob TABLE 2 0 Socket Head Cap Screw 400-0246 (b) Thrust Washer 406-0220 2 Drive Screw 0750-0203 3 Guide Bushing Assm. 0750-020 4 Washer, Special 406-0006 5 Adjusting Spring TABLE 6 Nozzle TABLE 2 7 O-Ring (Nozzle Body) 407-0282 8 Seat Assembly TABLE 2 9 Valve Spring 0762-0006 20 Gland 0708-0003 2 Friction Damper 408-0033 22 Bottom Guide 0708-008 23 Inlet Nut TABLE 2 24 Inlet Swivel w/filter TABLE 2 24A Inlet Filter 077-0003 (a) 25 Pipe Plug 05-004 26 Outlet Connection TABLE 2 27 Relief Valve TABLE 3 28 Gauge, Low Pressure TABLE 29 Gauge, High Pressure TABLE 30 Decal, Bonnet Gas I.D. TABLE 2 3 Decal, Rear Body Gas Info. TABLE 2 (a) Cylinder models only. (b) ESS3 uses five (5) screws, ESS4 uses six (6) screws. Items most commonly required for regulator repair and recommended for stock. INLET INLET 5.69 5.88
ESS3/ESS4-4 - SECTION TABLE - Diaphragm, Adjusting Spring & Gauges Ref. No. 29 Gauge, High Pressure (f) 424=053 424=053 424=053 424=05 (f) To replace Lens only - Replacement Lens Part No. 429-0029. TABLE 2 - Inlet & Outlet, Seat Assembly & Nozzle, Color Coded Items Gas Inlet Type I.D. Color ESS3 ESS4 ESS3 ESS4 ESS3 ESS4 Oxygen CGA 540 GREEN 0790-0209 0790-0200 0702-0085 0702-0068 0740-058 0740-03 0967-0044 0967-0032 0950-0068 45-0790 45-0792 Oxygen 992 GREEN 0790-0209 0790-0200 0702-0085 0702-0068 0740-058 0740-03 0992-0003 0970-005 0950-0068 45-0790 45-0792 Argon/Helium/Nitrogen CGA 580 BLACK 0790-024 0790-0208 0702-0085 0702-0068 0740-058 0740-03 0973-0003 0970-005 0950-007 (e) 45-0799 45-0798 Air (Industrial) CGA 590 BLACK 0790-024 0790-0208 0702-0085 0702-0068 0740-058 0740-03 0974-0003 0970-005 0960-004 45-0805 45-0804 Air (Breathing) CGA 346 YELLOW 0790-029 0790-026 0702-0085 0702-0068 0740-058 0740-03 0972-005 0972-0009 0960-004 45-0807 45-0806 Carbon Dioxide CGA 320 (d) GREY 0790-022 0790-0206 0702-0085 0702-0068 0740-058 0740-03 0985-0030 0985-0058 (d) 0950-007 (e) 45-080 45-0800 Nitrous Oxide CGA 326 BLUE 0790-02 0790-0205 0702-0085 0702-0068 0740-058 0740-03 0963-005 0963-0009 0950-0080 45-0803 45-0802 Hydrogen & Methane CGA 350 RED 0790-020 0790-0204 0702-0085 0702-0068 0740-058 0740-03 0983-0003 0983-0005 0960-0029 45-0809 45-0808 Acetylene CGA 50 RED 0790-020 0790-0204 0702-0068 0740-00 0970-0003 0970-005 0960-0029 45-0789 45-0793 Acetylene CGA 300 RED 0790-020 0790-0204 0702-0068 0740-00 0968-0003 0968-0005 0960-0029 45-0789 45-0793 Acetylene 993 RED 0790-020 0790-0204 0702-0068 0740-00 0993-0003 0970-005 0960-0029 45-0789 45-0793 LP Gases CGA 50 ORANGE 0790-023 0790-0207 0702-0068 0740-00 0970-0003 0970-005 0960-0029 45-0797 45-0796 (d) CGA 320 inlet requires inlet washer part number 408-0065. (e) Flow Gauge (FG) models must use Outlet Connection with orifice - Part No. 0950-020. TABLE 3 - Relief Valve Ref. No. All Other Models Flow Gauge Models Acetylene LP Gas LP Gas ESS3-FG-580 Description ESS3-5-50 ESS4-5-50 ESS3-40-50LP ESS4-40-50LP ESS4-25-50LP ESS3-FG-320 ESS3-40- ESS4-40- ESS3-25- ESS4-25- ESS3-200- ESS4-200- 4 Diaphragm Assembly 0730-0024 0730-0063 0730-0024 0730-0063 0730-0063 0730-0024 0730-0024 0730-0063 0730-0024 0730-0063 0730-0024 0730-0068 4A Back-Up Ring 0736-0002 5 Adjusting Spring 076-007 076-0089 076-0060 076-0093 076-0098 076-0060 076-0060 076-0093 076-0080 076-0098 28 Gauge, Low Pressure (f) 424=054 424=055 424=052 424=056 Ref. No. 9 Adjusting Knob (w/decal) 6 Nozzle 8 Seat Assembly 23 24 26 30 3 Acetylene LP Gas Hydrogen (Vented Relief Valve) All Other Models Description All Models All Models 40 psi Delivery 25 psi Delivery 200 psi Delivery 5 psi Delivery 40 psi Delivery 25 psi Delivery 200 psi Delivery Relief Valve Nominal Set Pressure 60 200 400 30 60 200 400 27 Relief Valve Complete Assembly Pipe Plug Pipe Plug or Pipe Plug 05-004 05-004 0600-0060 0600-0066 0600-007 0600-0003 0600-0005 0600-004 0600-008 27A Body 060-0006 060-0006 060-0006 060-0004 060-0004 060-0004 060-0006 27B Seat 0608-0006 0608-0006 0608-0009 0608-0006 0608-0006 0608-0006 0608-0009 27C Seat Retainer 0609-0006 0609-0006 0609-0006 0609-0003 0609-0003 0609-0003 0609-0006 27D Upper Seat 0608-0023 0608-0023 0608-002 0608-008 0608-008 0608-008 0608-0023 27E Disc 406-007 406-007 406-007 406-006 406-006 406-006 406-007 27F Spring 060-006 060-006 060-004 060-0004 060-0005 060-0008 060-003 27G Cap 064-0004 064-0004 064-0004 064-0006 27H Cap (Vented) 064-006 064-006 064-006 27I Spring Button 0606-0005 0606-0005 0606-0005 27J Adjusting Screw 40-0007 40-0008 40-0008 27K Cap Nut 403-0024 403-0024 403-0024 424=055 424=05 Inlet Nut Inlet Swivel (w/filter) 424=052 424=05 Outlet Connection Decal, Bonnet Gas I.D. 076-0098 424=053 424=05 Decal, Rear Body Gas Info.
SERVICE & REPAIR PROCEDURES ESS3 & ESS4 Single Stage EDGE Series Regulators DISASSEMBLY PROCEDURES Refer to the exploded view for reference numbers [Shown in brackets]. Mount the Inlet Swivel Assembly Plug in the Bench Vise and firmly attach the Regulator. 2. Remove the Knob Decal [6], and remove the #0-32 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 [0]. 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 [2], Guide Bushing [3], and Thrust Washer []. The Guide Bushing can be separated from the Drive Screw by removing the #0-32 Screw [7] and Washer [4] 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 [5], Diaphragm Assembly [4], and Back-Up Ring [4A] (if so equipped), and then remove the Nozzle [6] from the Body. 6. Remove the Seat Assembly [8], Valve Spring [9], Gland [20], Friction Damper [2] 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-80 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. 0. 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. ESS3/ESS4-5 - SECTION
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 0790-062 ESS3 Repair Kit for Oxygen, Inert Gases, Air, CO 2, N 2 O, Hydrogen. RK-ESS4-HP 0790-063 ESS4 Repair Kit for Oxygen, Inert Gases, Air, CO 2, N 2 O, Hydrogen. RK-ESS4-HP200 0790-064 ESS4 Repair Kit - 200 PSIG Delivery Models Only - for Oxygen, Inert Gases, Air, CO 2, N 2 O, Hydrogen. RK-ESS3-F 0790-065 ESS3 Repair Kit for Acetylene, LP Gas. RK-ESS4-F 0790-066 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. 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-27 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 oxygencompatible. When using Loctite #222 Threadlocker where noted: Apply two to three drops to the second and third thread, leaving the first thread clean. ESS3/ESS4-6 - SECTION
. Wrap the Low and High Pressure Gauges [28, 29] with Teflon tape. 2. Holding the Body [] 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 0 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 /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 /8-27 NPT Gauge thread will move the Gauge closer to the Body by approximately /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-80 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 0. 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 5 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 0. 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. ESS3/ESS4-7 - SECTION
Regulator Max. Delivery Pressure Mating Relief Valve (Nominal) Recommended Blow-off Pressure 5 PSIG 30 PSIG 27 to 33 PSIG 40 PSIG 60 PSIG 55 to 66 PSIG 25 PSIG 200 PSIG 80 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. 0. 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 5 ft-lbs.. Apply only Loctite #222 threadlocker to the Outlet Connection [26] threads. Install the Outlet Connection into the Body and torque to 5 ft-lbs. 2. 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. 3. 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. 4. Preassemble the seat components: Push the Friction Damper [2] into the Gland [20], and then slip the Valve Spring [9], Gland and Friction Damper onto the shaft of the Seat Assembly [8]. 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. 5. Install the new O-Ring [7] onto the Nozzle [6], 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 5 ft-lbs. Note that 5 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 5 ft-lbs torque is being applied to both the Nozzle threads and the Inlet Swivel threads. 6. Preassemble the Adjusting Mechanism: Apply CHRISTO-LUBE #29 Lubricant to the entire length of the threads of the Drive Screw [2], and screw the Guide Bushing [3] 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 #0-32 Screw [7], and install the Screw and Washer [4] 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. 7. Install the Diaphragm Assembly [4], Adjusting Spring [5], preassembled Adjusting Mechanism and Thrust Washer [] onto the Regulator Body. Note that the Diaphragm ESS3/ESS4-8 - SECTION
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. 8. 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. 9. Install the five (for ESS3) or six (for ESS4) Socket Head Cap Screws [0] into the Bonnet. Tighten all bolts until snug, then torque each to 2-5 ft-lbs in the sequence shown in FIGURE. FIGURE - Torque Sequence for Bonnet Screws 20. Apply a small amount of CHRISTO-LUBE #29 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. 2. Install the #0-32 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, 3] 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 ESS3/ESS4-9 - SECTION
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.. Adjust the Test Manifold to the proper pressure shown in TABLE 4. Gas Service Acetylene & LP Gas CO 2 & N 2 O Air, Argon, Hydrogen, Helium, Nitrogen, Oxygen Manifold Pressure for Testing 250±20 PSIG 00±00 PSIG 2000±00 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 ESS3-5- ESS4-5- ESS3-40- ESS4-40- ESS3-25- ESS4-25- ESS3-200- ESS4-200- A Pressure Set for Leak Test B Pressure Set for Creep/Drop Test C Drop Allowance D Initial Shut-off Allowance 5 PSIG 5 PSIG 3 PSIG PSIG 40 PSIG 0 PSIG 3 PSIG PSIG 25 PSIG 20 PSIG 4 PSIG PSIG 200 PSIG 50 PSIG 5 PSIG PSIG TABLE 5 Edge Regulator Test Values ESS3/ESS4-0 - SECTION
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:. 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. 0. 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:. 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.. Close the Manifold Valve and release all pressure from the Regulator by opening the Test Gun. Turn the Adjusting Knob counterclockwise until it stops. 2. Remove the Test Gun from the Regulator. 3. Remove the Regulator from the Test Manifold. The Regulator is now ready to use. ESS3/ESS4 - - SECTION
TROUBLESHOOTING CAUSES POSSIBLE CORRECTIVE ACTIONS. 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. 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. 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. b. Damaged Adjusting Mechanism or missing components. 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. 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 Inspect system and remove restriction. Regulator. ESS3/ESS4-2 - SECTION
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. Replace with correct Adjusting Spring. 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. b. Loose connection Inlet Swivel to Regulator Body. c. Loose connection High Pressure Gauge to Regulator Body. Insure Regulator is securely tightened to the Manifold. Tighten the Swivel using 20 ft-lbs torque. Tighten the High Pressure Gauge using 0 ftlbs torque minimum (See STEP 2 of the Assembly Procedure). d. Loose connection Rear Pipe Plug. Tighten Pipe Plug using 5 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 5 ft-lbs torque minimum. c. Loose connection Bonnet to Body. Tighten Bonnet Screws using 2-5 ft-lbs. Follow the sequence shown in STEP 9 FIGURE of the Assembly Procedure. d. Damaged Diaphragm. Replace Diaphragm Assembly. ESS3/ESS4-3 - SECTION
CAUSES POSSIBLE CORRECTIVE ACTIONS 0. Rapid pressure drop on both High and Low Pressure Gauges. a. Loose connection Bonnet to Body. b. Loose connection Regulator to Test Manifold. Tighten Bonnet Screws using 2-5 ft-lbs. Follow the sequence shown in STEP 9 FIGURE of the Assembly Procedure. Insure Regulator is securely tightened to the Manifold.. 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. d. Improper Adjusting Spring (spring too long). Clean seating surfaces and/or replace Seat Assembly. Inspect and install or replace O-Ring as necessary. Replace Adjusting Spring. 2. Relief Valve opens at a greater or less than marked pressure (outside a pressure tolerance of ±5% 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. ESS3/ESS4-4 - SECTION
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 /2, 5 /8, 9 /6, /6 and 7 /8 Sockets and Socket Wrench Torque Wrench 9 /6 and Open End Wrenches /8, 3 /6 and /4 Hex Keys/Drivers Flat Bottom Punch Set Small, Long Shank Screwdriver Bench Vise Repair Tool RT-80 (8 Leverage Bar with /4-8 NPT [M] End) Oxygen-compatible Teflon Tape Loctite #222 Threadlocker CHRISTO-LUBE #29 Lubricant. ESS7/EST4/ESL4/ELC4-5 - SECTION 3
L.P. GAUGE 29 H.P. GAUGE 30 EXPLODED VIEW - ESS7 HIGH-FLOW INFO DECAL 3 NOZZLE 9 THRUST WASHER 4 OUTLET 27 FRICTION DAMPER 5 GLAND 6 O-RING 8 DRIVE SCREW 3 SEAT ASSM. 2 DECAL 9 PLUG 20 SEAT GUIDE 4 VALVE SPRING 7 SCREW 0 WASHER GUIDE BUSHING 2 ADJUSTING SPRING 22 SCREW 0 RELIEF VALVE 28 (a) (See DETAIL A) DIAPHRAGM ASSM. 2 BONNET 5 BONNET SCREWS WASHER 6 7 KNOB LOCK WASHER 8 RETAINING RING 25 BODY 200 PSIG DELIVERY ONLY 23 (a) Pipe Plug replaces Relief Valve on fuel gas models (50, 300, 993). (b) Used on E Range (200 PSIG Delivery) models only. BACKUP RING 2A (b) Body INLET NUT INLET SWIVEL 24 26 INLET FILTER SPRING BUTTON 28I Vented SPRING 28F UPPER SEAT 28D SEAT 28B 3 Diaphragm Assembly Back-Up Ring Orientation In Assembly (b) Bonnet CAP NUT 28K ADJ. SCREW 28J VENTED CAP 28H CAP 28G Non-Vented DISC 28E SEAT RET. 28C BODY 28A DETAIL A - Relief Valve (a) - 6 - SECTION 3
EXPLODED VIEW - ESL4 / EST4 / ELC4 PLUG 20 EST4 EST4-R ELC4 BODY INFO DECAL 3 L.P. GAUGE 29 RETAINING RING 25 EST4-R ELC4 INLET FILTER 3 INLET NUT 24 EST4 ESL4 INLET SWIVEL 26 PLUG 20 O-RING 8 NOZZLE 9 VALVE SPRING 7 SEAT ASSM. 2 FRICTION DAMPER 5 GLAND 6 SEAT GUIDE 4 OUTLET 27 EST4 EST4-R ELC4 ESL4 ELC4 EST4-R EST4 PLUG 20 INLET FILTER 3 EST4 EST4-R ESL4 INLET NUT 24 INLET SWIVEL 26 ELC4 DRIVE SCREW 3 THRUST WASHER 4 DECAL 9 SCREW 0 WASHER 7 WASHER GUIDE BUSHING 2 SCREW 0 BONNET SCREWS 6 ADJUSTING SPRING 22 KNOB 23 DIAPHRAGM ASSM. 2 DIAPHRAGM SHIM 2B BONNET 5 O-RING 2D DIAPHRAGM ASSM. (STAINLESS STEEL) 2C LOCK WASHER 8-7 - SECTION 3
ESS7/EST4/ESL4/ELC4-8 - SECTION 3 PARTS LIST - ESS7, EST4, ESL4 and ELC4 Model Regulators Part Numbers EST4 Ref. EST4-R No. Description ESS7 ESS7-200 ESL4 ELC4 Qty. Body 070-0697 070-0697 070-0696 070-0696 2 Diaphragm Assembly 0730-0063 0730-0068 0730-0063 2A Backup Ring 0736-0002 2B Diaphragm Shim 0736-0003 2C Diaphragm Assm. (Stainless St.) 0730-0096 2D Diaphragm O-Ring 407-025 3 Filter 077-0003 077-0003 077-0007 077-0007 (Common Parts) 4 Seat Guide 0708-009 5 Friction Damper 408-0033 6 Gland 0708-0003 7 Valve Spring 0762-0006 8 O-Ring (Nozzle) 407-035 9 Nozzle 0702-0088 0 Screw (#0-32) 400-0239 2 Washer (Special) 406-0006 2 Guide Bushing 0750-020 3 Drive Screw 0750-0203 4 Thrust Washer 406-0220 5 Bonnet 0720-0342 6 Screw (/4-20) 400-0246 6 7 Washer 406-0050 8 Lock Washer 406-025 9 Decal, Knob 45-079 20 Pipe Plug 05-004 A/R (Configuration-Specific Parts) 2 Seat Assembly SEE TABLE 22 Adjusting Spring SEE TABLE 23 Knob SEE TABLE 24 Inlet Nut SEE TABLE 25 Retaining Ring SEE TABLE 26 Inlet Swivel SEE TABLE 27 Outlet Connection SEE TABLE 28 Relief Valve SEE TABLE 2 29 Gauge, Low Pressure SEE TABLE 30 Gauge, High Pressure SEE TABLE 3 Decal, Gas Information SEE TABLE Items most commonly required for regulator repair and recommended for stock. ESL4 ELC4 E = EDGE Series Type: SS = Single Stage, Standard Inlet SL = Line Regulator ST = Station Regulator LC = Liquid Cylinder Regulator ESS7 Model Number Stamping Location (All Models) E XX X XXX XXX Delivery Pressure: (5, 40, 25, etc.) EST4 Model Numbering Scheme Size: 4 = High Capacity (Large) 7 = Ultra-High Capacity (High Flow) Inlet Connection: CGA 540, 50, 024, etc. 250 = /4 NPT (F) Inlet/Outlet 250A = /4 NPT (F) Inlet/Outlet for Acetylene 250F = /4 NPT (F) Inlet/Outlet for H.P. Fuel Gases 250X = /4 NPT (F) Inlet/Outlet for Oxygen
ESS7/EST4/ESL4/ELC4-9 - SECTION 3 TABLE - Diaphragm, Adjusting Spring & Gauges Ref. No. 2 22 23 24 25 26 27 29 30 3 (Sorted by Model/Pressure/Connection) Knob Max Seat Adjusting Knob Inlet Retaining Inlet Outlet Gauge, Low Gauge, High Decal, Gas Edge Model Gas Service Color Inlet Assembly Spring (w/decal) Nut Ring Swivel Connection Pressure (c) Pressure (c) Information ESS7-5-50 Acetylene RED 350 0740-007 076-0089 0790-0204 0970-0003 0970-0005 (e) 0960-007 424=0525 424=0529 0707-426 ESS7-25-50LP LP Gas ORANGE 350 0740-007 076-0098 0790-0207 0970-0003 0970-0005 (e) 0960-007 424=0528 424=0529 0707-43 ESS7-25-540 Oxygen GREEN 3000 0740-0070 076-0098 0790-0200 0967-0044 406-030 0967-0034 (e) 0950-0024 424=0528 424=0532 0707-424 ESS7-25-580 Inert Gas BLACK 3000 0740-0070 076-0098 0790-0208 0973-0003 0970-0005 (e) 0950-0024 424=0528 424=0532 0707-428 ESS7-200-346 Air YELLOW 3000 0740-0070 076-0098 0790-026 0972-005 0972-000 (e) 0950-0024 424=0529 424=0532 0707-429 ESS7-200-350 Hydrogen, Methane RED 3000 0740-0070 076-0098 0790-0204 0983-0003 0983-0008 (e) 0960-007 424=0529 424=0532 0707-430 ESS7-200-540 Oxygen GREEN 3000 0740-0070 076-0098 0790-0200 0967-0044 406-030 0967-0034 (e) 0950-0024 424=0529 424=0532 0707-424 ESS7-200-580 Inert Gas BLACK 3000 0740-0070 076-0098 0790-0208 0973-0003 0970-0005 (e) 0950-0024 424=0529 424=0532 0707-428 ESS7-200-992 Oxygen GREEN 3000 0740-0070 076-0098 0790-0200 0992-0003 0970-0005 (e) 0950-0024 424=0529 424=0532 0707-424 EST4-5-025 Acetylene RED 200 0740-007 076-0089 0790-0204 0966-0003 0952-000 0960-0029 424=0525 0707-427 EST4-5-025R Acetylene RED 200 0740-007 076-0089 0790-0204 0966-0003 0952-0000 0960-0029 424=0525 0707-427 EST4-40-024 Oxygen GREEN 200 0740-0070 076-0093 0790-0200 0965-0005 0952-000 0950-0068 424=0526 0707-425 EST4-40-024R Oxygen GREEN 200 0740-0070 076-0093 0790-0200 0965-0005 0952-0000 0950-0068 424=0526 0707-425 EST4-80-024 Oxygen GREEN 200 0740-0070 076-0080 0790-0200 0965-0005 0952-000 0950-0068 424=0527 0707-425 EST4-80-024R Oxygen GREEN 200 0740-0070 076-0080 0790-0200 0965-0005 0952-0000 0950-0068 424=0527 0707-425 EST4-80-025 Hydrogen, Methane, Natural Gas & LP Gas RED 200 0740-007 076-0080 0790-0204 0966-0003 0952-000 0960-0029 424=0527 0707-435 EST4-80-025R Hyd, Meth, LP Gas RED 200 0740-007 076-0080 0790-0204 0966-0003 0952-0000 0960-0029 424=0527 0707-435 EST4-25-024 Oxygen GREEN 200 0740-0070 076-0098 0790-0200 0965-0005 0952-000 0950-0068 424=0528 0707-425 EST4-25-024R Oxygen GREEN 200 0740-0070 076-0098 0790-0200 0965-0005 0952-0000 0950-0068 424=0528 0707-425 EST4-25-025 Hydrogen, Methane, Natural Gas & LP Gas RED 200 0740-007 076-0098 0790-0204 0966-0003 0952-000 0960-0029 424=0528 0707-435 EST4-25-025R Hyd, Meth, LP Gas RED 200 0740-007 076-0098 0790-0204 0966-0003 0952-0000 0960-0029 424=0528 0707-435 EST4-25-034 Inert Gas BLACK 200 0740-0070 076-0098 0790-0208 0956-0000 0952-000 0950-007 424=0528 0707-434 EST4-25-034R Inert Gas BLACK 200 0740-0070 076-0098 0790-0208 0956-0000 0952-000 0950-007 424=0528 0707-434 ESL4-5-250A Acetylene RED 350 0740-007 076-0089 0790-0204 424=0525 0707-426 ESL4-80-250F Hyd, Meth, LP Gas RED 350 0740-007 076-0080 0790-0204 424=0527 0707-436 ESL4-25-250 Air, Oxygen, CO2, N2O & Inert Gas BLACK 3000 0740-0070 076-0098 0790-0208 424=0528 0707-432 ESL4-25-250X Oxygen GREEN 3000 0740-0070 076-0098 0790-0200 424=0528 0707-424 ESL4-25-250F Hyd, Meth, LP Gas RED 350 0740-007 076-0098 0790-0204 424=0528 0707-436 ELC4-25-320 Carbon Dioxide GREY 3000 0740-0070 076-0098 0790-0206 0985-0030 0985-0003 (d) 0950-007 424=0528 0707-433 ELC4-25-540 Oxygen GREEN 3000 0740-0070 076-0098 0790-0200 0967-0044 406-030 0967-0005 0950-0068 424=0528 0707-424 ELC4-25-580 Inert Gas BLACK 3000 0740-0070 076-0098 0790-0208 0973-0003 0970-0004 0950-007 424=0528 0707-428 ELC4-325-580 Inert Gas BLACK 3000 0740-0070 0799-0809 0790-0208 0973-0003 0970-0004 0950-007 424=0529 0707-428 (c) To replace Lens only, use Replacement Lens Part No. 429-0028. (d) CGA 320 Inlet Connection requires Inlet Seal Washer Part No. 408-0065. (e) Swivels include Filter 077-0003 pre-installed. TABLE 2 - Relief Valve Ref. No. 28 28A 28B 28C 28D 28E 28F 28G 28H 28I 28J 28K Edge Model ESS7-25 ESS7-200 ESS7-200-350 (VENTED) Nominal Set Pressure 200 400 400 Complete Assembly Body Seat 0600-004 0600-008 0600-007 060-0004 060-0006 060-0006 0608-0006 0608-0009 0608-0009 Seat Retainer 0609-0003 0609-0006 0609-0006 Upper Seat Disc Spring Cap 0608-008 0608-0023 0608-002 406-006 406-007 406-007 060-0008 060-003 060-004 064-0004 064-0006 Vented Cap 064-006 Spring Button 0606-0005 Adjusting Screw 40-0008 Repair Kit Part No. 0790-069 0790-069 0790-067 0790-067 0790-068 0790-068 0790-068 0790-068 0790-068 0790-07 0790-07 0790-070 0790-070 0790-070 0790-070 0790-07 0790-07 0790-070 0790-070 0790-07 0790-07 0790-070 0790-070 0790-07 0790-07 0790-070 0790-070 0790-07 0790-072 0790-072 0790-072 0790-072 Cap Nut 403-0024
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]. 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 [9], and remove the #0-32 Screw [0], Lock Washer [8] and Washer [7] located inside the Knob [23]. The Knob can now be removed. 3. Remove the 6 Socket Head Cap Screws [6]. The Bonnet [5] 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 [3], Guide Bushing [2], and Thrust Washer [4]. The Guide Bushing can be separated from the Drive Screw by removing the #0-32 Screw [0] and Washer [] 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 [2], 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-80 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. 0. If necessary, disassemble the Relief Valve as shown in Page, DETAIL A. ESS7/EST4/ESL4/ELC4-20 - SECTION 3
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 on Page 3 for your specific application. Repair Kit Part No. Description RK-ESS7-X 0790-067 ESS7 Repair Kit for Oxygen, Inert Gases, Air, CO 2, N 2 O, Hydrogen. RK-ESS7-X200 0790-068 ESS7 Repair Kit - 200 PSIG Delivery Models Only - for Oxygen, Inert Gases, Air, CO 2, N 2 O, Hydrogen. RK-ESS7-F 0790-069 ESS7 Repair Kit for Acetylene, LP Gas. RK-STSL-X 0790-070 EST4/ESL4 Repair Kit for Oxygen, Inert Gases, Air, CO 2, N 2 O. RK-STSL-F 0790-07 EST4/ESL4 Repair Kit for Acetylene, LP Gas, Hydrogen. RK-ELC4-X 0790-072 ELC4 Repair Kit for Oxygen, Inert Gases, Air, CO 2 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. 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-27 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 oxygencompatible. When using Loctite #222 Threadlocker where noted: Apply two to three drops to the second and third thread, leaving the first thread clean. ESS7/EST4/ESL4/ELC4-2 - SECTION 3
. 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-80, 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 0 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 0. 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 5 PSIG 30 PSIG 27 to 33 PSIG 40 PSIG 60 PSIG 55 to 66 PSIG 25 PSIG 200 PSIG 80 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 0 ft-lbs. ESS7/EST4/ESL4/ELC4-22 - SECTION 3
0. Apply only Loctite #222 threadlocker to the Outlet Connection [27] threads. Install the Outlet Connection into the Body and torque to 5 ft-lbs.. 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. 2. 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. 3. 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 [2]. 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. 4. 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. 5. Preassemble the Adjusting Mechanism: Apply CHRISTO-LUBE #29 Lubricant to the entire length of the threads of the Drive Screw [3], and screw the Guide Bushing [2] 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 #0-32 Screw [0], and install the Screw and Washer [] 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. 6. 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. ELC4 Models: Apply a very light coat of CHRISTO-LUBE #29 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. ESS7/EST4/ESL4/ELC4-23 - SECTION 3
7. Install the Adjusting Spring [22], preassembled Adjusting Mechanism and Thrust Washer [4] onto the Regulator Body. Don t forget the Thrust Washer! Regulator function will be impaired without it. 8. Install the Bonnet [5] 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. 9. Install the six Socket Head Cap Screws [6] into the Bonnet. Tighten all bolts until snug, then torque each to 2-5 ft-lbs in the sequence shown in FIGURE. FIGURE - Torque Sequence for Bonnet Screws 20. Apply a small amount of CHRISTO-LUBE #29 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. 2. Install the #0-32 Screw [0], Lock Washer [8] and Washer [7] to hold the Knob on. Torque this Screw a minimum of 30 in-lbs. 22. Apply new Knob or Gas Information decals [9, 3] 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 ESS7/EST4/ESL4/ELC4-24 - SECTION 3