ESAB ESS3 ESS4 Single Stage Regulator Troubleshooting instruction

Brand: ESAB

Model: ESS3 ESS4 Single Stage Regulator

Type: Troubleshooting instruction

PARTS, SERVICE

& REPAIR BULLETIN

Issue Date: May 2010Revision: C Form No.: 0056-1966

ESS3

ESS4

Single Stage Regulators

ESS3 ESS4

Description Part No. Part No. Qty.

Body 0701-0705 0701-0706 1

Bonnet 0720-0343 0720-0342 1

Gauge Guard 1429-0071 1429-0070 1

Diaphragm Assembly 0730-0024 TABLE 1 1

Back-Up Ring --- TABLE 1 1

Screw (Gauge Guard) 1400-0248 1400-0239 2

Decal, Knob 1415-0788 1415-0791 1

Screw 2

Washer 1

Knob 1

Socket Head Cap Screw (b)

Thrust Washer 1

Drive Screw 1

Guide Bushing Assm. 1

Washer, Special 1

Adjusting Spring 1

Nozzle 1

O-Ring (Nozzle Body) 1

Seat Assembly 1

Valve Spring 1

Gland 1

Friction Damper 1

Bottom Guide 1

Inlet Nut 1

Inlet Swivel w/Filter 1

24A

Inlet Filter 1

Pipe Plug 1

Outlet Connection 1

Relief Valve 1

Gauge, Low Pressure 1

Gauge, High Pressure 1

Decal, Bonnet Gas I.D. 1

Decal, Rear Body Gas Info. 1

(a) Cylinder models only.

(b) ESS3 uses ﬁve (5) screws, ESS4 uses six (6) screws.

TABLE 2

TABLE 3

TABLE 1

TABLE 2

0717-0003 (a)

1105-0014

0708-0018

1408-0033

0708-0003

0762-0006

TABLE 1

TABLE 2

1407-0282

TABLE 2

1406-0220

1406-0006

0750-0201

0750-0203

1400-0239

1406-0050

TABLE 2

1400-0246

Ref.

No.



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

PARTS LIST - ESS3 and ESS4 Model Regulators

ESS3 Model

(ESS3-125-540 Shown)

ESS4 Model

(ESS4-125-540 Shown)

5.69

2.18

5.88

2.55

3.23

3.82

INLET

OUTLET

RELIEF

INLET

OUTLET

RELIEF

- 1 -

(a)

24A

(b)

(See Detail A)

(c)

Diaphragm

Assembly

Body

Bonnet

Back-Up Ring

Orientation

In Assembly

(c)

EXPLODED VIEW - ESS3 AND ESS4 MODELS

27A

27C

27E

27B

27D

27F

27G

DETAIL A - Relief Valve

(b)

(a) ESS3 models use ﬁve Screws for Bonnet, ESS4 models use six Screws.

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

27I

27H

27J

27K

Vented

Non-Vented

- 2 -

TABLE 3 - Relief Valve

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

60 200 400 30 60 200 400

Relief Valve Complete Assembly

or Pipe Plug

27A

Body

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

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 0608-0021 0608-0018 0608-0018 0608-0018 0608-0023

27E

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

27F

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

27G

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

27H

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

27I

Spring Button

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

27J

Adjusting Screw 1401-0007 1401-0008 1401-0008

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

27K

Cap Nut 1403-0024 1403-0024 1403-0024

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

0600-0005 0600-0014 0600-0018

Acetylene

All Models

---

Pipe Plug

1105-0014

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

All Other ModelsHydrogen (Vented Relief Valve)

Relief Valve Nominal Set Pressure >

Ref.

No.

LP Gas

All Models

---

Pipe Plug

1105-0014

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

Gas Inlet Type I.D. Color ESS3 ESS4 ESS3 ESS4 ESS3 ESS4 [ 23 ] [ 24 ] [ 26 ] [ 30 ] [ 31 ]

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

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

0740-0131

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

Argon/Helium/Nitrogen CGA 580

BLACK

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

0740-0131

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

Air (Industrial) CGA 590

BLACK

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

0740-0131

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

Air (Breathing) CGA 346

YELLOW

0790-0219 0790-0216 0702-0085 0702-0068 0740-0158

0740-0131

0972-0015 0972-0009 0960-0014 1415-0807 1415-0806

Carbon Dioxide CGA 320 (d)

GREY

0790-0212 0790-0206 0702-0085 0702-0068 0740-0158

0740-0131

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

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

0740-0131

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

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

0740-0131

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

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

(f) To replace Lens only - Replacement Lens Part No. 1429-0029.

(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.

0740-0101

Nozzle

Inlet Nut

Inlet Swivel

(w/Filter)

0740-0101

Outlet

Connection

Decal,

Rear Body

Gas Info.

Adjusting Knob (w/Decal)

[ 9 ] [ 18 ]

Decal,

Bonnet

Gas I.D.[ 16 ]

Seat Assembly

0702-0068

TABLE 1 - Diaphragm, Adjusting Spring & Gauges

ESS3-FG-580

Description ESS3-FG-320 ESS3-40- ESS4-40- ESS3-125- ESS4-125- ESS3-200- ESS4-200-

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

Back-Up Ring

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

Adjusting Spring 0761-0107 0761-0089 0761-0060 0761-0093 0761-0098 0761-0060 0761-0060 0761-0093 0761-0080 0761-0098

Gauge, Low Pressure (f) 1424=0512 1424=0516

Gauge, High Pressure (f) 1424=0513 1424=0511

All Other ModelsFlow Gauge Models

1424=0513

1424=0511

0761-0098

1424=0515

1424=0511

--- ---

1424=0512

1424=0511

LP Gas

ESS3-40-510LP ESS4-40-510LP ESS4-125-510LP

LP Gas

---

1424=0515

1424=0513

ESS3-15-510 ESS4-15-510

Ref.

No.

Acetylene

1424=0514

1424=0513

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



- 3 -

- 4 -

SERVICE & REPAIR INSTRUCTIONS

ESS3 and 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

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

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”,

/8”,

/16”,

/16” and

/4” Sockets

• Socket Wrench

• Torque Wrench

•

/16”,

/4” and

/16” Open End Wrenches

•

/8”,

/64”,

/16” and

/4” Hex Keys

• Bench Vise

• Repair Tool RT-180 (8” Leverage Bar with

/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.

- 5 -

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

can now be removed.

TIP: Be careful when removing the Bonnet, as the Diaphragm Assembly can

sometimes stick to it when disassembling.

4. Remove the Drive Screw [12], Guide Bushing [13], and Thrust Washer [11]. The Guide

Bushing can be separated from the Drive Screw by removing the #10-32 Screw [7] and

Washer [14] installed in the bottom of the Drive Screw.

TIP: Make sure you’ve got the Thrust Washer. If it’s not sitting on top of the Drive

Screw, it may still be up inside the Bonnet.

5. Remove the Adjusting Spring [15], Diaphragm Assembly [4], and Back-Up Ring [4A] (if

so equipped), and then remove the Nozzle [16] from the Body.

6. Remove the Seat Assembly [18], Valve Spring [19], Gland [20], Friction Damper [21]

and Bottom Guide [22] from the Body.

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

necessary) from the Body.

8. Screw the Leverage Bar Tool RT-180 into the outlet port of the Body (lightly hand tight),

and use the bar to unscrew the Body off the Inlet Swivel [24].

TIP: Watch the Inlet Swivel while trying to turn the Body. If the Swivel is turning with

the Body, then you need to tighten the Inlet Nut tighter on the Inlet Swivel Assembly

Plug.

9. Holding the Body by hand, or lightly in the Bench Vise (with the top surface of the body

protected from damage), remove the Gauge Guard [3] (held on by two screws [5]) and

then remove the Gauges [28, 29].

TIP: Step 9 can be done before Step 8 if desired, but it’s usually easier to remove the

Gauge Guard and Gauges with the Inlet Swivel Assembly Plug out of the way.

NOTE ON ESS4 MODELS: The lower Gauge Guard Screw cannot be accessed until

the Relief Valve has been removed (if so equipped). Subsequently, the Gauge Guard

(and Gauges) must be installed into the Body prior to installing the Relief Valve.

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

 CAUTION! Discard the used Nozzle O-Ring, Inlet Filter, Diaphragm Assembly,

Seat Assembly and Friction Damper. Replace them with new parts each time you

assemble a Regulator.

All of these recommended components are available together in convenient repair kits for

your ESS3 or ESS4 model Regulator:

Repair Kit Part No. Description

RK-ESS3-HP 0790-0162 ESS3 Repair Kit for Oxygen, Inert Gases, Air, CO

O, Hydrogen.

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

O, Hydrogen.

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

for Oxygen, Inert Gases, Air, CO

, N

O, Hydrogen.

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

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

- 6 -

CLEANING PARTS

It is recommended to clean all metal parts for oxygen service, regardless of Regulator Model

being repaired. There are several ways to clean components for oxygen service; the

following standards are recommended reading for more detailed information on methods and

processes:

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

• ASTM G-93 “Standard Practice for Cleaning Methods and Cleanliness Levels for

Material and Equipment Used in Oxygen-Enriched Environments”

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

Systems”

For metal parts, Victor brand suggests using CCI Envirospray Liquid, used per the

manufacturer's instructions, followed by a hot water rinse and thorough drying. Additional

information can be found at

http://www.ccichemical.com.

DO NOT allow non-metal parts to come in contact with cleaning solvents. Cleaning solvents

can cause non-metal parts to swell and/or crack. To clean these parts, use a non-petroleum

based mild soap solution, followed by a thorough rinsing in water. Dry parts completely prior

to reassembling.

ASSEMBLY PROCEDURES

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

 IMPORTANT NOTES ABOUT SEALING PIPE THREADS:

• When using Teflon® tape where noted: Apply two to three layers around the

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

compatible.

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

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

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

2. Holding the Body [1] by hand, or lightly in the Bench Vise (with the top surface of the

Body protected from damage), install the Gauges into the Body and torque each to 10 ft-

lbs minimum. Then install the Gauge Guard [3] using the two mounting Screws [5],

tightening them until snug (the Gauge Guard firmly held in position).

TIP: If you cannot get a torque wrench on the Gauges, some simple rules will help

insure adequate tightness: When the Gauges are tight, nearly all of the

/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.

- 7 -

5. Screw the Body onto the Inlet Swivel, screw the Leverage Bar Tool RT-180 into the outlet

port of the Body (light hand tight), and then use the Leverage Bar to tighten the Body

onto the Inlet Connection. At this point, tighten enough so that the body cannot be turned

by hand without the assistance of the Leverage Bar. Final torque for the Inlet Connection

will occur in upcoming STEP 10.

6. Apply either Teflon® tape or Loctite® #222 to the Pipe Plug [25] threads. Install the Pipe

Plug into the rear Body high pressure port, and torque to 15 ft-lbs.

7. Preassemble the Relief Valve (if so equipped): Assemble (or reassemble) the Relief

Valve [27] as shown in DETAIL A. Use no lubricants or sealants. If your Regulator

model has a Pipe Plug instead of a Relief Valve, or if your Relief Valve is already

assembled and tested, you can skip to STEP 10.

8. To ensure proper Relief Valve performance, perform the following test procedures before

assembling the Relief Valve in the Regulator.

a. Attach the Relief Valve to a 450 PSIG source of oil-free air or dry nitrogen.

b. Slowly pressurize the Relief Valve, increasing to the recommended blow-off pressure

listed below. Note that

VICTOR Relief Valves are stamped with their nominal set

pressure, in case you’re unsure which Relief Valve you have.

Non-Vented Relief Valves:

If the Relief Valve vents before the minimum blow-off pressure is reached, then a

second Disc [27E] may be added.

If it still vents, then the Spring [27F] must be replaced.

Vented Relief Valves:

If the Vented Relief Valve fails to vent within the recommended blow-off pressure,

reset the Adjusting Screw [27J] as necessary and perform this step again. Make

sure you fully bleed off all pressure each time you test for blow-off pressure.

Regulator Max.

Delivery Pressure

Mating Relief

Valve (Nominal)

Recommended

Blow-off Pressure

15 PSIG 30 PSIG 27 to 33 PSIG

40 PSIG 60 PSIG 55 to 66 PSIG

125 PSIG 200 PSIG 180 to 220 PSIG

200 PSIG 400 PSIG 360 to 440 PSIG

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

[27K] on the Vented Relief Valve.

10. Apply either Teflon® tape or Loctite® #222 to the Relief Valve (or Pipe Plug) [27]

threads. Install the Relief Valve (or Pipe Plug) into the Body and torque to 15 ft-lbs.

11. Apply only Loctite® #222 threadlocker to the Outlet Connection [26] threads. Install the

Outlet Connection into the Body and torque to 15 ft-lbs.

12. At this point, thoroughly blow out the Body assembly with pressurized oil-free air or dry

nitrogen to insure it is completely free of chips and debris.

13. Install the Bottom Guide [22] into the Body – it should slip in freely. Note its orientation

when installing – the cupped end with the hex on it should face up.

14. Preassemble the seat components: Push the Friction Damper [21] into the Gland [20],

and then slip the Valve Spring [19], Gland and Friction Damper onto the shaft of the Seat

Assembly [18].

TIP: The Friction Damper should have enough tension to hold the Gland and the

Valve Spring in position on the shaft of the Seat Assembly. If there appears to be no

- 8 -

tension (if the parts just seem to want to fall off), then there may be a problem with

your Friction Damper, or the Friction Damper may not be firmly pushed up in place

inside the Gland.

Then install the preassembled seat components into the Regulator Body – with the

Friction Damper and Gland fitting down into the cup shape of the Bottom Guide.

15. Install the new O-Ring [17] onto the Nozzle [16], taking care to guide it carefully over the

Nozzle threads to avoid nicks or tears. DO NOT use lubricant on the O-Ring. Install the

Nozzle/O-Ring into the Regulator Body and torque to 15 ft-lbs. Note that 15 ft-lbs is the

same recommended torque for the Inlet Connection Swivel, so as you torque down the

Nozzle, you’re also finish-tightening the Inlet Swivel to the correct torque value.

TIP: Watch the Inlet Swivel while you torque down the Nozzle. If the Swivel is turning

with the Body, then you need to tighten the Inlet Nut tighter on the Inlet Swivel

Assembly Plug. You want to be sure that the 15 ft-lbs torque is being applied to both

the Nozzle threads and the Inlet Swivel threads.

16. Preassemble the Adjusting Mechanism: Apply CHRISTO-LUBE® #129 Lubricant to

the entire length of the threads of the Drive Screw [12], and screw the Guide Bushing

[13] onto the Drive Screw (by hand) all the way up until it stops (do not over tighten!).

Note that this is a left hand thread. Next, apply only Loctite® #222 to the threads of the

#10-32 Screw [7], and install the Screw and Washer [14] into the Drive Screw –

tightening until snug.

TIP: Make sure you’ve got the Drive Screw oriented correctly – the Screw and

Washer you just installed should be in the end that’s opposite the square flats.

17. Install the Diaphragm Assembly [4], Adjusting Spring [15], preassembled Adjusting

Mechanism and Thrust Washer [11] onto the Regulator Body. Note that the Diaphragm

centers itself in a recessed pocket in the top of the Body. Don’t forget the Thrust

Washer! Regulator function will be impaired without it.

18. Install the Bonnet [2] onto the Body. Take care while slipping the Bonnet down over the

internal components – the ribs inside the Bonnet must slide into the scallops of the Guide

Bushing.

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

oriented correctly with the Gas I.D. decal facing front.

19. Install the five (for ESS3) or six (for ESS4) Socket Head Cap Screws [10] into the

Bonnet. Tighten all bolts until snug, then torque each to 12-15 ft-lbs in the sequence

shown in FIGURE 1.

FIGURE 1 - Torque Sequence for Bonnet Screws

- 9 -

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 a minimum of 30 in-lbs.

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

maintains clear visual identification.

TIP: If you’re replacing the rear Body Gas I.D. decal, make sure you don’t cover up

the model number stamped on the Body. The Gas I.D. decal should be positioned

right next to the stamping, with the arrow on the decal pointing to the stamped model

number.

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

ready to test.

RECOMMENDED TOOLS AND SUPPLIES FOR TEST PROCEDURES

• Test Gun (quick opening on/off valve) with #52 (.0635”) restricting orifice

• Source of oil-free air or dry nitrogen

TEST PROCEDURES

 WARNING! 

For your safety, and the safety of others:

• Always test with oil-free air or dry nitrogen only.

• Always wear eye protection while testing a Regulator.

• Always perform all of the following test procedures after reassembling a Regulator.

1. Adjust the Test Manifold to the proper pressure shown in TABLE 4.

Gas Service Manifold Pressure for Testing

Acetylene & LP Gas 250±20 PSIG

& N

O 100±100 PSIG

Air, Argon, Hydrogen, Helium, Nitrogen,

Oxygen

2000±100 PSIG

TABLE 4 – Edge™ Regulator Test Pressures

2. Attach the Regulator to the Manifold connection or test adapter. Start the nut by hand

(do not force), and tighten securely with a wrench to create a seal.

3. Turn the Regulator Adjusting Knob clockwise two or three times until you feel slight

tension being applied to the Adjusting Spring.

4. Slowly open and close the Manifold Valve two or three times to remove contamination

that may cause malfunctions. Leave the Manifold Valve closed.

a. If no flow comes through the Regulator, determine the cause – refer to the

TROUBLESHOOTING CHART at the end of this section.

5. Turn the Adjusting Knob counterclockwise until it stops, and attach the Test Gun (with a

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

6. Open the Test Manifold Valve and close the Test Gun.

a. Manifold working pressure will appear on the High Pressure Gauge.

- 10 -

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

Pressure Set

for Leak Test

Pressure Set for

Creep/Drop Test

Drop

Allowance

Initial Shut-off

Allowance

ESS3-15-

ESS4-15-

15 PSIG 5 PSIG 3 PSIG 1 PSIG

ESS3-40-

ESS4-40-

40 PSIG 10 PSIG 3 PSIG 1 PSIG

ESS3-125-

ESS4-125-

125 PSIG 20 PSIG 4 PSIG 1 PSIG

ESS3-200-

ESS4-200-

200 PSIG 50 PSIG 5 PSIG 1 PSIG

TABLE 5 – Edge™ Regulator Test Values

8. LEAK TEST

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

deliver A PSIG.

b. Close the Manifold Valve and turn the Adjusting Knob one turn counterclockwise.

c. Observe the Low Pressure and High Pressure Gauges for five (5) minutes:

1. If the High Pressure Gauge reading drops, there is a leak in the Cylinder Valve,

Inlet Connection, High Pressure Gauge or the rear plugged high pressure port.

2. If the Low Pressure Gauge reading drops, there is a leak in the downstream

equipment, Low Pressure Gauge, Outlet Connection or Relief Valve port.

3. If the High Pressure Gauge reading drops at the same time the Low Pressure

Gauge reading increases, there is a leak in the Regulator Seat.

d. If any leaks are found, isolate if possible using a liquid leak detector, disassemble and

repair or replace parts as needed, and start the test over again. Refer to

TROUBLESHOOTING CHART for more detailed cause and possible corrective

action information.

9. DROP TEST

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

deliver B PSIG.

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

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

10. CREEP TEST / SLOW SHUT-OFF TEST

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

deliver B PSIG.

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

gun closed.

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

1. During the first minute, an initial shut-off increase of D PSIG is permissible.

2. During the next 4 minutes, no further increase (creep) is allowed.

- 11 -

11. Close the Manifold Valve and release all pressure from the Regulator by opening the

Test Gun. Turn the Adjusting Knob counterclockwise until it stops.

12. Remove the Test Gun from the Regulator.

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

TROUBLESHOOTING

CAUSES POSSIBLE CORRECTIVE ACTIONS

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

indicate pressure.

a. Inlet or Inlet Filter is plugged. Blow 40-45 PSIG of air through the Filter in

reverse direction of the normal gas flow.

b. Empty Supply Cylinder. Replace the Cylinder.

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

pressure.

a. Damaged Adjusting Mechanism or

missing components.

Check the Drive Screw, Guide Bushing and

Thrust Washer – insure they are installed

correctly and moving freely in the Bonnet.

b. Adjusting Knob not installed

correctly.

Make sure the square of the Drive Screw is

properly mated into the square in the

Adjusting Knob.

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

any debris.

d. Broken Adjusting Spring. Replace the Adjusting Spring.

e. Broken Seat Stem. Replace the Seat Assembly.

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

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

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

a. Incorrect Adjusting Spring used

during repair.

Replace with correct Adjusting Spring.

b. Damaged Adjusting Mechanism or

missing components.

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

Regulator.

Inspect system and remove restriction.

- 12 -

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.

Replace with correct Adjusting Spring.

e. Low Cylinder pressure or Manifold

test pressure.

Check Cylinder and Manifold pressure and

adjust/replace as needed.

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

the Regulator.

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

a. Loose Nozzle. Tighten Nozzle to 20 ft-lbs torque.

b. Missing or damaged Nozzle O-Ring. Inspect and install or replace O-Ring as

necessary.

c. Accumulation of foreign particles on

Seat Assembly or seating surfaces.

Clean seating surfaces and/or replace Seat

Assembly.

8. With the cylinder valve closed, the High Pressure Gauge indicator drops, and

there is no immediate increase in pressure indicated on the Low Pressure

Gauge.

a. Loose connection – Regulator to

Test Manifold.

Insure Regulator is securely tightened to the

Manifold.

b. Loose connection – Inlet Swivel to

Regulator Body.

Tighten the Swivel using 20 ft-lbs torque.

c. Loose connection – High Pressure

Gauge to Regulator Body.

Tighten the High Pressure Gauge using 10 ft-

lbs torque minimum (See STEP 2 of the

Assembly Procedure).

d. Loose connection – Rear Pipe

Plug.

Tighten Pipe Plug using 15 ft-lbs torque

minimum.

e. Leaking Gauge. Replace the Gauge.

9. Low Pressure Gauge indicator slowly drops, and there is no decrease in

pressure on the High Pressure gauge when the Manifold Valve is closed.

a. Test Gun is not attached securely. Tighten the Test Gun.

b. Loose connections at the

Regulator Body – Outlet

Connection, L.P. Gauge or Relief

Valve/Plug

Tighten connections using 15 ft-lbs torque

minimum.

c. Loose connection – Bonnet to

Body.

Tighten Bonnet Screws using 12-15 ft-lbs.

Follow the sequence shown in STEP 19

FIGURE 1 of the Assembly Procedure.

d. Damaged Diaphragm. Replace Diaphragm Assembly.

- 13 -

CAUSES POSSIBLE CORRECTIVE ACTIONS

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

a. Loose connection – Bonnet to

Body.

Tighten Bonnet Screws using 12-15 ft-lbs.

Follow the sequence shown in STEP 19

FIGURE 1 of the Assembly Procedure.

b. Loose connection – Regulator to

Test Manifold.

Insure Regulator is securely tightened to the

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

torque.

b. Heavy accumulation of foreign

particles on Seat Assembly or

seating surfaces.

Clean seating surfaces and/or replace Seat

Assembly.

c. Internal crack on the high pressure

side of the Body.

Replace the Body.

d. Missing or damaged Nozzle O-

Ring.

Inspect and install or replace O-Ring as

necessary.

e. Improper Adjusting Spring (spring

too long).

Replace Adjusting Spring.

12. Relief Valve opens at a greater or less than marked pressure (outside a pressure

tolerance of ±15% of the marked pressure).

a. Incorrect Spring used. Replace with correct Spring.

b. Relief Valve not set properly. Repeat Relief Valve assembly/test procedure

STEP 8.

WOR L D H E ADQUARTE RS : 16052 Swingley Ridge Road, Suite 300 • St. Louis, Missouri 63017 U.S.A

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ESAB ESS3 ESS4 Single Stage Regulator Troubleshooting instruction

ESAB ESS3 ESS4 Single Stage Regulator Troubleshooting instruction

ESAB ESS3 ESS4 Single Stage Regulator Troubleshooting instruction

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