ESAB SGS 500 Series Stainless Steel Regulators Troubleshooting instruction

Brand: ESAB

Model: SGS 500 Series Stainless Steel Regulators

Type: Troubleshooting instruction

ESAB SGS 500 Series Stainless Steel Regulators are built to endure and are designed for maximum performance with a variety of gases, these regulators provide precise control and measurement of gas flow. They are ideal for use in welding, cutting, brazing, and other industrial applications. The SGS 500 Series Regulators are made from high-quality stainless steel, which makes them resistant to corrosion and wear. They feature a diaphragm-operated design that provides precise control of gas flow, even at low pressures.

PARTS & SERVICE BULLETIN

SGS 500 Series

Stainless Steel Regulators

FORM NO. 0056-1316 EFFECTIVE December 1996

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

1 x 10

-9

scc/sec. Always leak test with helium after servicing the regulators. DO NOT ser-

vice the regulators if you do not have access to helium leak testing facilities. Take the

regulators to a qualified repair technician with helium leak testing equipment.

Apparatus improperly operated, maintained or repaired can be dangerous. Some parts

and accessories manufactured by others may fit VICTOR apparatus but not conform to

VICTOR’s exacting standards. For your own protection, specify and use ONLY VICTOR-

made parts and accessories with your VICTOR apparatus.

Service or repair of VICTOR apparatus should be performed only by a qualified techni-

cian. Improper service, repair or modification of the the product could result in damage to

the product or injury to the operator.

CHART 1

SGS 500-15

0761-0109

1424-0312

1424-0311

SGS 500-40

0761-0110

1424-0313

1424-0311

SGS 500-80

0761-0111

1424-0314

1424-0311

SGS 500-125

0761-0112

1424-0315

1424-0311

CHART 2

CGA NO.

240

330

350

540

580

590

660

705

INLET SWIVEL

0998-0003

0985-0006

0983-0014

0967-0022

0970-0051

0995-0017

0998-0011

INLET NUT

0998-0006

0986-0007

0983-0013

0967-0052

0973-0004

0974-0010

0995-0007

0998-0012

INLET WASHER

1408-0018

1408-0023

N/A

1408-0024

1408-0032

ITEM NO.

NO. DESCRIPTION PART NO. REQ’D

1 HOLE PLUG 0919-0028 1

2 ADJUSTING KNOB 0750-0111 1

3 LOCKNUT 1409-0079 1

4 LOCKWASHER 1406-0110 2

5 ADJ. SCREW ASSY. 0750-0143 1

6 HOUSING CAP 0720-0221 1

7 ADJUSTING SPRING See Chart 1 1

9 DIAPHRAGM PLATE 0735-0047 1

10 DIAPHRAGM 0731-0021 1

11 CARTRIDGE ASSY. 0739-0024 1

12 BODY 0701-0233 1

13 CARTRIDGE GASKET 1408-0114 1

17 L.P. GAUGE See Chart 1 1

18 H.P. GAUGE See Chart 1 1

19 DIFF. RES. VALVE 0660-0519 1

20 BUSHING 0910-0081 1

21 INLET SWIVEL See Chart 2 1

22 INLET NUT See Chart 2 1

23 WASHER See Chart 2 1

24 PIPE PLUG 1105-0021 1

ITEM NO.

NO. DESCRIPTION PART NO. REQ’D

A BODY 0658-0011 1

B POPPET GUIDE 0783-0014 1

C SPRING 0762-0040 1

D SEAT ASSEMBLY 0740-0142 1

E DIAPHRAGM (copper) 0731-0053 1

F DIAPHRAGM (SST) 0731-0054 2

G NOSE, ADJ.SCREW 0751-0088 1

H ADJUSTING SCREW 0667-0039 1

J CAP 0659-0004 1

K GASKET 1408-0100 1

L LOCK NUT 1409-0003 2

M LOCKWASHER 1406-0110 1

N ADJUSTING KNOB 0750-0107 1

P HOLE PLUG 0919-0028 1

SGS 500 REGULATOR

DRK VALVE

SGS 500-200

0761-0113

1424-0316

1424-0311

Description

Adjusting Spring

L. P. Gauge

H. P. Gauge

SERVICE PROCEDURES

Recommended Tools and Supplies:

Bench Vise

Inlet Swivel Ass’y Plug RT-2 (CGA 350) (1420-0009)

Inlet Swivel Ass’y Plug RT-4 (CGA 540) (1420-0014)

Inlet Swivel Ass’y Plug RT-85 (CGA 580) (1420-0134)

Inlet Swivel Ass’y Plug RT-86 (CGA 590) (1420-0135)

9/16” Open-End Wrench

5/8”, 1

” and 1

” Hex Sockets

Torque Wrench

Lubricant (0034-0020)

TEFLON® Tape (0028-0028)

For additional information, refer to Apparatus Service

and Testing Procedures (Form No.0056-0886) and Repair Tools

Manual (Form No. 0056-0121).

Disassembly Procedure

1. Secure the Holding Fixture in the Bench Vise. Place the Regulator

in the Holding Fixture with the Gauges face up.

2. Remove the Nameplate from the Adjusting Knob.

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

Housing Cap.

4. Remove the Spring Button, Adjusting Spring, Slip Ring and

Diaphragm from the Body. Discard the Slip Ring.

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

Discard the Cartridge Gasket.

6. Remove the Gauges from the Body.

DO NOT attempt to repair the Gauges.

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

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

Bushing.

If the DRK Valve requires repair, refer to the

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

9. Remove the Bushing from the Body.

10. Clamp the appropriate Inlet Swivel Assembly Plug in the Bench

Vise. Attach the Regulator to it.

11. Remove the Inlet Swivel from the Body. DO NOT damage the

Inlet Swivel seating surfaces. Remove the Inlet Nut from the Inlet

Swivel.

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

Discard the Slip Ring, Cartridge Gasket and

Filter. Replace them each time you reassemble a Regulator.

Cleaning Regulator Parts

Clean all metal parts with a cleaner that is safe for use with oxygen.

Contact a chemical/cleaning supply distributor for recommended clean-

ers for use with oxygen. Always use cleaning solvents in accordance

with the manufacturer’s instructions.

DO NOT allow nonmetal parts to come in contact with

any cleaning solvent! Cleaning solvents cause elastomeric and plastic

parts to swell and stress crack. If these parts require cleaning, use a

mild soap solution, followed by thorough rinsing in water. Dry these

parts completely before installing in the Regulator. REPLACE NON-

METAL PARTS THAT HAVE COME IN CONTACT WITH OIL,

GREASE OR ANY OTHER PETROLEUM BASED SUBSTANCE!

Assembly Procedures

1. Install the Body in the Body Wrench.

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

Inlet Swivel.

3. Clamp the appropriate Inlet Swivel Assembly Plug in the Bench

Vise. Screw the Inlet Nut onto the Plug and tighten firmly.

4. Wrap two or three layers of TEFLON® tape around the second

and third threads of the Inlet Swivel. Install the Inlet Swivel in the

Body. Tighten to a torque of 20-25 ft.lbs.

5. Wrap two or three layers of TEFLON® tape around the second

and third threads on both ends of the Bushing. Install the Bushing

in the Body. Tighten to a torque of 14-18 ft.lbs.

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

ft.lbs. minimum.

7. Wrap two or three layers of TEFLON® tape around the second

and third threads of the L.P. and H.P. Gauges. Install the Gauges

in the Body. Tighten to a torque of 10 ft.lbs. minimum.

8. Wrap two or three layers of TEFLON® tape around the second

and third threads of the Relief Valve or Pipe Plug. Install the Pipe

Plug in the Body. Tighten to a torque of 14-18 ft.-lbs.

9. Remove the Regulator from the Body Wrench. Secure the Holding

Fixture in the Bench Vise. Place the Body in the Holding Fixture

with the Gauges face up.

10. Remove any contaminants that may otherwise cause the

Regulator to malfunction by connecting the Regulator to a source

of oil-free air. Slowly open and close the Manifold Valve two or

three times. Blow out the inside of the Body with pressurized

oil-free air.

Always wear eye protection when cleaning the

Regulator Body with pressurized air.

11. Place the new Cartridge Gasket in the Body.

12. Install the Cartridge in the Body. Tighten the Cartridge to a torque

of 60 ft.lbs maximum.

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

14. Place the Adjusting Spring over the Diaphragm.

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

around the Spring Button.

16. Carefully place the Housing Cap over the Adjusting Spring.

Screw the Housing Cap onto the Body. Tighten the Housing Cap

to a torque of 100 ft.lbs maximum.

Test Procedure

Recommended Tools and Supplies:

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

#70 (0.0280) Orifice

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

(SGS 500)

Always perform the following test procedure after

assembling a Regulator. Test with oil-free air or dry nitrogen ONLY!

Always wear eye protection when testing a Regulator. NEVER stand

directly in front of or behind a Regulator when opening the Cylinder

Valve or Test Manifold. Always stand so that the Cylinder Valve or

Test Manifold is between you and the Regulator.

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

gen, slowly open and close the Cylinder Valve several times. This

dislodges any particles which may otherwise enter the Regulator.

Leave the Valve closed.

2. Connect the Regulator to the Test Cylinder or Manifold. Back out

the Adjusting Screw until no pressure is on the Adjusting Spring.

3. Attach the Test Gun (with #70 orifice) to the Regulator or Valve

Outlet. Open the DRK Valve, if applicable.

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

5. Setting the Adjusting Screw:

a. Open the Test Manifold.

b. Adjust the Adjusting Set Screw until the Regulator delivers the

appropriate pressure listed below:

15 Range - 30 PSIG Max. No Flow

15 PSIG Min. Flowing

40 Range - 60 PSIG Max. No Flow

40 PSIG Min. Flowing

80 Range - 100 PSIG Max. No Flow

80 PSIG Min. Flowing

125 Range - 200 PSIG Max. No Flow

125 PSIG Min. Flowing

200 Range - 400 PSIG Max. No Flow

200 PSIG Min. Flowing

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

turned off, run the lock nut in a clockwise direction until it is

flush (not tight) against the gaskets above the packing nut.

Make sure the lockwasher is placed on the adjusting screw

between the stop nut and the knob. Slip the knob down onto the

adjusting screw. Install the top lockwasher and nut loosely.

Hold the knob position firmly with one hand and tighten the

nut to 8-10 ft.lbs. of torque. Adjust the control knob in a coun-

terclockwise (decrease) direction until the knob stops turning.

Bleed pressure from the test gun. Readjust the regulator clock-

wise (increase) to assure that the regulator is set to the desired

rated pressure. If the setting is not correct, repeat Step C. After

the setting is correct, snap the nameplate plug into the recess of

the knob.

6. CREEP TEST/SLOW SHUT-OFF TEST:

a. Close the Test Gun.

b. Adjust the Regulator to deliver the appropriate pressure listed

below:

15 Range - 5 PSIG

40 Range - 10 PSIG

80 Range - 10 PSIG

125 Range - 20 PSIG

200 Range - 20 PSIG

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

two (2) minutes, slow shut-off (delivery rise due to the Seat

closing slowly) should not exceed 2 PSIG. During the next

three (3) minutes, no creep (0 PSIG) is allowed. Creep is indi-

cated by an increase in the L.P. Gauge reading.

7. DROP TEST:

a. Close the Test Gun.

b. Adjust the Regulator to deliver the appropriate pressure listed

below.

15 Range - 5 PSIG

40 Range - 10 PSIG

80 Range - 10 PSIG

125 Range - 20 PSIG

200 Range - 20 PSIG

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

in delivery from no-flow to flow) should not exceed the appro-

priate pressure listed below.

15 Range - 2 PSIG

40 Range - 3 PSIG

80 Range - 3 PSIG

125 Range - 4 PSIG

200 Range - 10 PSIG

8. LEAK TEST:

a. Close the Test Gun.

b. Adjust the Regulator to deliver the appropriate pressure listed

below.

15 Range - 15 PSIG

40 Range - 40 PSIG

80 Range - 80 PSIG

125 Range - 125 PSIG

200 Range - 200 PSIG

c. Close the Test Manifold Valve.

d. Turn the Adjusting Knob counterclockwise one turn. Observe

the Gauges for five (5) minutes. If the Gauge readings change,

a leak exists. Disassemble the Regulator. Clean the compo-

nents as described under Cleaning Regulator Parts. Replace

any damaged parts. Reassemble and retest the Regulator.

9. Open the Test Gun to release pressure from the Regulator. Turn

the Adjusting Knob counterclockwise until there is no pressure on

the Adjusting Spring. Close the Valve.

10. Remove the Test Gun from the Regulator.

11. Remove the Regulator from the Test Manifold.

12. HELIUM LEAK TEST:

Helium leak test (mass spectrometer) these regulators to an

inboard rate of 1 x 10

-9

scc/sec or better. If you do not have heli-

um leak testing facilities, take the Regulator to a qualified repair

technician with proper facilities.

If the Regulator does not perform properly during testing, refer to the

Troubleshooting Chart in the Apparatus Service and Testing Procedures

(Form No. 0056-0886).

International Customer Service Thermadyne Canada Thermadyne UK Thermadyne Asia Sdn. Bhd. Cigweld Australia

Oakville, Ontario, Canada Oakville, Ontario Canada Chorley, England Kuala Lumpur, Malaysia Melbourne, Australia

Ph: (1) 905-827-9777 Ph: (1) 905-827-1111 Ph: (44) 1257-261755 Ph: (603) 6092-2988 Ph: (61) 3-9487-1234

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Ph: (55) 21-485-8859 Ph: (971) 4-332-9060 Ph: (52) 5696-7407 Ph: (81) 6-4809-8411 Ph: (39) 039-204-991

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

800-426-1888 • FAX 800-535-0557

International Offices

WORLD HEADQUARTERS: 101 S. Hanley Road • St. Louis, MO 63105 • 314-721-5573 • FAX 314-746-2161

ESAB SGS 500 Series Stainless Steel Regulators Troubleshooting instruction

ESAB SGS 500 Series Stainless Steel Regulators Troubleshooting instruction

ESAB SGS 500 Series Stainless Steel Regulators Troubleshooting instruction

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