Safety, Installation, Operations & Service
Contents
1. Safety Installation Operations amp Service Manual Rev A Published 06 15 DOPSM2080X012 TESCOM Corporation 2015 All Rights Reserved TESCOM is a business unit of Emerson Process Management Regulator Technologies Inc Trademarks are property of divisions of Emerson Process Management The contents of this publication are presented for information purposes only and while effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available on request We reserve the right to modify or improve the designs or specifications of our products at any time without notice a MERSON gement Le Fro in2. NOTE Do NOT apply any type of grease to the inlet or outlet connections 4 Valve seat must be installed with the chamfered side towards the valve 5 Standard Regulator with Control Knob The body and bonnet are best joined by holding the bonnet assembly open end up and lowering all required items into place one at a time The last item to be placed in the bonnet will be the diaphragm It can be centered on the seating surface of the bonnet before the body assembly is inverted and screwed into the bonnet firmly hand tight The 44 2300 is an exception In this case stack the diaphragm diaphragm back up plate load spring and spring button on top of the body Lower the bonnet and screw the bonnet onto the body firmly hand tight Regulator should then be placed in vise and bonnet re torqued to correct specifications See Assembly Drawing 6 Dome Combination Spring and Dome Loaded Regulators are more easily reassembled by holding regulator firmly in vise and reinstalling dome WARNING After regulator has been reassembled it MUST be connected to a pressure source with media compatible with the use of the regulator and pressurized to check for internal and external leakage and operating characteristics Back Pressure Regulators Piston Sensed General TESCOM piston sensed back pressure regulators are specifically engineered for applications requiring dependable pressure regulation These regulators are especially appropriate for i
3. Operations amp Service Manual Section 3 DOPSM2080X012 Rev 06 15 3 6 5 3 7 3 7 1 3 1 2 315 3 7 4 Reassembly The valve is reassembled in the reverse order of disassembly observing the following pre cautions Please reference Bill of Materials and Assembly Drawing for the correct location of the replacement parts and correct torque specifications 1 Inspect all parts and replace those worn or damage with TESCOM replacement parts 2 All parts should be cleaned to the cleanliness level required for safe operation with the media and system the valve will be used in All parts in the flow stream must be free of particles which could prevent proper seating on the valve stem 3 Apply a thin uniform coating of fluorocarbon grease to the following parts threaded portion of the adjusting screw the lower part of the threaded area of the stem retain er all the o rings NOTE Do NOT apply any type of grease to the inlet and outlet connections 4 Valve seat must be installed with the chamfered side towards the valve stem 5 Thread the stem retainer into body hand tight Valve should be placed into a vise and the stem retainer re torqued to specifications See Assembly Drawing A WARNING After valve has been reassembled it must be connected to a pressure source with a media compatible with the use the valve and pressurized to check for internal and external leakage and operation characteristics Valves TESCOM VA V
4. Products purchased by Seller from a third party for resale to Buyer Resale Products shall carry only the warranty extended by the original manufacturer Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products If buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period Seller shall at its option correct any errors that are found by Seller in the firmware of services or repair or replace F O B point of manufacture that portion of the goods or firmware found by Seller to be defective or refund the purchase price of the defective portion of the goods services All replacements or repairs necessitated by inad equate maintenance normal wear and usage unsuitable power sources or environmental conditions accident misuse improper installation modification repair storage or han dling or any other cause not the fault of Seller are not covered by this limited warranty and shall be at buyer s expense Seller shall not be obligated to pay any costs or charges incurred by buyer or any other party except as may be agreed upon in writing in advance by Seller All costs of dismantling reinstallation and freight and the time and expenses of Seller s personnel and representatives for site travel and diagnosis under this warranty clause shall be borne by buyer unless accepted in
5. Reducing Regulators Diaphragm Sensed General TESCOM s diaphragm sensed pressure reducing regulators are specifically engineered for applications requiring dependable pressure regulation These regulators are especially appropriate for installations where high system pressures up to 6000 psi must be reduced to levels suitable for actuating low pressure 28 vac to 500 psi instruments and related equipment Pressure Activation Methods TESCOM uses three basic types of activation methods The activation method provides the means by which the operator can set the force that determines the outlet pressure of a regulator Control Knob Delivery pressure is increased by turning the control knob The control knob applies a load through a spring to the diaphragm Dome Load Delivery pressure is increased by applying pressurized gas or liquid to the dome of a regulator at a pressure equal to the outlet pressure desired This dome pressure is normally provided by a second regulator called the pilot regulator Combination Spring and Dome Delivery pressure is increased by applying a spring force as well as the introduction of pressurized gas or liquid Operation Control Knob Adjustment Controlled outlet pressure settings are obtained using TESCOM pressure reducing regulators by adjusting the control knob Rotating the knob clockwise raises the outlet pressure while a counterclockwise rotation coupled with venting of the downstream side of
6. applying pressurized gas or liquid to the dome of a regulator at a pressure equal to the outlet pressure desired This dome pressure is normally provided by a second regulator called the pilot regulator Combination Spring and Dome Back pressure is increased by applying a spring force as well as the introduction of pressurized gas or liquid Operation Control Knob Adjustment Controlled back pressure settings are obtained using TESCOM back pressure regulators by adjusting the control knob Rotating the knob clockwise raises the back pressure while a counterclockwise rotation will lower the back pressure Final adjustments should be made in the direction of increasing pressure to obtain the most accurate back pressure set pressure TESCOM regulators will operate with any liquid or gaseous media compatible with the wetted materials Some series modifications come with an internal filter designed to stop random contamination resulting from the installation of the regulator An auxiliary upstream filter is recommended for use in all but the cleanest media Gaseous media should be free of excessive moisture to prevent icing of the regulator at high flow rates A WARNING A back pressure regulator is not intended to be used as a system safety relief device When the regulator is not in use the inlet pressure should be turned off 13 Section 3 Rev 06 15 Safety Installation Operations amp Service Manual DOPSM2080X012 3 4 4 3
7. the regulator plumbing lowers the outlet pressure Final adjustments should be made in the direction of increasing pressure to obtain the most accurate set point TESCOM regulators will operate with any liquid or gaseous media compatible with the wetted materials Some series modifications come with an internal filter designed to Section 3 Rev 06 15 Safety Installation Operations amp Service Manual DOPSM2080X012 3 2 4 stop random contamination resulting from the installation of the regulator An auxiliary upstream filter is recommended for use in all but the cleanest media Gaseous media should be free of excessive moisture to prevent icing of the regulator at high flow rates A WARNING Aregulator is not intended to be used as a shutoff device When the regulator is not in use the inlet supply should be turned off As a safety precaution a pressure relief device should be installed downstream of the regulator Maintenance The following procedures are provided to enable the customer to perform all normal maintenance and repair operations These operations are more easily performed with the regulator removed from the line However in some cases repair may be accomplished without removal of the regulator body as long as the supply has been shut off and the inlet and outlet pressures have been vented An Assembly Drawing and Bill of Material for the regulator will be needed to complete maintenance procedures The Assembly Dra
8. to not damage valve A Special service tool Part number 6557 3 may be ordered from the factory to aid in the disassembly of the main valve assembly found in TESCOM Regulator Models 26 1000 26 2000 44 1100 50 2000 and 54 2000 NOTE Several TESCOM regulators are supplied with internal filters They will be located either in the inlet port or in the main valve area of the regulator In each case they should be removed and replaced before reassembly Reassembly The regulator is reassembled in the reverse order of disassembly observing the following precautions Please reference the Bill of Material and Assembly Drawing for the correct location of replacement parts and correct torque specifications 1 Inspect all parts and replace those worn or damaged with TESCOM replacement parts 2 All parts should be cleaned to the cleanliness level required for safe operation with the media and system they will be used in All parts in the flow stream must be free of particles which could prevent proper seating of the main valve 3 Apply a thin uniform coating of fluorocarbon grease to any or all of the following parts indentation of spring button threaded portion of adjusting screw entire threaded area of the bonnet all O rings all threaded parts internal to regulator NOTE Do NOT apply any type of grease to the inlet or outlet connections 4 Valve seats must be installed with the chamfered side towards the main valve 5 Standard Regulat
9. 4 5 Maintenance The following procedures are provided to enable the customer to perform all normal maintenance and repair operations These operations are more easily performed with the regulator removed from the line However in some cases repair may be accomplished without removal of the regulator body as long as the supply has been shut off and the inlet and outlet pressures have been vented An Assembly Drawing and Bill of Material for the regulator will be needed to complete maintenance procedures The Assembly Drawing and Bill of Material are separate from this manual and available by contacting TESCOM see pg 39 for TESCOM contact information The following steps outline the disassembly of back pressure regulators for maintenance and repair 1 Clamp the regulator in a vise by the flats on the bottom and or side of the regulator body 2 Turn control knob and or spring adjustment mechanism counterclockwise to insure removal of all spring force on the diaphragm NOTE Dome loaded regulators All pressurized gas or liquid must be vented from dome before disassembly 3 Remove upper portion of regulator bonnet and or dome Some models require the mounting bracket to be removed first NOTE Upper portion of regulator may also include spring button load spring back up plate and diaphragm etc Review correct drawing to ensure that all parts have been disassembled 4 The valve parts can now be removed from the regulator bod
10. G and VT Series General TESCOM VA VG and VT Series valves are specifically engineered for application requiring dependable controls These valves are especially appropriate for installations where high system pressures up to 10 000 psig are used Actuation types The valve is closed or opened by applying low air pressure to the actuation port Operation The normally closed spring closed VA and VG valves require a minimum pressure of 60 psi applied to the actuation port to open The normally open spring open VA and VG valves require a minimum pressure of 60 psi applied to actuation port to close The VT valve requires a minimum pressure of 80 psi for actuation pressure TESCOM valves will operate with any liquid or gaseous media compatible with the wetted materials A filter is recommended for use in all but the cleanest media Gaseous media should be free of excessive moisture to prevent icing of the valve at high flow rates Maintenance The following procedures are provided to enable the customer to perform all normal maintenance and repair operations These operations are more easily performed with the valve removed from the line However in some cases repair may be accomplished without removal of the valve body as long as the supply has been shut off and the inlet and outlet pressures have been vented Section 3 Rev 06 15 Safety Installation Operations amp Service Manual DOPSM2080X012 3 1 9 The following st
11. Operations amp Service Manual DOPMS2080X012 Rev 06 15 Safety Installation Operations amp Service TESCOM Product Manual Do not attempt to select install use or maintain this product until you have read and fully understood this manual This manual is available in multiple languages online at www tescom com 4 TESCDM EMERSON Process Management Safety Installation Operations amp Service Manual Rev 06 15 DOPSM2080X012 Section 1 Symbols Val SDs es sscciss caseessssceseed evans cdihigescadanesdacevesecusgeieede xe Suh da sakes satevde cde ekcscseveegehsveaiszens 3 Section 2 Safety and Installation Precautions 2 1 Regulators and Valves rsisi arrens sneins nesnese a oe EEE ene EEEn iE 3 Section 3 Operations and Service 31 Types OF REGUIALOMS cece sess cessdveese sesetsssecesseceessi ssiecsdeods onkedsuestoscunsecedeusessaieasssedsse ce 6 3 2 Pressure Reducing Regulators Diaphragm Sensed scssccesceseteeteceeeeeeeeees 7 3 3 Pressure Reducing Regulators Piston Sensed cscesseesseeseceeeeeeeseeceeeeeeeeaes 10 3 4 Back Pressure Regulators Diaphragm Sensed cescccsceesecereeeeeseeeeeeeteeeaee 13 3 5 Back Pressure Regulators Piston Sensed cccssecssseessecesseseseeceseecsseeesseeeees 15 3 6 Valves TESCOM 30 Series issccsssseccssssccstsescasessnasecavecsessacosesanescessaceceseaoecaadonscetie 18 3 7 Valves TESCOM VA VG and VT Series csseeseceseesscesceceeesece
12. ake any repairs you do not understand Have qualified personnel make repairs Return any equipment in need of service to your equipment supplier for evaluation and prompt service Equipment is restored to the original factory performance specifications if repairable There are flat fee repair charges for each standard model The original equipment warranty applies after a complete overhaul A CAUTION Proper component selection 1 Consider the total system design when selecting a component for use in a system 2 The user is responsible for assuring all safety and warning requirements of the application are met through his her own analysis and testing Section 3 Rev 06 15 Safety Installation Operations amp Service Manual DOPSM2080X012 3 TESCOM may suggest material for use with specific media upon request Suggestions are based on technical compatibility resources through associations and manufacturers TESCOM does NOT guarantee materials to be compatible with specific media THIS IS THE RESPONSIBILITY OF THE USER 4 Component function adequate ratings proper installation operation and maintenance are the responsibilities of the system user A WARNING Do not modify equipment or add attachments not approved by the manufacturer Failure to do so can result in death serious injury and or property damage Section 3 Operations and Service 3 1 ASSEMBLY INSTALLATION DRAWINGS amp BILLS OF MATERIAL drawings and pa
13. and system the valve will be used in All parts in the flow stream must be free of particles which could prevent proper seating on the valve stem 3 Apply a thin uniform coating of fluorocarbon grease to the following parts The bonnet threads and all o rings NOTE Do NOT apply any type of grease to the inlet and outlet connections 4 Place the valve body into a vise ad re torque the bonnet of specifications See Assembly Drawing A WARNING After valve has been reassembled it must be connected to a pressure source with a media compatible with the use the valve and pressurized to check for internal and external leakage and operation characteristics 20 Safety Installation Operations amp Service Manual Section 4 DOPSM2080X012 Rev 06 15 Section 4 Limited Warranty 4 1 Limited Warranty Tescom Corporation Seller warrants that the licensed firmware embodied in the goods will execute the programming instructions provided by Seller and that the goods manufac tured or services provided by Seller will be free from defects in materials or workmanship under normal use and care until the expiration of the applicable warranty period Goods are warranted for twelve 12 months from the date of initial installation or eighteen 18 months from the date of shipment by Seller whichever period expires first Consumables and services are warranted for a period of 90 days from the date of shipment or comple tion of the services
14. ceeeneeseeceeceeeeaes 19 Section 4 Limited Warranty A Limited Wartanty E E T A A ers eee eens Ge Aes 21 This manual is available in multiple languages online at www tescom com Safety Installation Operations amp Service Manual Section 1 DOPSM2080X012 Rev 06 15 Section 1 Symbols 1 1 Symbols Paragraphs highlighted by the CAUTION icon contain information that must be followed to maintain a safe and successful operating environment A WARNING Paragraphs highlighted by the WARNING icon contain information about practices or cir cumstances that can lead to personal injury or death property damage or economic loss Section 2 Safety and Installation Precautions 2 1 Regulators and Valves Do not attempt to select install use or maintain this regulator valve or accessory until you have read and fully and fully understood these instructions Be sure this information reaches the operator and stays with the product after installation Do not permit untrained persons to install use or maintain this regulator valve or accessory Improper selection improper installation improper maintenance misuse or abuse of regulators valves or related accessories can cause death serious injury and property damage Oxygen service requires special expertise and knowledge of system design and material compatibility in order to minimize the potential for death serious injury and or property damage Possibl
15. e consequences include but are not limited to e High velocity fluid gas or liquid discharge e Parts ejected at high speed e Contact with fluids that may be hot cold toxic or otherwise injurious e Explosion or burning of the fluid e Lines hoses whipping dangerously e Damage or destruction to other components or equipment in the system A CAUTION Safety Precautions 1 Inspect the regulator valve and accessories before each use 2 Never connect regulators valves or accessories to a supply source having a pressure greater than the maximum rated pressure of the regulator valve or accessory Section 2 Rev 06 15 Safety Installation Operations amp Service Manual DOPSM2080X012 21 Refer to product label model specific for maximum inlet pressures If this rated pressure cannot be found contact your local TESCOM representative for the rated pressure prior to installation and use Verify the designed pressure rating of all equipment e g supply lines fittings connections filters valves gauges etc in your system All must be capable of handling the supply and operating pressure Clearly establish flow direction of the fluid before installation of regulators valves and accessories It is the responsibility of the user to install the equipment in the correct direction Remove pressure from the system before tightening fittings gauges or components Never turn regulator or valve body Instead hold regulat
16. ed in Operations and Service procedures Oil and grease are easily ignited and may combine violently with some fluids under pressure 25 Have emergency equipment in the area if toxic or flammable fluids are used 26 Upstream filters are recommended for use with all fluids 27 Do not bleed system by loosening fittings 28 Prevent icing of the equipment by removing excess moisture from the gas 29 Always use proper thread lubricants and sealants on tapered pipe threads Installation CAUTION Do not open packaging until ready for installation or in a clean environment Product is cleaned in accordance with CGA 4 1 and ASTM G93 Verification Type 1 Test 1 and Test 2 With periodic verification of cleaning process to MIL STD 1330D A WARNING Make sure that the components and materials used in the fluid handling system are compatible with the fluid and have the proper pressure rating Failure to do so can result in death serious injury and or property damage Inspect the regulator valve and accessories for physical damage and contamination Do not connect the regulator valve or accessory if you detect oil grease or damaged parts If the regulator valve or accessory is damaged contact your local TESCOM representative to have the regulator cleaned or repaired Repair Service If a regulator or valve leaks or malfunctions take it out of service immediately You must have instructions before doing any maintenance Do not m
17. eps outline the disassembly of the VA VG and VT series valves for main tenance and repair For field repairs and maintenance it is recommended to use the valve modules for repair Module numbers are located on the datasheets or call TESCOM for the module number An Assembly Drawing and Bill of Material for the valve will be needed to complete mainte nance procedures The Assembly Drawing and Bill of Material are separate from this manu al and available by contacting TESCOM see pg 39 for TESCOM contact information Special repair tools are available for field servicing valve modules P N 64084 for VA mod ule and JT103871 for VG module 1 Clamp the valve body in a vise 2 Remove the upper portion of the valve bonnet The actuation side 3 For the VT valve also remove the lower bonnet NOTE Upper portion of the valve may also include stem seals and o rings Review correct draw ing to ensure that all parts have been disassembled A CAUTION Care must be used to not damage sealing components Reassembly The valve is reassembled in the reverse order of disassembly observing the following pre cautions Please reference Bill of Materials and Assembly Drawings for the correct location of the replacement parts and correct torque specifications 1 Inspect all parts and replace those worn or damaged with TESCOM replacement parts 2 All parts should be cleaned to the cleanliness level required for safe operation with the media
18. erials A filter is recommended for use in all but the cleanest media Gaseous media should be free of excessive moisture to prevent icing of the valve at high flow rates Maintenance The following procedures are provided to enable the customer to perform all normal maintenance and repair operations These operations are more easily performed with the valve removed from the line However in some cases repair may be accomplished without removal of the valve body as long as the supply has been shut off and the inlet and outlet pressures have been vented An Assembly Drawing and Bill of Material for the valve will be needed to complete maintenance procedures The Assembly Drawing and Bill of Material are separate from this manual and available by contacting TESCOM see pg 39 for TESCOM contact information The following steps outline the disassembly of the 30 Series valve for maintenance and repair 1 Clamp the valve body in a vise 2 Turn the hand knob counterclockwise several turns to ensure the valve stem is not contacting the seat 3 Remove the hand knob to expose the flats on the upper portion of the stem retainer Note Upper portion of the valve may also include stem seal o rings seat retainer Review correct drawing to ensure that all parts have been disassembled 4 The 30 1100 series seat is accessed from the bottom of the valve body 7 CAUTION Care must be used to not damage sealing components Safety Installation
19. ety Data Sheet MSDS for each fluid used in your system Never use materials for regulators valves or accessories that are not compatible with the fluids being used Users must test components for material compatibility with the system operating conditions prior to use in the system Vent fluids to a safe environment and in an area away from personnel Be sure that venting and disposal methods are in accordance with Federal State and Local requirements Locate and construct vent lines to prevent condensation or gas accumulation Make sure the vent outlet is not obstructed by rain snow ice vegetation insects birds etc Do not interconnect vent lines use separate lines if more than one vent is needed Do not locate regulators valves or accessories controlling flammable fluids near open flames or any other source of ignition Safety Installation Operations amp Service Manual Section 2 DOPSM2080X012 Rev 06 15 2 1 1 rA 22 Some fluids when burning do not exhibit a visible flame Use extreme caution when inspecting and or servicing systems using flammable fluids to avoid death or serious injury to personnel Provide a device to warn personnel of these dangerous conditions 23 Many gases can cause suffocation Make certain the area is well ventilated Provide a device to warn personnel of lack of Oxygen 24 Never use oil or grease on these regulators valves or accessories unless recommended as specifi
20. ions See Assembly Drawing 6 Dome Spring combination and Dome Loaded regulators are more easily reassembled by holding regulator firmly in vise and reinstalling dome 7 Reinstalling wire mesh inlet filter Insert filter into primary inlet port It must then be expanded to fit correctly This can be accomplished by inserting a metal tool the same size as the port and then lightly tapping it with a hammer A WARNING After regulator has been reassembled it must be connected to a pressure source with media compatible with the use of the regulator and pressurized to check for internal and external leakage and operating characteristics 17 Section 3 Rev 06 15 Safety Installation Operations amp Service Manual DOPSM2080X012 3 6 3 6 1 3 6 2 3 6 3 3 6 4 Valves TESCOM 30 Series General TESCOM 30 Series shut off manuals are specifically engineered for applications requiring dependable controls These valves are especially appropriate for installations where high system pressures up to 10 000 psi are used Actuation Types These are hand knob manual control The valve is closed by turning the hand knob clockwise Operation The valve is closed by turning the hand knob clockwise and opened by turning the hand knob counterclockwise The hand knob rotation changes the position of the valve stem in relation to the seat TESCOM valves will operate with any liquid or gaseous media compatible with the wetted mat
21. is recommended for use in all but the cleanest media Gaseous media should be free of excessive moisture to prevent icing of the regulator at high flow rates Safety Installation Operations amp Service Manual Section 3 DOPSM2080X012 Rev 06 15 3 3 4 A WARNING Aregulator is not intended to be used as a shutoff device When the regulator is not in use the inlet supply should be turned off As a safety precaution a pressure relief device should be installed downstream of the regulator Maintenance The following procedures are provided to enable the customer to perform all normal maintenance and repair operations These operations are more easily performed with the regulator removed from the line However in some cases repair may be accomplished without removal of the regulator body as long as the supply has been shut off and the inlet and outlet pressures have been vented An Assembly Drawing and Bill of Material for the regulator will be needed to complete maintenance procedures The Assembly Drawing and Bill of Material are separate from this manual and available by contacting TESCOM see pg 39 for TESCOM contact information The following steps outline the disassembly of pressure reducing regulators for maintenance and repair 1 Clamp the regulator in a vise by the flats on the bottom and or side of the regulator body 2 Turn control knob and or spring adjustment mechanism counterclockwise to insure removal of all spri
22. ng force on the piston NOTE Dome loaded regulators All pressurized gas or liquid must be vented from dome before disassembly 3 Remove upper portion of regulator bonnet and or dome Some models require the hand knob and or mounting bracket to be removed first NOTE Upper portion of regulator may also include spring button load spring back up plate and piston sensor etc Review correct drawing to ensure that all parts have been disassembled NOTE Two Stage Regulator TESCOM Model Series BB 5 is a two stage regulator that has portions on both ends of the regulator body that must be removed It is TESCOM s recommendation that two stage regulators be returned to the factory for repair 4 The valve parts can now be removed from the regulator body by turning the seat retainer and or back cap counterclockwise until it is free of the regulator body A CAUTION TESCOM Models 26 1000 and 44 1100 valve parts are held in place by the use of left handed threads When removing valve parts from a regulator that has a back cap care must be taken to insure the main valve stem remains vertical If the main valve stem is not removed correctly parts may remain in the regulator 5 To disassemble main valve assembly and or valve clamp valve in smoothed jaw vise Clamping should be done on flats 11 Section 3 Rev 06 15 Safety Installation Operations amp Service Manual DOPSM2080X012 IRI A CAUTION Care must be used
23. nstallations where the system or process requires the pressure to be limited to a maximum pressure The control pressure range can be up to a maximum of 20 000 psi Pressure Activation Methods TESCOM uses four basic types of activation methods The activation method provides the means by which the operator can set the force that determines the outlet pressure of a regulator Control Knob Delivery pressure is increased by turning the control knob The control knob applies a load through a spring to the piston Dome Load Delivery pressure is increased by applying pressurized gas or liquid to the dome of a regulator at a pressure equal to the outlet pressure desired This dome pressure is normally provided by a second regulator called the pilot regulator Combination Spring and Dome Delivery pressure is increased by applying a spring force as well as the introduction of pressurized gas or liquid Air Actuated Multiplier Delivery pressure is controlled by applying 0 100 psig pilot pressure to the air actuator resulting in full outlet pressure range control 15 Section 3 Rev 06 15 Safety Installation Operations amp Service Manual DOPSM2080X012 3 55 3 5 4 Operation Control Knob Adjustment Controlled back pressure settings are obtained using TESCOM back pressure regulators by adjusting the control knob Rotating the knob clockwise raises the inlet pressure while a counterclockwise rotation will lower the inlet pre
24. or or valve body and turn fitting nut If a regulator or valve leaks or malfunctions take it out of service immediately Do not modify equipment or add attachments not approved by the manufacturer For pressure reducing regulators it is highly recommended that the control knob or adjusting screw be turned fully counterclockwise before applying inlet pressure Apply pressure to the system gradually avoiding a sudden surge of fluid or pressure shock to the equipment in the system Regulators are not shut off devices Install a pressure relief device downstream of the regulator to protect the process equipment from overpressure conditions Shut off the supply pressure when the regulator is not in use Periodic inspection and scheduled maintenance of your equipment is required for continued safe operation The frequency of servicing is the responsibility of the user based on the application Positive seal tied diaphragm regulators require the downstream pressure vented before turning the hand knob counterclockwise to reduce the outlet pressure Damage may occur to the regulator if this procedure is not followed Never allow problems or lack of maintenance to go unreported Read and follow precautions on compressed gas cylinder labels It is important that you analyze all aspects of your application and review all available information concerning the product or system Obtain read and understand the Material Saf
25. or with Control Knobs The body and bonnet are best joined by holding the bonnet assembly open end up and dropping all required items into place one at a time The last item to be placed in the body of most all of TESCOM regulators is the piston sensor Place all O rings and back up rings that are external to the piston sensor in the body before placing the sensor in place O rings should always be installed before back up rings The bonnet and body may now be attached This is best done by holding the body in one hand and the bonnet in the other Tilt the body at a 45 angle and then attach the bonnet by screwing it into the body firmly hand tight Regulator should then be placed in vise and bonnet re torqued to correct specifications See Assembly Drawing 6 Dome Spring Combination and Dome Loaded Regulators are more easily reassembled by holding regulator firmly in vise and reinstalling dome 7 Self Venting Regulator If your regulator has an adjustable vent valve mechanism it is set on final assembly at the factory and usually will not require further adjustment If adjustment becomes necessary use the following procedure after regulator has been installed Step 1 Remove hole plug located in control knob Step 2 Using control knob apply 100 to 150 psi on downstream side Step 3 Turn vent adjusting screw clockwise located under hole plug until media can be heard escaping through vent valve Step 4 Turn screw counter clockwise un
26. place those worn or damaged with TESCOM replacement parts 2 All parts should be cleaned to the cleanliness level required for safe operation with the media and system they will be used in All parts in the flow stream must be free of particles which could prevent proper seating of the main valve 3 Apply a thin uniform coating of fluorocarbon grease to any or all of the following parts Indentation of spring button threaded portion of adjusting screw entire threaded area of the bonnet all O rings all threaded parts internal to regulator NOTE Do NOT apply any type of grease to the inlet or outlet connections 4 Valve seats must be installed with the chamfered side towards the main valve 5 Standard regulator with control knobs The body and bonnet are best joined by holding the bonnet assembly open end up and lowering all required items into place one at a time The last item to be placed in the body of the majority of TESCOM regulators is the piston sensor Place all O rings and back up rings that are external to the piston sensor in the body before placing the sensor in place O rings should always be installed before back up rings The bonnet and body may now be attached This is best done by holding the body in one hand and the bonnet in the other Tilt the body at a 45 angle and then attach the bonnet by screwing it into the body firmly hand tight Regulator should then be placed in vise and bonnet re torqued to correct specificat
27. ply any type of grease to threaded internal parts of regulators that come standard with metal to metal diaphragm seals These models include the following regulator series 23 449 254 44 2200 44 2300 44 2500 44 2600 44 2800 44 2900 44 3200 44 4600 44 4700 44 5800 64 2600 64 2800 64 3600 64 5400 74 2400 74 3000 AND 74 3800 NOTE Do NOT apply any type of grease to the inlet or outlet connections 4 Valve seat must be installed with the chamfered side towards the main valve 5 Standard Regulator with Control Knob The body and bonnet are best joined by holding the bonnet assembly open end up and dropping all required items into place one at a time The last item to be placed in the bonnet will be the diaphragm It can be centered on the seating surface of the bonnet before the body assembly is inverted and screwed into the bonnet firmly hand tight Regulator should then be placed in vise and bonnet re torqued to correct specifications See Assembly Drawing 6 Dome Combination Spring and Dome Loaded Regulators are more easily reassembled by holding regulator firmly in vise and reinstalling dome 7 Self Venting Regulator If your regulator has an adjustable relief valve mechanism it is set on final assembly at the factory and usually will not require further adjustment If adjustment becomes necessary use the following procedure after regulator has been installed Step 1 Remove hole plug in control knob Step 2 Using cont
28. pressure regulators for maintenance and repair 1 Clamp the regulator in a vise by the flats on the bottom and or side of the regulator body 2 Turn control knob and or spring adjustment mechanism counterclockwise to insure removal of all spring force on the piston NOTE Dome loaded regulators All pressurized gas or liquid must be vented from dome before disassembly 3 Remove upper portion of regulator bonnet and or dome Some models require the hand knob and or mounting bracket to be removed first NOTE Upper portion of regulator may also include spring button load spring back up plate and piston sensor etc Review correct drawing to ensure that all parts have been disassembled 4 The seat parts can now be removed from the regulator body by turning the seat retainer counter clockwise until it is free of the regulator body 5 To disassemble sensor and valve assembly and or valve clamp the spring plate in a smoothed jaw vise or hold with pliers Clamping should be done on flats Safety Installation Operations amp Service Manual Section 3 DOPSM2080X012 Rev 06 15 3 5 5 A CAUTION Care must be used to not damage valve surfaces Reassembly The regulator is reassembled in the reverse order of disassembly observing the following precautions Please reference the Bill of Material and Assembly Drawing for the correct location of replacement parts and correct torque specifications 1 Inspect all parts and re
29. rol knob apply 10 to 15 psi on downstream side Step 3 Turn CW vent adjusting screw located under hole plug until media can be heard escaping through vent valve Section 3 Rev 06 15 Safety Installation Operations amp Service Manual DOPSM2080X012 3 3 5 3 1 33 2 3 3 3 Step 4 Turn screw CCW until media flow stops plus 1 2 turn Replace hole plug 8 Reinstalling wire mesh inlet filter Insert filter into primary inlet port It then must be expanded to fit correctly This can be accomplished by inserting a metal tool the same size as the port and then lightly tapping it with a hammer A WARNING After regulator has been reassembled it MUST be connected to a pressure source with media compatible with the use of the regulator and pressurized to check for internal and external leakage and operating characteristics Pressure Reducing Regulators Piston Sensed General TESCOM piston sensed pressure reducing regulators are specifically engineered for applications requiring dependable pressure regulation These regulators are especially appropriate for installations where high system pressures up to 20 000 psi must be reduced to levels suitable for actuating low pressure 0 to 20 000 psi instruments and related equipment Pressure Activation Methods TESCOM uses four basic types of activation methods The activation method provides the means by which the operator can set the force that determines the outlet press
30. rts lists for your product may be obtained by contacting TESCOM Tescom will provide these by email fax or mail Your local Tescom representative can provide additional assistance Be sure to have your complete model number ready See page 39 for contact information for the TESCOM location closest to you Types of Regulators Diaphragm Sensed Pressure Reducing Regulators By Series e 04 e 44 2600 e 64 3400 e DK o lz e 44 2800 e 64 3600 e FR 2000 e 15 e 44 3200 e 64 5000 e PH 1800 e 26 1100 e 44 3400 e 64 5400 e PH 2200 e 26 1200 e 44 4600 e 74 2400 e PH 2600 e 26 1500 e 44 5000 e 74 3000 e PH 3200 e 26 1600 e 44 5800 e 74 3800 e PS3400 e 22 2200 e 449 254 e DA gt SG1 SG2 SG3 e 22 5400 e 64 2600 e DG o 23 e 64 2800 e DH e 44 2200 e 64 3200 e DH 16 Diaphragm Sensed Back Pressure Regulators By Series e 26 2300 e 26 2700 e 44 2300 e 44 4700 e 26 2500 e 26 2900 e 44 2500 e DV Safety Installation Operations amp Service Manual Section 3 DOPSM2080X012 Rev 06 15 3 2 3 2 1 3 2 2 3 2 3 Piston Sensed Pressure Reducing Regulators By Series e 20 1000 e 44 1800 e 50 2200 e BB 1 e 20 1100 e 44 1300 e 50 4000 e CP3200 e 20 1200 e 44 4000 e 50 4100 e 26 1000 e 44 4200 e 54 2000 e 26 2000 e 44 5200 e 54 2200 e 44 1100 e 44 7400 e 54 2800 e 44 1500 e 50 2000 e 56 2000 Piston Sensed Back Pressure Regulators By Series e 26 1700 e 44 2900 e 54 2300 e 54 3500 e 44 1700 e 54 2100 e 54 2700 e BB 3 e 44 5500 Pressure
31. ssure Final adjustments should be made in the direction of increasing pressure to obtain the most accurate back pressure set pressure TESCOM regulators will operate with any liquid or gaseous media compatible with the wetted materials Some series modifications come with an internal filter that only are designed to stop random contamination resulting from the installation of the regulator An auxiliary upstream filter is recommended for use in all but the cleanest media Gaseous media should be free of excessive moisture to prevent icing of the regulator at high flow rates A WARNING A back pressure regulator is not intended to be used as a system safety relief device When the regulator is not in use the inlet pressure should be turned off Maintenance The following procedures are provided to enable the customer to perform all normal maintenance and repair operations These operations are more easily performed with the regulator removed from the line However in some cases repair may be accomplished without removal of the regulator body as long as the supply has been shut off and the inlet and outlet pressures have been vented An Assembly Drawing and Bill of Material for the regulator will be needed to complete maintenance procedures The Assembly Drawing and Bill of Material are separate from this manual and available by contacting TESCOM see pg 39 for TESCOM contact information The following steps outline the disassembly of back
32. the main valve stem is not removed correctly parts may remain in the regulator 5 To disassemble main valve assembly and or valve clamp valve in smoothed jaw vise or hold with pliers Clamping should be done on flats Safety Installation Operations amp Service Manual Section 3 DOPSM2080X012 Rev 06 15 3 2 5 A CAUTION Care must be used to not damage valve A WARNING Several TESCOM regulators are supplied with internal filters They will be located either in the inlet port or in the main valve area of the regulator In each case they should be removed and replaced before reassembly Reassembly The regulator is reassembled in the reverse order of disassembly observing the following precautions Please reference the Bill of Material and Assembly Drawing for the correct location of replacement parts and correct torque specifications 1 Inspect all parts and replace those worn or damaged with TESCOM replacement parts 2 All parts should be cleaned to the cleanliness level required for safe operation with the media and system they will be used in All parts in the flow stream must be free of particles which could prevent proper seating of the main valve Apply a thin uniform coating of fluorocarbon grease to any or all of the following parts Indentation of spring button threaded portion of adjusting screw entire threaded area of the bonnet all O rings all threaded parts internal to regulator A WARNING Do not ap
33. til media flow stops plus 1 2 turn Replace hole plug 12 Safety Installation Operations amp Service Manual Section 3 DOPSM2080X012 Rev 06 15 3 4 3 4 1 3 4 2 3 4 3 8 Reinstalling wire mesh inlet filter Insert filter into primary inlet port It must then be expanded to fit correctly This can be accomplished by inserting a metal tool the same size as the port and then lightly tapping it with a hammer A WARNING After regulator has been reassembled it should be connected to a pressure source with media compatible with the use of the regulator and pressurized to check for internal and external leakage and operating characteristics Back Pressure Regulators Diaphragm Sensed General TESCOM s diaphragm sensed back pressure regulators are specifically engineered for applications requiring dependable pressure regulation These regulators are especially appropriate for installations where the system or process requires the pressure to be limited to a maximum pressure The control pressure range can be up to a maximum of 500 psig Pressure Activation Methods TESCOM uses three basic types of activation methods The activation method provides the means by which the operator can set the force that determines the back pressure of a regulator Control Knob Back pressure is increased by turning the control knob The control knob applies a load through a spring to the diaphragm Dome Load Back pressure is increased by
34. ure of a regulator Control Knob Delivery pressure is increased by turning the control knob The control knob applies a load through a spring to the piston Dome Load Delivery pressure is increased by applying pressurized gas or liquid to the dome of a regulator at a pressure equal to the outlet pressure desired This dome pressure is normally provided by a second regulator called the pilot regulator Combination Spring and Dome Delivery pressure is increased by applying a spring force as well as the introduction of pressurized gas or liquid Air Actuated Multiplier Delivery pressure is controlled by applying 0 100 psig pilot pressure to the air actuator resulting in full outlet pressure range control Operation Control Knob Adjustment Controlled outlet pressure settings are obtained using TESCOM pressure reducing regulators by adjusting the control knob Rotating the knob clockwise raises the outlet pressure while a counterclockwise rotation coupled with venting of the downstream side of the regulator plumbing lowers the outlet pressure Final adjustments should be made in the direction of increasing pressure to obtain the most accurate set point TESCOM regulators will operate with any liquid or gaseous media compatible with the wetted materials Some series modifications come with an internal filter that only are designed to stop random contamination resulting from the installation of the regulator An auxiliary upstream filter
35. wing and Bill of Material are separate from this manual and available by contacting TESCOM see pg 39 for TESCOM contact information The following steps outline the disassembly of pressure reducing regulators for maintenance and repair 1 Clamp the regulator in a vise by the flats on the bottom and or side of the regulator body 2 Turn control knob and or spring adjustment mechanism counterclockwise to insure removal of all spring force on the diaphragm NOTE Dome loaded regulators All pressurized gas or liquid must be vented from dome before disassembly 3 Remove upper portion of regulator bonnet and or dome Some models require the mounting bracket to be removed first NOTE Upper portion of regulator may also include spring button load spring back up plate and diaphragm etc Review correct drawing to ensure that all parts have been disassembled NOTE Two Stage Regulator TESCOM Model Series 44 3400 64 3400 and PS3400 are two stage regulators that have portions on both ends of the regulator body that must be removed It is TESCOM s recommendation that two stage regulators be returned to the factory for repair 4 The valve parts can now be removed from the regulator body by turning the seat retainer and or back cap counterclockwise until it is free of the regulator body A CAUTION When removing valve parts from a regulator that has a back cap care must be taken to insure the main valve stem remains vertical If
36. writing by Seller Goods repaired and parts replaced by Seller during the warranty period shall be in warranty for the remainder of the original warranty period or ninety 90 days whichever is longer This limited war ranty is the only warranty made by Seller and can be amended only in a writing signed by Seller THE WARRANTIES AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EXPRESSED OR IMPLIED AS TO MERCHANTABILITY FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOOD OR SERVICES 21 Emerson Process Management Regulator Technologies Inc TESCOM AMERICAS 12616 Industrial Blvd Elk River MN 55330 USA T 1 800 447 1250 1 763 241 3238 F 1 763 241 3224 na tescom emerson com www tescom com EUROPE An der Trave 23 25 23923 Selmsdorf Germany T 49 0 388 23 31 287 F 49 0 38823 31 140 eu tescom emerson com www tescom europe com Brandon House 23 25 Brandon Street Hamilton ML3 6DA South Lanarkshire UK T 44 1698 424 254 F 44 1698 459 299 uk tescom emerson com www tescom com TESC M ASIA PACIFIC 3 F Building 2 No 1277 Xin Jin Qiao Road Jinqiao E P Z Pudong Shanghai 201206 China T 86 21 2892 9970 F 86 21 2892 9001 ap tescom emerson com www tescom com MIDDLE EAST amp AFRICA PO Box 17033 Jebel Ali Free Zone South Zone 2 Dubai UAE T 971 4811 8443 F 971 4 886 5465 mea tescom emerson com www tescom com
37. y by turning the seat retainer and or back cap counterclockwise until it is free of the regulator body 5 To disassemble diaphragm valve assembly and or valve clamp valve in smoothed jaw vise Clamping should be done on flats A CAUTION Care must be used to not damage valve Reassembly The regulator is reassembled in the reverse order of disassembly observing the following precautions Please reference the Bill of Material and Assembly Drawing for the correct location of replacement parts and correct torque specifications 1 Inspect all parts and replace those worn or damaged with TESCOM replacement parts 2 All parts should be cleaned to the cleanliness level required for safe operation with the media and system they will be used in All parts in the flow stream must be free of particles which could prevent proper seating of the main valve 3 Apply a thin uniform coating of fluorocarbon grease to any or all of the following parts Indentation of spring button threaded portion of adjusting screw entire threaded area of the bonnet all O rings all threaded parts internal to regulator Safety Installation Operations amp Service Manual Section 3 DOPSM2080X012 Rev 06 15 3 5 3 2 3 9 2 A WARNING Do not apply any type of grease to threaded internal parts of regulators that come standard with metal to metal diaphragm seals These models include the following regulator series 44 2300 44 2500 44 2900 and 44 4700
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