Emerson Tescom 04 series Setup guide

Safety, Installation, Operations & Service

TESCOM Product Manual

Operations & Service Manual

DOPMS2080X012

Rev. 06/15

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.

Rev. 06/15

Safety, Installation, Operations & Service Manual

DOPSM2080X012

Contents

Section 1: Symbols

1.1 Symbols.................................................................................................................................................3

Section 2:

Safety and Installation Precautions

2.1 Regulators and Valves......................................................................................................................3

Section 3: Operations and Service

3.1 Types of Regulators ..........................................................................................................................6

3.2 Pressure Reducing Regulators - Diaphragm-Sensed............................................................7

3.3 Pressure Reducing Regulators - Piston-Sensed................................................................... 10

3.4 Back Pressure Regulators - Diaphragm-Sensed................................................................... 13

3.5 Back Pressure Regulators - Piston-Sensed............................................................................. 15

3.6 Valves - TESCOM 30 Series........................................................................................................... 18

3.7 Valves - TESCOM VA, VG and VT Series.................................................................................... 19

Section 4: Limited Warranty

4.1 Limited Warranty ............................................................................................................................ 21

This manual is available in multiple languages online at www.tescom.com.

Section 1

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DOPSM2080X012

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.

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.

Possible consequences include but are not limited to:

• High velocity fluid (gas or liquid) discharge

• Parts ejected at high speed

• Contact with fluids that may be hot, cold, toxic, or otherwise injurious

• Explosion or burning of the fluid

• Lines/hoses whipping dangerously

• Damage or destruction to other components or equipment in the system

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.

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3. 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.

4. 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.

5. Remove pressure from the system before tightening fittings, gauges or components.

6. Never turn regulator or valve body. Instead hold regulator or valve body and turn

fitting nut.

7. If a regulator or valve leaks or malfunctions, take it out of service immediately.

8. Do not modify equipment or add attachments not approved by the manufacturer.

9. Apply pressure to the system gradually, avoiding a sudden surge of fluid or pressure

shock to the equipment in the system.

10. 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.

11. Periodic inspection and scheduled maintenance of your equipment is required for

continued safe operation.

12. The frequency of servicing is the responsibility of the user based on the application.

13. 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.

14. Never allow problems or lack of maintenance to go unreported.

15. Read and follow precautions on compressed gas cylinder labels.

16. 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 Safety Data Sheet (MSDS) for each fluid used in your system.

17. Never use materials for regulators, valves, or accessories that are not compatible with

the fluids being used.

18. Users must test components for material compatibility with the system operating

conditions prior to use in the system.

19. 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.

20. Do not locate regulators, valves, or accessories controlling flammable fluids near open

flames or any other source of ignition.

21. 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.

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22. Many gases can cause suffocation. Make certain the area is well ventilated. Provide a

device to warn personnel of lack of Oxygen.

23. Never use oil or grease on these regulators, valves, or accessories unless recommended

as specified in Operations and Service procedures. Oil and grease are easily ignited and

may combine violently with some fluids under pressure.

24. Have emergency equipment in the area if toxic or flammable fluids are used.

25. Upstream filters are recommended for use with all fluids.

26. Do not bleed system by loosening fittings.

27. Prevent icing of the equipment by removing excess moisture from the gas.

28. Always use proper thread lubricants and sealants on tapered pipe threads.

2.1.1 Installation

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.

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.

2.1.2 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 make 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.

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.

3. TESCOM may suggest material for use with specific media upon request.

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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.

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

ASSEMBLY/INSTALLATION DRAWINGS & BILLS OF MATERIAL drawings and parts 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.

3.1 Types of Regulators

Diaphragm-Sensed - Pressure Reducing Regulators

By Series

• 04

• 12

• 15

• 26-1100

• 26-1200

• 26-1500

• 26-1600

• 22-2200

• 22-5400

• 23

• 44-2200

• 44-2600

• 44-2800

• 44-3200

• 44-3400

• 44-4600

• 44-5000

• 44-5800

• 449-254

• 64-2600

• 64-2800

• 64-3200

• 64-3400

• 64-3600

• 64-5000

• 64-5400

• 74-2400

• 74-3000

• 74-3800

• DA

• DG

• DH

• DH-16

• DK

• FR-2000

• PH-1800

• PH-2200

• PH-2600

• PH-3200

• PS3400

• SG1, SG2, SG3

Diaphragm-Sensed - Back Pressure Regulators

By Series

• 26-2300

• 26-2500

• 26-2700

• 26-2900

• 44-2300

• 44-2500

• 44-4700

• DV

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Piston-Sensed - Pressure Reducing Regulators

By Series

• 20-1000

• 20-1100

• 20-1200

• 26-1000

• 26-2000

• 44-1100

• 44-1300

• 44-1500

• 44-1800

• 44-4000

• 44-4200

• 44-5200

• 44-7400

• 50-2000

• 50-2200

• 50-4000

• 50-4100

• 54-2000

• 54-2200

• 54-2800

• 56-2000

• BB-1

• CP3200

Piston-Sensed - Back Pressure Regulators

By Series

• 26-1700

• 44-1700

• 44-5500

• 44-2900

• 54-2100

• 54-2300

• 54-2700

• 54-3500

• BB-3

3.2 Pressure Reducing Regulators - Diaphragm-

Sensed

3.2.1 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.

3.2.2 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.

3.2.3 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 designed to

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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 regulator 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.

3.2.4 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 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.

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 or

hold with pliers. Clamping should be done on flats.

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Care must be used to not damage valve.

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.

3.2.5 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.

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: 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 control 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.

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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.

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.

3.3 Pressure Reducing Regulators - Piston-Sensed

3.3.1 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.

3.3.2 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.

3.3.3 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 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.

Section 3

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A regulator 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.

3.3.4 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 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.

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.

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.

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Care must be used 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.

3.3.5 Reassembly