Emerson TESCOM Setup guide

This manual is available in multiple languages online at www.Emerson.com/Tescom
Do not attempt to select, install,
use or maintain this product until
you have read and fully understood
this manual.
Installation Manual
TR000238ENUS-01_12-20
December 2020
TESCOM™
Safety, Installation, Operations & Service Manual
Installation Manual

2TESCOM™ Safety, Installation, Operations & Service Manual
Content
December 2020
Installation Manual
TR000238ENUS-01_12-20

3
Installation Manual
Content
December 2020
Installation Manual
TR000238ENUS-01_12-20
Contents
Chapter 1
Chapter 2
Chapter 3
Chapter 4
1. Symbols.....................................................................................................................4
1.1Symbols.............................................................................................................................4
2. Safety and Installation Precautions............................................................................4
2.1 Regulators and Valves........................................................................................................4
2.1.1 Intended Use............................................................................................................6
2.1.2Installation................................................................................................................6
2.1.3RepairService............................................................................................................7
3.Operationsandservice................................................................................................8
3.1 Pressure Reducing Regulators - Diaphragm - Sensed..........................................................8
3.1.1 General.....................................................................................................................8
3.1.2 Pressure Activation Methods.....................................................................................8
3.1.3 Operation (Control Knob Adjustment)......................................................................9
3.1.4 Maintenance.............................................................................................................9
3.1.5 Reassembly.............................................................................................................10
3.2 Pressure Reducing Regulators - Piston-Sensed.................................................................11
3.2.1 General...................................................................................................................11
3.2.2 Pressure Activation Methods...................................................................................11
3.2.3 Operation (Control Knob Adjustment)....................................................................12
3.2.4 Maintenance...........................................................................................................12
3.2.5 Reassembly.............................................................................................................13
3.3 Back Pressure Regulators - Diaphragm-Sensed.................................................................14
3.3.1 General...................................................................................................................14
3.3.2 Pressure Activation Methods...................................................................................14
3.3.3 Operation (Control Knob Adjustment)....................................................................15
3.3.4 Maintenance...........................................................................................................15
3.3.5 Reassembly.............................................................................................................16
3.4 Back Pressure Regulators - Piston-Sensed.........................................................................16
3.4.1 General...................................................................................................................16
3.4.2 Pressure Activation Methods...................................................................................17
3.4.3 Operation (Control Knob Adjustment)....................................................................17
3.4.4 Maintenance...........................................................................................................17
3.4.5 Reassembly.............................................................................................................18
3.5 Valves - TESCOM Multi-Turn and Metering Valves.............................................................19
3.5.1 General...................................................................................................................19
3.5.2 Actuation Types......................................................................................................19
3.5.3 Operation (Control Knob Adjustment)....................................................................19
3.5.4 Maintenance...........................................................................................................19
3.5.5 Reassembly.............................................................................................................20
3.6 Valves - TESCOM On-Off and Diverting Valves..................................................................21
3.6.1 General...................................................................................................................21
3.6.2 Actuation Types......................................................................................................21
3.6.3 Operation (Control Knob Adjustment)....................................................................21
3.6.4 Maintenance...........................................................................................................21
3.6.5 Reassembly.............................................................................................................22
4. Limited Warranty.....................................................................................................23

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1Symbols
Symbols
CAUTION
Paragraphs highlighted by the CAUTION icon contain information that must be followed to
maintain a safe and successful operating environment.
WARNING
Paragraphs highlighted by the WARNING icon contain information about practices or
circumstances that can lead to personal injury or death, property damage or economic
loss.
Safety and Installation Precautions
Regulators and Valves
WARNING
Do not attempt to select, install, use, or maintain this regulator, valve, or accessory until
you have read and fully understood these instructions.
Be sure this information reaches the operator and stays with the product after installation.
The appliance may only be used for its intended purpose as described in these instructions
for use (see Section “Intended Purpose”).
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uid(gasorliquid)discharge
•Parts ejected at high speed
• Contactwithuidsthatmaybehot,cold,toxicorotherwiseinjurious
• Explosionorburningoftheuid
•Lines/hoses whipping dangerously
•Damage or destruction to other components or equipment in the system
2
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1.1

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CAUTION
Safety Precautions
•Inspect the regulator, valve, and accessories before each use.
•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.
•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ttings,gaugesorcomponents.
•Never turn regulator or valve body. Instead hold regulator or valve body and turn
tting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.
•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
SafetyDataSheet(SDS)foreachuidusedinyoursystem.
•Never use materials for regulators, valves, or accessories that are not compatible with
theuidsbeingused.
•Users must test components for material compatibility with the system operating
conditions prior to use in the system.
•Ventuids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ammableuidsnearopen
amesoranyothersourceofignition.
•Avoid subjecting the regulator/valve to sudden impact, jolts, falls, and vibrations.
•Unit should be stored in a dry, environmental controlled location before installation
and use.

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•Someuidswhenburningdonotexhibitavisibleame.Useextremecaution
wheninspectingand/orservicingsystemsusingammableuidstoavoiddeathor
serious injury to personnel. Provide a device to warn personnel of these dangerous
conditions.
•Many gases can cause suffocation. Make certain the area is well ventilated. Provide a
device to warn personnel of lack of Oxygen.
•Never use oil or grease on these regulators, valves, or accessories unless
recommendedasspeciedinOperationsandServiceprocedures.Oilandgreaseare
easilyignitedandmaycombineviolentlywithsomeuidsunderpressure.
•Haveemergencyequipmentintheareaiftoxicorammableuidsareused.
•Upstream filters are recommended for use with all fluids.
•Donotbleedsystembylooseningttings.
•Prevent icing of the equipment by removing excess moisture from the gas.
•Always use proper thread lubricants and sealants on tapered pipe threads.
Intended Use
Regulators: Pressure regulators are intended to be used to regulate the pressure at which
uidsareadministeredinanapplication.Additionalregulationsthatsupplementorlimit
theintendedusemayapplydependingontheregulatorandmediaorindustry-specic
standards. Regulators are not intended for use as a pressure or safety relief valve.
Valves:TESCOMValvesareintendedtobeusedtocontrolgasowinpipedsystems.They
are not intended for use as a pressure reducer.
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,VericationType1,Test1andTest2.
WithperiodicvericationofcleaningprocesstoMIL-STD-1330D.
WARNING
Makesurethatthecomponentsandmaterialsusedintheuidhandlingsystemare
compatiblewiththeuid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.
2.1.1
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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qualied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specications,ifrepairable.Thereareatfee
repair charges for each standard model. The original equipment warranty applies after a
complete overhaul.
CAUTION
Proper component selection:
•Consider the total system design when selecting a component for use in a system.
•The user is responsible for assuring all safety and warning requirements of the
application are met through his/her own analysis and testing.
•TESCOMmaysuggestmaterialforusewithspecicmediauponrequest.
TESCOM does NOTguaranteematerialstobecompatiblewithspecicmedia--This is
the responsibility of the user!
•Component function, adequate ratings, proper installation, operation, and
maintenance are the responsibilities of the system user.
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.
2.1.3

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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 12 for contact information for the TESCOM
location closest to you.
Stem seal leakage usually results from seal wear, and can usually be corrected by
tightening the bonnet bushing or packing nut. Overtightening can cause high stem
friction, accelerated wear and shortened stem seal life.
WARNING
Information detailed here is generic and applies to a select subset of TESCOM regulators
andvalves.SomeTESCOMproductshavedetailed,product-specicInstallation,
Operations and Service manuals. Please look up the corresponding manual for your
product series on Emerson.com to ensure you are using the appropriate installation &
operations instructions.
Pressure Reducing Regulators -
Diaphragm - Sensed
General
TESCOM’sdiaphragmsensedpressurereducingregulatorsarespecicallyengineeredfor
applications requiring dependable pressure regulation. These regulators are especially
ppropriate 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.
3
3.1
3.1.1
3.1.2

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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/modicationscomewithaninternallter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.
WARNING
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 regulatorto do so can result in death, serious injury, and/or
property damage.
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 last page 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ats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rstRemoveupperportionofregulator(bonnet
and/ordome).Somemodelsrequirethemountingbrackettoberemovedrst.
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.
3.1.3
3.1.4

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NOTE: Two-stage regulators 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.
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 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ats.
CAUTION
Care must be used to not damage valve.
WARNING
SeveralTESCOMregulatorsaresuppliedwithinternallters.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specications:
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owstreammustbefreeof
particles which could prevent proper seating of the main valve.
3. Applyathinuniformcoatingofuorocarbon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.
WARNING
Do not apply any type of grease to threaded internal parts of regulators that come
standard with metal to metal diaphragm seals. Regulators with metal to metal diaphragm
seals have Metal listed as the diaphragm material on their installation drawing.
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rmly–handtight.Regulatorshouldthenbeplacedin
viseandbonnetre-torquedtocorrectspecications.SeeAssemblyDrawing.
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6. Dome/Combination Spring and Dome Loaded Regulators are more easily
reassembledbyholdingregulatorrmlyinviseandreinstallingdome.
7. Self-Venting Regulator - If your regulator has an adjustable relief valve mechanism, it
issetonnal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 clockwise vent adjusting screw (located under hole plug) until
media can be heard escaping through vent valve.
Step 4. Turnscrewcounterclockwiseuntilmediaowstops,plus1/2turn.
Replace hole plug.
8. Reinstallingwiremeshinletlter:Insertlterintoprimaryinletport.Itthenmust
beexpandedtotcorrectly.Thiscanbeaccomplishedbyinsertingametaltoolthe
same size as the port and then lightly tapping it with a hammer.
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specically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 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.
3.2.1
3.2.2
3.2

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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/modicationscomewithaninternallterthatonlyare
designed to stop random contamination resulting from the installation of the regulator.
Anauxiliaryupstreamlter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ow
rates.
WARNING
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.
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 last page 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ats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rst.
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 regulators 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.
3.2.3
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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.
CAUTION
Some TESCOM models have valve parts that 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ats.
CAUTION
Care must be used to not damage valve. Special service tools may be available to aid in
the disassembly of the main valve assembly in certain models. Please contact your local
TESCOM representative to learn more.
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specications:
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owstreammustbefreeof
particles which could prevent proper seating of the main valve.
3. Applyathinuniformcoatingofuorocarbon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.
5. Valve seats must be installed with the chamfered side towards the main valve.
6. Standard Regulator 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rmly,hand
tight.
Regulator should then be placed in vise and bonnet re-torqued to correct
specications.SeeAssemblyDrawing.
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7. Dome/Spring Combination and Dome Loaded Regulators are more easily
reassembledbyholdingregulatorrmlyinviseandreinstallingdome.
8. Self-Venting Regulator - If your regulator has an adjustable vent valve mechanism, it is
setonnal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Turnscrewcounter-clockwiseuntilmediaowstops,plus1/2turn.
Replace hole plug.
9. Reinstallingwiremeshinletlter-Insertlterintoprimaryinletport.Itmustthen
beexpandedtotcorrectly.Thiscanbeaccomplishedbyinsertingametaltoolthe
same size as the port and then lightly tapping it with a hammer.
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specically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 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.
3.3.1
3.3.2
3.3

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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/modicationscomewithaninternallterdesignedto
stop random contamination resulting from the installation of the regulator. An auxiliary
upstreamlter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owrates.
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 last page 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ats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rst.
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 body 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ats.
CAUTION
Care must be used to not damage valve.
3.3.3
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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specications.
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owstreammustbefreeof
particles which could prevent proper seating of the main valve.
3. Applyathinuniformcoatingofuorocarbon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.
WARNING
Do not apply any type of grease to threaded internal parts of regulators that come
standard with metal to metal diaphragm seals. Regulators with metal to metal diaphragm
seals have Metal listed as the diaphragm material on their installation drawing.
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rmly–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rmly-
hand tight. Regulator should then be placed in vise and bonnet re-torqued to correct
specications.SeeAssemblyDrawing.
6. Dome/Combination Spring and Dome Loaded Regulators are more easily
reassembledbyholdingregulatorrmly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specically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
20,000 psi.
3.3.5
3.4.1
3.4

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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.
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 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/modicationscomewithaninternallterthatonlyare
designed to stop random contamination resulting from the installation of the regulator.
Anauxiliaryupstreamlter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ow
rates.
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 last page for TESCOM contact
information).
3.4.2
3.4.3
3.4.4

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The following steps outline the disassembly of back pressure regulators for maintenance
and repair:
1. Clamptheregulatorinavisebytheats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rst.
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ats.
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specications.
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owstreammustbefreeof
particles which could prevent proper seating of the main valve.
3. Applyathinuniformcoatingofuorocarbon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rmly,
hand tight. Regulator should then be placed in vise and bonnet re-torqued to correct
specications.SeeAssemblyDrawing.
6. Dome/Spring combination and Dome Loaded regulators are more easily reassembled
byholdingregulatorrmlyinviseandreinstallingdome.
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3.5.1
3.5.2
3.5.3
3.5.4
7. Reinstallingwiremeshinletlter-Insertlterintoprimaryinletport.Itmustthenbe
expandedtotcorrectly.Thiscanbeaccomplishedbyinsertingametaltoolthesame
size as the port and then lightly tapping it with a hammer
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.
Valves - TESCOM Multi-Turn
and Metering Valves
General
TESCOMMulti-TurnandMeteringValvesarespecically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 (Control Knob Adjustment)
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
materials.Alter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ow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 last page for TESCOM contact
information).
3.5

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The following steps outline the disassembly of the Multi-Turn and Metering Valves 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ats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. Please check
your assembly drawing to verify.
CAUTION
Care must be used to not damage sealing components.
Reassembly
The valve is reassembled in the reverse order of disassembly, observing the following
precautions.
Please reference Bill of Materials and Assembly Drawing for the correct location of the
replacementpartsandcorrecttorquespecications.
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thevalvewillbeusedin.Allpartsintheowstreammustbe
free of particles which could prevent proper seating on the valve stem.
3. Applyathinuniformcoatingofuorocarbongreasetothefollowingparts:threaded
portion of the adjusting screw, the lower part of the threaded area of the stem
retainer, 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specications.SeeAssemblyDrawing.
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.
3.5.5