Pressure Tech LW-TS414 Series Service manual

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THE LW-TS414 SERIES
Operating and Service Manual
Series includes all variants of LW-TS414
Issue A
Feb 2023

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TABLE OF CONTENTS
1. Description.............................................................................................................................3
2. Installation .............................................................................................................................3
3. Operation...............................................................................................................................4
4. Special Conditions for Safe Use .............................................................................................4
5. Hazardous Location Usage.....................................................................................................4
6. Servicing and Maintenance....................................................................................................5
6.1. Servicing the LW-TS414 ..........................................................................................6
6.1.1. Accessing the Main Valve Assembly 1st Stage ....................................................6
6.1.2. Accessing the Main Valve Assembly 2nd Stage....................................................7
6.1.3. Re-setting the First Stage....................................................................................8
6.1.4. Adjusting the Set Point .......................................................................................9
6.1.5. Figure 1 –Sectional View of the LW-TS414 ......................................................10
7. Technical Data......................................................................................................................11
8. Warranty Statement ............................................................................................................11

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1. Description
The LW-TS414 is a lightweight, two-stage piston-sensed regulator, providing stable pressure
control under decaying inlet conditions, capable of a maximum 414bar inlet pressure
(300bar with PCTFE seat), which can then be reduced down to a maximum 12bar outlet
pressure.
Its ‘solid disk’ seat design is more robust for aggressive or high temperature applications,
offering users an extended life cycle.”
2. Installation
Important: Please note that this pressure regulator is supplied as a ‘pressure accessory’ and
not a ‘safety accessory’. As such a suitably sized pressure relief device is recommended on
both the inter-stage port (RLF Port) and downstream of the LW-TS414.
Before system start-up, it is recommended that all systems be pressure tested, leak tested
and purged with an inert gas such as nitrogen.
Prior to placing into service ensure that the regulator is in the fully closed position, with the
adjusting mechanism turned completely anti-clockwise.
Check the model number reference to ensure that the pressure range complies with the
installation requirements.
Visually inspect the regulator for any signs of damage or contamination. If any foreign
materials are present and cannot be removed from the regulator, or if the threads on the
regulator appear to be damaged, please contact the office immediately to arrange for the
regulator to be returned for service.
The Inlet and Outlet ports are clearly marked. Select the correct size and type of connection
fittings for these ports which are indicated in the regulators part number. National Pipe
Thread (NPT) ‘N’ options are available as standard on this regulator. For NPT threads, ensure
that PTFE tape is applied correctly to the fittings, applying two overlapping layers in the
direction of the thread, taking care that the tape does not come into contact with the first
thread. Any gauge ports on the regulator will be 1/4” NPT unless otherwise stated. If any
gauge port is not required, ensure that the port is plugged prior to installation.
The media supplied to the regulator must be clean. Contamination can damage the seat
which may cause the regulator to fail. Filtration suited to the application is recommended
upstream of the regulator. Should further assistance or information be required in relation
to installation of any Pressure Tech regulator please contact the office, giving reference to
the regulators part number and/or serial number.

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3. Operation
The first stage of the regulator is pre-set at the factory and locked to prevent alteration. The
second stage of the regulator, with a PCTFE seat as standard, can be adjusted by the user
between various outlet pressures with the selected range. The first pressure reduction acts
as the supply to the second stage. As a result, the LW-TS414 regulator is able to provide a
stable pressure control under decaying inlet conditions.
To reduce the outlet pressure, the adjusting mechanism should be turned anti-clockwise
whilst the media is flowing, or whist venting downstream of the regulator.
The desired outlet pressure should be set whilst increasing the pressure. Do not exceed the
maximum inlet and outlet pressures of the regulator which are indicated on the regulator
label.
4. Special Conditions for Safe Use
The LW-TS414 series are non-venting type regulators, therefore the outlet pressure shall be
reduced by venting downstream of the regulator whilst simultaneously turning the adjusting
mechanism anti-clockwise.
Periodic inspection and scheduled maintenance of your equipment is required for continued
safe operation.
Note: The frequency of servicing is the responsibility of the user based on the application.
5. Hazardous Location Usage
This equipment has not been manufactured specifically for use in potentially explosive
atmospheres and as such an ignition hazard assessment has not been carried out on this
product. If the user should wish to use this product in such an environment where there
may be a potentially explosive atmosphere then it is the responsibility of the user to
conduct an ignition hazard assessment against 99/92/EC.

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6. Servicing and Maintenance
Servicing and maintenance work on the LW-TS414 regulators should only be performed
after fully reading and understanding the Operating and Servicing Manual. Due to the
compressibility of gases, the operator should not endanger themselves or others by working
on this regulator without prior knowledge of the Health and Safety risks relating to handling
of technical gases. Any uncertainty should be clarified with Pressure Tech before working on
the regulator.
Pressure Tech Ltd recommends the use of Krytox GPL 205 as a lubricant (or equivalent) for
O-rings and the Adjusting Screw during servicing.
Prior to commencing service, please ensure that:
-The equipment has been de-pressurised
-The load spring has been de-compressed by turning the actuator fully anti-clockwise
-Applications involving toxic, flammable or corrosive media have been fully purged
-Ensure that the service engineer has the relevant Service Repair Kit (SRK) for the
regulator type that they will be servicing.
To ensure the best possible results from servicing, when re-assembling the regulator and
any assemblies within it, ensure that all areas of the components and the regulator body are
cleaned and free from contaminants which may result in failure of the regulator.
It is recommended that all parts in the repair kits are used. Any defect parts removed during
the service should be disposed of.

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6.1. Servicing the LW-TS414
*NOTE: Fig 1 should be used as a reference for the following set of instructions
6.1.1. Accessing the Main Valve Assembly 1st Stage
Please be aware that the first stage let down pressure will require re-setting after service.
To access the Main Valve Assembly (MVA):
i. With the flats of the regulator body (17) secured in a vice*, use a 13mm open
ended spanner to remove the dome nut (22).
*NOTE: Soft vice jaws must be used, when securing the body within the vice
against flats. Due to the position of the flats, it may be necessary to angle the
body in the vice with the 1st stage facing upright for access.
ii. Using a slotted screwdriver, turn the short adjusting screw (11) anti clockwise
until the load from the spring (9) has been released.
iii. Loosen and remove the 1st stage bonnet (13) using a 27mm open ended wrench.
iv. Remove the upper spring rest (16) and load spring (9) from the assembly.
v. Remove the sensor (14) (inclusive of O-ring 5), by using pliers to grip the flats of
the sensor and lift from the assembly.
vi. Remove/replace the O-ring (5) from around the sensor (14), ensuring that
adequate lubrication is used.
vii. The seat retainer (8) can then be removed using a 12mm socket.
viii. Remove the soft seat* (15) and O-ring (4).
*NOTE: inspect the sealing face of the soft seat, for any potential damage and
replace where necessary.
ix. Remove the main valve* (6) and main valve spring (7) from the assembly.
*NOTE: inspect the sealing cone face of the main valve, for any potential damage
and replace where necessary.
Re-assembly
x. Place the main valve spring (7) over the lower stem main valve (6) and place both
parts into the regulator body (17)
xi. Place the O-ring (4) into regulator body (17).
xii. Guide the soft seat* (15) over the upper stem of the main valve (6) and into the
regulator body (17), ensuring that the O-ring (4) is seated into the O-ring groove
of the soft seat (15).
*NOTE: Taking care not to damage its sealing face against the tip of the valve.
xiii. Guide the seat retainer (8), over the upper stem of the main valve (6) and
screw/tighten into the regulator body (17), using a 12mm socket and torque to
17Nm.
xiv. Place the sensor (14) (inclusive of O-ring 5), into the regulator body (17).
xv. Place the load spring (9) onto the sensor (14) and place the upper spring rest (16)
onto the top of the load spring (9).
xvi. Screw the 1st stage bonnet (13) onto the assembly and using a torque wrench
with a 27mm open ended attachment, tighten to 20Nm.

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*Note: The first stage will now require pressure setting before the regulator can be used
(*Ref. 6.1.3).
6.1.2. Accessing the Main Valve Assembly 2nd Stage
To access the Main Valve Assembly (MVA):
i. With the flats of the regulator body (17) secured in a vice*, use a 13mm open
ended spanner to loosen/remove the lock nut (10).
*NOTE: Soft vice jaws must be used, when securing the body within the vice
against flats. Due to the position of the flats it may be necessary to angle the
body in the vice with the 2nd stage facing upright for access.
ii. Using a slotted screwdriver, turn the short adjusting screw (11) anti clockwise
until the load from the spring (9) has been released.
iii. Loosen and remove the 2nd stage bonnet (13) using a 27mm open ended wrench.
iv. Remove the upper spring rest (12) and load spring (20) from the assembly.
v. Remove the sensor (14) (inclusive of O-ring 5), by using pliers to grip the flats of
the sensor and lift from the assembly.
vi. Remove/replace the O-ring (5) from around the sensor (14), ensuring that
adequate lubrication is used.
vii. The seat retainer (8) can then be removed using a 12mm socket.
viii. Remove the soft seat* (15) and O-ring (4).
*NOTE: inspect the sealing face of the soft seat, for any potential damage and
replace where necessary.
ix. Remove the main valve* (6) and main valve spring (7) from the assembly.
*NOTE: inspect the sealing cone face of the main valve, for any potential damage
and replace where necessary.
Re-assembly
i. Place the main valve spring (7) over the lower stem main valve (6) and place both
parts into the regulator body (17)
ii. Place the O-ring (4) into regulator body (17).
iii. Guide the soft seat* (15) over the upper stem of the main valve (6) and into the
regulator body (17), ensuring that the O-ring (4) is seated into the O-ring groove
of the soft seat (15).
*NOTE: Taking care not to damage its sealing face against the tip of the valve.
iv. Guide the seat retainer (8), over the upper stem of the main valve (6) and
screw/tighten into the regulator body (17), using a 12mm socket and torque to
17Nm.
v. Place the sensor (14) (inclusive of O-ring 5), into the regulator body (17).
vi. Place the load spring (20) onto the sensor (14) and place the upper spring rest
(12) onto the top of the load spring (20).
vii. Screw the 2nd stage bonnet (13) onto the assembly and using a torque wrench
with a 27mm open ended attachment, tighten to 20Nm.
*NOTE: The first stage will now require pressure setting before the regulator can be used
(*Ref. 6.1.3)

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Following re-assembly of the regulator, pressure tests should be made to both the inlet and
outlet side of the regulator, to ensure there is no internal or external leakage across the
regulator.
To ensure that the main valve assembly has been correctly and effectively installed it may
be required to perform the appropriate seat leak test as per ANSI/FCI 70-3.
6.1.3. Re-setting the First Stage
The following instruction should only be performed after complete reassembly of the
regulator as per 6.1.1 and 6.1.2.
i. Secure the regulator firmly in a vice* and install correct fittings to the regulator
inlet port and inter-stage port (relief port).
*NOTE: Soft vice jaws must be used, when securing the body within the vice
against flats. Due to the position of the flats, it may be necessary to angle the
body in the vice with the 1st stage facing upright for access.
ii. Connect upstream pipe work and connect a suitable pressure gauge to the inter-
stage port.
iii. Remove the dome nut (22), using a 13mm spanner.
iv. Ensuring that the adjusting screw (11) of the first stage is completely wound off,
apply inlet pressure up to the maximum working pressure allowed by the seat
material (*Ref. Section 7.)
v. Use a slotted screwdriver to increase the outlet pressure of the first stage by
turning the short adjusting screw (11) (this will be seen on the pressure gauge via
the inter-stage port).
vi. For second stage pressure ranges <1 Bar, increase until ~12 Bar is achieved on
the first stage.
vii. When the pressure has been set, install the dome nut (22) onto the adjusting
screw (11) to lock and set.
viii. Isolate pressure supply to the regulator and then gradually deplete all the
pressure from the regulator.
ix. Ensure that the relief port is plugged using the hex hollow plug (21) after re-
setting.
Note: It is recommended that where possible, a pressure relief valve is installed in the relief
port. The relief valve should be set approximately 4 Bar higher than the set point of the first
stage. This relief valve would protect the second stage in the event of a potential seat failure.

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6.1.4. Adjusting the Set Point
Note: It is not recommended (or necessary) to remove the Hand Wheel during service as this
will affect the set point of the regulator. Should it be required to adjust the set point please
follow the instructions below:
i. Secure the regulator firmly in a vice* and install correct fittings to the regulator
inlet port and inter-stage port (relief port).
*NOTE: Soft vice jaws must be used, when securing the body within the vice
against flats. Due to the position of the flats, it may be necessary to angle the
body in the vice with the 2nd stage facing upright for access.
i. Loosen the lock nut (10) such that it is able to spin freely on the adjusting screw
(11).
ii. Connect the correct test fittings to the Inlet and Outlet ports of the regulator.
NOTE: Ensure that any gauge ports are plugged or that the correct gauge is
fitted.
iii. Gradually apply the Maximum Working Pressure (MWP) to the Inlet of the
regulator.
iv. Connect the outlet port to a calibrated pressure test gauge appropriate to the
required set pressure. As the regulator is non-venting, ensure that a ball/needle
valve is fitted to allow pressure to be relieved downstream of the regulator.
v. Using a slotted screwdriver, turn the adjusting screw (11) clockwise until the
desired set point has been reached.
vi. Ensure repeatability by allowing flow through the regulator using the
downstream ball/needle valve.
vii. With the outlet pressure set, screw the lock nut (10) to the base of the adjusting
screw (11) against the bonnet (13) and ensure that the lock nut (10) is sufficiently
tightened, taking care not to adjust the desired set point.
viii. If the set point is not correct, repeat steps v. to viii.
ix. Isolate the upstream pressure, then allow all the pressure to be depleted by
opening the downstream ball/needle valve until flow diminishes completely –
then the regulator can be removed from test set up.

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6.1.5. Figure 1 –Sectional View of the LW-TS414
© Copyright of Pressure Tech Ltd
PARTS LIST
ITEM
QTY
PART NUMBER
DESCRIPTION
1
1
FILT-SCRM7801040S
SCREEN FILTER - 8mm
2
1
FIT-472008-SS-CIRCLIP
INTERNAL CIRCLIP - 9mm
3
2
FIT-471009-SS-CIRCLIP
EXTERNAL CIRCLIP - 9mm
4
2
OR-0060-10
O' RING STD
5
2
OR-BS4518-0251-16
O' RING STD
6
2
PT-C-001-023
MAIN VALVE - SOLID
7
2
PT-C-006-002
MAIN VALVE SPRING
8
2
PT-C-007-015
SEAT RETAINER
9
1
PT-C-011-020
LOAD SPRING
10
1
PT-C-020-003
LOCKNUT
11
2
PT-LW-351-001
ADJUSTING SCREW
12
1
PT-LW-351-002
UPPER SPRING REST
13
2
PT-LW-351-003
LW351 BONNET
14
2
PT-LW-351-005
LW351 SENSOR - 28mm
15
2
PT-LW-351-006
PCTFE SEAT
16
1
PT-LW-351-009
UPPER SPRING REST
17
1
PT-LW-TS414-A-02B-X1
BODY
20
1
SPR-YCMS20-H4S17-X
LOAD SPRING
21
1
SLOK-SS-4-HP
HOLLOW HEX PLUG 1/4" NPT
22
1
PT-TS-300-004
DOME NUT

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7. Technical Data
Fluid Media: All gases and liquids compatible with materials of
construction
Max Inlet Pressure*: 300 bar (4350 Psi) (with PCTFE Seat)
414 bar (6,000 Psi) (with PEEK Seat)
Outlet Pressure Range: 0-1 bar
Operating Temperature: -20°C to +80°C
Materials: Body and Trim: Aluminum 6082
Seat: PCTFE
Flow Capacity (Cv): 0.06
Leakage: Gas: Bubble tight
Liquid: Zero drops of water at max inlet
*Max Inlet Pressure determined by seat material and Cv of regulator.
8. Warranty Statement
Pressure Tech Ltd guarantee all products correspond with their specification at the time of
delivery and, with exception to wear and tear, wilful damage, negligence, and abnormal
working conditions, will be free from defects for a period of 12 months from date of
delivery.
Pressure Tech (Head Office and Registered Office):
Unit 24 Graphite Way, Hadfield, Glossop, Derbyshire, SK13 1QH.
Telephone: [phone]
Email: [email protected]