FLOTEC INC

7625 West New York Street

Indianapolis, IN 46214-4911
317-273-6960
(Fax) 317-273-6979
E-mail: flotec@floteco2.com
Website: http://www.floteco2.com

Service Manual
Flopac

Regulator

Page 1 of 15
M-Service Manual FP.doc (03-06-07) Eng.

I. TOOLS, TEST EQUIPMENT AND SERVICE MATERIAL

A. TOOLS
B. TEST EQUIPMENT
C. SERVICE MATERIALS

II. SPECIFICATIONS

III. THEORY OF OPERATION

IV. DEFINITION OF STATEMENTS

V. PRODUCT CLASSIFICATION DATABASE

VI. INSTALLATION INSTRUCTIONS

VII. TORGUE SPECIFICATIONS

VIII. TRANSFILLING PROCEDURE

a. VENTING AND VACUUMING PROCEDURE
b. TRANSFILLING OXYGEN PROCEDURE

IX. SERVICE AND REPAIR

A. CLEANING, LUBRICATION AND SEALING

B. FLOPAC REGULATOR COMPONENTS:

1. INLET CONNECTIONS
a. REMOVABLE CGA 540 OR SPECIFIC GASES CHECK VALVE
b. TESTING CGA 540 OR SPECIFIC GASES CHECK VALVE
c. SERVICE CGA 540 OR SPECIFIC GASES CHECK VALVE
d. ASSEMBLY CGA 540 OR SPECIFIC GASES CHECK VALVE
e. INSTALLATION CGA 540 OR SPECIFIC GASES CHECK VALVE

2. SHUT-OFF VALVE
a. REMOVEL
b. SERVICE
c. INSTALLATION SHUT-OFF VALVE

3. DISS AUXILIARY OUTLETS

a. REMOVAL
b. SERVICE
c. INSTALLATION

4. INTERNAL CONTENTS GAUGE

a. RESETTING
b. MAINTENANCE

5. FLOWMETER

Page 2 of 15
 a. REMOVAL
b. SERVICE
c. INSTALLATION

6. FLOPAC CONNECTOR
a. REMOVAL
b. SERVICE
c. ASSEMBLY

7. BURST DISK
a. REMOVAL
b. SERVICE
c. INSTALLATION

8. PISTON-MANIFOLD SET
a. REMOVAL
b. SERVICE
c. INSTALLATION

9. HANDLE ASSEMBLY WITH FLANGE WASHER

a. REMOVAL
b. SERVICE
c. INSTALLATION HANDLE ASSEMBLY WITH FLANGE WASHER

X. TESTING
A. FLOPAC HIGH PRESSURE LEAK TEST PROCEDURE
B. FLOPAC OUTLET PRESSURE/ FLOW CALIBRATION PROCEDURE

XI. REPLACEMENT PARTS LIST FOR FP-XX-XXX-XXXXX

XII. TROUBLESHOOTING GUIDE

XIII. DRAWINGS:

a. FLOPAC PICTURE W/ ALL INTERNAL PARTS,

b. FLOPAC PICTURE IN POS. NO PRESSURE AND MODULATED FLOW, 05-02-06
c. FLOPAC REGULATOR WITH CYLINDER, , FPX-XXX-XX-XXXXX, REV “D”
d. ENGINEERING SPECIFICATION #FES04-016 REV. 4

Page 3 of 15
I. TOOLS, TEST EQUIPMENT AND SERVICE MATERIAL

A. TOOLS

Screwdriver - (1/4 in. (6 mm) flat blade

Screwdriver-No.2 Phillips
Notched Spanner Driver for screw size #10
Torque Wrench 0-150 in-lbs
Torque Wrench 0-50 Ft-lbs
Torque Wrench 0-70 Ft-lbs
Torque Wrench 0-150 Ft-lbs
Torque Screwdriver 0-12 in-lbs
Open end wrenches – 7/16 in, 9/16 in, 5/8 in, 11/16 in
Open end ½” drive 1 7/16” Crowfoot Wrench for torque Flopac connector
Open end 3/8” drive 9/16” Crowfoot Wrench for pre-set Flopac Handle
Adjustable Wrench-10 in (25) cm
Hex key Wrench-1/16”
Internal retaining ring pliers
Punch-1/8 in (3mm)
Standard paper clip
Hammer
C-Clamp-3 in (8cm)
Dental Pick (or similar pointed instrument)
Pins dia: .173, .174, .175- for check Swivel body hole and dia .281, .282, .283- for check Connector’s On-off
valve hole.

B. TEST EQUIPMENT

Test Flowmeter FL-110, flow 0-100 ml/min, with an accuracy of + or – 2% if reading @ 70 degrees F (21
degrees C) and 14.7 psi (101 kPa)

Test Flowmeter FL-111, flow 0-626 cc/min

Mass Flowmeter FMA 1812, flow 0-500 ml/min
Mass Flowmeter BW509003, flow 0-10 lpm

Mass Flowmeter Omega # FMA1842, flow 0-100 lpm

Test Flowmeter Omega FL-1448C, flow 0-60 lpm

Test pressure gauge with a range of 0-100 psi (0-690 kPa) and accuracy in according to ASME 40.1-1998,
Grade “B”, permissible error (+/-% of span):
- lower ¼ of scale (0-25 psig) = +/- 3%;
- middle ½ of scale (25-75 psig) = +/-2%;
- upper ¼ of scale (75-100 psig) = +/- 3%.

Vacuum gauge with a range 0-30 in Hg vac.

Page 4 of 15
 Leak detector – Nupro “Snoop” or equivalent (oxygen compatible)

C. SERVICE MATERIALS
Krytox 240 AC Fluorinated Grease (DuPont)
Teflon tape – ¼ in (6mm)
Isopropyl alcohol
Cloth – lint free
Oxygen tubing – ¼ in (6mm) I.D.
Screw – 6-32 UNC
Service Instructions:
810-6554-061 Rev “E” – for Oxygen
810-6554-081 Rev “D”- for Heliox (80%% He & 20% Oxy.)
810-6571-071 Rev”A” – for Medical Air

II. SPECIFICATIONS

Flotec Flopac Regulators are small, lightweight devices that are available in a variety of configurations to meet the
various requirements for medical gas delivery. Flotec Flopac Regulators can be equipped with a 12 position, detented
flow control valve or a variety of designated inlet flow connectors. Units are also available with single or dual high flow
DISS outlets. Every Flopac Regulator design has an internal safety burst disk to prevent over-pressurization of the
Flopac Regulator. Both small cylinder and large cylinder inlet connections are available on all regulators. The following
instructions provide information to assist qualified personnel in the service and repair of Flotec Flopac Regulators. It is
recommended that the repair technician read this service and repairs instructions thoroughly before servicing Flotec
Flopac Regulators.

Storage Temperature: -40 degrees F to 140 degrees F

Operating Temperature: -20 degrees F to 150 degrees F
Materials: Brass, Bronze, Anodized Aluminum, Stainless Steel, Teflon, Viton, Neoprene, Silicone.
Filtration: 30 micron Sintered Cooper-Nickel Low Pressure filter
Supply Pressure Range: 250 to 3000 psi
Operating Pressure: 50 psi (17, 20, 24, 30, 40, 58, 70, 90, 110 PSI available upon request)
Relief Valve Pressure: 75 PSI or 95 PSI (for operating pressure 50 and 70 psi).
Inlet Connections: Any CGA inlet connection is available for specific gases and most International applications are
available upon request. Any CGA inlet connector must include a special Check Valve for venting- vacuuming and
transfilling Flopac cylinder.
Dimensions: Variable depending on type and style specified, as usual it is approximately 6.4” (and 5.3” after install into
cylinder). Handle has clearance 2.0”-2.3” above Flopac FM knob.

Flopac Regulator options:

FP1- Integral Shut Off Valve w/ Knurled Knob, Halo Handle Welded
FP3- Integral Shut Off Valve w/ Knurled Knob, Bent Handle
FP4- Integral Shut Off Valve w/ Knurled Knob, Halo Handle
FP5- Integral Shut Off Valve w/ Knurled Knob, Bent Handle, CGA 280 (Heliox)
FP6- Integral Shut Off Valve w/ Knurled Knob, Halo Handle, CGA 346 (Medical Air)
FP7- Integral Shut Off Valve w/ Knurled Knob, Halo Handle, ½-14 NGT (for steel cylinder)
FP8- Integral Shut Off Valve w/ Knurled Knob, Halo Handle Welded, ½-14 NGT (for steel cylinder)
FP9- Integral Shut Off Valve w/ Knurled Knob, Halo Handle Welded, External 1.4”, 3000 psi Gauge
FPA- Integral Shut Off Valve w/ Knurled Knob, Halo Handle Welded, ½-14 NGT, External 1.4”, 3000 psi Gauge
FPP- Integral Shut Off Valve w/ Knurled Knob, No Handle

Weight: Variable depending on type and style specified, but no more than 2.0 lbs w/out handle and approximately 2.5 lbs
with handle and protect s.s. ring.
Indicators: Cylinder Contents, Pressure Medical Gas Flow Rate

Page 5 of 15
 Power take off Outlet Connections: none, 1 or 2 of any combination of the following: DISS check valve, plugged 1/8”
FNPT ports.
Flowmeter Outlet Connection: DISS fitting or Hose Barb

III. THEORY OF OPERATION

The Flotec Flopac Regulator is a single stage piston-type regulator. When it is initially attached to a high-pressure gas
cylinder, the internal components are in the position shown in enclosed drawings. When the Flopac “On-Off valve” is
closed, the spring exerts force against the piston assembly and pushes the piston assembly away from the regulator seat.

When the Flopac “On-Off valve” is opened, high-pressure medical gas (approximately 2000-2200 psi for a full cylinder)
passes through special flow- hole into the Flopac connector and flows through the seat. The gas then flows through the
shaft of the piston and exits to the regulated output cavity.

The gas continues to flow into this area until the cavity builds enough pressure to overcome the force of the spring,
which occurs at 50 psi. The piston assembly then moves toward the seat and the seal blocks the flow path and prevents
the pressure from rising above 50psi. This all occurs in a fraction of a second. When gas is let out of the output cavity
through the flow-controlling device, the pressure in the cavity drops. The spring then pushes the piston assembly away
from the seat to allow the oxygen or specific gases to restore the pressure to 50 psi and deliver the flow through the flow-
controlling device at the prescribed rate. This too happens in a fraction of a second.

In the unlikely event that the Flopac Regulator does not regulate properly and should the internal pressure rise above ( 75
psi or 95 PSI) the relief valve will unseat and safely release gas through the vent holes in the side of the swivel body.

NOTE The Flotec Flopac Regulator adjustable flow regulator is shown in enclosed drawings. The internal Flopac
Regulator components are common to all Flotec Ingage™ Regulators and Pressure Reducers.

IV. DEFINITION OF STATEMENTS

Statements in this manual proceeded by the following words are of special significance.

WARNING means there is the possibility of injury or death to you or others.

CAUTION means there is the possibility of damage to the unit or other property.

NOTE indicates points of particular interest for more efficient and convenient operation.

Always disassemble, inspect, clean and repair regulator components in accordance with these instructions. Be aware of
all the potential hazards associated with handling and using high-pressure gas equipment. Also, be aware that the
possibility of fire exists when the combination of a combustible material, a source of ignition and oxygen is present
(Called the Fire Triangle).

WARNING Replacement of parts on high-pressure Flopac regulators should be made only by qualified personnel
familiar with their operation. Do no remove or install parts with the Flopac regulator installed on a cylinder. Always
verify that oxygen or specific gases in cylinder is empty before disconnecting the regulator from the cylinder. Use
only the proper repair tools and parts. Always wear eye protection when servicing high-pressure regulators.

Page 6 of 15
 WARNING Contaminants or hydrocarbons may, in the presence of an ignition source and oxygen or specific gases may
combine and burn violently. Never permit oil, grease or other combustible substances to come in contact with oxygen
cylinders, regulator parts or repair tools. Provide a clean; oil free surface on which to place disassembled regulator parts.

WARNING Always open high-pressure Flopac “Shut-Off valve” SLOWLY. This should always be done in order to
allow the heat of gas compression to dissipate. Always verify that oxygen or specific gases in cylinder is exactly empty
before disconnecting the regulator from the cylinder. Check it! Open Flopac “Shut-off valve”, briefly rotate Flopac flow
selector knob to max rate position while verifying flow is existing from outlet port. Gently depress DISS-1240 Check-
Valve (if equipped) to re-ensure all remaining regulator internal residual pressure has been evacuated.

WARNING Do not obstruct the vent holes in the swivel body of the Flopac Regulator. These holes must be open to
atmosphere for proper regulator operation.

V. PRODUCT CLASSIFICATION DATABASE

FDA 21 Classification

Device- Regulator, Pressure, Gas Cylinder

Device Description- Pressure regulator
Medical Specialty Anesthesiology
Product Code CAN
Regulation Number FDA #868.2700
Device Class 1
GMP Exempt? No
510(k) Exempt? Yes

European Commision Meddev 2.4/1 Rev 8 Part 2 Rule 11 – Active devices to administer, remove medicines and
other substances to or from body, or Directive 93/42/EEC – Class 2B – Pressure regulator for medical gases.

Health Canada CAN/CSA-Z305 87M- Medical Devices Regulations Classification Rules for Medical devices, Part 1,
Rule 9- Active devices to administer or withdraw energy to or from the body- Class 2 – Medical Pressure regulator.

VI. INSTALLATION INSTRUCTIONS

See Install Instructions provided with each Flopac Regulator of the Flotec Engineering Specification #FES04-016 Rev 4.

VII. TORQUE SPECIFICATIONS

See Engineering Torque Specifications for different modifications of the Flopac Regulators FES04-016 Rev “4”.

VIII. TRANSFILLING PROCEDURE

a. VENTING AND VACUUMING PROCEDURE

See Flopac Transfilling procedure Instruction, part A. of the Flotec Engineering Specification #FES04-016 Rev 4.

b. TRANSFILLING OXYGEN PROCEDURE

See Flopac Transfilling procedure Instruction, part B. of the Flotec Engineering Specification #FES04-016 Rev 4.

IX. SERVICE AND REPAIR

NOTE Always perform the Flopac Regulator test procedures in this manual before placing a repaired Flopac Regulator
back in service.

NOTE Refer to the Parts List and Parts Illustration for identification of parts referenced with bold numbers.

Page 7 of 15
A. CLEANING, LUBRICATION AND SEALING

Clean metal parts of the Flopac Regulator with isopropyl alcohol and thoroughly blow dry with dry, oil free
compressed gas. Use a mild solution of soap and water to clean plastic parts. Use a clean lint free cloth with
isopropyl alcohol to clean internal parts, being certain to remove any residual fibers.

O-ring seals that have been cleaned or are new replacements should be lubricated with a film of KRYTOX 240AC
Fluorinated Grease.

Whenever pipe threaded (NPT) connections must be disassembled, reseal the threads with Teflon tape. When
applying teflon tape remove old sealant from the male and female threads and wrap the male threads with Teflon
tape in a clockwise direction, starting 1 to 2 threads back from the end.

B. FLOPAC REGULATOR COMPONENTS:

1. INLET CONNECTIONS
a. REMOVABLE CGA 540 (003-3000-452) OR SPECIFIC GASES CHECK VALVE (003-3000-453; -454)
1. Using “1” socket wrench remove the Flopac CGA 540 or specific gases Check valve Assembly from
Flopac Connector 9/16-18 UNF-2A female port.

b. TESTING CGA 540 (003-3000-452) OR SPECIFIC GASES CHECK VALVE (003-3000-453 or

003-3000-454)
1. Testing Check valve for leaking on the Special Flopac Test station for 2000 psi Oxygen. Repeat this
test 2-3 times by pressurizing and de- pressurizing of the Check valve Assy.

c. SERVICE
1. Using 5/32” and 9/64” T-handle Hex Tool remove Flopac Check valve Nut and Retainer.
2. Remove Flopac Check valve poppet w/urethane O- ring and spring.
3. Check all Flopac CGA-540 or specific gases Check valve components, especially straight THD
O-ring, threads of the body, poppet, retainer. Clean all Check valve components with isopropyl alcohol
and thoroughly blow dry.
4. Inspect the CGA-540 or specific gages Check valve urethane O- ring for cuts and wear.
Replace as necessary with new square cut ring.
5. Where possible, blow out the CGA-540 or specific gases Check Valve body chamber using clean, dry
compressed air or Nitrogen to remove any foreign particles.

d. ASSEMBLY CGA 540 OR SPECIFIC GASES CHECK VALVE.

1. Install poppet w/urethane O- ring into body.
2. Using special plate, screw s.s. nut and poppet w/urethane O- ring.
3. Install spring on the poppet and screw retainer into body.
4. Install urethane O-ring to special groove of 9/16-18 THD.

e. INSTALLATION CGA 540 OR SPECIFIC GASES CHECK VALVE.

1.Using 1” socket and torque wrench , tighten Flopac CGA-540 or specific gases Check valve
Assy to 37 ft. lbs (50 N.m).

2. SHUT-OFF VALVE
a. REMOVAL
1. Using Notched Spanner Driver (For screw size #10) unscrew Stem nut.
2. Remove Knurled Knob with Lock washer.
3. Using 11/16” socket wrench unscrew Bonnet w/Stem assy from Flopac Connector.
4. Unscrew Stem Assy from Bonnet.

Page 8 of 15
 b. SERVICE
1. Check all Shut-Off valve components. Check internal and external Bonnet thread.
2. Check Stem 3/8-24 UNF-2A and 10-24 UNC-2A threads.
3. Inspect Back-up ring and O-ring for cuts and wear. Check Nylon seal for wear. Replace as necessary
with new O-ring, Back-up ring and Nylon seal.
4. Clean all Shut-Off valve components with isopropyl alcohol and thoroughly blow dry. O-ring and
Back-up rings should be lubricated with a film of KRYTOX 240 AC Fluorinated Grease.

c. INSTALLATION SHUT-OFF VALVE

1. Screw Stem Assy with Bonnet by hand
2. Using 11/16” socket and torque wrench, tighten Bonnet w/Stem Assy to Flopac Connector to
25-30 ft.lbs (34-40.5 N.m)
3. Install Knurled Knob to Stem square in pos. “OFF” when Shut-Off valve is closed.
4. Install Lock washer
5. Using Notched Spanner Driver, screw Stem nut, torque to 5 ft.lbs (6.8N.m).

3. DISS AUXILIARY OUTLETS

a. REMOVAL
1. Using a 5/8” open end wrench, remove the DISS auxiliary outlet from the Flopac Regulator
2. Remove old sealant from the male and female threads. CAUTION Hold the Flopac Regulator with
the DISS auxiliary outlet ports down so that any particulate matter will fall out of the port.

b. SERVICE
1. Disassemble the DISS auxiliary outlet by depressing the check valve plunger until the opposite end
containing the o-ring clears the body. Remove the 0-ring to gain access to the plunger and spring.
2. Inspect the components for wear or damage and replace as necessary. Reassemble in reverse order.

c. INSTALLATION
1. Reseal the male threads on the DISS auxiliary outlet with Teflon tape.
2. Thread the outlet into the regulator body and tighten 30 in.lbs (3.5 N.m).

4. INTERNAL CONTENTS GAUGE

a. RESETTING
1. Insert Pocket Scriber with ¼” Handle dia. into Swivel body special slot .38x.05 and turn Gauge
body until gauge aligns with (-0-) PSI.

a. MAINTENANCE
1. Keep internal contents gauge free of debris and contaminates.
2. Do not use oil or other lubricants with internal contents gauge.

WARNING The Flotec Flopac Regulator contains an internal contents gauge, which should only be removed or
replaced by a trained Flotec Technician.

5. FLOWMETER

Before attempting to disassemble the flow control valve to resolve a flow related problem, perform the
following procedures for back flushing the valve to remove any debris from the valve orifices. NOTE: The
flow control valve must be removed from the regulator before back flushing.

Page 9 of 15
 a. REMOVAL
1. Using a vise with Holding Fixture, place swivel body with Flowmeter assy and turn the Flowmeter
counter clockwise to loosen.

b. SERVICE
1. Backflush all 11 flow positions with a medical gas. Check the screw holding the rotor assembly onto
the knob shaft for tightness. NOTE: Any other service work must be done by the manufacturer; there
are no user serviceable parts in the flowmeter assembly. If the flowmeter needs to be returned to the
manufacturer reassemble the flowmeter with the upper body before returning.
2. CAUTION The flow control valve is manufactured to exacting tolerances and utilizes a number of
extremely small orifices. To prevent improper valve operation due to contaminants, ensure hands,
tools and worktable are clean when disassembling and servicing the flow control valve. There are no
user serviceable parts in the flowmeter assembly
3. Clean all flow control valve components with isopropyl alcohol and thoroughly blow dry.
4. CAUTION Do not allow a lubricant film applied on the rotor face to accumulate in the rotor orifices.
5. WARNING Do not interchange rotors and flow control valve bodies. Always assemble rotor with its
original flow control valve body.
6. Verify that the valve shaft rotates smoothly and stops at each detented position.

c. INSTALLATION
1. Replace the O-ring on the Flowmeter assembly as needed.
2. Using a vise with Holding Fixture, place swivel body with Flowmeter assy and turn the Flowmeter
assy clockwise to 15-20 ft.lbs (20.3-27.1 N.m).

6. FLOPAC CONNECTOR

a. REMOVAL
1. Place Flopac Connector Assy into a Vise w/ Holding Fixture and using 1 7/16” Crown foot wrench,
un-torque swivel body.
2. Remove In-gage Assy

b. SERVICE
1. Check Bonded Seal; All O-rings 90 DURO Neoprene and Hex Head cap screw. Replace as
necessary with new O-rings, Bounded Seal or Hex Head cap screw.
2. Inspect .024 orifice hole, it should be free passage of the special pin .0230-.0240 dia.
3. Inspect all internal and external threads for wear or damage. Do not use Flopac Connector with
wear or damage threads.
4. Where possible, blow out the Flopac Connector chamber using clean, dry compressed air or Nitrogen
to remove any foreign particles.
5. Every six months check the torque on the Flopac unit. The flow meter assembly to swivel body
assembly torque should be 15 to 20 ft lbs (20.3-27.1 Nm) and the torque for the swivel body assembly
to connector body assembly should be 21 to 26 ft lbs (28.5-35.3 Nm) .

c. ASSEMBLY FLOPAC CONNECTOR

1. Install Bonded Seal and using Arm Hex Key 3/16”, screw Brass Hex Head cap ¼-28” screw.
2. Install if necessary O-rings 90 DURO Neoprene.
3. Install In-gage Assy.

7. BURST DISK

a. REMOVAL
1. Using special Torque wrench with T30 driver, un-torque Sherwood Burst Disk or Erie Plug Body
ASSY(see 010-6211-xxx).
2. For Erie Burst Disk, remove Fusible disk and Burst disk gasket.

Page 10 of 15
 b. SERVICE
1. Inspect Rupture Disk and external thread for damage. Do not use Burst Disk ASSY with any damage.

c. INSTALLATION BURST DISK

1. Install Sherwood Burst Disk or Erie Burst disk gasket into Flopac Connector Burst disk port.
2. For Erie Burst disk, install Fusible disk.
3. Using Torque Wrench with T30 Torx Driver, tighten Sherwood or Erie Burst Disk ASSY into Flopac
Connector to 50-65 in.lbs – for Sherwood Burst Disk and 95 in.lbs – for Erie Burst Disk.

8. PISTON-MANIFOLD SET

a. REMOVAL
1. Remove Piston- Manifold set from Swivel body.

b. SERVICE
1. Remove the large O-ring from the piston for inspection. Clean the piston with isopropyl alcohol
and thoroughly blow dry. Inspect both O-rings for wear or damage. Replace as necessary with
new O-rings that have been lubricated with a film of Krytox 240AC lubricant. Inspect the seal on
the end of the piston for cuts or abrasions. WARNING Failure to install the piston seal will render
the Flopac Regulator inoperative and will result in uncontrolled high flows through the relief valve
vent ports.
2. Inspect manifold O-ring for wear or damage. Replace as necessary with new O-ring.
3. Clean the inside swivel body with isopropyl alcohol and a lint free cloth and thoroughly blow dry.
Inspect the seat for damage. Apply a film of Krytox 240AC lubricant approximately ½” wide to
the inner surface of the swivel body.

c. INSTALLATION
1. Install assembled piston-manifold set to swivel body.

9. HANDLE ASSEMBLY WITH FLANGE WASHER

a. REMOVAL
1. Using 9/16” wrench, unscrew Tube nuts from Flange washer (for old style w/CPI connection).
2. Using special ½” DR Crowfoot Wrench (#0150. dwg), remove handle assembly with flange
washer
from Flopac medical gas cylinder.

b. SERVICE
1. Inspect Flange washer thread (7/16-20 UNF-2A) for damage (for old style CPI connection).
2. Inspect Ferrules and Tube nuts for damage (for old style CPI connection).
Replace as necessary with new Ferrules and Tube nuts. Using special Swagelok tool (400 series)
and 9/16” Torque wrench, pre-set Coating handle with Ferrules and Tube nuts for 8 Fft/lbs.
(for old style CPI connection).
3. Inspect welded flange washer and handle for damage.

c. INSTALLATION COATING HANDLE ASSY WITH FLANGE WASHER

1. Insert pre-set handle assembly into 2 male ports w/ 7/16-20 UNF-2A threads and using
9/16 wrench, screw Tube nuts. Torque up to 9 Ft.lbs for old style CPI connections).
2. Used a small amount of Krytox RFE (PFPE O-ring lubricant) to lubricate large and
small o-rings.
3. Insert either style or welded style handle with flange washer into Flopac connector ¾-16 thread
with two lubricated o-rings (one is upper and other is lower of the flange washer).

X. TESTING
Perform the following test procedures after servicing the Flopac Regulator or to determine if

Page 11 of 15
 Flopac Regulator problem exists.

WARNING If service to the internal components of the Flopac Regulator has been performed, conduct a preliminary
static pressure test per the “FLOPAC HIGH PRESSURE LEAK TEST PROCEDURE” Instruction and “FLOPAC
OUTLET PRESSURE/ FLOW CALIBRATION PROCEDURE” Instruction with a medical gas cylinder pressure of
approximately 250 PSI. Conduct the preliminary static pressure test before beginning any functional testing to verify
that all regulator internal components have been installed correctly.

NOTE All functional testing should be performed using a full cylinder of gas at 1900 to 2100 PSI.

A. FLOPAC HIGH-PRESSURE LEAK TEST PROCEDURE

See “Flopac high-pressure leak test procedure” Instruction.

B. FLOPAC OUTLET PRESSURE/ FLOW CALIBRATION TEST PROCEDURE

See “Flopac outlet pressure/ flow calibration test procedure” Instruction.

XI. REPLACEMENT PARTS LIST FOR FPX-XXX-XX-XXXXX

DESCRIPTION FLOTEC PART #

FLOPAC HANDLE W/ WELDED

S.S. RING AND FLANGE WASHER 010-6258-012

FLOPAC SHUT-OFF VALVE ASSY 010-6246-001

FLOPAC SHERWOOD BURST DISK ASSY 010-6211-32A

FLOPAC ERIE BURST DISK ASSY 010-6211-245

ON-OFF VALVE ALUMINUM KNOB W/NUT 810—6892-001

AND WASHER 810-6865-012
110-2120-010

EXERNAL GAUGE FOR FP-9 AND FPA REG. 010-6100-081

DISS-1240 CHECK-VALVE 1/8” MNPT DCV-1240

DISS-1240 FITTING 1/8” MNPT DF-1240

HOSE BARB GREEN HB12

HOSE BARB SILVER HB122
HOSE BARB YELLOW HB124

XII. TROUBLESHOOTING GUIDE

INTERNAL CONTENTS GAUGE:

SYMPTOM PROBABLE CAUSE ACTION

Pointer does not move after Cylinder is empty Replace cylinder

cylinder valve is turned on Contents gauge is damaged Replace Gauge

Page 12 of 15
Reading drops sharply
with flow through
regulator
Ingage is not in pos. “0”
when Shut-Off valve is closed
THE FLOPAC REGULATOR LEAKS AT:
Vent holes in body
Auxiliary DISS outlet
Adjustable flow outlet
with knob in off position
Flowmeter Assy
Flopac Connector
CGA 540 or specific gases
check valve
Zone “A” between Flopac unit
and Handle flange washer and
Zone “B” between flange
washer and cylinder
Shut-Off valve
Cylinder valve “cracked” open
Bourdon tube clip is detached
from Gauge ring slot
Particulate matter in Flopac
regulator
Connector small O-ring
leaks
Piston O-ring leaks
Piston seal leaks
Relief valve gasket leaks
Check valve O-ring leaks
Flowmeter not functioning
properly
FM Body thread leaks
FM Hose barb or DISS-1240
leak
Connection between Cylinder
and Flopac Connector leaks
Ingage displays pressure
when Shut-Off valve is closed
Urethane O- ring leaks
Straight thread O-ring
Large and small O-rings
are leaking
Stem O-ring and Buck-up
rings leak
Bonnet thread leaks
Stem seal leaks
Page 13 of 15
Fully open cylinder valve
Insert Scriber into Swivel
body special slot, turn Gauge
ring until gauge aligns with “0”.
Clean Flopac Reg. internal
components
Replaced connector
small O-ring (I.D. 0.118”)
Replace piston O-rings (2)
Replace piston seal
Replace relief valve gasket
Replace check valve O-ring
Return to Flotec
Tighten the FM ASSY to
15-20 ft.lbs (20.3-27.1 N.m)
Tighten Hose barb or DISS-1240
to 30 in.lbs (3.4 N.m)
Tighten Flopac Connector to
50-55 Ft.lbs or replace ¾-16
UNF-2A thread o-ring and Flange
washer O-ring
Replace bonded seal of
brass ¼-28 screw or
replace Shut-Off valve stem seal
Replace urethane O- ring
Tighten CGA 540 Check
Valve body into Flopac
Connector to 37.0 ft.lbs (50 N.m)
or replace O-ring
Used a small amount of Krytox to
lubricate large and small O-rings
and install lubricated large and small O-rings
Replace O-ring & Back-up
rings
Tighten the Bonnet to
25-30 Ft.lbs (34-40.7 N.m)
Replace Stem seal
Threaded (NPT) Loose connections Disassemble
connections clean and reseal threads,
reassemble and tighten

Burst Disk Burst Disk thread leaks Tighten Burst Disk to:
50-65 in.lbs – Sherwood Burst Disk ASSY
95 in.lbs- Erie Burst Disk ASSY
Rupture Disk leaks Install a new Burst Disk

THERE IS NO FLOW OR Shut-Off valve is turned off Turn Shut-Off valve Knob to
INACCURATE FLOW AT pos. “Flow”
THE METERED FLOW
OUTLET

Flowmeter/flow control is Turn flowmeter/flow

turned off control to desired setting

Flowmeter not functioning Refer to Flowmeter

properly service Instructions

Flow control valve is Remove flow control

obstructed valve from regulator and
backflush

Flow control knob is Align knob set screw

incorrectly positioned with flat on shaft and
on shaft tighten securely

THERE IS NO FLOW AT THE Cylinder is empty Refill Cylinder

AUXILIARY DISS OUTLET
Hose connector not properly Re-engage and
engaged tighten hose connector

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