ESAB R-83 and R-84 High-Capacity Station Regulators User manual

Brand: ESAB

Model: R-83 and R-84 High-Capacity Station Regulators

Type: User manual

INSTRUCTIONS for

F-4660-P

April, 2005

R-83 and R-84

HIGH-CAPACITY STATION REGULATORS

Table 1 - Speciﬁcations

Max Approximate

Regulator Nominal** Max. Delivery Inlet Dimensions

Gas Capacity* Inlet Pressure Pressure, & Outlet and

Model Part No. Service cfh (m

/hr) psig (bars) psig (bars) Connection Weight

Oxygen

R-83 2103822 Oil-Free Air, 40,000 (1132) 350 (24.1) 150 (10.4) Length 18-5/8-in. (473 mm)

Less pilot 2103823 or Inert Gases 2-in. NPT Width-12 1/4-in. (311 mm)

(See Note) Depth - 9-in. (228 mm)

Fuel Gas Weight - 75 lbs. (34 kg)

R-84 2103957 Including 8,000 (226) 15 (1.03) 12 (0.83)

Less pilot 2104002 Acetylene

* See page 3 for complete capacity data.

** If using fuel gas other than acetylene with the R-84 regulator, the maximum allowable inlet pressure is 150 psig (10.35 bars)

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for oxy-

fuel gas equipment, we urge you to read our booklet “Precautions and Safe Practices for Welding, Cutting, and Heating,” Form 2035. The

same information appears in the “Oxy-Acetylene Handbook” which may be purchased from any ESAB distributor. Do NOT permit untrained

persons to operate this equipment. Do NOT attempt to operate this equipment until you have read and fully understand these instructions.

If you do not fully understand these instructions, contact your supplier for further information.

The regulators covered by these instructions are listed by Underwriter’s Laboratories only when used in combination with parts manu

factured by ESAB Welding & Cutting Products to the speciﬁcations on ﬁle with Underwriter’s Laboratories, Inc., and when they are used in

the gas service for which they are designed and listed. The use of other parts that cause damage or failure to the equipment will void the

manufacturer’s warranty.

CAUTION

Be sure this information reaches the operator.

You can get extra copies through your supplier.

INSTALLATION

1. A suitable line ﬁlter (P/N 2116735) is required and must be

connected between the supply valve and the R-83 oxygen

regulator. Extra heavy pipe free of oil and grease should be

used. Teﬂon tape or paste or an approved pipe compound

should be used on all pipe threads.

For the R-84 fuel gas regulator, a suitable line filter (P/N

2116363) must be connected between the supply valve and

the regulator. A hydraulic back-pressure valve (H-11-6M for

acetylene or H-12-6M for other fuel gases) must be installed in

the piping between the supply valve and regulator according

to NFPA 51 Standards.

2. Before connecting the regulator, open the station valve slightly

for an instant (this is termed “cracking the valve”). This will blow

out dust, dirt or any foreign substance that may have collected

while installing the ﬁlter or hydraulic and piping for connection

of the regulator.

NOTE: The regulators (with pilot regulators) are equipped with

2-in. NPT, 300-pound ANSI Standard 8-bolt ﬂanges at inlet

and outlet connections. Gaskets and mounting bolts are

supplied but mating ﬂanges are not. Mating ﬂanges should

be ordered from your nearest mill supply house.

All flange and pipe connections on the regulator were

factory tested for leak tightness. DO NOT rotate ﬂanges

or pipes on regulator to line up with existing mating pipe

line ﬂanges. DO NOT apply heat to the regulator body or

ﬂanges.

Also note that R-83 and R-84 regulators made prior to early

1980 were ﬁtted with 4-bolt ﬂanges. If replacing an older

regulator with a new, the ﬂanges on the piping system

should be changed to match the 8-bolt style. The overall

length of the regulators did not change.

CAUTION: Never crack a gas supply valve near combustible

material or a source of ﬂame.

3. Install mating ﬂanges on the pipe running from the ﬁlter or

hydraulic outlet and on the pipe that will connect to the regu

lator outlet.

4. Mount the regulator. Make sure the gasket is properly posi-

tioned. Tighten the bolts ﬁrmly and evenly with a wrench.

5. MAKE SURE the pressure-adjusting screw is backed out (turn

counterclockwise) as far as it can go.

REMOTE INSTALLATION OF PILOT REGULATOR

In some installations, such as with many scarﬁng machines, it may

be desirable to operate the main regulator with the pilot regulator

at a remote location. To do this, proceed as follows:

1. Remove pilot regulator by disconnecting the delivery tube as

sembly (2103952 or 2104010) and removing three 3/8-in.—24

hex nuts (63200137).

2. Replace pilot regulator connector (03Z35) with plug (35Z35)

supplied with the regulator.

3. Install tube adaptor (18Z76) supplied with the regulator into

the inlet of the pilot of the regulator.

4. Mount the pilot regulator at the desired location. The same

hardware used for mounting the pilot regulator to the main

regulator may be used here.

5. Use 1/4-in. O.D. x 0.035-in. wall brass tubing and suitable 1/4-in.

NPT tube connecting ﬁttings for connecting pilot regulators

inlet to a tap on gas inlet supply line and for connecting pilot

regulator outlet to the main regulator.

NOTE: Copper tubing may be used for conveying any gas except

acetylene. It should NEVER be used for acetylene.

OPERATION

LEAK TESTING

1. Back out pressure-adjusting screw.

2. Open the station valve SLOWLY.

3. With valves downstream of regulator closed, turn in (clockwise)

the pressure adjusting screw to the approximate desired work-

ing pressure and check all joints and connections for leakages

using Leak Test solution suitable for oxygen service, such a P/N

998771 (8 oz. container). Correct leaks before starting opera

tions.

MAINTENANCE

If the regulator does not operate properly, stop work im-

mediately and investigate the cause of the malfunction.

Maintenance and repair work must be performed only by an

experienced and qualiﬁed person. Do not permit untrained

persons to inspect, clean, or repair this regulator. Use only

recommended replacement parts.

ADJUST PRESSURE

1. To increase delivery pressure, turn pressure-adjusting screw to

the right (clockwise). To decrease delivery pressure, turn the

pressure-adjusting screw to the left (counterclockwise).

2. When making the initial delivery pressure adjustment, the

torch or downstream valve should be open for obtaining the

true operating pressure.

NOTE: Piped or distributed acetylene pressure should never exceed

15 psig.

RELEASING PRESSURE

If work is to be stopped for a half-hour or more, you should

release all pressure from the regulator. To do this, proceed as

follows:

1. Close station valve.

2. Open torch or downstream valve.

3. When pressure on the delivery-pressure gauge of regulator

reaches zero, back out pressure-adjusting screw on pilot regula-

tor as far as it can go.

4. Close the torch or downstream valve.

If regulator is to be out of service for a few days or more, turn in

the pressure-adjusting screw enough to move the valve stem

oﬀ the seat. When returning regulator back to service, BE SURE

to back out the pressure-adjusting screw completely before

admitting pressure into the regulator.

If necessary to remove the regulator from the installation, follow

the above procedures for shutting down. Cover inlet and outlet

ﬁttings on the regulator and piping installation with suitable

caps to keep out dust or dirt.

TABLE 2 - REGULATOR CAPACITY DATA

R-83 REGULATOR - P/N 2103822, 2103823

INLET

PRESS., REGULATOR DELIVERY PRESSURE, psig

psig 25 50 75 100 125 150

100 66,000 62,000 49,000

150 85,000 85,000 85,000 79,000 54,000

200 85,000 85,000 85,000 85,000 85,000 85,000

250 85,000 85,000 85,000 85,000 85,000 85,000

INLET

PRESS., REGULATOR DELIVERY PRESSURE, bars*

bars 1.7 3.5 5.2 6.9 8.6 10.3

6.9 1,869 1,756 1,387

10.3 2,407 2,407 2,407 2,437 1,529

13.8 2,407 2,407 2,407 2,407 2,407 2,407

17.2 2,407 2,407 2,407 2,407 2,407 2,407

* If using R-83 for gases other than oxygen, multiply given ﬂow rates by the following correc-

tion factors:

Nitrogen - 1.08 Argon - 0.90

R-84 REGULATOR - P/N 2103957, 2104002

INLET

PRESS., REGULATOR DELIVERY PRESSURE, psig

psig 3 5 7 9 12

7 10,184

9 10,184 9,751 7,243

11 10,184 10,184 10,184 7,498

13 10,184 10,184 10,184 10,184 5,600

15 10,184 10,184 10,184 10,184 9,904

INLET

PRESS., REGULATOR DELIVERY PRESSURE, bars**

bars 0.21 0.35 0.48 0.62 0.83

0.5 289

0.6 289 289 205

0.8 289 289 289 261

0.9 289 289 289 289 162

10.3 289 289 289 289 280

** If using the R-84 for fuel gases other than natural gas, multiply given ﬂow rates by the fol-

lowing corrections factors: Acetylene - 1.038; Propane - .797

MAXIMUM NATURAL GAS FLOW, ft

/hr

MAXIMUM NATURAL GAS FLOW m

/hr**

MAXIMUM OXYGEN FLOW m

/hr*

MAXIMUM OXYGEN FLOW ft

/hr*

Supplied:

PILOT REG. TUBE ADAPTOR - 18Z76

BODY PLUG - 35Z35

NOZZLE •

SEAT ASSY. •

O-RING•

BUSHING •

RING - 78Z64

BACK CAP -

31Z72

SPRING -

40A15 (R-83)

28Z69 (R-84)

O-RING •

NUT - 1/4"—20 -

63300100

STEM •

SEAT HOLDER •

MAIN CAP - 31Z28

DIAPHRAGM •

PLATE - 2114337

WASHER - 53Z67

NUT -

1/2"—13 •

SCREW -

35Z78 (R-83)

35Z77 (R-84)

PLATE - 2222545

SCREW - 35Z76

GUIDE •

PLATE - 2114336

(10) SCREW -

5/8" x 2-1/2"

41436305

(10) LOCKWASHER

64302920

O-RING •

Tin & Sweat

GAUGE -

999440 (R-83)

2105314 (R-84)

NIPPLE (LONG) -

2103824

STUD (SHORT) - 38A45

ELBOW (90°) - 68143283

CONNECTOR - 03Z35

ELBOW (45°) - 68143078

(2) CONNECTOR -

3389 (R-83)

3390 (R-84)

NIPPLE (SHORT) - 2103946

TUBE ASSY. -

2103952 (R-83)

2104010 (R-84)

BODY -

06Z23

PLATE -

30Z42

WASHER -

73Z11

WASHER -

53Z68

PLATE -

30Z41

NUT -

36Z78

SCREW -

35Z46

PILOT REGULATOR ASSEM. -

2103951 (R-83)

2103991 (R-84)

SCREW ASSY. - 31Y11

includes:

NUT - 33A49

WASHER - 45A38

SCREW - 71A30

CAP - 31Z29

WASHER - 53Z79

SPRING -

28Z26 (R-83)

28Z70 (R-84)

DIAPHRAGM -

30Z40

SPRING -

28Z59

VALVE -

21813

PILOT REGULATOR -

(See inset)

(2) RING •

STRAINER -

82Z52

SNAP RING -

38Z56

(2) FLANGE - 68188001

Tin & Sweat

(2) STUD (LONG) - 38A46

(3) WASHER - 45A39

(3) NUT - 3/8"—24 - 63200137

(16) SCREW - 5/8" — 2-1/2"

61341228

(16) LOCKWASHER - 64302920

(16) NUT - 63300230

(2) GASKET - 77050057

R-83 Oxygen Regulator Assembly - P/N 2103822

R-84 Fuel Gas Regulator Assembly - P/N 2103957

R-83 Oxygen Regulator (less Pilot) - P/N 2103823

R-84 Fuel Gas Regulator (less Pilot) - P/N 2104002

• Supplied with R-83/R-84 Regulator Replacement Parts Kit

P/N 2105955 which includes the following:

For all repairs other than those covered below, send the ap-

paratus to ESAB Remanufacturing Center, Ebenezer Road,

Florence, SC 29501. Improperly repaired apparatus is hazard-

ous. Be sure pressure has been removed and isolated from

regulator before disassembly.

A twice-yearly overhaul is recommended if regulator is operated

almost continuously. Note in the parts illustration that seat, dia

phragm, O-rings, and few other critical parts are supplied in an R-

83/R-84 Replacement Parts Kit (P/N 2105955) for the convenience

of an overhaul. Convenient periodic inspections or overhauls can

avoid inopportune and expensive shutdowns.

INSTALLING A NEW MAIN VALVE SEAT AND NOZZLE

1. Remove the back cap (31Z72) by turning it to the left (coun

terclockwise).

2. Remove the valve-closing spring (40A15 or 28Z69).

3. Lift out the complete valve-stem assembly.

P/N Description Qty.

2219360 Seat 1

2219761 Seat Holder 1

30Z64 Diaphragm 1

32Z36 Valve Nozzle 1

63140183 Jam Nut, .50-13 1

33Y36 Valve Stem Assembly 1

85W34 O-ring, 2.234" ID x 0.139" 1

78Z65 Valve Guide Bushing 1

78Z66 Stem Guide 1

85W10 O-ring, 0.239" ID x 0.070" 1

85W44 O-ring, 0.424" ID x 0.103" 2

85W52 O-ring, 1.484" ID x 0.139" 1

10.

11.

12.

F-4660-P 04/2005 Printed in U.S.A.

4. Remove the nozzle by turning it to the left (counter-clockwise),

using a suitable socket wrench.

5. Install new O-ring on new nozzle, and then assemble to regula

tor.

6. Remove the 1/4—20 hex steel valve-stem nut from the rear

of the valve-stem assembly.

7. Pull the valve stem out of the valve-seatholder, (2219761).

8. Lift the seat washer oﬀ the seat assembly.

9. Reassemble seat washer and new seat assembly onto the valve

stem.

10. Replace O-ring in seat holder with new O-ring, and then con

tinue to reassemble in reverse order

11. Replace O-ring on back cap with new one. Then reassemble

back cap to regulator.

INSTALLING A NEW MAIN DIAPHRAGM (30Z64)

1. Remove the ten 5/8-in. – 18 x 2 1/2-in. cap screws.

2. Remove the main cap (31Z28).

3. Remove the diaphragm assembly and unscrew the diaphragm

screw locking nut (1/2" – 13 brass hex jam nut).

4. Remove the upper diaphragm plate assembly (2114337) and

diaphragm.

REPLACING THE PILOT-REGULATOR VALVE (21813)

1. Disconnect the pilot-regulator delivery tube (2103952 or

2104010).

2. Remove the three 3/8—24 hex steel nuts holding the pilot

regulator to the main body, and remove the pilot regulator.

3. Turn the pressure-adjusting screw to the left (counter-clock

wise) as far as it will go.

4. Remove the cap and pressure-adjusting screw assembly

(31Y11) by turning it to the left (counterclockwise).

5. Remove the spring (28Z26 or 28Z70), spring washer (53Z79),

diaphragm washer (53Z68), diaphragm assembly, and valve-

closing spring (28Z59).

6. Remove the valve (21813) by turning it to the left (counter

clockwise), using a tire-valve wrench.

7. Install a new valve, and test for leakage by applying Leak Test

solution (998771) over the head of the valve and then applying

gas pressure to the inlet of the pilot regulator.

8. Reassemble in reverse order and again test for leakage around

the cap on the outlet elbow (68143283) with Leak Test Solu

tion.

REPLACING THE PILOT-REGULATOR DIAPHRAGM

(30Z40)

1. With diaphragm assembly removed from step 5 above, remove

the diaphragm clamping nut (36Z78), upper diaphragm plate

(30Z41), and diaphragm (30Z40) from the diaphragm assem

bly.

2. Place the pilot regulator in an upright position and connect

the inlet, by means of hose or tubing, to a source of oxygen

supply.

3. Insert a diaphragm gauge so that it rest on the body shoulder

located just below the diaphragm clamping edge. The gauge

should be made of brass shim, 1.625" O.D. X 1-1/8" I.D. X

thick.

4. Insert, in the normal position, the valve-adjusting screw (35Z46)

and lower diaphragm plate (30Z42) as an assembly.

5. Hold the assembly ﬁrmly in place with lower diaphragm plate

resting centrally on the diaphragm gauge. Screw the adjusting

screw clockwise until valve (21813) starts to open, as indicated

by the passing of oxygen, then back out the screw until the

valve just seals.

6. Remove the diaphragm plate and screw assembly, and com-

plete the assembly of the unit by assembling the diaphragm

sealing washer, diaphragm, top diaphragm plate, and clamping

nut. Tighten the clamping nut ﬁrmly, making certain the lower

diaphragm plate does not turn on the valve-adjusting screw.

7. Remove the diaphragm gauge from the pilot regulator, and

proceed with the assembly of the pilot regulator in the normal

manner.

REPLACING THE PILOT-REGULATOR INLET STRAINER

(82Z52)

1. Disconnect the pilot-regulator delivery tube.

2. Remove the three 3/8—24 hex steel nuts holding the pilot

regulator to the main body, and remove the pilot regulator.

3. Remove the snap ring (38Z56), after which the strainer disk

(82Z52) should fall out.

4. Install a new strainer disk, and reassemble in the reverse or-

der.

5. Reassemble in reverse order, making certain that the heavier

diaphragm plate is next to the valve stem. In tightening down

the cap, tighten the 10 cap screws uniformly, working back and

forth from opposite sides of the regulator until the cap screws

are tight.

ESAB R-83 and R-84 High-Capacity Station Regulators User manual

ESAB R-83 and R-84 High-Capacity Station Regulators User manual

ESAB R-83 and R-84 High-Capacity Station Regulators User manual

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