ESAB R-5210 and R-99 High-Capacity Station Regulators Troubleshooting instruction

Brand: ESAB

Model: R-5210 and R-99 High-Capacity Station Regulators

Type: Troubleshooting instruction

This manual is also suitable for

ESAB R-52, R-52-200, R-5210 and R-99 High-Capacity Station Regulators deliver high-performance gas regulation for a variety of industrial applications.

The R-52 regulator is ideal for use with oxygen, oil-free air, or inert gases, delivering up to 10,000 ft3/hr (283 m3/hr) of gas with a maximum inlet pressure of 350 psig (24.1 bars) and a maximum delivery pressure of 150 psig (10.3 bars).

The R-52-200 regulator is also suitable for oxygen, oil-free air, or inert gases, but offers a higher maximum delivery pressure of 175 psig (12.0 bars).

ESAB R-52, R-52-200, R-5210 and R-99 High-Capacity Station Regulators deliver high-performance gas regulation for a variety of industrial applications.

The R-52-200 regulator is also suitable for oxygen, oil-free air, or inert gases, but offers a higher maximum delivery pressure of 175 psig (12.0 bars).

F-12-859-F

January, 2001

INSTRUCTIONS for

R-52, R-52-200, R-5210 and R-99

HIGH-CAPACITY STATION REGULATORS

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

tices 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

manufactured by ESAB Welding & Cutting Products to the specifications on file with Underwriter 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.

Table 1 - Specifications

Max.

Regulator Nominal Max. Delivery Inlet &

Gas Capacity Inlet Pressure Pressure, Outlet

Model Part No. Service ft

/hr (m

/hr) psig (bars) psig (bars) Connections

Oxygen

R-52 20A16 Oil-free Air, 10,000 (283) 350 (24.1) 150 (10.3)

or Inert Gases

R-52-200 2117105 Oxygen,

Oil-Free Air, 10,000 (283) 350 (24.1) 175 (12.0)

or Inert Gases

Fuel Gas

R-5210 524193 including 2,000 (57) 15 (1.0)* 12 (0.8) 3/4" NPT

Acetylene

Fuel Gas

R-99 04X50 except 3,000 (85) 350 (24.1) 40 (2.8)

Acetylene

*If using fuel gas other than acetylene with the R-5210 regulator, the maximum allowable inlet pressure is 150 psig (10.3 bars).

3. Before connecting the regulator, open the station

valve slightly for an instant (this is termed crack-

ing the valve). This will blow out dust, dirt or any

foreign substance that may have collected while

installing the filter and piping for connection of the

regulator.

Never crack a gas supply valve near combustible

material or a source of flame.

4. After connecting regulator, back out (turn counter-

clockwise) the pressure-adjusting screw until it

turns freely.

I. OPERATING INSTRUCTIONS

A. TO CONNECT

R-52

1. A suitable line filter (P/N 2116734 is recommended)

should be connected between the station valve and

the regulator, 3/4-in. extra heavy pipe free of oil and

grease should be used. Teflon tape or paste or an

approved pipe compound must be used on all pipe

threads.

2. Standard 3/4-in. pipe unions should be installed at

each end of the regulator so that it can be removed

conveniently from the piping system for general

maintenance work.

CAUTION

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

5. Open the station valve slowly.

6. Test all connections with Leak Test Solution that is

suitable for oxygen service, such as P/N 998771 (8

oz. container).

R-5210 and R-99 Regulators:

The instructions are the same as above except that a

suitable line filter for fuel gas (P/N 2116339 is recom-

mended) should be installed just ahead of the regulator.

The fuel gas piping system should also include a suit-

able hydraulic back-pressure valve. OXWELD H-9 or

H-11-6M is recommended when using acetylene. OX-

WELD H-19 or H-12-6M is recommended when using

fuel gases other than acetylene such as natural gas,

propane, hydrogen, etc.

B. TO ADJUST PRESSURE

To increase delivery-pressure, turn the pressure-adjust-

ing screw to the right (clockwise). To decrease delivery-

pressure, turn the pressure-adjusting screw to the left

(counterclockwise). The torch oxygen (or fuel gas) valve

(and any other valve in the line between the regulator

and torch) should be open whenever you are adjusting

delivery pressure. If they are not open, you will not get a

true work-pressure reading on the delivery-pressure

gauge.

C. TO RELEASE PRESSURE

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

should release all pressure from the regulator as fol-

lows:

1. Close the station valve.

2. Open the torch valve (oxygen valve if using the R-

5210 or R-99) until the regulator gauge hand returns

to the pin.

3. Release the pressure-adjusting screw by turning it

to the left (counterclockwise) until it turns freely.

4. Close the torch valve.

Always follow the steps outlined above before you re-

move a regulator from a station. If the regulator is to be

out of service for several days, or longer, turn in the pres-

sure-adjusting screw enough to move the seat off the

nozzle.

II. MAINTENANCE INSTRUCTIONS

If the regulator does not operate properly, stop work

immediately and investigate the cause of the malfunc-

tion. 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.

For all repairs other than those covered below, send

the apparatus to the ESAB Remanufacturing Cen-

ter, Florence SC. Improperly repaired apparatus is

hazardous. Be sure pressure has been removed and

isolated from regulator before disassembly.

A. TO REPLACE THE MAIN REGULATOR VALVE

SEAT

If the regulator gauge hand climbs excessively, turn the

pressure-adjusting screw out (counterclockwise) as far

as it will go. Test for valve leakage by placing a film of

leak test solution across the regulator outlet. If leakage

is present, replace the main regulator valve seat. To do

this:

1. Disconnect the regulator from the pipe line system

and hold it in a vise.

2. Unscrew the front cap (24A19).

3. Remove the valve closing spring (40A24) and the

complete valve unit.

4. Hold the valve unit in a vise by clamping the hex

sides of the seat holder between the vise jaws with

the valve stem pointing down.

5. Using a screwdriver, unscrew the vibration damp-

ener locknut.

6. Push the valve stem down through the seat.

7. Replace the valve seat* and reassemble the valve

unit in reverse order, making sure the inner edge of

the rubber seat is completely in the valve stem

groove and vibration dampener is securely locked

in position.

8. Clean the seating surface of the valve nozzle with a

clean cloth. Replace the nozzle if it is marred.

9. Assemble the valve unit and valve closing spring in

the regulator.

10. Replace O-ring and then screw the front cap into

position, tightening it with a wrench.

B. TO REPLACE THE PILOT REGULATOR VALVE

SEAT

If leakage is still present at the regulator outlet, replace

the pilot regulator valve seat. To do this:

1. Hold the regulator in a vise.

2. Unscrew the pilot regulator rear cap (2029446).

3. Remove the valve closing spring (40A26) and the

pilot regulator valve seat. Removal of the valve clos-

ing spring allows the valve seat to slide out of the

yoke.

4. Clean the valve nozzle with a clean cloth. Replace

the valve nozzle if the seating surface is marred.

5. Replace the valve seat and reassemble in the regu-

lator in reverse order.

*Use a little leak test solution on the stem at the point

where the seat is located. This will prevent cutting of the

rubber on the stem. After assembly, wipe clean.

5. Unscrew the locknut (37Z57). The diaphragm and

diaphragm plate can then be lifted off.

6. Replace the diaphragm and reassemble in reverse

order. Tighten the diaphragm nut to 70 in.-lbs.

E. REPLACING THE MAIN REGULATOR INLET FIL-

TER SCREEN

1. Remove the 3/4-in. x 1-in. NPT reducing bushing

(68100376).

2. Remove the spring (2029452), and then remove and

discard the filter screen.

3. Install new filter screen. BE SURE NO OIL OR

GREASE COMES IN CONTACT WITH THE

SCREEN.

4. Reassemble in reverse order.

CAUTION: Never reassemble the bushing without a fil-

ter screen.

F. TO TEST FOR LEAKS

1. Connect the regulator to the pipe line system and

slowly open the station valve. Be sure the adjusting

screw is turned out (counterclockwise) before ad-

mitting pressure to the regulator.

2. Place a film of leak test solution across the regula-

tor outlet to test for valve leakage.

3. Install a clean 3/4-in. NPT pipe into the regulator

outlet. Set the pressure to at least 50 psi (20 psi for

R-99; 12 psi for R-5210) and paint the entire regula-

tor with the leak test solution. Look for leakage at all

joints and connections.

4. Remove the 3/4-in. NPT plug. Wipe off all leak test

solution with a clean oil-free cloth.

Do not use oil on this apparatus. Oil and grease are

easily ignited and burn violently in the presence of

oxygen under pressure.

C. TO REPLACE MAIN REGULATOR DIAPHRAGM

If uniformly tightening the hexhead capscrews securing

the back cap does not stop the leakage between the

back cap (24A20) and the body, replace the diaphragm.

To do this:

1. Remove the regulator from the pipe line system and

hold it in a vise.

2. Remove the back cap and lift out the complete dia-

phragm assembly.

3. Lift out baffle (2114592), replace O-ring, and then

reinstall baffle.

4. Unscrew the diaphragm clamping nut and the dia-

phragm washer.

5. Replace the diaphragm and reassemble in reverse

order. Tighten diaphragm nut to 200 in.-lbs.

NOTE: Be sure the small hole in the diaphragm and the

corresponding small hole in the back cap line

up with the small tube which protrudes from the

flanged face of the body. In tightening the nuts

which secure the back cap, tighten the nuts di-

rectly opposite each other, tightening them uni-

formly a little tighter each time you progress

around the cap.

D. TO REPLACE PILOT REGULATOR DIAPHRAGM

If the pilot regulator cap (2029443) is securely tightened

into the regulator and leakage is still present, replace

the pilot regulator diaphragm. To do this:

1. Place the regulator securely in a vise.

2. With a wrench, unscrew and remove the pilot regu-

lator cap and spring.

3. Lift out the complete diaphragm assembly.

4. Hold the complete diaphragm assembly in a vise by

clamping the hex sides of the diaphragm attaching

screw (35Z81) between the vise jaws.

WARNING

GAUGE - 999440 (R-52)

999442 (R-52-200)

999437 (R-5210)

999434 (R-99)

SPRING - 29Z38 (R-52)

2116071 (R-52-200)

281524 (R-5210)

40A25 (R-99)

P. A. SCREW - 2029235

HOW TO ORDER REPLACEMENT PARTS

The parts picture below covers all replacement parts for the R-52, R-52-200, R-5210 and R-99 regulators as currently

manufactured. To order, identify the required parts from the drawing and specify by part number and name.

F-12-859-F 01/2001 Printed in U.S.A.

GAUGE FILTER SCREW

998311t

DIAPHRAGM

30Z76t

RING - 82Z18

LOCKNUT - 37Z57

SPRING - 2029452

VALVE ASSEMBLY - 33Y60t

includes

SEAT - 32Y26

STEM - 48Z34

GUIDE - 82Z20

LOCKNUT - 37Z58

DAMPENER - 29Z39

SPRING - 40A24

O-RING -

2115137t

CAP - 24A20

BAFFLE - 2114592

DIAPHRAGM -

19A11t

NUT - 33A36

INSERT - 2029460

NOZZLE - 2114309

WASHER - 45A23

(8) CAPSCREW, 7/16"  14 x 1-1/8" - 61341164

t Parts included with R-52/R-99 Regulator Parts Replacement Kit - P/N 2117610.

R-52, R-52-200, R-5210, and R-99 Regulators

PLATE - 70A15

O-RING - 187W02t

SLEEVE - 74A49t

CAP - 24A19

includes

SCREEN - 05Y16t

BUSHING, 1" X 3/4" NPT - 68100376

CAP - 2029443

CAP - 2029446

SEAT - 47A19t

SPRING - 40A26

O-RING - 2029450t

DIAPHRAGM - 19A23t

RING - 37A27

NOZZLE - 32Z71

YOKE - 2029453

SCREW - 35Z81

PLATE - 30Z75

CUP - 82Z45

ESAB R-5210 and R-99 High-Capacity Station Regulators Troubleshooting instruction

Brand: ESAB

Model: R-5210 and R-99 High-Capacity Station Regulators

Type: Troubleshooting instruction

This manual is also suitable for

ESAB R-52, R-52-200, R-5210 and R-99 High-Capacity Station Regulators deliver high-performance gas regulation for a variety of industrial applications.

The R-52-200 regulator is also suitable for oxygen, oil-free air, or inert gases, but offers a higher maximum delivery pressure of 175 psig (12.0 bars).

Download PDF

report

ESAB R-5210 and R-99 High-Capacity Station Regulators Troubleshooting instruction

This manual is also suitable for

ESAB R-5210 and R-99 High-Capacity Station Regulators Troubleshooting instruction

Related papers

Other documents