ESAB Trimline Regulators User manual

Brand: ESAB

Model: Trimline Regulators

Type: User manual

Trimline Regulators

Designed For Reduced Risk,

Built For Performance

F-5310-B 11/99

Risk Reduction

Minimizing the risk of injury from misuse was

the motivating force behind the development

and production of Trimline. The major design

goal of Trimline was to reduce personal injury

and property damage associated with what is

referred to as Oxygen Regulator Burnout (RBO).

This is essentially spontaneous ignition within

a regulator, and can occur when oxygen comes

in contact with hydrocarbons and other types of

contaminants. Such burnouts can happen when

prescribed practices for the safe handling and

use of cylinders and regulators are not adhered

to.

The exact mechanism which causes ignition is

not known, yet there is no question that the re-

sult of the ignition can create damage to the

regulator and, at times, serious personal injury

and property damage. A regulator can become

completely gutted and the parts of the regula-

tor may become flying projectiles.

Despite our best efforts, it is evident that be-

cause equipment can be used in ways which

are not recommended, it is impossible to guar-

antee that regulator burnout will not occur. The

next best thing is to build features into the regu-

lator to contain a burnout to minimize the risk of

injury. This is what we set about doing with

Trimline.

The Trimline design of gas regulators is truly

something different. It is different than other

OXWELD and PUROX lines, it is different than

anything our competitors have put on the market.

Trimline was designed to minimize the risk of in-

jury, and its high level of reliability reflects that

fact. Yet even though they were designed first and

foremost to reduce the risk of personal injury,

Trimline regulators also achieve a new level of

performance.

Over $500,000 and seven years of research and

development went into the making of the Trimline

line of regulators. This investment has

paiddividends in the form of greatly improved

regulators. Among other things Trimline regula-

tors are machined from solid brass bar stock,

whereas virtually all other regulators are forged.

The net result is that Trimline’s walls are thicker

for durability and burnout containment. By the

same token, reduced internal cavities cause

smaller bangs should a burnout occur.

These regulators also have massive baffle plates

to protect the diaphragms, and thin diaphragms

for tighter seals and reduced leaks. Trimline regu-

lator gauges are color-coded and include a printed

message intended to prevent misuse. Two-stage

models have long flame quench inlet passages,

and first-stage pistons, which provide positive

shut-off. A relatively small quantity of seat mate-

rial serves to lower burnout intensity should one

occur.

Trimline two-stage regulators also have a feed-

back mechanism to save gas. They contain brass/

zinc materials to reduce galling and corrosion.

Coarse adjusting threads permit quick adjustment,

while a low spring constant helps assure accu-

rate settings. Additionally, maximum delivery pres-

sures are factory adjusted for improved consis-

tency from one regulator to the next.

Fewer Models, Parts,

And Problems

Another major Trimline feature is that the design

allows the same flexibility as was available with

previous Linde lines, but with fewer regulators, and

parts. The fewer models and reduced number of

parts provide for easier selection and more con-

venient distributor inventorying.

In all, there are some 40 Trimline models, in-

cluding single and two-stage regulators, which

incorporate a total of about 120 part numbers for

finished parts and assemblies. This is less than

half the number of parts used in our former line.

The part numbers have been reduced not only

because we have gone from two series to one,

but also because the Trimline regulators have a

high degree of parts interchangeability between

single-stage and two-stage units. In fact, with the

exception of the body, all of the single-stage parts

are also used in the two-stage regulator.

Testing For Protection

Burnout test methods were developed which in-

clude the introduction of hydrocarbon contami-

nants into a regulator body along with the use of

a guaranteed ignition source. Since regulator

burnouts occur infrequently, this induced burnout

approach was necessary to determine the degree

to which our own regulators and many competi-

tive varieties were able to withstand a burnout.

After submitting many regulator models to this

test, the regulators were evaluated based upon

the degree of destruction and potential for opera-

tor injury.

In these extensive tests our latest Trimline de-

sign provided more operator protection than any

other regulator we tested ours or theirs. Experi-

ence also shows that Trimline regulates gas pres-

sure more accurately. With numerous design in-

novations the Trimline saves gas, resists corro-

sion, and operates more smoothly than the best

of the other regulators in use today.

ID System

And Precautionary

Message For

Proper Use

Trimline regulators incorporate a new identi-

fication system to aid in determining the type

of service that the regulator is designed for.

For example:

-77-150-540: identifies the Two-stage 77

series regulator, capable of producing 150

psig maximum delivery pressure, with cylin-

der oxygen service CGA 540.

-76-15-510: identifies the single-stage 76

series regulator, capable of producing 15 psig

maximum delivery pressure, with acetylene ser-

vice CGA 5 10.

The pressure gauges on Trimline are color-coded

for an added degree of safety:

Oxygen - Green

Fuel Gases - Red

All other gases - Blue

In addition, we have added a message which

states the type of service for which the gauge is

intended. For example, the oxygen gauge says

“Use ONLY With Oxygen”. The acetylene and

other gas gauges say

“Do Not Use with Oxygen “.

We hope that these precautions will preclude

the accidental use of gauges for the wrong type

of service. When such misuse occurs the

potential for contamination exists. Subsequent

use of a contaminated gauge with high-purity

oxygen thereby increases the potential for

operator injury.

Built With

Bar Stock Body

Both the single- and two-stage Trimline regulator

bodies are machined from solid brass bar stock.

This is a drastic departure from the manner in

which their predecessors were manufactured, as

well as from the techniques used by the majority

of our competitors.

Most regulator bodies are manufactured from

forgings. Forging is a process is which a small

slug of metal is hammered into a blank. The blank

is then machined into its final shape.

Trimline’s bar stock body provides heavy wall

thicknesses which help contain a burnoutand,

keep internal cavities to a minimum. This reduces

the amount of gas that can accumulate in the body

and contribute to the seriousness of an incident

should one occur. We call this the “Small Bang”

concept.

The cost of manufacturing this body is directly

related to the amount of metal which is machined

from that bar. The less removed, the more eco-

nomical the process. Hence, the impetus for both

safety and manufacturing economy is in the same

direction.

Design and Operation

In addition to the bar stock concept, there are

a number of other unique characteristics

about the Trimline design which contribute to

its risk reduction and reliability in operation.

Refer to illustration #1.

In the first stage of the two-stage design, the

high-pressure gas enters the inlet to the first stage

through a long, narrow passage (1) intended to

quench or reduce the intensity of any fire which

could come in from the inlet connection. That high-

pressure gas then reverses its direction and

comes out through the center of the first stage

nozzle (2), where it impinges upon the synthetic

seating material (3), which is embedded in the

small diameter end of the first stage piston (4).

The amount of synthetic material is kept to a mini-

mum, so as not to contribute unnecessary

amounts of fuel to a burnout. The piston design

provides the positive shut-off of an attached stem

while, at the same time, eliminating the need for

a diaphragm and simplifying regulator assembly.

Piston Controls 1st

Stage and

Diaphragm-2nd Stage

In the relaxed state, the first stage piston valve is

in the open configuration, as illustrated. The high

incoming gas pressure tends to blow against the

piston and it is, therefore, a pressure opening

valve design. The piston is sealed on both ends

with “0” rings. The gas exits the nozzle (2) and

enters the small hole on the side of the piston (5).

That hole transports the gas through the piston

to the delivery chamber (6) of the first stage.

That delivery chamber of the first stage is also

the inlet chamber for the second stage. As the

pressure builds, it exerts a force against the large

end of the piston (7) which now overcomes the

spring tension (8) and begins pushing the seat

(3) against the valve (2), closing the valve. If a

leak should occur at the first stage piston seat

(3), the pressure and resulting force on the large

end of the piston (7) will increase until it shuts off

due to brute force. It is this action that makes it

identical to the operation of an attached stem dia-

phragm design.

into the diaphragm chamber (12), where it rests

against the diaphragm plate (13).

Baffle Plate

Protects Diaphragm

Trimline single- and two-stage models both in-

corporate what is called a diaphragm baffle plate

(14). That plate screws into the body and sup-

ports the push rod for the second stage valve.

One end of the stem is supported very snugly by

the baffle plate, while the other end is of very loose

fit. The loose fitting end provides the valve orifice

(11) for gas passage. When the gas passes

through the orifice, it enters the cross drill hole

(15) which allows it to exit to the hoses and torch

without passing through the diaphragm chamber

(12).

The diaphragm baffle plate is another important

risk reduction feature in Trimline because it pro-

tects the diaphragm by keeping it out of the main

gas stream. In this way the neoprene diaphragm

(16) is not directly exposed to hot gases or fire

which could destroy it. Small bleeder holes (17)

are provided in the baffle plateto allow the dia-

phragm to function and respond to demand for

greater or lesser amounts of gas supply.

The single-stage Trimline Regulator contains all

of the component parts beginning with the sec-

ond stage valve slider (18) through to the pres-

sure adjusting screw.

The single- and two-stage Trimline Regulators

have brass bar stock bodies (19) which have con-

siderably less internal volume than do many

forged body designs of either our competitors or

other OXWELD and PUROX lines.

The zinc die cast cap (20), provides excellent met-

allurgical thread engagement while, at the same

time, minimizing tendencies toward corrosion and

galling. Linde had used zinc die castings in com-

bination with brass bodies for many years in our

PREST-O-LITE line Regulators. For added resis-

tance to abrasion and for appearance, the cap is

plated with a hard bright chrome.

The second stage seat design incorporates a syn-

thetic material (9) with a push rod (10) at its cen-

ter. This is a pressure closing valve, since incom-

ing gas tends to close the valve, That push rod

passes through the second stage valve (11) and

Better ColdBetter Cold

Better Cold

Weather Performance

Trimline Regulators incorporate fabric reinforced

neoprene diaphragms (16) that are one of the

thinnest Linde has ever made. The fabric gives

them high strength. These were developed to pro-

vide maximum flexibility in all temperatures and

types of service, and to eliminate problems as-

sociated with cold weather diaphragm leakage.

When heavy diaphragms are used, the rubber

shrinks in sub-zero temperatures and causes

leakage to result between the body and cap (21).

Trimline diaphragms are only slightly more than

1/32 of an inch thick and, as a result, they shrink

less and, thereby, minimize leaks.

Trimline Saves Gas

The Trimline two-stage Regulator has what we

call a “Gas Saver” feature. Conventional oxygen

cylinder regulators with delivery pressure capa-

bilities of 150 psig will generally have a first-stage

valve designed to deliver 300 psig to the second

stage. This means that, as the cylinder is con-

sumed and the internal pressure drops, the first

stage of conventional regulators will cease to func-

tion once the cylinder pressure reaches about 300

psig, regardless of whether the delivery pressure

is 5 psig or 150 psig. From there on down the

user has single stage operation, with the first stage

valve wide open and non -functioning, If the ap-

plication and delivery pressure control are criti-

cal, the cylinder should be changed and replaced

with a fresh one once that 300 psig level is

reached. That means returning approximately 15

percent of the gas to the supplier.

Trimline has a better idea. AD of the Trimline

two-stage regulators, regardless of the type of gas

service for which they are intended, incorporate

a feedback mechanism wherein second stage

delivery pressure (15) is bled back into the piston

spring chamber (22) between the “0” rings of the

large and small diameter to assist the spring (8)

in keeping the piston open. The first stage of a

Trimline two-stage regulator will function down to

pressures of about 50 psig above the actual sec-

ond stage delivery. For example, an oxygen regu-

lator that is adjusted for delivery pressure to the

torch of 150 psig will function as a two-stage regu-

lator until the cylinder pressure has reached the

low level of 200 psig. Almost 50 percent of the

residual cylinder pressure is used instead of re-

turning it to the distributor. If, on the other hand,

the oxygen delivery pressure to the torch is read-

justed for 5 psig, the first stage will continue to

function until the incoming pressure has reached

a level of about 55 psig. Trimline, therefore, does

provide a gas saver feature; and in those appli-

cations where two-stage regulation is desired, can

actually pay for itself in a short period of time with

the more efficient use of cylinder product.

Illustration 1

What’s Up Front

Refer to illustration #2.

The front end assemblies of both the single-stage

and two-stage Trimline regulators are identical.

Only the pressure adjusting spring (1) is changed,

depending upon the type of gas service and de-

livery pressure for which the regulator is intended.

Springs

Trimline Regulators incorporate low spring rate

pressure adjusting springs. These have a num-

ber of advantages to the end user:

• Pressure adjustments are smooth because of

the gradual manner in which loading of the dia-

phragm is created.

• Coarse threads can be used on the pressure

adjusting screw (2) to reduce fatigue in adjust-

ment.

• To provide more constant pressure on the dia-

phragm while the valve is opening and closing to

keep delivery pressure smooth.

Pressure Adjustments

Are Smooth And

Consistent

The pressure adjusting screw (3) is hollow and

incorporates a small trim screw (4) at the internal

end to assure that reliable delivery pressures can

be achieved with every regulator that leaves the

factory. This adjustment assures consistent per-

formance from one regulator to the next.

The trim screw is adjusted and secured with a

drop of cement before it is shipped. It is not in-

tended to be adjusted in service. However, in cer-

tain critical applications, the customer may wish

to use the

trim screw to limit delivery pressure. A metallic

decal covers the opening in the external end of

the pressure adjusting screw (5) to camouflage

its existence. Pressure adjusting screws are also

provided with a small male thread (6) on the in-

ternal end of the screw to accept a lock nut which

will prevent the pressure adjusting screw from

being removed from the cap in those applications

where screws are routinely misplaced, stolen, or

vibrate loose in transit.

An advance in the state of the art for minimizing

risk from misuse.

Easier to select and order.

More durable because of bar stock design.

More dependable in cold weather service.

A gas saver because of the feedback feature.

Factory preset for greater product consistency.

In Summary,

Trimline is:

Illustration 2

EQUIPMENT, MATERIALS and SUPPLIES

for all your welding needs.

A complete line of system-engineered torches, wire feeders and power sources;

welding wires of carbon and low alloy steels, stainless and non-ferrous; manual

and mechanized packages.

HELIARC products from the company that introduced TIG welding in 1942; a

complete selection of manual and mechanized equipment, rods and accesso-

ries.

Equipment packages, over 14 fluxes and 15 wires to fill all carbon steel weld-

ing needs.

High-quality high-speed welding and cutting products by the inventers of plasma

arc; exclusive underwater cutting process available for highest quality.

The famous OXWELD and PUROX lines of welding and cutting equipment

that have been industry standards for more than 80 years; OXWELD steel and

bronze rods for joining.

From straight-line modles to sophisticated N/C installations; a machine for ev-

ery size shop and every application.

For personal protection in welding and cutting.

MIG...

TIG...

SUBMERGED ARC...

PLASMA ARC...

OXYFUEL...

CUTTING

MACHINES...

WELDING SAFETY EQUIPMENT and SUPPLIES...

F-5310-B 11/99 Printed in U.S.A.

The terms HELIARC, OXWELD, PREST-O-LITE, and PUROX are registered trademarks of ESAB Welding & Cutting Products.

Call the Authorized ESAB Welding & Cutting Products Distributor serving your area.

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

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ESAB Trimline Regulators User manual

ESAB Trimline Regulators User manual

ESAB Trimline Regulators User manual

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