F-5310-B 11/99
Trimline Regulator s
Designed For Reduced Risk,
Built For Performance
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 injury, and its high level of reliability reflects that
fact. Y et 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 T rimline
line of regulators. This investment has
paiddividends in the form of greatly improved
regulators. Among other things Trimline regulators 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 regulator gauges are color-coded and include a printed
message intended to prevent misuse. T wo-stage
models have long flame quench inlet passages,
and first-stage pistons, which provide positive
shut-off. A relatively small quantity of seat material serves to lower burnout intensity should one
occur.
Trimline two-stage regulators also have a feedback 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 accurate settings. Additionally , maximum delivery pressures are factory adjusted for improved consistency from one regulator to the next.
Fewer Models, Par ts,
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 convenient 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.
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 result 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 regulator may become flying projectiles.
Despite our best efforts, it is evident that because equipment can be used in ways which
are not recommended, it is impossible to guarantee that regulator burnout will not occur. The
next best thing is to build features into the regulator to contain a burnout to minimize the risk of
injury. This is what we set about doing with
Trimline.
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Testing For Protection
Burnout test methods were developed which include the introduction of hydrocarbon contaminants 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 competitive 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 operator injury.
In these extensive tests our latest Trimline design provided more operator protection than any
other regulator we tested ours or theirs. Experience also shows that Trimline regulates gas pressure more accurately. With numerous design innovations the Trimline saves gas, resists corrosion, and operates more smoothly than the best
of the other regulators in use today.
ID System
And Precautionar y
Message For
Proper Use
Trimline regulators incorporate a new identification 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 cylinder oxygen service CGA 540.
-76-15-510: identifies the single-stage 76
series regulator, capable of producing 15 p sig
maximum delivery pressure, with acetylene ser-
vice CGA 5 10.
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
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.
“Do Not Use with Oxygen “.
Built With
Bar Stock Body
Both the single- and two-stage T rimline 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 economical the process. Hence, the impetus for both
safety and manufacturing economy is in the same
direction.
The pressure gauges on Trimline are color-coded
for an added degree of safety:
Oxygen - Green
Fuel Gases - Red
All other gases - Blue
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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 highpressure 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 minimum, 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
Diaphr agm-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 diaphragm design.
The second stage seat design incorporates a synthetic material (9) with a push rod (10) at its center. This is a pressure closing valve, since incoming gas tends to close the valve, That push rod
passes through the second stage valve (11) and
into the diaphragm chamber (12), where it rests
against the diaphragm plate (13).
Baffle Plate
Protects Diaphr agm
Trimline single- and two-stage models both incorporate what is called a diaphragm baffle plate
(14). That plate screws into the body and supports 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 protects 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 diaphragm 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 second stage valve slider (18) through to the pressure adjusting screw.
The single- and two-stage Trimline Regulators
have brass bar stock bodies (19) which have considerably 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 metallurgical thread engagement while, at the same
time, minimizing tendencies toward corrosion and
galling. Linde had used zinc die castings in combination with brass bodies for many years in our
PREST-O-LITE line Regulators. For added resistance to abrasion and for appearance, the cap is
plated with a hard bright chrome.
Better ColdBetter Cold
Better Cold
Better ColdBetter 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 provide maximum flexibility in all temperatures and
4
types of service, and to eliminate problems associated 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 capabilities 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 consumed and the internal pressure drops, the first
stage of conventional regulators will cease to function 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 application and delivery pressure control are critical, 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 second stage delivery . For example, an oxygen regulator that is adjusted for delivery pressure to the
torch of 150 psig will function as a two-stage regulator until the cylinder pressure has reached the
low level of 200 psig. Almost 50 percent of the
residual cylinder pressure is used instead of returning it to the distributor. If, on the other hand,
the oxygen delivery pressure to the torch is readjusted for 5 psig, the first stage will continue to
function until the incoming pressure has reached
a level of about 55 psig. T rimline, therefore, does
provide a gas saver feature; and in those applications 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
5
W h at ’s Up Fr o nt
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 delivery pressure for which the regulator is intended.
Springs
Trimline Regulators incorporate low spring rate
pressure adjusting springs. These have a number of advantages to the end user:
• Pressure adjustments are smooth because of
the gradual manner in which loading of the diaphragm is created.
• Coarse threads can be used on the pressure
adjusting screw (2) to reduce fatigue in adjustment.
• To provide more constant pressure on the diaphragm 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 performance 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 intended to be adjusted in service. However, in certain 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 internal 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.
In Summar y,
Trimline is:
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.
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1
2
6
3
5
4
Illustration 2
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