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Answers on choosing, fitting and looking after single stage oxygen regulators for cutting and welding.
A single stage regulator reduces cylinder pressure to the working pressure in one step. A two stage regulator does it in two steps. The practical effect is on how steady the working pressure stays as the cylinder empties.With a single stage regulator the outlet pressure can shift as the cylinder pressure falls, so the pressure may need adjusting during a long job. A two stage regulator holds the outlet pressure steadier without readjustment. Single stage regulators are well suited to typical workshop cutting and welding, where the pressure is set and checked regularly. Check the maker's data for the performance of a particular regulator.
Regulators can have a contents gauge on the cylinder side showing supply pressure, and a second gauge on the outlet side showing the working pressure. Some adjustable regulators have no gauges but a pressure indication marked on the housing, and some give a fixed pressure.Two gauges let you see how much gas is left and set the working pressure accurately, which suits cutting where you need to match the tip chart. A gaugeless type gives you no direct contents reading, so it is better where the pressure needs are simple and you have another way to judge the cylinder. Gauges should meet the relevant standard, which includes safe venting if the gauge fails.
The inlet is the nut that connects to the cylinder valve, and the outlet is the connection for the hose or flashback arrester. On UK oxygen regulators you will commonly see a 5/8 inch BSP right-hand inlet and a 3/8 inch BSP outlet, but the exact fitting depends on the cylinder valve and the maker.Oxygen connections use right-hand threads, while fuel gas connections use left-hand threads, partly to avoid mix-ups. Check the cylinder valve outlet and the hose or arrester thread before ordering, and note that a regulator made for another country's cylinder connection will not fit a UK cylinder.
It is only about how the regulator meets the cylinder valve. A bottom entry regulator has the inlet underneath, so it sits upright on a cylinder with an upward-facing valve outlet. A side entry regulator has the inlet on the side, so the gauges face the right way on a cylinder whose valve outlet points sideways.The threads are normally the same. The choice does not change whether the regulator is single or two stage. You can use either style with an adaptor, but the gauges may then end up at an awkward angle, so choose the style that matches your cylinder valve and keeps the gauges easy to read.
Check the maximum inlet pressure on the regulator before connecting it. Regulators are made for different maximum supply pressures, and it is possible to connect a regulator designed for 200 bar to a 300 bar cylinder valve. The HSE notes this mismatch may not fail immediately, but with oxygen the internal components may not be suitable at the higher pressure.The maximum inlet pressure is marked on the regulator body and in the instructions. Only use a regulator rated for at least the pressure of the cylinder you are connecting it to, and ask if you are unsure.
Follow the regulator maker's and gas supplier's instructions, as the recommended steps can differ. Wipe the cylinder valve outlet and the regulator connection with a clean lint-free cloth and check both are free from grease, grit and dirt, then make the connection.With the regulator outlet closed and the pressure adjuster backed off, open the cylinder valve very slowly, then open the regulator outlet slowly. This avoids sudden compression of oxygen inside the regulator, which can heat and ignite internal parts. Do not use tape or jointing compound on the connections.