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By David Pryor
In the world of oxy-fuel welding and cutting, the gas regulator often does not get the attention or the respect that it deserves. Needing to operate across the entire range of cylinder pressures, this piece of equipment is the workhorse of the oxy-fuel process. Over the course of a day, as all professionals know, the regulator plays a critical role in the quality of the weld or cut, and in the safety of those performing the operation.
 There had not been any significant improvement in the regulator industry since the early 1900s. The road to recent innovation, however, began when Thermadyne Industries conducted research with end users and distributors to determine problems common to traditional regulators. The question we asked was: What new capabilities can we provide to bring even greater value to our customers?
The safety of regulators was of utmost concern to all parties, which was an area where Thermadyne has always been an industry leader. Its Victor brand was founded in 1913 by L.W. Stettner, a welder who after suffering the loss of an eye from a welding accident, set out to design and build better, safer welding products. Making the gauges on regulators less vulnerable to damage and more user friendly were identified as key areas for improvement.
Once we had feedback, our engineers went to work. After 11 rounds of product design, and lengthy testing, Thermadyne launched the Victor Professional Edge Series regulators in 2009.
Since gas cylinders are often hit by steel or dropped on the ground which damages regulator gauges, the Edge was designed with a single point of contact to minimize potential impact points to protect the integrity of the gas delivery system. Dual, built-in gauges were recessed into the body for additional protection.
And for additional durability and safety, an exclusive Shock Limitation and Absorption Mechanism (SLAM) technology was developed and built right into the knob of the regulator, where a multi-layer shock zone slows velocity to reduce the force of impact in the event of a fall. SLAM is designed to protect regulator vitals and the cylinder valve itself by absorbing more than 5,000 pound-force of impact energy.
Additionally, since welding is often done in harsh environments, an innovative internal vent system was designed to protect the regulator internals from weather elements. As professional welders know, an inherent safety issue is the incompatibility of oxygen with hydrocarbon materials or particles. The oxy-fuel process has the potential to cause a violent energy release. Contaminants, even minor ones like dust from the regulator being stored under a workbench, can cause combustion. In order to make conditions as safe as possible, the Victor Edge Series was developed to include a new patent pending particle trap feature to stop contaminants from entering the seat mechanism. The new design meets or exceeds all industry standards, including UL 252 and CGA E-4 Heated Oxygen Impact Test. In fact, the new design offers the highest resistance to oxygen-related fires in the industry, passing the stringent ASTM G-175 Promoted Ignition Test which is administered in the medical gas regulator industry. The design is “fault tolerant” in the event of an inboard ignition source in oxygen use, offering unsurpassed resistance to oxygen.
Along with the improving safety and durability, our engineers found ways to make regulators more userfriendly. The Edge includes easy-to-read indicators, easy-to-grip controls, and color-coded knobs for rapid identification of the type of gas in use.
This simple regulator is breathing new life into gas control technology with results that are resonating at every level, from the welder who uses it daily to the safety coordinators who will find fewer accidents as a result of these innovations. Fewer accidents will reduce insurance and health claims, ultimately helping with overall operational costs. And with less down time, there will be better productivity and additional cost savings.
It is a common misconception that all regulators are alike. With the new technology introduced by the Victor Professional Edge, however, those perceptions are being changed. There is a new standard for safety, durability and ease of use in the gas industry.
David Pryor is Director of Engineering for Thermadyne’s Global Gas Equipment. He can be contacted at David_Pryor@thermadyne.com
New ESS3 regulators are available in Contender and Performer outfits.
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