ESAB OXWELD C-60 and C-60-S Machine Cutting Torches and 1700-ACA-1 Powder Cutting Attachment Troubleshooting instruction

INSTRUCTIONS for

F-9040-N

October, 2000

C-60 and C-60-S

MACHINE CUTTING TORCHES and

1700-ACA-1

POWDER CUTTING ATTACHMENT

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe prac­tices for oxy-fuel gas equipment, we urge you to read our booklet “Precautions and Safe Practices for Welding, Cutting and
Heating”, Form 2035. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install
or 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 cutting torches covered by these instructions are listed by Underwriter’s Laboratories only when using parts manufactured
by ESAB Welding & Cutting Products, to the specifications on file with Underwriter’s 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.

I. DESCRIPTION

The C-60 and C-60-S Machine Cutting Torches are
for use with any of the commonly used fuel gases such
as acetylene, natural gas, propane and many of the
proprietary gases. A minimum of 10 psi fuel gas pres­sure is required for proper operation.

The basic difference between the C-60 and C-60-S
torches is in their overall length. The C-60 torch is ap­proximately 6 feet long, while the C-60-S is approxi­mately 2 1/2 feet long. The 1700-ACA-2 Power Cut­ting Attachment is only for use with the C-60 torch.

II. INST ALLATION AND CONNECTION

A. INSTALLATION

F-9040-N

1. A filter designed to screen out dirt and scale should
be installed upstream of the cutting oxygen regu­lator which supplies the C-60 Torch. Use of a filter
reduces the possibility of accidental hose burn­outs.

The 1-in. NPT Pipeline Filter Assembly (P/N

2116734) is recommended if the cutting oxygen

supply regulator is an Oxweld R-52 feeding a single
cutting station. In the case of multiple torch instal­lations supplied by a single oxygen regulator, such
as an Oxweld R-83, filter (P/N 21 16735) is recom­mended.

2. A 1-in. quick opening full flow shutof f valve should
be installed in the cutting oxygen hose line at least
6 feet ahead of the torch and convenient to the op­erating position.

3. For control of the preheat gases, “C” size oxygen
and acetylene needle valves should be inserted in
the preheat oxygen and fuel gas hose lines at least
6 feet ahead of the torch.

Standard commercial valves can be used after they
are cleaned and lubricated, to oxygen standards,
as described in maintenance procedures.

4. If using the 1700-ACA-2 Power Cutting Attachment
(10Y95) on the C-60, the ACV-4 Powder Pinch
Valve (16X36) should be installed in the powder
hose line about 5 feet ahead of the torch and con­venient to the operator.

5. Connect the front clamp of powder cutting attach­ment to front body of torch. Connect the two rear
clamps to the cutting-oxygen tube on the torch. (See
Fig. 2.)

Be sure this information reaches the operator.
You can get extra copies through your supplier.

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SAFETY PRECAUTIONS

These Safety Precautions are for your protection. They sum­marize precautionary information from the references listed
in Additional Safety Information section. Before performing any
installation or operating procedures, be sure to read and fol­low the safety precautions listed below as well as all other
manuals, material safety data sheets, labels, etc. Failure to ob­serve Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS - Some
welding, cutting and gouging processes are
noisy and require ear protection. Hot metal can
cause skin burns and heat rays may injure
eyes. Training in the proper use of the pro­cesses and equipment is essential to prevent
accidents. Also:

1. Always wear safety glasses with side shields in any work area,
even if welding helmets, face shields, or goggles are also re­quired.

2. W ear flameproof gauntlet type gloves, heavy long-sleeve shirt,
cuffless trousers, high-topped shoes, and a welding helmet or
cap for hair protection, to protect against hot sparks and hot
metal. A flameproof apron may also be desirable as protection
against radiated heat and sparks.

3. Hot sparks or metal can lodge in rolled up sleeves, trousers
cuffs, or pockets. Sleeves and collars should be kept buttoned,
and open pockets eliminated from the front of clothing.

4. Protect other personnel from hot sparks with a suitable non­flammable partition or curtains.

5. Use goggles over safety glasses when chipping slag or grind­ing. Chipped slag may be hot and can travel considerable dis­tances. Bystanders should also wear goggles over safety
glasses.

FIRES AND EXPLOSIONS - Heat from a flame
can act as an ignition source. Hot slag or sparks
can also cause fires or explosions. Therefore:

1. Remove all combustible materials well away from the work
area or completely cover the materials with a protective non­flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and coat­ings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in
floors or wall openings and cause a hidden smoldering fire on
the floor below. Make certain that such openings are protected
from hot sparks and metal.

3. Do not weld, cut, or perform any other hot work on materials,
containers, or piping until it has been completely cleaned so
that no substances on the material can produce flammable or
toxic vapors. Do not do hot work on closed containers. They
may explode.

4. Have fire extinguishing equipment handy for inst ant use, such
as a garden hose, a pail of water or sand, or portable fire
extinguisher. Be sure you are trained in its use.

5. After completing operations, inspect the work area to be sure
that there are no hot sparks or hot metal which could cause a
later fire. Use fire watchers when necessary.

6. For additional information, refer to NFPA Standard 51B, “Fire
Prevention in Use of Cutting and Welding Processes”, which
is available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

FUMES AND GASES - Fumes and gases, par­ticularly in confined spaces, can cause dis­comfort or injury. Do not breathe fumes or
gases from welding or cutting, Therefore:

1. Always provide adequate ventilation in the work area by natu­ral or mechanical ventilation means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel, copper,
zinc, lead, beryllium, or cadmium unless positive mechanical
ventilation is provided. Do not breathe fumes and gases from
these materials.

2. If you develop momentary eye, nose, or throat irritation while
operating, this is an indication that ventilation is not adequate.
Stop work at once and take necessary steps to improve venti­lation in the work area. Do not continue to operate if physical
discomfort persists.

3. Refer to ANSI/ASC Standard Z49.1 listed below for specific
ventilation recommendations.

4. WARNING: This product, when used for welding or

1. Always have qualified personnel perform the installation,
troubleshooting, and maintenance work. Do not operate or
repair any equipment unless you are qualified to do so.

2. Keep all oxy-fuel equipment free of grease or oil. Grease, oil,
and other similar combustible materials, when ignited, can burn
violently in the presence of oxygen.

3. Do not abuse any equipment or accessories. Keep equipment
away from heat and wet conditions, oil or grease, corrosive
atmospheres and inclement weather.

4. Keep all safety devices in position and in good repair.

5. Use equipment for its intended purpose. Do not modify it in
any manner.

1. Use the proper gas for the process and use the proper pres­sure reducing regulator designed to operate from the com­pressed gas cylinder. Do not use adaptors to mount the regu­lator on the cylinder. Maintain hoses and fittings in good con­dition. Follow manufacturer’s operating instructions for mount­ing the regulator to the gas cylinder.

2. Always secure cylinders in an upright position by chain or strap
to suitable hand trucks, benches, walls, post, or racks. Never
secure cylinders to work tables or fixtures where they may
become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have the valve
protection cap in place on top of the cylinder if no regulators is
installed. Secure and move cylinders by using suitable hand
trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, or flame of a weld­ing, cutting, or gouging operation. Never strike an arc on a
cylinder.

5. For additional information, refer to CGA Standard P-1, “Pre­cautions for Safe Handling of Compressed Gases in Cylin­ders:, which is available from the Compressed Gas Associa­tion, 1235 Jefferson Davis Highway, Arlington, VA 22202.

The following publications, which are available from the American
Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are
recommended to you:

1. ANSI/AWS Z49.1 - “Safety in Welding and Cutting”.

2. AWS F4.1 - “Recommended Safe Practices for the Prepara­tion for Welding and Cutting of Containers and Piping That
Have Held Hazardous Substances”/

3. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

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cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety Code §25249.5 et seq.)

EQUIPMENT MAINTENANCE - Faulty or improp­erly maintained equipment, such as torches, hoses
and regulators, can result in poor work, but even
more important, it can cause injury or death
through fires. Therefore:

GAS CYLINDER HANDLING - Gas cylinders, if mis­handled, can rupture or explode violently . Sudden
rupture of a cylinder, valve or relief device can in­jure or kill you. Therefore:

ADDITIONAL SAFETY INFORMATION - For more
information on safe practices for oxy-fuel welding
and cutting equipment, ask your distributor for a
copy of “Precautions and Safe Practices for Gas
Welding, Cutting, and Heating”, Form 2035. Gas
apparatus safety guidelines are also available on
video cassettes from your distributor.

MEANING OF SYMBOLS - As used throughout
this manual: Means Attention! Be Alert! Your
safety is involved.

Means immediate hazards which, if not avoided,
will result in immediate, serious personal in-

jury or loss of life.
Means potential hazards which could result in

personal injury or loss of life.
Means hazards which could result in minor

personal injury.

SP-GA 10/98

B. CONNECTION

1. Hoses — Use 3/4 in. cutting oxygen hose with “D”
size fittings, 1/2-in. preheat oxygen and fuel gas
hoses with “C” size fittings. Use 1/4-in. Powder
hose for lengths up to 50-ft., if powder is to be used.
Powder hose should never exceed 50-ft. in length.

quently; (3) operating pressures are correct; and (4)
throttle valves are adjusted properly. Should a flash­back occur, IMMEDIATEL Y shut of f the torch. Allow it
to cool off for at least a minute. Then check your nozzle
or tip, gas pressures, readjust regulator if necessary,
and relight the torch. If flashback recurs, send the cut­ting torch with nozzle to your distributor for repair.

NOTE: If new hose is used, use compressed air to

clear hose of dirt, dust, etc.

2. Torch — Attach the preheat oxygen, cutting oxy­gen and fuel gas hoses to the torch. Attach the
powder hose, when used, to the powder attach­ment. Make certain all connections are gas-tight.
Attach the desired nozzle to the torch.

Flashbacks can cause serious burns.

Be sure gas flow is sufficient for head or nozzle size.
Adjust regulators for proper psig pressures.
Adjust throttle valves properly .
Keep torch in good repair.
DO NOT throttle back gasses to use large head or
nozzle on thin material.

III. OPERATION

A. OPERA TING PRECAUTIONS
Flow: There must be proper flow of gases for safe

operation and full performance. This requires the
following three conditions: (1) the regulators that
determine the inlet pressure to the hoses must be set
to the correct pressure: (2) the hoses and their
connectors must have adequate capacity for the job
(hoses that are too long, too small or have connectors
with small passageways can cause problems); and (3)
the throttle valves on the torch must be adjusted with
the procedure shown in these instructions.

Note: Items (1) and (2) can be checked by measuring
the gas pressures at the torch. Gauge adaptors are
available for this purpose.

Backfire: Improper operation of the torch may cause
the flames to go out with a loud 'pop'. Such a backfire
may be caused by contact of nozzle with the work, by
spatter from the work, by the use of incorrect gas pres­sures, or by leakage at the cutting nozzle seats due to
dirt or nicks on the seats or to a loose nozzle nut.

Flashback: Under certain circumstances, the flame
may not 'pop' out (backfire) but instead burn back in­side the torch with a shrill hissing or squeal. This is
called a 'flashback'. A flashback should never occur if
(1) the equipment is in good condition; (2) preheat ports
on the cutting nozzles or welding tips are cleaned fre-

B. ADJUSTMENT OF CUTTING OXYGEN

PRESSURE

Open the cutting oxygen control valve wide. Turn in
the pressure-adjusting screw on the cutting oxygen
regulator until the pressure gauge on the torch indicates
the correct cutting oxygen pressure. Close the cutting
oxygen valve.

C. ADJUSTMENT OF PREHEA T GAS PRESSURE

Open the throttle valve in the preheat lines. Turn in the
pressure-adjusting screw on the preheat oxygen regu­lator until the delivery pressure gauge indicates the
correct oxygen pressure. Adjust the fuel gas pressure
the same way, but do not leave the valves open any
longer than necessary . Make sure there are no sparks
or flame near the nozzle flame ports during adjustment
of pressure.

D. ADJUSTMENT OF POWDER DISPENSER,

WHEN USING POWDER

Open the dispenser bleeder valve wide. Adjust the air
regulator to provide approximately 5 psi pressure at
the hopper. Gradually reduce the bleeder valve open­ing until powder flow from the two outlet tubes on the
powder cutting attachment becomes steady. A slight
adjustment of hopper pressure may be necessary to
obtain the desired powder flow rates. Check the pow­der flow rate by collecting, in a container, the powder
discharged for 1 minute. If weighing facilities are not
available, a household measuring cup may be used to
approximate the weight of powder discharged. One cup
contains approximately 24 ounces of loosely packed
powder.

E. LIGHTING AND SHUTOFF OF TORCH

Open the preheat oxygen valve a small fraction of a
turn. Open the fuel gas nozzle about 1/4 turn and light
the gas at the nozzle with a friction lighter. Adjust the
flames with the preheat oxygen valve. If the flames are
shorter than desired, open the fuel gas valve and pre­heat oxygen valve to secure flames of the desired
length. If the flames burn away from the end of the
nozzle, or blow off as soon as lighted, or if the flame
length is greater than desired, close the fuel gas valve
slightly and readjust the preheat oxygen valve.

T o shutoff the torch, first close the cutting oxygen valve,
then the fuel gas valve and finally the preheat oxygen
valve. When powder is used, shut off the air supply

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