INSTRUCTIONS for
November, 1999
®
C-97 CUTTING TORCH
Cutting Range using Acetylene ................................ 1/8" - 12"
Cutting Range using any fuel gas ............................ 1/8" - 16"
Cutting Nozzles ...................................................... 1500 Series
T orch-Hose Connections ................ Oxy. - CGA-022 (9/16"-18)
F.G.. - CGA-023 (9/16"-18LH)
T orch-Overall Length ........................................................ 21-in.
Weight .......................................................................... 3-1/2 lbs.
CAUTION
!
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 ESAB booklet Precautions and Safe
Practices for Welding, Cutting and Heating, Form 2035. Do NOT permit untrained persons to operate this
equipment. DO NOT attempt to 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.
F-15-347-A
OPERATING INSTRUCTIONS
The C-97 can be used with any fuel gas including acetylene.
CONNECTING
1. Attach regulator to the oxygen cylinder or station
valve; attach fuel gas regulator to cylinder or station
valve unless fuel gas to be supplied through a hydraulic or check valve from a pipeline at desired pressure.
2. Attach oxygen hose to the oxygen regulator; attach
fuel gas hose to the fuel gas station valve or regulator. Attach both hoses to torch. Tighten all connection nuts with a wrench.
3. Attach nozzle to torch head, and tighten connection
nut with a wrench.
4. Check valve stem packing nuts for tightness.
WARNING
!
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.
ADJUSTING GAS PRESSURES
Fuel Gas: If fuel gas is supplied from a station outlet
without a regulator, merely open the station valve. If fuel
gas is being supplied through a station or cylinder regulator, open the fuel gas valve on the torch, turn in the
pressure-adjusting screw on the regulator until the regulator delivery-pressure gauge indicates the desired pressure (see chart on page 4). Then immediately close the
fuel gas valve.
Oxygen: Open the cutting oxygen valve by depressing
its valve lever fully. Turn in the pressure-adjusting screw
until the regulator delivery-pressure gauge registers the
desired pressure (see cutting chart on page 4). Then
release the cutting oxygen lever.
NOTE: When gaugeless regulators are used, do not
open torch valves. Merely turn in the pressureadjusting screws to the desired pressures as
indicated on the scales of the regulator caps.
TESTING FOR LEAKS
Every cutting outfit should be thoroughly tested for leaks
after it is first hooked up, and at regular intervals thereafter. After all connections have been made, make sure
all valves on the torch handle are closed. Then adjust
regulators, or open station valves, to apply 60 psi oxygen pressure and up to 10 psi fuel gas pressure on the
hoses.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
ESAB
ESAB Welding &
Cutting Products
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. Wear 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 instant 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.
3. Refer to ANSI/ASC Standard Z49.1 listed below for specific
ventilation recommendations.
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:
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.
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:
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 manufacturers 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.
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.
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.
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.
This symbol appearing in this manual means
Attention! Be Alert! Your safety is involved.
Used to call attention to immediate hazards
which, if not avoided, will result in immediate,
serious personal injury or loss of life.
Used to call attention to potential hazards
which could result in personal injury or loss of
life.
Used to call attention to hazards which could
result in minor personal injury.
2
SP-GA 7/97
Using Leak Test Solution (P/N 998771), or any other
solution suitable for oxygen service, check for leaks at
the cylinder valves, the cylinder-to-regulator connections,
the regulator-to-hose connections, and the hose-to-torch
connections. If bubbling at any point indicates leakage,
tighten the connection. If this does not stop the leakage,
close the appropriate cylinder valve, open the corresponding torch valve to remove all pressure from the
line, and finally release the regulator pressure-adjusting
screw by turning it counterclockwise; then break the
leaky connection, wipe metal seating surfaces with a
clean dry cloth, and examine them for nicks and
scratches. Remake the connection(s) and retest. Do not
try to light the torch until you are satisfied that all connections are gas-tight.
SHUTTING OFF
Release the cutting oxygen valve lever. Then close the
fuel gas valve, and finally the preheat oxygen valve.
If operations are to be stopped for half-hour or more, all
pressure should be released from the torch, hoses, and
regulators by doing the following:
1. Close each cylinder or station valve.
2. Open torch valves.
3. After relieving the gases, back out the pressure-adjusting screw of each regulator and close the torch
valves.
OPERATING PRECAUTIONS
After lighting the torch and adjusting the flames, use leak
test solution to check for leakage at all torch valves and
at the nozzle nut.
LIGHTING AND FLAME ADJUSTMENT
1. Open the preheat oxygen valve on the torch about
one (1) turn.
2. Open the fuel gas valve about one turn. Light the
gas at the nozzle with a friction lighter. DO NOT
USE A MATCH. Use of a match can seriously burn
your hand.
3. If using acetylene, open fuel gas valve 1/4 turn. Depress lever to open cutting oxygen valve and then
readjust preheat flame to neutral by opening preheat oxygen valve gradually.
If using FG-2 or any other gases except acetylene,
open fuel gas valve until flame just starts to leave
the end of the nozzle and open the preheat oxygen
valve until the flames are at their shortest length.
Depress the cutting oxygen valve lever and then
readjust the preheat flames to the shortest length
by opening the preheat oxygen valve gradually.
The above procedure usually provides adequate
preheat for the nozzle in use. If desiring to change
the preheat flames, always hold the cutting oxygen
valve open while readjusting the preheat oxygen and
fuel gas valves.
Because of several factors involved (injector,
Note:
nozzle size, gas pressures) the adjustment procedures given above do not apply in all situations. However this is a good rule-of-thumb if
you want preheat flames of maximum effectiveness: you should usually be able to keep one preheat valve wide open if regulator oxygen pressure has been set correctly for the nozzle in use.
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 seats or 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 cutting
nozzles or welding tips are cleaned frequently; (3) operating pressures are correct; and (4) throttle valves are
adjusted properly. Should a flashback occur, IMMEDIATELY shut off the torch. Allow it to cool off for at least a
minute. Then check your nozzle or tip, gas pressure,
readjust regulators if necessary, and relight the torch. If
flashback reoccurs, send the torch handle and welding
head or cutting attachment to your distributor or to ESAB
Remanufacturing Center, Ebenezer Road, Florence, SC
29501-0545 for repair.
3
OPERATING DATA, CLEANING DATA, & PART NUMBERS
GENERAL NOTES:
1. Pressures given are measured at the torch; therefore, pressure drop through the hose should be considered when setting pressure at
the regulator. Generally, 1/4-in. hoses up to 25-ft. long are adequate for cutting steel up to 4-in. thick. If longer hoses are required and if
cutting thicker steel, 3/8-in. hoses should be used. If using low-pressure fuel gas, 3/8-in. fuel gas hose should be used for all cutting
operations.
2. The table below shows average values based on typical conditions, the type and quality of steel, its surface condition, the purity of
oxygen, etc. will always have a bearing on the end results.
1534
1567
Fuel Gas T wo-Piece Cutting Nozzles
Nozzle Internal Nat. Gas FG-2 FG-2 Thickness psig ft3/hr Drill Size
Nozzle Part No. Steel Gas Pressure, Gas Consumption, Cleaning
Size Part No. Propane mapp mapp in. mm. Oxygen Fuel Gas Oxygen FG-2n Nat. Gas Cutting
1567 Series (High Preheat)
1/8" 639614 1/8 3 20 - 40 5 - 10 20 - 25 79
1/4" 639615 1/4 6 45 - 65 5 - 10 20 - 25 69
1/2" 639616 639322 998277 998557 1/2 13 40 3 - 5 65 - 85 5 - 10 20 - 25 65
3/4" 639617 3/4 19 70 - 90 5 - 10 20 - 25 61
1" 639618 1 25 95 - 115 5 - 10 25 - 30 54
2" 639619 2 50 175 - 200 8 - 15 30 - 35 51
3" 639620 3 75 235 - 260 8 - 15 35 - 40 47
4" 998734 14Z39 114Z08 998561 4 100 300 - 335 10 - 15 35 - 40 46
8" 998735 6 150 40 450 - 480 10 - 15 40 - 45 39
12" 998736 10 250 50 - 60 840 - 900 15 - 20 55 - 65 31
16" 998737 14 350 50 - 60 1120 - 1340 15 - 20 65 - 75 20
1534 Series (Medium Preheat)
2 14Z66 1/8 3 25 25 - 45 76
3 14Z50 14Z38 114Z07 998560 1/4 6 30 3 - 5 45 - 65 5 - 10 15 - 20 68
4 14Z51 1/2 13 30 70 - 90 60
6 14Z52 14Z39 114Z08 998561 3/4 19 30 3 - 5 125 - 145 5 - 10 15 - 20 53
8 14Z53 14Z39 114Z08 998561 3 75 40 3 - 5 280 - 300 8 - 15 30 - 40 46
Sleeve (External)
14Z77 639755 998558 8 200 55 - 60 5 - 10 560 - 590
*
12 300 60 - 70 900 - 970
14Z69 998269 998559 16 400 60 - 70 10 - 15 1340 - 1480
1 25 35 140 - 160
2 50 25 200 - 220
4 100 40 300 - 335
Use where high preheat intensity is desired.
Consumption of MAPP or propane is approximately the same as FG-2.
Use soft-bristled brush (750F99) to clean preheat slots of internal nozzles.
Heavy-duty sleeve (14Z96) available for use in place of 14Z77 sleeve.
*
Acetylene Cutting Nozzles, 1502 Series, (Medium Preheat)
Steel
Thickness
Size
1/4" 08Z67 1/4 6 20 5 35 - 45 6 - 8 69 68
1/2" 15Z17 1/2 13 30 65 - 75 8 - 10 66 60
1-1/2" 15Z18 3/4 19 35 6 120 - 135 14 - 16 65 53
4" 15Z19 3 75 35 6 205 - 255 16 - 20 61 46
8" 15Z20 6 150 50 7 395 - 460 20 - 25 57 39
12" 15Z21 10 250 60 7 630 - 710 40 - 45 56 31
Part No.
(in.)
1 25 130 - 140 14 - 16
2 50 185 - 210 16 - 20
4 100 235 - 285 19 - 22
8 200 545 - 625 30 - 35
12 300 790 - 905 45 - 55
(mm).
Gas Pressure, psig
Oxygen Acetylene
Gas Consumption, ft3/hr
Oxygen Acetylene
1502
Cleaning
Preheat
4
Drill Size
Cutting
MAINTENANCE INSTRUCTIONS
For all repairs other than those covered below, send the
apparatus to the nearest ESAB distributor or to ESAB
Remanufacturing Center, 411 S. Ebenezer Road, Florence, SC 29501. Improperly repaired apparatus is hazardous.
Preheat Valves: Leakage around either valve stem can
usually be corrected by tightening packing nut slightly. If
this does not stop the leakage, replace the throttle valve
assembly.
6. Screw valve assembly into body. Before reassembling cutting lever, connect torch to oxygen source,
apply at least 60 psi pressure, and check for leakage through the valve, around the stem, and around
the guide.
7. Reassemble cutting lever to torch.
Injector: To remove the injector for inspection or replacement, first unscrew the injector chamber plug and remove the injector spring. Then run a long No. 1032
machine screw into the threads in the end of the injector
and withdraw the injector by pulling on the screw.
If either preheat valve fails to shut off completely, remove the throttle valve assembly from the torch. With
clean cloth, wipe the ball in the end of the stem. Then
reinsert valve assembly and tighten it several times with
maximum force. If this does not eliminate leakage, try a
new throttle valve assembly. If then the valve does not
shut off completely, send the torch to a repair station for
reseating of the body.
After installing a new throttle valve assembly, tighten the
packing nut until the throttle valve can be turned only
with great difficulty, and set the unit aside, for three or
four hours at least, to set the packing. Then back off the
packing nut until the throttle valve turns readily.
Cutting Valve: If leakage develops around the cutting
valve stem or between the cutting valve guide and the
torch body, or if the cutting valve fails to shut off completely, proceed as follows:
1. Remove cutting valve lever by merely driving out
the fulcrum spiral-pin, using a drill or piece of rod (7/
32-in. dia. or smaller).
2. Unscrew cutting valve guide and lift out entire valve
assembly; guide (with external and internal O-rings)
valve stem, spring, and O-ring retaining washer.
3. Pull stem out of guide. Replace it with new part unless the molded rubber seat appears to be in excellent condition.
4. Remove the internal O-ring (85W10) from the guide
and insert a new O-ring. Replace the external Oring (86W70) if it shows distinct signs of wear.
5. Reassemble by placing retaining washer and spring
in guide, then placing stem through spring and Oring in guide.
Before reinstalling a previously-used injector, be sure
that the O-rings at each end of the injector assembly
are in good condition. Replace them if necessary. Also
be sure the injector chamber plug is fitted with an O-ring
in good condition (even in cases where the plug carried
no O-ring originally).
Cleaning Cutting Nozzles: If the cutting nozzle does
not produce straight, uniform flames, or if any of the
nozzle orifices become clogged, clean them by hand
with the correct size twist drills shown in the table on
page 3, or with OXWELD tip cleaners. (The relationship
between OXWELD tip cleaners and drill sizes is shown
on the tip cleaner case.) Maintaining clean orifices is
highly recommended for reducing any incidence of flashbacks.
For longer life, nozzles should be cleaned periodically in
a solution of OXWELD nozzle cleaning compound (Part
No. 761F00) made up and used as directed on the jar in
which it is packed.
PARTS INFORMATION
All parts which can be replaced without breaking soldered or brazed joints are illustrated on the next page.
When ordering parts, please give both part number and
description (including size, where appropriate). Parts
may be ordered from your ESAB welding equipment distributor or from ESAB Welding & Cutting Products, Customer Service Department, Florence, SC.
5
GUIDE - 638243
O-RING - 86W70
O-RING - 85W10
WASHER - 638241
SPIRAL PIN
50Z38
THUMBPIECE
DRILL AT ASSEMBLY
No. 52 (0635) DRILL
PIN
62620009
50Z37
LATCH
638981
LEVER ASSEMBLY
7/32" x 1"
62399001
51Z31
INSERT
SPRING - 29Z97
STEM - 638891
6
187W01
O-RING
7/8"-20
33A56 Nut
INJECTOR ASSEMBLY - 22052 (MPHC)
C-97-75°-21" ......................................................... Part No. 22053
C-97-90°-21" ......................................................... Part No. 22054
C-97-75°-36" .......................................................... Part No.
22186
C-97-90°-36" .......................................................... Part No.
22187
OTHER LENGTHS AVAILABLE UPON REQUEST
86W04
O-RING
40A39
SPRING
C-97 Cutting Torches
86W85
O-RING
134Z55
PLUG (9/16"-24)
3/8" - 24
(2) 54A87
THROTTLE VALVE ASSEMBLY
7
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information
Telephone: (800)362-7080 / Fax: (800) 634-7548
Telephone: (800)783-5360 / Fax: (800) 783-5362
Telephone: (800) 235-4012/ Fax: (888) 586-4670
B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693
Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations
D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548
E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
Eastern Distribution Center
Central Distribution Center
Western Distribution Center
Hours: 7:30 AM to 4:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com
F-15-347-A 11/99 Printed in U.S.A.
Hours: 7:30 AM to 5:00 PM EST
ESAB Welding & Cutting Products
PO Box 100545 Florence SC 29501-0545
8
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