INSTRUCTIONS for
W-24R WELDING TORCH
P/N 10A48
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 Gas 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.
The welding torches covered by these instructions are listed by Underwriters Laboratories only when used in
combination with tips and parts manufactured to ESAB Welding & Cutting Products to the specifications on file
with Underwriters 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 voids the manufacturers
warranty.
F-31 19-R
October, 2000
SPECIFICATIONS
Welding Range ........................... Thin gauge to over 1-in.
Heating Range ........................... 1 to 250 cfh acetylene
Length .................................................................. 8-1/4-in.
Weight........................................................................ 1 lb.
Torch-Hose Connections ....... ORS Oxy - 41/6418 fem.
ORS F.G. - 41/6418 LH fem.
Equivalent to approximately 1400 to 37,000 Btu/hr.
Acetylene and other fuel gases may be used.
OPERATING INSTRUCTIONS
CONNECTING
1. Attach regulators to the oxygen and acetylene cylinders. Follow all instructions supplied with your
regulators.
2. Attach oxygen and acetylene hoses to the regulators and to the torch handle, after making sure all
metal seating surfaces are clean. Tighten all connection nuts with a wrench.
3. Attach welding or heating head to the torch handle.
Tighten the connection nut with a wrench, but use
only slight force, since the threads have a low pitch
and excessive force may distort them.
4. Check throttle valve packing nuts for tightness.
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 gases to use large head or
nozzle on thin material.
ADJUSTING GAS PRESSURES
Medium-Pressure Fuel Gas: Open the torch fuel gas
valve one-half turn. Turn in the pressure-adjusting
screw on the fuel gas regulator until delivery-pressure
gauge indicates a pressure of 5 psi. IMMEDIATELY
close the acetylene valve.
Low-Pressure Acetylene: Open the shut-off valve at
the station.
Oxygen: Open the torch oxygen valve at least one full
turn. Turn in the pressure-adjusting screw on the oxygen regulator until its delivery-pressure gauge indicates
the desired pressure. (See table on pg. 4.) Close the
oxygen valve.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
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.
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 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.
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.
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.
2
SP-GA 10/98
LIGHTING AND FLAME ADJUSTMENT
1. Open the torch oxygen valve one-quarter of a turn.
2. Open the torch fuel gas valve one-half turn (two
full turns if low-pressure acetylene is being used)
and light the gas at the tip with a friction lighter. DO
NOT USE A MATCH. Use of a match can seriously burn your hand.
3. Open the oxygen valve wide and adjust the fuel
gas valve to secure the desired flame. If a softer
flame is desired, reduce the oxygen flow by throttling the oxygen valve and then readjust the fuel
gas valve.
NOTE: When operating with a very soft flame, the
welding head will tend to heat up and transfer
some of this heat to the torch handle. This may
create some discomfort to the operator.
SHUTTING OFF
Close the fuel gas valve first, then the oxygen valve.
If operations are to be stopped for a 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 pressureadjusting screw of each regulator and close the
torch valves.
IMPORTANT OPERATING NOTES
1. Do not attempt to operate head size 100 or larger
from a low-pressure acetylene supply.
2. Head size number on each welding and heating
head indicates the rated acetylene flow capacity in
cubic feet/hour (cfh). For example, No. 55A requires about 55 cfh of acetylene at normal operating pressure. However, on heating heads designed
for other fuel gases, the size indicates the approximate equivalent heating capacity in terms of acetylene flow. For example, No. 100A and No. 100FG
provide the same average heating output (147,000
Btu/hr) but No. 100FG head really requires about
62 cfh of FG-2, 57 cfh of propane, or 147 cfh of
natural gas.
For consumption purposes, the following are the
oxygen/fuel gas ratios normally required for welding and heating:
1.1 to 1.5 cfh oxygen/1.0 cfh acetylene
3.2 to 3.6 cfh oxygen/1.0 cfh FG-2
3.5 to 4.5 cfh oxygen/1.0 cfh propane
1.7 to 2.0 cfh oxygen/1.0 cfh natural gas
PRECAUTIONS - NO. 55 and LARGER HEADS
Large welding and heating heads (No. 55 and above)
require high flow of oxygen and fuel gas for proper
operation. Failure to follow the following precau-
tions can result in serious overheating, flashback,
and possible operator injury.
1. Read and understand the operating instructions
packed with your torch as well as these precautions before lighting up the welding or heating head.
2. Always operate with oxygen and fuel gas pressures
given in the tables.
3. Do NOT use hose line reverse flow check valves
when using No. 100 or larger welding or heating
head.
4. Use 3/8-in. I.D. hoses when using No. 5 or larger
welding or heating head.
5. Do NOT use whip hose, hose splices, nor hose
nipples smaller than 1/4-in. I.D. (B-size).
6. If using hose lengths greater than 25-ft., or if there
is any doubt about the adequacy of gas flows, use
an oxygen test gauge adaptor (P/N 07X17) and
either the acetylene (P/N 262510) or fuel gas (P/N
639422) test gauge adaptor while the torch is operating to make sure that the recommended operating pressures are available at the torch inlet.
7. Manifold two or more fuel gas cylinders to assure
adequate supply of fuel gas. The tables show the
number of commonly used cylinders recommended for manifolding when using larger heads.
If using other cylinders or gases, check with your
fuel gas supplier for recommended withdrawal rate
information.
8. In the event of a flashback, immediately close both
oxygen and fuel gas valves on the torch (preferably oxygen valve first). For greater protection, install 1/4-turn quick shutoff valve (P/N 999306) on
the torch oxygen hose connection.
Acetylene
Head Flowrate, Min. No. of Cylinders Requires*
Size cfh WK Cyl (300 cf) WTL Cyl. (390 cf)
55 55 2 1
70 70 2 2
100 100 3 2
150 150 4 3
200 200 5 4
250 250 6 5
* Based on that max. hourly flowrate should not exceed 1/7 of
cylinder capacity at 70° F. Example: 1/7 (300 cf WK cyl.) = 43
cfh max.
3
Head Min. No. of Min. No. Of
FG-2 (104 lb. cyl.) Propane (100 lb. cyl.)
Size Flowrate Cyl. Reqd* Flowrate Cyl. Reqd**
70 43 1 40 1
100 62 1 58 1
150 93 1 86 2
200 124 2 116 2
250 - - 144 3
* Based on max. continuous withdrawal rate of 110 cfh for 104 lb. cylinder,
1/2 full @ 70° F.
** Based on max. continuous withdrawal rate of 65 cfh for 100 lb. cylinder,
1/2 full @ 70° F.
Withdrawal rate will increase with wind velocity and intermittent usage;
reduce with lower temperature.
9. If the inner cone of the flame appears too short
(less than 1/4-in.), you are lacking fuel gas and the
head will tend to overheat. Recheck the above precaution with your set up.
10. Do not bring the head too close to the work. Maintain a distance of at least 1/4-in. between tip and
work.
RECOMMENDED HOSE SIZES
Oxygen, Acetylene (medium-pressure) and Natural Gas (at pipeline pressures over 5 psig): With
head sizes 4-30, 1/4-in. or 3/8-in. I.D. With head sizes
55 and larger, 3/8-in I.D. Acetylene (low-pressure) and
Natural Gas (at pipeline pressure below 5 psi): With
head sizes 4-70, 3/8-in. I.D. hose. Head sizes 100-250,
1/2-in. I.D. hose. Do not use over 25 feet of hose.
TESTING FOR LEAKS
Every welding and cutting outfit should be thoroughly
tested for leads after it is first hooked up, and at regular intervals thereafter. After all connections have been
made, make sure both valves on the torch handle are
closed. Then turn in the regulator pressure-adjusting
screw until the oxygen deliver-pressure gauge registers 50 psi, the acetylene delivery-pressure gauge registers 10 psi. Using Leak Test Solution suitable for oxygen service, such as P/N 998771 (8 oz. container),
check for leaks at the cylinder valves. The cylinder-toregulator 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 appropriate cylinder valve, open the 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.
After lighting the torch, and adjusting the flames, use
leak test solution to check for leakage at all torch valves,
and at the connection between the torch handle and
the welding head or cutting attachment.
Table 1 - Single-Flame Acetylene Welding Heads
Welding Head Metal Oxy. (Size No.) TipExtension
Assembly Thickness Press Tip Mixer for for (Accessory)
Size Part No. in. psin Tip Nut Tube Injector Tip Injector Length Part No.
4A 639974 1/32-1/16 7-8 639684 16Z26 01Z06 64 79 ¾¾
6A 639975 1/16-3/32 8-20 639685 16Z27 01Z07 58 77 ¾¾
9A 639976 3/32-1/8 10-24 639686 639870 16Z28 01Z08 55 75 ¾¾
12A 17271 1/8-3/16 11-25 17266 16Z29 01Z09 54 73 ¾¾
15A 639977 3/16-1/4 11-26 639687 16Z30 01Z10 53 71 ¾¾
30A 639978 1/4-1/2 18-29 17261 998847 16Z32 01Z12 44 65
50A 639979 1/2-3/4 25-39 998060 639969 639971 01Z14 33 59 12-in. 19X42
70A 639981 3/4-1 22-30 998061 639969 639972 01Z15 30 67
100A 11X71 45-55 998062 33A59 16Z54 01Z21 25 56 15-in. 19X43
150A 11X73 Heating 50-60 64Z22 33A58 16Z56 01Z23 17 54 18-in. 19X44
250A 11X75 70-80 12Z80 33A63 16Z58 01Z25 1/4-in. 52 21-in. 19X45
See Important Operating Notes on page 3.
n Acetylene pressure is 1/2 to 5 psi.
Replacement Parts Cleaning Drill
4
Table 2 - Rosebud Style Multiflame Heating Heads
Complete Pressure, Avg. Replacement Parts
Head Assembly psig Heat Tip Extension Tip
Size Part No. Oxy. Gas Flames Btu/hr. Assy. Stem Nut Tube or Mixer Nut Ring Length P/N Drill Size
For Oxy-Acetylene Use
100 O-A 999842 55-60 1/2-5 12 147,000 998799 998793 33A59 16Z54 01Z21 998596 37A41 15-in. 19X43 57
200 O-A 999844 15-20 9-12n 16 294,000 998800 998794 ¾ 998830 998832n 999910 998553 18-in. 998790 54
For Oxy-Fuel Gas FG-2, propane, natural gas etc.
100 O-FG 999843 50-70 1/2-5 8 148,000 999227 998793 33A59 16Z54 01Z99 998596 37A41 15-in. 19X43 49
200 O-FG 999845 30-55 6-11n 21 297,000 999230 998794 ¾ 998830 998832n 999910 998553 18-in. 998790 52
See Important Operating Notes on page 3.
Requires extension coupling 998838.
n IMPORTANT: P/N 998832 is a mixer; not an injector for low fuel gas pressure. Be sure to use operating pressures as given, using lower pressure can overheat
the tip and cause torch to flashback.
Fuel No. of Output Tip Tip Mixer Injector Head Retain. (Accessory) Cleaning
OPERATING 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 measur-
ing the gas pressures at the torch. Gauge
adaptors are available for this purpose.
Backfire: Improper operation of the torch may cause
the flame to go out with a loud pop. Such a backfire
may be caused by contact of the tip with the work, spatter from the tip, or by attempting to operate with too
small a flame. After a backfire, you can normally relight the flame immediately. If backfires occur repeatedly, shut off the torch. Then reopen the oxygen valve,
check for correct oxygen pressure, and test for leakage at the welding head connection nut and tip connection nut. If there is leakage at either point, correct it
(by tightening the tip, or cleaning the seating surfaces
on the injector and in the torch body) before resuming
work.
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 recurs, send the torch
handle and welding head or cutting attachment to your
distributor for repair.
MAINTENANCE INSTRUCTIONS
For all repairs other than those covered below, send
the apparatus to your welding equipment distributor or to ESABs Remanufacturing Center, Ebenezer
Road, Florence, SC 29501. Improperly repaired
apparatus is hazardous.
Torch Valves: Leakage around either throttle valve can
usually be corrected by tightening the packing nut
slightly. If it cannot be corrected, replace throttle valve
assembly.
If either valve fails to shut off completely, remove the
throttle valve assembly from torch and wipe the ball
seat on the end of the stem with a clean cloth. Then
reinstall the valve and tighten it heavily several times.
If this does not eliminate leakage, try a new throttle
valve assembly. If then the valve does not shut off completely, send the torch handle to a repair station for
reseating of the body.
Tip Cleaning: If a welding tip produces a distorted,
irregular flame, clean the tip with an OXWELD tip
cleaner, or the correct size twist drill (see table on page
4). Do not attempt to clean with any other type of tool.
When using cleaning drills, push the drill straight in
and out; do not twist.
Injector Cleaning: The relatively small central oxygen
orifice in an injector may become partially clogged with
small particles conveyed in the oxygen stream or carbon particles produced by backfires. To clean or replace an injector, remove it from the mixer tube (after
removing the connection nut retaining ring and sliding
the nut forward) by grasping it with a pair of pliers between the seating surfaces and pulling it straight out
with steady force. Take great care not to mar the injector seats or O-rings with the pliers. Clean the central
(oxygen) orifice with the correct size twist drill (see table
on page 4). Use no other tools. Replace O-rings if damaged or worn. Replace the injector if its rear seats are
marred. When reinstalling injector, be sure to push it in
until its retaining O-ring is firmly seated in the mixer
tube.
5
PARTS INFORMATION
All parts which can be replaced without breaking soldered or brazed joints are illustrated and listed below. When
ordering parts, please give both part number and description (including size, where appropriate). Parts may be ordered from your welding equipment distributor or from ESAB Welding & Cutting Products, Customer Service Department, Florence, SC.
W-24R Welding Torch, P/N 10A48
Welding and Heating Head Parts
6
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-3119-R 10/2000 1M Printed in U.S.A.
Hours: 7:30 AM to 5:00 PM EST
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