Operator’s Manual
AFA-1, AFA-2, &
AFP-1 Torch Kits
AFA-1 (50210) Torch kit
AFP-1 (50212) Torch kit
AFA-2 (50211) Torch Kit
WARNING: Do not assemble, install, or operate this equipment without reading ALL of
this manual and the safety precautions and warnings illustrated in this manual.
KDAR Company
1 Mulch Lane
St. Louis, MO 63044
Tel: (314) 692-8555
Fax: (314) 692-8578
Web Site: www.hotmaxtorches.com
SAFETY PRECAUTIONS AND WARNINGS
PLEASE READ BEFORE USING EQUIPMENT
WARNING
ARC RAYS CAN BURN SKIN AND EYES
Arc rays when welding produce intense ultraviolet and infrared rays that can burn skin and eyes
Where face protection, either helmet or shield when operating with ANSI Z49.1 approved shade
Wear approved safety glasses with side shields under the face protection
Warn others not to stare at the welding area as it can cause damage to the eyes. Provide barriers
Wear flame resistant gloves, clothing, and shoes when operating
FUMES AND GASES CAN BE HAZARDOUS
Gas welding produces fumes and gases and breathing these gases is hazardous to your health
Keep your head out of the fumes and do not breath the fumes while welding or cutting
Work only in a confined area if it has sufficient ventilation, or while wearing an air supplied res-
Read the MSDS sheets and the instructions from manufacturers for metals to be welded, coat-
Do not use the torch near hydrocarbon vapors coming from degreasing, cleaning, or spraying
Do not weld or cut coated metals, such as galvanized, lead, or cadmium plated steel. Before
Do not weld or cut containers with toxic, flammable, or reactive elements stored in them. They
Keep children away from this equipment
Protect your self and others from possible injury
Pacemaker wearers should consult with their doctor before operating
Read and follow all instructions in this manual before operating
All installation, operation, and maintenance procedures are to be per-
formed only by qualified individuals
#5 recommended for all welding and cutting with these torch kits. The lens should conform to
ANSI Z87.1 standards for testing.
to protect other workers in the area from the arc while operating
pirator. Fumes from welding and cutting deplete the oxygen supply and can be harmful. Always
be sure there is ample breathing air
ings, and cleaners
operations. The heat and rays can react with solvent vapors to create the gas phosgene, a very
toxic gas and other irritating gases
welding, all plating must be removed. The area must be well ventilated or an air supplied hood
must be used. The coatings and chemicals when burned cause highly irritating and toxic fumes.
must be emptied and properly prepared before welding or cutting.
WELDING SPARKS CAN CAUSE INJURY, FIRE, OR EXPLOSION
Remove all flammable materials from the welding area.
Always have a charged fire extinguisher available in the welding area.
When not welding make sure the welding gas cylinder valves are closed.
Avoid welding near hydraulic lines, fuel lines, electrical cords, air hoses, or welding gas lines.
Sparks and hot metal fly out from the work area when welding, wear approved safety glasses with
side shields under approved helmets, wear proper body and hand protection, and wear flame resistant ear plugs to keep sparks from entering the ears
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1
CYLINDERS CAN EXPLODE IF DAMAGED
Gas cylinders contain gas under very high pressure. If damaged they can result in that cylinder ex-
ploding. Gas cylinders are a major part of metalworking and must be treated with care.
Protect gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs
Always keep cylinders in an upright position securely fastened to a fixed support
Valve protection caps should always be in place and hand tight except when the cylinder is in use
Keep all cylinders away from any welding or electrical circuits
Never allow the flame or arc from a welder to contact a cylinder
Never cut any type of pressurized cylinder, an explosion could result
Always turn your face away from the valve when opening the cylinder
Read and follow all instructions on compressed gas cylinders, associated equipment, and CGA pub-
lication P-1 listed in the Safety Standards before using
HOT PARTS CAN CAUSE SERIOUS BURNS
Do not touch hat parts without wearing protection.
Allow the torch to cool sufficiently before working with parts that could potentially be hot.
NOISE CAN DAMAGE HEARING
Prolonged noise exposure from welding equipment can cause damage if levels of noise exceed the
OSHA standards
Wear approved hearing protectors
Warn other workers nearby of the high noise level and hazard
CALIFORNIA PROPOSITION 65 WARNINGS
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause
birth defects, and in some cases, cancer. (California Health and Safety Code Section 25249.5 et seq.)
PRINCIPAL SAFETY STANDARDS
AMERICAN WELDING SOCIETY
AWS C5.2, Recommended Practices for Plasma Arc Cutting
AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting
OSHA STANDARDS
OSHA 29 CFR 1910, Safety and Health Standards
NATIONAL FIRE PROTECTION ASSOCIATION
NFPA Standard 70, National Electric Code
NFPA Standard 51B, Cutting and Welding Processes
AMERICAN NATIONAL STANDARDS INSTITUTE
ANSI Standard Z87.1, Safe practices for Occupation and Educational Eye and Face Protection
ANSI Standard Z49.1, Safety in Welding and Cutting
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Installation & Setup
PACKAGE CONTENTS
AFA-1 Quick Connect Acetylene Kit
Quick Connect Handle
12’ Hose, A x A Fittings
Single Stage Acetylene Regulator with
CGA - 200 MC Fitting
“B” Tank Adapter CGA-520 with Nut
Single Flint Striker
4 Quick Connect Tips
HA-5, HA-8, HA-14, & HA-32
AFA-2 Screw Connect Acetylene Kit
Screw Connect Handle
12’ Hose, A x A Fittings
Single Stage Acetylene Regulator with
CGA - 200 MC Fitting
“B” Tank Adapter CGA-520 with Nut
Single Flint Striker
4 Screw Connect Tips
HS-3, HS-4, HS-5, & HS-6
AFP-1 Quick Connect Propane Kit
Quick Connect Handle
12’ Hose B x B Fittings
Single Stage Regulator, Propane or Mapp,
with CGA-510P Connector
Single Flint Striker
Quick Connect LP Tips
HT-2, HT-3, HT-4, & HT-5
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Installation & Setup
Tanks
The AFA-1 and AFA-2 are designed to be used with CGA 200 and CGA 520 type acetylene tanks. These
tanks can purchased or leased from your local gas distributor. Different welding gas suppliers handle tank filling differently; some will fill the tanks while you wait while others require a tank exchange. You will need to
select the type of supplier you prefer.
The AFP-1 uses standard liquid propane (LP) vapor draw tanks with CGA 510P valves. These are the typical
BBQ grill tanks.
2
1
Assembling AFA-1 and AFA-2 Acetylene
Torches
1. Secure the acetylene tank to an immovable object
such as a wall or a cart specifically designed to
hold the tank.
2. Briefly open the acetylene tank valve (1) to remove any debris that may have accumulated and
immediately close the valve.
3. Wipe the acetylene regulator threaded fitting (2)
with a clean dry cloth and tread the fitting onto the
tank valve and tighten with a wrench. Figure 1
below shows the CGA 200 fitting already attached
to the regulator and the CGA 520 adapter that
comes with the torch kits.
4. Using compressed air, blow out the hose prior to
using it for the first time. Attach the hose to the
regulator and tighten with a wrench (3).
5. Attach the other end of the hose to the fitting on
the torch handle and tighten with a wrench (4).
Note: The acetylene hose has left han d (rever se)
treads and is marked with notches in the fitting.
Acetylene
Regulator
Acetylene Tank with
3
Acetylene Tank with
CGA 200 Valve
1
CGA 520 Valve
CGA 200 Adapter
CGA 520 Adapter
4
Figure 1
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Installation & Setup
Assembling AFP-1 Propane Torch
1. Secure the propane tank to an immovable object
such as a wall or a cart specifically designed to
hold the tank.
2. Briefly open the propane tank valve (1) to remove
any debris that may have accumulated and immediately close the valve.
3. Wipe the propane regulator threaded fitting (2)
with a clean dry cloth and tread the fitting onto the
tank valve and tighten with a wrench.
4. Using compressed air, blow out the hose prior to
using it for the first time. Attach the hose to the
regulator and tighten with a wrench (3).
5. Attach the other end of the hose to the fitting on
the torch handle and tighten with a wrench (4).
Propane
Regulator
3
1 2
Propane Tank with
CGA 510P Valve
4
Installing the Different Tips
The AFA-1 and AFP-1 have quick connect tips. Simply select the tip size you would like to use and insert it
into the torch handle. Pull back on the collar on the top of the torch handle and fully insert the tip into the handle. Releasing the collar will lock the tip into place. Gently pull on the quick connect tip to assure that it is
attached to the torch handle.
The AFA-2 has screw connect tips. Simply thread the tip into the top of the torch handle and tighten with a
wrench.
Quick Connect Tip Screw Connect Tip
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Operation
It is important that all fittings have been tightened
with a wrench by this point. Insure the tank
valve, regulator valve handle, and torch handle
valve is turned to the off position.
Opening Valves
1. Slowly open the cylinder valve to allow gas to
flow to the regulator. Once the regulator begins to
register pressure, open the cylinder valve an additional 1 to 1 1/2 turns.
Note: This must be done slowly, as a sur ge of
pressure could damage the regulator diaphragm.
2. Open the regulator valve 2-3 turns (1).
3. Check for leaks at every connection point including both sides of the regulator and both ends of
the hose. Leaks can not be seen, therefore, use
soapy water on all connection points to insure
there are no leaks.
Note: The best initial r egulator pr essur e setting
for Acetylene is 5 PSI and it should never be set
above 15 PSI. The best initial regulator pressure
setting for propane is 14 PSI and it should never
be set above 25 PSI.
WARNING
1
At this point the operator should be wearing appropriate protective clothing such as
gloves and goggles. Prior to lighting the torch make sure the hoses are behind the operator and that there is no chance of them being hit by a hot spark or slag.
Lighting the Torch
1. Open the control knob on the torch handle (2) just
enough to let some gas flow.
2. Holding the striker close to the welding tip
squeeze it a few times to create the sparks required to light the gas.
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Operation
Adjusting the Flame
The amount of gas that you use will depend on the tip
size you are using, the thickness of the material you
are working on, the settings of the regulator, and possibly other factors. You will need to experiment with
the different settings in order to get the desired result.
Basically you are looking for the flame pattern in Figure 2.
Shutting Down
1. Shut the control valve completely off at the torch
handle.
2. Shut the tank valve completely off at the tank.
3. Open the control valve at the torch to relieve the
pressure on the regulator and hose. Watch the
regulator gauge, it should return to zero. The regulator and hose should not be left with fuel pressure in the line.
4. Reclose the control valve on the torch handle.
This helps prevent any moisture or debris from
entering the hose.
5. Remove the regulators from the fuel tanks and
replace any protective covers.
Primary Envelope
Figure 2
Secondary Envelope
Beginning
of Cone
General Maintenance
1. Prior to EVERY use, inspect hose for damage.
Note: Never tr y to r epair damaged gas hoses.
Damaged hoses should be replaced.
2. Prior to EVERY use, check all connections for
leaks.
.
Note: Never use oil, grease, pipe dope or Teflon
tape on any part of the torches.
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Warranty
KDAR Company, and its affiliates, warrants that
all torch kit components (except hoses) covered
under this warranty are free from defects in material and workmanship for two years from the date
of purchase. KDAR also warrants that all hose
assemblies are free from defects in material and
workmanship for 90 days from the date of purchase. This warranty is extended to the original
purchaser who uses the product in a consumer
application (personal, residential or household
usage). All torch kits covered under this limited
warranty which are used in commercial applica-
tions (i.e. income producing) are warranted to be
free from defects in material and workmanship
for 90 days from the date of original purchase.
The products covered under this warranty are the
AFA-1, AFA-2, and AFP-1.
KDAR Company, and its affiliates, will repair or
replace, at KDAR’s sole discretion, parts found to
be defective in material or workmanship within
the warranty period. Warranty service will be
scheduled according to the normal work flow and
business hours of the service center doing the
work as well as the availability of replacement
parts. All decisions from KDAR Company regarding this limited warranty shall be final.
Original Purchaser’s Responsibility:
1. Retain the original cash register receipt as
proof of purchase.
2. Follow manual instructions regarding the care
and operation of your torch.
3. If warranty work is required, DO NOT RE-
TURN THIS TORCH KIT TO THE RETAILER. Contact KDAR Company for in-
structions. Visit www.hotmaxtorches.com or
call KDAR Company M-F 8AM-5PM CST to
locate the nearest Authorized Service Center.
Not Covered:
1. Transportation charges for sending or delivering the torch to the Authorized Service Center
or returning the repaired or replacement torch
back to the customer. These charges are the
responsibility of the customer.
2. Damages caused by ordinary wear, abuse, rain,
freeze damage, negligence, accident or failure
to operate or maintain the torch kit in accordance with the instructions in the operator’s
manual supplied with the torch kit.
3. Damage caused by unauthorized repair or al-
terations.
Exclusions and Limitations:
KDAR Company makes no other warranty of
any kind, express or implied. Implied warranties, including warranties of merchantability
and of fitness for a particular purpose, are
hereby disclaimed. The warranty service described above is the exclusive remedy under
this warranty; liability for incidental and conse-
quential damages is excluded to the extent per-
mitted by law.
This warranty gives you specific legal rights, and
you may have other rights which vary from state to
state. Some states do not allow a disclaimer of implied warranties, or the exclusion of incidental and
consequential damages, so the above disclaimers
and exclusions may not apply to you.
For warranty service or to obtain service parts
or accessories:
Call: (314) 692-8555 M-F 8-5 PM, CST
Visit: www.hotmaxtorches.com
Write: KDAR Company
1 Mulch Lane
St. Louis, MO 63044
KDAR Company
1 Mulch Lane
St. Louis, MO 63044
Phone: (314) 692-8555 Fax: (314) 692-8578
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