Cutting, Heating
and Welding Guide
Set-Up and Safe Operating Procedures
OXY-FUEL EQUIPMENT
English
Français
Español
Revision: C Issue Date: September, 1 2009 Manual No: 0056-3260
OXY-FUEL
EQUIPMENT
Cutting, Heating
and Welding Guide
English
Français
Español
SET-UP AND SAFE
OPERATING PROCEDURES
Issue Date: September, 1 2009 Manual No: 0056-3260Revision: C
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Victor® product. We are proud to
have you as our customer and will strive to provide you with the
best service and reliability in the industry. This product is backed
by our extensive warranty and world-wide service network. To
locate your nearest distributor or service agency, please contact
a representative at the address and phone number in your area
listed on the back cover of this guide, or visit us on the web at
www.victorequip.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Victor® product. Your satisfaction
with this product and its safe operation is our ultimate concern.
Therefore, please take the time to read the entire manual, especially
the Safety Precautions. They will help you to avoid potential hazards
that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Victor® is a Global Brand of Gas Equipment Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
ii
WARNING
Read and understand this entire Manual and your employer’s safety practices before
installing, operating, or servicing the equipment. While the information contained
in this Manual represents the Manufacturer’s judgment, the Manufacturer assumes
no liability for its use.
Cutting, Heating and Welding Guide
Set-up and Safe Operating Procedures
Instruction Guide Number 0056-3260
Published by:
Thermadyne® Industries, Inc.
2800 Airport Rd.
Denton, TX. 76208
(940) 566-2000
www.victorequip.com
U.S. Customer Care: (800) 426-1888
International Customer Care: (940) 381-1212
Copyright © 2009 Thermadyne Industries, Inc. All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this Manual, whether such error results from
negligence, accident, or any other cause.
Publication Date: September 1, 2009
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:
iii
Table of Contents
SECTION 1: INTRODUCTION ............................................................................... 1-1
1.01 How to Use this Manual ..............................................1-1
SECTION 2: SAFETY PRECAUTIONS .................................................................. 2-2
2.01 Housekeeping ..............................................................2-2
2.02 Protective Apparel .......................................................2-3
2.03 Fire Prevention ............................................................ 2-3
2.04 Cylinders ..................................................................... 2-4
SECTION 3: INDUSTRIAL GASES ....................................................................... 3-6
3.01 Oxygen ........................................................................3-6
3.02 Acetylene ..................................................................... 3-7
3.03 Natural Gas and Propane ............................................. 3-8
3.04 Propylene and Propylene-Based Fuel Gases .............. 3-10
3.05 Fuel Gases with Natural Gas or Propane
Base Plus Liquid Hydrocarbon Additives ...................3-11
SECTION 4: OXY-FUEL APPARATUS ................................................................. 4-12
4.01 Oxygen and Fuel Supply ............................................4-12
4.02 Regulators ................................................................. 4-12
4.03 Torch Handle .............................................................4-15
4.04 Cutting Attachment ....................................................4-17
SECTION 5: SETTING UP EQUIPMENT FOR WELDING ...................................... 5-21
5.01 Cylinders ................................................................... 5-21
5.02 Regulators ................................................................. 5-22
5.03 Gas Hoses .................................................................5-24
5.04 Torch Handle .............................................................5-24
5.05 Welding Nozzle .......................................................... 5-25
5.06 Setting Up To Weld, Lighting the Torch,
and Adjusting the Flame ............................................5-26
SECTION 6: WELDING PROCEDURES ............................................................... 6-29
6.01 Preparing the Metals to be Welded ...........................6-29
6.02 Preventing The Metals from Warping .......................6-29
6.03 Forehand and Backhand Welding Techniques ............ 6-30
6.04 Starting and Finishing the Weld .................................6-30
6.05 Oxy-Fuel Brazing and Braze Welding .........................6-32
SECTION 7: SETTING UP THE EQUIPMENT FOR CUTTING................................ 7-34
7.01 Setting up for Cutting Applications ............................ 7-34
SECTION 8: TROUBLESHOOTING ..................................................................... 8-41
SECTION 9: SPECIFICATIONS .......................................................................... 9-42
SECTION 10: GLOSSARY ............................................................................... 10-48
SECTION 11: STATEMENT OF WARRANTY ..................................................... 11-54
iv
SET-UP AND SAFE OPERATING PROCEDURES
SECTION 1:
INTRODUCTION
1.01 HOW TO USE THIS MANUAL
This guide contains important information related to the safe and effi cient operation of oxy-fuel
welding, cutting, and heating apparatus.
There are several potential hazards present when using oxy-fuel equipment. It is, therefore, necessary
that proper safety and operating procedures are understood prior to using such apparatus.
READ THIS BOOKLET THOROUGHLY AND CAREFULLY BEFORE ATTEMPTING TO OPERATE
OXY-FUEL WELDING, CUTTING, AND HEATING APPARATUS. A thorough understanding of the
proper safety and operating procedures will help to minimize the potential hazards involved, and
add to the effi ciency and productivity of your work.
Welding, cutting, and heating operations should conform to applicable Federal, State, County or City
regulations for installation, operation, ventilation, fi re prevention, and protection of personnel.
Detailed safety and operating instructions can be located within the ANSI Standard Z49.1, “Safety
in Welding and Cutting”, available from the American Welding Society, P.O. Box 351040, Miami,
FL. 33135 or www.aws.org. Other publications containing safety and operating instructions
are available from the following organizations: American Welding Society, (AWS) www.aws.org,
Occupational Safety and Health organization (OSHA) www.osha.gov, Compressed Gas Association
(CGA) www.cganet.com and National Fire Protection Agency (NFPA) www.nfpa.org.
Do Not attempt to use the apparatus unless you are trained in its proper use, or are under competent
supervision. Remember, the safest equipment, if incorrectly operated, may result in a mishap.
A system of notes, cautions and warnings emphasize important safety and operating information
in this booklet. These are as follows:
NOTE
NOTE conveys installation, operation, or maintenance information which is important
but not hazard-related.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may
result in injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
1-10056-3260
Introduction
CUTTING, HEATING AND WELDING GUIDE
SECTION 2:
SAFETY PRECAUTIONS
Be sure to read and understand all safety and operating instructions provided before using this
apparatus. RETAIN THESE INSTRUCTIONS IN A READILY AVAILABLE LOCATION FOR FUTURE
REFERENCE.
The following preliminary safety checklist is the basis for further specifi c safety information noted
throughout this booklet.
WARNING
This product contains chemicals, including lead, or otherwise produces chemicals known
to the State of California to cause cancer, birth defects and other reproductive harm. Wash
hands after handling. (California Health & Safety Code § 25249.5 et seq.)
WARNING
DO NOT attempt to use this apparatus unless you are trained in its proper use or are under
competent supervision. For your safety, practice the safety and operating procedures
described in this guide every time you use the apparatus. Deviating from these procedures
may result in fi re, explosion, property damage and/or operator injury.
If, at any time, the apparatus you are using does not perform in the usual manner, or
you have diffi culty in the use of the apparatus, shut the system off and STOP using it
immediately. DO NOT use the apparatus until the problem has been corrected.
WARNING
Service or repair of apparatus should be performed by a qualifi ed repair technician
only. Improper service, repair, or modifi cation of the product could result in damage
to the product or injury to the operator.
NOTE
The term “Qualifi ed Repair Technician” refers to repair personnel capable of servicing
apparatus in strict accordance with all applicable Victor “Parts & Service Bulletins”
and literature.
2.01 HOUSEKEEPING
1. The work area must have a fi reproof fl oor.
2. Work benches or tables used during welding, cutting, and heating operations must have
fi reproof tops.
3. Use heat resistant shields or other approved material to protect nearby surfaces from
sparks and hot metal.
4. Move all combustible material away from the work area.
Safety Precautions
2-2
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
5. Ventilate welding, cutting, and heating work areas adequately to prevent accumulation
of explosive or toxic concentrations of gases. When working with lead, lead bearing
materials, steel coated with lead paints, cadmium-coated materials or any objects
containing metals that may generate or give off toxic fumes, always ensure that suitable
respiratory protection equipment is utilized.
6. When welding, be sure to read and understand the Material Safety Data Sheet (MSDS)
for the alloy being used.
7. Place the oxygen and fuel cylinders close to the location to where you are working.
Ensure the cylinders are at a safe distance from sparks or hot metal. Individually chain
or otherwise secure the cylinders to a wall, bench, post, cylinder cart, etc. to keep the
cylinders upright, and secure them from falling over.
2.02 PROTECTIVE APPAREL
1. Protect yourself from sparks, fl ying slag, and fl ame brilliance at all times. Gas fl ames
produce infrared radiation that may have a harmful effect on the skin and especially
on the eyes. Select the appropriate goggles or mask with tempered lenses shaded 5 or
darker to protect your eyes from injury and provide good visibility of the work.
2. Always wear appropriate protective gloves and fl ame resistant clothing to protect skin
and clothing from sparks and slag. Keep collars, sleeves, and pockets buttoned. DO
NOT roll up sleeves or cuff pants.
3. Remove all fl ammable and readily combustible materials from your pockets, such as
matches and cigarette lighters.
4. Keep all clothing and protective apparel completely free of oil or grease.
5. Do not wear clothing that is easily ignited, such as polyester pants or shirts.
2.03 FIRE PREVENTION
Welding, cutting, and heating operations use fi re or combustion as a basic tool. The process is
very useful when properly controlled. However, it can be extremely destructive if not performed
correctly in the proper environment.
Practice fi re prevention techniques whenever oxy-fuel operations are in progress. A few simple
precautions can prevent most fi res and help minimize damage in the event a fi re does occur.
1. Keep ALL apparatus clean and free of grease, oil, and other fl ammable substances.
Inspect oxy-fuel apparatus for oil, grease, or damaged parts. DO NOT use the oxy-fuel
apparatus if oil or grease are present, or if damage is evident.
2. Never use oil, grease, or lubricant on or around any oxy-fuel apparatus. Even a trace of
oil or grease can ignite and burn violently in the presence of oxygen.
3. Keep fl ames, heat, and sparks away from cylinders, regulators, and hoses.
4. Flying sparks can travel up to a distance of 35 feet (10 m)or more. Remove all combustible
materials away from areas where oxy-fuel operations are being performed.
2-30056-3260
Safety Precautions
CUTTING, HEATING AND WELDING GUIDE
5. Operators may not become aware of a fi re starting while operating apparatus. Their
vision is seriously hampered by the welding goggles and dark lenses. Depending upon
the circumstances of the work location, it may be advisable to have a fi re watcher to
operate an extinguisher and sound a fi re alarm in case of a fi re.
6. Keep an approved fi re extinguisher of the proper size and type in the work area. Inspect it
regularly to ensure that it is in proper working order. Know how to use the fi re extinguisher.
7. Use heat resistant shields or other approved material to protect nearby surfaces, ceilings
and equipment from sparks and hot metal.
8. Only use oxy-fuel equipment with the fuel gas it was designed for.
9. After the equipment has been properly set up, open the acetylene cylinder valve
approximately 3/4 of a turn, but NO MORE than 1-1/2 turns. Keep the cylinder wrench,
if one is required, on the cylinder valve so the cylinder may be turned off quickly if it
becomes necessary.
10. All gases except acetylene: Open the fuel gas cylinder valve completely to seal the
cylinder back seal packing.
11. Never test for gas leaks with a fl ame. Use an approved leak-detector solution.
12. Never perform welding, cutting, and heating operations on a container that has held
toxic or combustible liquids or vapors.
13. Never perform welding, cutting, and heating operations in an area containing combustible
vapors, fl ammable liquids, or explosive dust.
14. Never perform welding, cutting, and heating operations on a closed container or vessel,
which may explode when heated.
15. Avoid operating the equipment in rooms with sprinkler systems unless there is suffi cient
ventilation to keep the area cool.
16. When the work is complete, inspect the area for possible fi res or smoldering materials.
2.04 CYLINDERS
All Government and insurance regulations relating to the storage of oxygen, acetylene and LPG
cylinders should be closely observed.
Industrial gas cylinders are made to rigid specifi cations and are inspected each time they are
refi lled by your supplier. They are safe if properly handled.
For additional information on the safe handling of gas cylinders, contact your gas supplier or
refer to the Compressed Gas Association publication P-1, “Safe Handling of Compressed Gases
in Containers”.
• Keep all cylinders, empty or full, away from radiators, furnaces and other sources of heat.
• Avoid contact with electrical circuits.
• Keep oil and grease away from cylinders.
• Cylinders should be screened against direct rays from the sun.
• Protect cylinder valves from bumps and falling objects.
Safety Precautions
2-4
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
• Inspect the cylinder valves for damaged parts. Keep the valves clean, free from oil, grease,
and all foreign materials.
• Close cylinder valves when not in use, when empty, or when moving cylinders.
• Always be sure the cylinder valve is tightly closed before removing the regulators.
• Always replace the cylinder valve cap, if applicable, when the cylinder is not in use.
• Never allow anyone to strike an arc or tap an electrode against any cylinder.
• Never try to fi ll a cylinder or mix gases in a cylinder. Never draw gas from cylinders except
through properly attached pressure regulators or equipment designed for the purpose. If
damaged, send the regulator to the supplier or qualifi ed repair technician for repairs. Do
not tamper with or alter cylinder numbers or markings.
• Never use cylinders as supports or rollers.
• When transporting cylinders with a crane, use an approved cylinder cradle only. Never use
a “magnet” crane to move cylinders
• Never lift the cylinder by its protective cap.
• If you are unable to make a gas-tight seal between the cylinder valve and a regulator nipple,
check to see if the connection nut is tight. If so, check the regulator inlet connection for
damage. If the cylinder valve is damaged, remove the cylinder from service and notify the
gas supplier.
• Never insert washers of lead or other material between the regulator and cylinder valve.
Never use oil or grease on the connections.
• Never use compressed gas cylinders without a pressure reducing regulator attached to
the cylinder valve.
• Never drag cylinders or roll them on the bottom edge, use a suitable cylinder cart.
• Never transport gas cylinders inside a passenger vehicle. Only transport gas cylinders in
a suitable ventilated service vehicle. See CGA PS-7, “CGA Position statement on the Safe
Transportation of Cylinders in Passenger Vehicles”.
• Use only standard cylinder keys to open cylinder valves, never extend the length of these
keys under any circumstances. If valves cannot be opened by hand, do not use a hammer
or a wrench; notify the supplier.
• Leave the cylinder key in position when fuel gas cylinder valves are open.
• Some cylinder valves, most notably acetylene cylinder valves, may require adjustment of
the valve packing. Consult your gas supplier for the proper method of adjusting the packing.
DO NOT use the cylinder if the packing is leaking.
WARNING
Cylinders are highly pressurized. Handle with care. Serious accidents can result
from improper handling or misuse of compressed gas cylinders. DO NOT drop the
cylinder, knock it over, expose it to excessive heat, fl ames or sparks. DO NOT strike
a cylinder in any manner.
2-50056-3260
Safety Precautions
CUTTING, HEATING AND WELDING GUIDE
SECTION 3:
INDUSTRIAL GASES
CAUTION
Fuel Gases may be toxic. Contact your gas supplier for the appropriate Material Safety
Data Sheet (MSDS) for each gas you use. The Hazardous Materials Regulations of
the Department of Transportation (DOT) regulates the transportation of industrial
gases and the cylinders used to transport them. Disposal of fuel gases may also be
controlled. Contact your local or state Department of Labor for further information.
3.01 OXYGEN
Gaseous chemical element, symbol: “O”; it is of great interest because it is the essential element
in the respiratory processes of most living cells and in combustion processes. It is the most
abundant element in the Earth’s crust. Nearly one fi fth (in volume) of the air is oxygen. Oxygen
can be separated from air by fractionated liquefaction and distillation. One of the main applications
for oxygen is melting, and the refi ning and manufacturing of steel and other metals. Oxygen is
required to support any burning process. It is, therefore, combined with a “fuel” gas to produce
the desired operating fl ame. Oxygen itself is not fl ammable. However, the presence of pure
oxygen will dramatically accelerate the burning process. Oxygen can easily turn a small spark
into a roaring fl ame or explosion.
WARNING
Never allow oxygen to contact grease, oil, or other fl ammable substances. Although
oxygen by itself will not burn, these substances become highly explosive and may ignite
and burn rapidly when supported by pure oxygen. Oil or grease combined with oxygen
may ignite or even explode without the presence of excessive heat or fl ame.
Oxygen is ordinarily supplied in standard drawn steel cylinders. The 244 ft³ (7 m³) cylinder is the
most commonly used. Smaller and larger sizes are available. Full oxygen cylinders are normally
pressurized in excess of 2000 psi (900 Kg/cm²). Determine oxygen cylinder contents by reading
the inlet pressure gauge on the regulator when in use. For example, half the full cylinder pressure
rating indicates half the volume (ft³ / m³) of oxygen remaining. The maximum fi ll pressure should
always be stamped on the cylinder.
Due to the high pressure under which oxygen is contained, cylinders must always be handled
with great care. THE POTENTIALLY VIOLENT REACTION OF OIL, GREASE, OR ALL OTHER
CONTAMINANTS IN THE PRESENCE OF OXYGEN CANNOT BE OVERSTRESSED. SERIOUS INJURY
OR DEATH MAY EASILY RESULT IF OXYGEN IS USED AS A SUBSTITUTE FOR COMPRESSED
AIR. Oxygen should never be referred to as “air”.
WARNING
Never use oxygen: in pneumatic tools; in oil pre-heating burners; to start internal
combustion engines, to blow out pipelines; to dust off clothing or work area; to create
pressure; for ventilation. In short, under no circumstances use oxygen as a substitute
for compressed air or other gases. Use oxygen only for appropriate oxy-fuel cutting,
heating and welding applications.
Industrial Gases
3-6
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
OXYGEN VALVE OUTLET AND REGULATOR INLET CONNECTIONS:
CGA 540 up to 3000 PSIG (3700 - 20700 kPa); CGA 577 up to 4000 PSIG (4000 - 28000 kPa);
CGA 701 up to 5500 PSIG (4800 - 38000 kPa)
3.02 ACETYLENE
Acetylene is a compound of carbon and hydrogen (C2H2). It is a versatile industrial fuel gas used
in cutting, heating, welding, brazing, soldering, fl ame hardening, metallizing, and stress relieving
applications. It is produced when calcium carbide is submerged in water or from petrochemical
processes. The acetylene gas produced is then compressed into cylinders or fed into piping
systems. Acetylene becomes unstable when compressed in its gaseous state above 15 PSIG
(103 kPa). Therefore, it cannot be stored in a “hollow” cylinder under high pressure the way
oxygen, for example, is stored. Acetylene cylinders are fi lled with a porous material (calciumsilicate) creating, in effect, a “solid” as opposed to a “hollow” cylinder. The porous fi lling is then
saturated with liquid acetone. When acetylene is pumped into the cylinder, it is absorbed by the
liquid acetone throughout the porous fi lling. It is held in a stable condition (see Figure 2). Filling
acetylene cylinders is a delicate process requiring special equipment and training. Acetylene
cylinders must, therefore, be refi lled only by authorized gas distributors. Acetylene cylinders
MUST NEVER be transfi lled.
POROUS FILLER: (calcium-sicilate) 8% - 10%
The filler, which completely occupies the steel shell, is
90% - 92% composed of millions of interconnected pores.
ACETONE: 42%
Acetone is equal to 42% of the internal volume, and is
dispersed throughout the filler.
ACETYLENE GAS: 36%
The acetylene gas is uniformly absorbed by the acetone.
The resulting mixture occupies 78% of the internal volume.
RESERVE VOLUME AT 70˚ F: 10% - 12%
Since acetone and acetylene gas will expand as temperature
rises, a safety reserve must be present even at 150˚ F.
dwg-00377
Figure 2: Acetylene Cylinder Interior
Acetylene Cylinders
All acetylene cylinders are fi tted with fusible plugs. These are designed to vent the cylinder contents
in the event of an unsafe condition arising in the cylinder that could be due to any number of
reasons, such as overheating from either incorrect operating techniques, faulty equipment, or in
conjunction with excessive temperature. In the event of a cylinder safety device malfunctioning,
remove the cylinder from service, place the cylinder in a well ventilated area, preferably outdoors,
and notify the supplier immediately.
3-70056-3260
Industrial Gases
CUTTING, HEATING AND WELDING GUIDE
Commonly Available Acetylene Cylinder Capacities
Cubic Feet / ft³ (Cubic Meters / m³)
10 (0.3) 130 (3.7) 330 (9.3)
40 (1.1) 190 (5.4) 360 (10.2)
60 (1.7) 225 (6.4) 390 (11.0)
75 (2.1) 290 (8.2) 850 (24.1)
100 (2.8) 300 (8.5)
Acetylene cylinders used in the U.S.A. must conform to DOT 8 and 8 AL specifi cations.
Specifi cations
SAFETY
Shock sensitivity
Explosive limits in oxygen (%) 3.0-93
Explosive limits in air (%) 2.5-80
Maximum allowable use pressure 15 PSIG (103 kPa)
Tendency to backfi re Considerable
Toxicity Low
Maximum Withdrawal Rate 1/7 of cylinder contents per hour
COMBUSTION PROPERTIES
Neutral fl ame temperature in °F (°C) 5720 (3160)
Burning velocity in oxygen in ft./sec. (m/sec) 22.7 (6.9)
Primary fl ame in BTU/ft³ (MJ/m³) 507 (18.9)
Secondary fl ame in BTU/ft³ (MJ/m³) 963 (35.9)
Total heat in BTU/ft³ (MJ/m³) 1470 (54.8)
Total heating value in BTU/lb. (kJ/kg) 21600 (50140)
Auto ignition temperature in °F (°C) 763 - 824 (406 - 440)
VALVE OUTLET AND REGULATOR INLET CONNECTIONS
• Standard connection CGA 510
• Alternate standard connection CGA 300
• Small valve series (10 ft³ (0.3 m³) cylinder) CGA 200
• Small valve series (40 ft³ (1.1 m³) cylinder) CGA 520
*All values are approximations*
If more detailed specifi cations are required, contact your fuel gas supplier for the specifi c
properties of the fuel gas.
Unstable over 15 PSIG (103 kPa)
outside of cylinder
3.03 NATURAL GAS AND PROPANE
Natural gas is available throughout most areas of the U.S.A. and Canada. Physical properties vary
according to the geographical location. Methane is a colorless, odorless gas and is the principal
component of natural gas, a mixture containing about 75% methane (CH4), 15% ethane (C2H6),
and 5% other hydrocarbons, such as propane (C3H8) and butane (C4H10).
Propane (C3H8) is a non-renewable fossil fuel, like the natural gas and oil it is produced from. It
is known in popular terms as LPG (Liquefi ed Petroleum Gas). Similar to natural gas (methane),
Industrial Gases
3-8
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
propane is colorless and odorless. Although propane is nontoxic and odorless, foul-smelling
mercaptan is added to it to make gas leaks easy to detect.
Liquid Petroleum (LP) gases were discovered in 1912 when an American scientist, Dr. Walter
Snelling, discovered that these gases could be changed into liquids and stored under moderate
pressure. The LP-gas industry got its start shortly before World War I when a problem in the natural
gas distribution process popped up. A section of the pipeline in one natural gas fi eld ran under a
cold stream, and the coldness led to a lot of liquids building up in the pipeline, sometimes to the
point of blocking the entire pipeline. Soon, engineers fi gured out a solution: facilities were built
to cool and compress natural gas, and to separate the gases that could be turned into liquids
(including propane and butane).
Both natural gas and propane are used as industrial fuel gases for fl ame cutting, scarfi ng, heating,
fl ame hardening, stress relieving, brazing, and soldering.
NATURAL GAS AND PROPANE CYLINDERS
Natural gas is transported by pipeline to most installations that use natural gas as a fuel gas.
Natural gas / Methane is authorized for shipment in a non-liquefi ed compressed gas cylinder
under DOT regulations.
Propane is available in on-site bulk storage tanks. It is also obtainable in 5-420 lb. (2-190 Kg) cylinders.
Specifi cations
SAFETY Natural Gas Propane
Shock sensitivity Stable Stable
Explosive limits in oxygen (%) 5.0-59 2.4-57
Explosive limits in air (%) 5.0-15 2.1-9.5
Maximum allowable use pressure Varies
Tendency to backfi re Slight Slight
Toxicity Low Low
Cylinder 120 PSIG @ 70°F
(800 kPa @ 21°C)
COMBUSTION PROPERTIES Natural Gas Propane
Neutral fl ame temperature in °F (°C) 4600 (2538) 4579 (2526
Burning velocity in oxygen in ft./sec. (m/sec) 15.2 (4.6) 12.2 (3.7)
Primary fl ame in BTU/ft³ (MJ/m³) 55 (2.0) 295 (11.0)
Secondary fl ame in BTU/ft³ (MJ/m³) 995 (37.1) 2268 (84.5)
Total heat in BTU/ft³ (MJ/m³) 1050 (39.1) 2563 (95.5)
Total heating value in BTU/lb. (kJ/kg) 24800 (57660) 21600 (50140)
Auto ignition temperature in °F (°C) 999 (537) 874 (468)
VALVE OUTLET AND REGULATOR INLET CONNECTION
Natural Gas By Pipeline
Methane CGA 350
Methane (5500 PSIG (38000 kPa) Max.) CGA 695
Propane CGA 510
*All values are approximations*
If more detailed specifi cations are required, contact your fuel gas supplier for the specifi c
properties of the fuel gas.
3-90056-3260
Industrial Gases
CUTTING, HEATING AND WELDING GUIDE
3.04 PROPYLENE AND PROPYLENE-BASED FUEL GASES
Propylene, also known by its IUPAC name propene, is an organic compound having the chemical
formula C3H6. It is the second simplest member of the alkene class of hydrocarbons, ethylene
(ethene) being the simplest. At room temperature and pressure, propylene is a gas. It is colorless,
highly fl ammable, and has an odor similar to garlic.
Propylene is found in coal gas and can be synthesized by cracking petroleum.
In newer designs, cracking takes place using a very active zeolite-based catalyst in a short-contact
time vertical or upward sloped pipe called the “riser”. Pre-heated feed is sprayed into the base
of the riser via feed nozzles where it contacts extremely hot fl uidized catalyst at 1230 to 1400°F
(665 to 760°C). The hot catalyst vaporizes the feed and catalyzes the cracking reactions that
break down the high molecular weight oil into lighter components, including LPG, gasoline, and
diesel. The catalyst-hydrocarbon mixture fl ows upward through the riser for just a few seconds
and then the mixture is separated via cyclones. The catalyst-free hydrocarbons are routed to a
main fractionator for separation into fuel gas, LPG, gasoline, light cycle oils used in diesel and
jet fuel, and heavy fuel oil.
These gases are industrial fuel gases used for fl ame cutting, scarfi ng, heating, fl ame hardening,
stress relieving, brazing and soldering. They may also be used in certain applications for welding
cast iron and aluminum.
Propylene and Propylene-Based Fuel Gas Cylinders
Available in on-site bulk storage tanks. Also available in portable 30 lb. (13.6 Kg) cylinders, and
larger 60-70 lb. (27.2-31.8 Kg) and 100-110 lb. (45.4 - 49.9 Kg) cylinders.
Specifi cations
SAFETY
Shock sensitivity Stable
Explosive limits in oxygen (%) 2.0-57
Explosive limits in air (%) 2.0-10
Maximum allowable use pressure
Tendency to backfi re Moderate
Toxicity Low
Cylinder 135 PSIG @ 70°F
(930 kPa @ 21°C)
COMBUSTION PROPERTIES
Neutral fl ame temperature in °F (°C) 5240 (2893)
Burning velocity in oxygen in ft./sec. (m/sec) 15.0 (4.6)
Primary fl ame in BTU/ft³ (MJ/m³) 403 (15.0)
Secondary fl ame in BTU/ft³ (MJ/m³) 1969 (73.4)
Total heat in BTU/ft³ (MJ/m³) 2372 (88.4)
Total heating value in BTU/lb. (kJ/kg) 20000 (46400)
Auto ignition temperature in °F (°C) 896 (480)
VALVE OUTLET AND REGULATOR INLET CONNECTION
• CGA 510 - 0.885 in (22.5 mm) - 14 NGO-LH-INT (POL Outlet)
*All values are approximations*
If more detailed specifi cations are required, contact your fuel gas supplier for the specifi c
properties of the fuel gas.
Industrial Gases
3-10
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
3.05 FUEL GASES WITH NATURAL GAS OR PROPANE BASE
PLUS LIQUID HYDROCARBON ADDITIVES
These fuel gases consist of a natural gas or propane base which is enriched by a liquid hydrocarbon
additive. The liquid hydrocarbon additive is usually a low-boiling point, petroleum ether fraction
of n-pentane and / or iso-pentane. N-pentane has a heating value of approximately 4249 BTU/ft³
(158 MJ/m³). Pentane added to natural gas will show a greater percentage increase in heating
value, as the BTU heat value of natural gas is approximately 1050 BTU/ft³ (34.1 MJ/m³) This is
not meant to imply that all the fuel gases listed above use n-pentane or iso-pentane as the liquid
hydrocarbon additive.
The physical and combustion properties of these fuel gases vary according to the percentage of
additives added to the base of natural gas or propane. Use the general specifi cations for natural
gas and propane as listed in the preceding pages as a guide only. Contact your fuel gas supplier
for the specifi c properties of the fuel gas if more detailed specifi cations are required.
3-110056-3260
Industrial Gases
CUTTING, HEATING AND WELDING GUIDE
SECTION 4:
OXY-FUEL APPARATUS
Typical oxy-fuel workstations normally include the following items, each designed to perform a
specifi c function:
• Oxygen and fuel supply • Cutting attachment and tip(s)
• Regulators • Welding nozzle(s)
• Hose • Heating nozzle(s)
• Torch Handle • Operator safety equipment
4.01 OXYGEN AND FUEL SUPPLY
There are two types of workstations, portable and stationary. The portable station is usually supplied
by cylinders mounted on a cart. The stationary units are supplied by piping or manifold systems.
The stationary system restricts the operator to the length of hose attached to the torch handle.
CAUTION
Always be aware of the gases in use at the station. Use only the type of apparatus
designed for use with those gases.
4.02 REGULATORS
Oxygen and fuel pressure regulators are attached to the cylinders or piping outlets to reduce high
cylinder or supply pressures to suitable lower working pressures for oxy-fuel applications. The
basic external features of a regulator are as shown in Figure 3. Figure 3 also shows: CGA inlet
connection with fi lter, pressure adjusting screw, inlet gauge, delivery gauge, outlet connection,
and relief valve (where provided).
LOW PRESSURE
GAUGE (DELIVERY)
RELIEF
VALVE
OUTLET
CONNECTION
Oxy-Fuel Apparatus
HIGH PRESSURE
GAUGE (SUPPLY)
PRESSURE
ADJUSTING
SCREW
INLET
INLET
CONNECTION
FILTER
Figure 3a: Regulator Features
4-12
PRESSURE
GAUGE
OUTLET
CONNECTION
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
HIGH PRESSURE
GAUGE (SUPPLY)
LOW PRESSURE
GAUGE (DELIVERY)
PRESSURE
ADJUSTING KNOB
INLET
FILTER
INLET
CONNECTION
OUTLET
CONNECTION
Figure 3b: Edge™ Regulator Features
WARNING
Always keep the regulator free of oil, grease and other fl ammable substances.
Never use oil or grease on the regulator, cylinder or manifold connection. Only use
the regulator for the gas and pressure for which it was designed. NEVER alter a
regulator for use with any other gas.
RELIEF
VALVE
Inlet Connection
Regulators are attached to the cylinders or piping outlets by their “inlet connections.” Inlet
connections must have a clean fi lter. All inlet connections conform to specifi cations and standards
set by the Compressed Gas Association (CGA) and are marked with an identifying CGA number.
CGA numbers identify the cylinder valve and gas service for which that inlet connection is
designed. Examples: CGA 510 has been designated for standard fuel gas cylinder connections
such as acetylene, propylene/propylene-based fuel gases and propane. CGA 540 connections
are designated for oxygen service only. Fuel gas inlet connections usually have left-hand threads.
Those with left-hand threads also have a “V” notch around the inlet nut to further designate the
connection for fuel gas service. All oxygen connections have right-hand threads.
Pressure Adjusting Screw
The regulator adjusting screw/knob controls the delivery pressure of the gas to the hose. As previously
stated, the regulator’s function is to reduce high supply pressures to a suitable working pressure
range. When the adjusting screw is turned clockwise, the regulator allows gases to fl ow through
the regulator to the hoses and to the torch. The threaded adjusting screw applies mechanical force
to a spring and diaphragm which controls a pressure valve in the regulator. If the adjusting screw is
turned fully counterclockwise, tension on the spring is released and the regulator normally does not
allow the gas to fl ow. The regulator adjusting screw is not intended as a “shut off” mechanism.
4-130056-3260
Oxy-Fuel Apparatus
CUTTING, HEATING AND WELDING GUIDE
Pressure Gauges
The inlet pressure gauge indicates the cylinder or supply pressure entering the regulator. The
delivery pressure gauge indicates the delivery pressure from the regulator to the hose. All gauges
are precision instruments; handle with care.
Outlet Connections
Gas hoses are attached to the regulator outlet connections. Most fuel gas regulators have lefthand threaded outlet connections to mate with the left-hand hose connections and have a “V”
notch around the outlet connection to further designate the connection for fuel gas service.
Oxygen regulators have right-hand threaded outlet connections to mate with the right-hand
hose connections.
Relief Valve (where provided)
Internal or external relief valves are designed to protect the low pressure side of the high pressure
regulator from damage due to an inadvertent high pressure surge.
WARNING
DO NOT tamper with the relief valve or remove it from the regulator. Relief valves
are not intended to protect downstream equipment from high pressures.
Hose
The gas hose transports low pressure gases (maximum 200 PSIG (1400 kPa)) from the regulators
to the cutting or welding torch. Proper care and maintenance of the hose assists the operator in
maintaining a safe, effi cient shop or work area.
Hose Construction
Industrial gas hose used in the U.S. is generally color-coded for gas service identifi cation. The
oxygen hose is normally green and the fuel hose is red. The colors are subject to change in
countries other than the U.S. The hose walls are constructed of continuous layers of rubber or
neoprene material over a braided inner section. The hose is marked to indicate its grade. All
approved domestically fabricated type VD grade “RM” and “T” hoses are fl ame retardant and
have an oil resistant cover. Grade “R” hose does not have an oil resistant cover. Grade “T” and
“RM” hose will burn, but will not support a fl ame if the heat source is removed. Grade “T” hose
is recommended for all fuel gases. Grade “R” and “RM” hose is for use with acetylene only.
WARNING
Grade “R” and “RM” hose are for use with acetylene only. These hoses have
rubber linings that are degraded by petroleum-based fuel gases. Grade “T” hose is
recommended for all fuel gases. It should be used with petroleum-based fuel gases
since it has a neoprene inner liner that is compatible with these gases.
Hose Care
Gas hoses are often exposed to severe abuse. They can provide effi cient service with proper care.
Hose splices and excessive hose length can restrict and reduce the amount of gas fl ow within the
hose. Molten slag and sparks may come into contact with hoses and burn into the hose exterior.
Falling metal during cutting operations might crush or cut into gas hoses. The operator should
frequently inspect the hoses and, when necessary, replace them.
Oxy-Fuel Apparatus
4-14
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
Safety Notes
• Falling metal during cutting operations might crush or cut into gas hoses.
• Never allow hoses to become coated with oil, grease, or dirt. Such coatings could conceal
damaged areas.
• Examine the hoses before attaching them to the gas torch handle or regulators. If cuts,
burns, cracks, worn areas, or damaged fi ttings are found, replace the hose.
• Completely replace the gas hose if it contains multiple splices or when cracks or severe
wear is noticed.
TERMS YOU SHOULD KNOW
BACKFIRE - The return of the fl ame into the torch, producing a popping sound. The fl ame will
either extinguish or re-ignite at the tip.
SUSTAINED BACKFIRE - The return of the fl ame into the torch with continued burning within the torch. This
condition may be accompanied by a popping sound followed by a continuous hissing or whistling sound.
FLASHBACK - The return of the fl ame through the torch into the hose and even into the regulator.
It may also reach the cylinder. This condition could possibly cause an explosion in the system.
4.03 TORCH HANDLE
A torch handle is essentially a set of gas tubes with control valves. One tube and valve controls
the fuel supply and the other tube and valve controls the oxygen supply. The torch handle is not
designed to mix the gases for oxy-fuel processes. The apparatus attached to the handle mixes
the oxygen and fuel gases. The handle is a means of control for the gas supply.
Victor® torch handles consists of six basic elements, shown in Figure 4. The control valves with
internal reverse fl ow check valves, the body “Y” with internal fl ashback arrestors, the barrel and
tubes (located inside the barrel) and the torch head.
NOTE
Victor® torch handle model numbers that contain the letters “FC” are equipped with
built-in fl ashback arrestors and check valves (i.e 315FC). Model numbers with a “C”
only contain built-in check valves (i.e. 315C). Earlier versions without an “F” or “C”
in the model number contain neither (i.e. 315). For all “C” model torch handles and
earlier versions, it is recommended that add-on fl ashback arrestors be installed.
Most add-on fl ashback arrestors also contain built-in check valves.
CONTROL
VALVES
TORCH HEAD
BODY “Y”
BARREL
INTERNAL FLASHBACK
ARRESTORS
INTERNAL REVERSE FLOW
Figure 4: Torch Handle Features
4-150056-3260
CHECK VALVES
Oxy-Fuel Apparatus
CUTTING, HEATING AND WELDING GUIDE
Body “Y” with Internal Flashback Arrestors
Most Victor® torch handles are equipped with built-in fl ashback arrestors. Flashback arrestors
are designed to prevent mixed gases from igniting upstream of the fl ashback arrestors.
CAUTION
It is not recommended to use accessory fl ashback arrestors on Victor ® FC torch handles
since these devices are already built-in. Excessive fl ow restrictions may occur.
General Information on Flashback Arrestors
• The fl ashback arrestors contained in this torch are designed to prevent a fl ashback fl ame
from entering the hose and gas supply system. A very fi ne “fi lter-like” sintered stainless
steel fl ame barrier stops fl ashback fl ame.
• For maximum service life of the fl ashback arrestor, completely purge all lines and hoses
before connecting to the torch. This removes loose material contained in the hose or
regulator that could restrict fl ow through the fl ashback arrestor.
• Flow restriction and torch over-heating results if dirt or “oily” LPG residuals are allowed to
fl ow into the fl ashback arrestor and cause clogging. Make sure not to draw liquid. Always
store and use cylinders in the upright position.
Control Valves with Internal Reverse Flow Check Valves
The body “Y” has two control valves attached to it. The valve bodies are marked to distinguish
between the two valves. The body of one valve has left-hand threads to accept the fuel gas hose.
The other valve body has right-hand threads to accept the oxygen hose. The control valves never
require lubricating. Occasionally, the packing nuts may require a slight adjustment.
Most Victor
reduce the possibility of mixing gases in the hoses and regulators.
®
torch handles are equipped with patented built-in reverse fl ow check valves to
CAUTION
Check valves are mechanical devices that can leak when dirty or if abused. Check
valves should be tested at least every six months, more often if hoses are frequently
disconnected. Careless usage, dirt or abuse can shorten the service life of check
valves, thus requiring more frequent testing. Follow the manufacture’s instructions
for testing the check valves.
NOTE
Reverse fl ow check valves are not the same as fl ashback arrestors. Check valves
are designed to help prevent reverse fl ow of gas upstream of the torch. Flashback
arrestors are designed to prevent mixed gases from igniting upstream of the
fl ashback arrestors.
Barrel
The barrel and inner oxygen tube unit is designed to keep the oxygen and fuel gases separated. A
tube-within-a-tube design allows the oxygen supply to move through the inner tube to the head
while the fuel supply travels through the interior barrel cavity.
Torch Head
The torch head is threaded onto the barrel, creating a metal to metal seal; there are no O-rings.
The oxygen supply from the inner tube is directed through the center hole in the head while the
Oxy-Fuel Apparatus
4-16
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
fuel supply passes through drilled orifi ces around the centered oxygen port. Tapered surfaces
inside the head mate with O-rings when the cutting or welding attachment is connected. This
creates a gas-tight seal. Never lubricate these surfaces. If damaged, the external threads and
internal surfaces of the head may be reconditioned by a qualifi ed repair technician.
4.04 CUTTING ATTACHMENT
The cutting attachment functions as a convenient and economical approach to cutting operations
where the frequency and/or application does not require a torch designed strictly for cutting. When
connected to a torch handle, the cutting attachment functions as a cutting torch. It provides the
operator with a wide range of cutting capabilities.
The cutting attachment consists of seven basic elements as shown in Figure 5. This fi gure shows:
the cone end, coupling nut, preheat oxygen control valve, mixing chamber, cutting oxygen lever
and tube, cutting attachment head, and tip nut.
CUTTING ATTACHMENT HEAD
MIXING CHAMBER
TIP
NUT
CUTTING OXYGEN LEVER
CONE END
COUPLING NUT
PREHEAT OXYGEN
CONTROL VALVE
Figure 5: Cutting Attachment Features
Cone End and Coupling Nut
The cone end and coupling nut are designed to permit easy attachment to the torch handle. The
tapered cone end is machined to mate with the internal taper of the torch handle head. O-rings
on the cone end allow continued separation of oxygen and fuel gases. The O-rings also provide
a hand-tight seal for the connection.
WARNING
There must always be two O-rings on the cone end. The absence or damage of either
of these O-rings will allow premixing and leaks of oxygen and fuel gases. This can
lead to a sustained backfi re within the torch handle or cutting attachment.
The center orifi ce of the cone end, like the center port of the torch handle head, allows the passage
of the oxygen supply. The orifi ces around the oxygen port allow the fuel gas to travel to the mixing
chamber in the lower tube of the cutting attachment.
Preheat Oxygen Control Valve
When the cutting attachment is connected to the torch handle, the preheat oxygen control valve on
the cutting attachment controls the preheat oxygen supply from the regulator. To function in this
manner, the oxygen valve on the torch handle must be opened completely. The preheat oxygen
supply is then increased or decreased by opening or closing the cutting attachment control valve.
The fuel supply is controlled by the fuel valve on the torch handle.
4-170056-3260
Oxy-Fuel Apparatus
CUTTING, HEATING AND WELDING GUIDE
Mixing Chamber Tube
Fuel and oxygen are mixed to produce the desired preheating fl ame. To accomplish the necessary
mixing of gases, oxygen and fuel are fed into a mixing chamber located in the forward portion of
the cutting attachment mixing chamber tube. Oxygen is directed to the mixer through the inner
oxygen tube. The fuel gas is drawn from the exterior cavity of the attachment’s lower tube around
the mixer. Mixed gases then fl ow through the preheat orifi ces of the cutting attachment head and
into the preheat orifi ces of the cutting tip.
Cutting Oxygen Lever and Tube
The cutting oxygen lever is located above the body of the cutting attachment. When the oxygen
control valve on the torch handle is open, depressing the lever allows cutting oxygen to fl ow
through the upper tube of the cutting attachment and the center port of the cutting attachment
head. The upper oxygen tube is designed to allow the maximum supply of oxygen to the cutting
operation and to provide structural strength by the utilization of high strength tubing.
Cutting Attachment Head
The cutting attachment head is designed to allow the cutting oxygen and the mixed preheat gas
to stay separated during the cutting operation. The exterior of the torch head is threaded and the
interior of the head is tapered. The internal taper of the head is stepped allowing the preheat gases
to feed the cutting tip through the exterior orifi ces and the cutting oxygen can travel uninterrupted
through the center port of the tip to the heated base metal (see Figure 6). The exterior threads
on the head allow a tip nut to compress a cutting tip into the tapered head. This creates a fi rm
gas-tight metal-to-metal seat.
Cutting Tip
Cutting tips are available in a wide variety of confi gurations and sizes. Cutting tips keep the preheat
gas mixture and cutting oxygen stream separated and provide fl ame characteristics needed for a
particular cutting application. Tips are sized according to the thickness of metal they can cut. For
instance, a number 000 tip is designed to cut metal 1/16" to 1/8" (1.6 - 3.2mm) in thickness, and
a number 00 tip will cut metal 1/8" to 1/4" (3.2 - 6.4mm) in thickness. For further information
on tip sizes and selections, refer to the charts located in Section 9.
CAUTION
Always make sure your equipment is rated for the size tip you have selected. A tip
with too much capacity for the equipment can starve or choke the tip. This causes
overheating of the head and a backfi re may result. Use only genuine Victor®, Cutskill®,
or Firepower® tips, welding nozzles and multi-fl ame nozzles to ensure leak-free
connections and balanced equipment.
Oxy-Fuel Apparatus
4-18
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
PREHEAT GAS
ORIFICES
OXYGEN ORIFICE
TAPERED
SEATING
SURFACES
TAPERED
SEATING
SURFACES
Figure 6: Cutting Tip (1-1-101, GPN)
Tapered Seating Surfaces
The tapered end of the tip is machined to fi t into the cutting attachment head. A tip nut secures
the tip into the head. The tapered surfaces form a metal-to-metal seal (see Figure 6). Inspect
both the head and tip tapers frequently for signs of damage or wear.
WARNING
A damaged seating surface on either the tip or the head can create a hazardous
condition, resulting in a backfi re or sustained backfi re. This may damage the cutting
attachment. If the seating surface of a tip becomes damaged, DO NOT use the tip.
Discard the damaged tip. If the head requires repair, take the torch to a qualifi ed
repair technician.
Preheat Orifi ces and Oxygen Orifi ces
Cutting tips are subjected to much abuse in cutting operations. Slag can splatter and stick to
the cutting tip, clogging or obstructing the passages through which the gas must fl ow. Remove
splatter from the tip orifi ces with appropriate tip cleaners.
NOTE
Repeated cleaning can affect the fl ame confi guration and render the tip unsuitable
for precision work.
Welding Nozzle
The welding nozzle is usually an assembly consisting of a welding elbow, a gas mixer, and a
coupling nut. A wide range of tip and nozzle confi gurations are available for attachment to the
torch handle. Typical tip and nozzle applications include welding, brazing, soldering, heating,
and hard facing.
4-190056-3260
Oxy-Fuel Apparatus
CUTTING, HEATING AND WELDING GUIDE
Welding Elbow
The welding elbow is a tellurium copper tube that has been swaged to a specifi c orifi ce size on one
end. Like cutting tips, welding tips have a calibrated orifi ce for welding various thicknesses of metal.
For further information on nozzle sizes and selections, please refer to the chart located in Section 9.
In the oxy-fuel welding process, slag can splatter and clog the tip orifi ce. Remove spatter from
the orifi ce with a round fi le (tip cleaner).
NOTE
Repeated cleaning may alter the orifi ce size, requiring adjustments to the gas supply.
Multi-Flame Heating Nozzles (Rosebuds)
The multi-fl ame heating nozzle is basically a large welding nozzle (see Figure 7). The coupling nut
and mixer assembly are similar in design to a welding nozzle. The multi-fl ame head is machined to
utilize numerous fl ames. This provides additional heating capacity for heavy heating applications.
HEATING NOZZLE
MIXER
COUPLING NUT
(ROSEBUD)
WELDING ELBOW
Figure 7: Welding Nozzle
Gas Mixer
The welding / heating nozzle cone end is similar to that of the cutting attachment cone end. The
difference is that the welding / heating nozzle cone end is designed to mix the oxygen and fuel
gases, whereas the cone end in the cutting attachment is not. When the oxygen meets with the
fuel gas, a homogenizing mixing effect occurs. This complete mixing of the gases results in a
well-balanced fl ame composition. Like the cutting attachment cone end, the welding / heating
nozzle has two O-rings. They maintain the separation of gases prior to the point at which mixing
occurs. They allow a hand-tight connection of the welding nozzle and the torch handle.
WARNING
There must always be two O-rings on the cone end. The absence or damage of
either of these O-rings allows premixing and leaks of oxygen and fuel gases. This
can lead to a backfi re or sustained backfi re within the torch handle.
Coupling Nut
The welding / heating nozzle coupling nut is similar in design to the coupling nut on the cutting
attachment. A locking ring in the coupling nut mates with a groove in the forward portion of the
welding nozzle mixer, thus allowing the nut to protect the cone end and O-rings (see Figure 7).
Examine the O-rings by twisting and pushing the coupling nut away from the cone end.
CAUTION
Use only genuine Victor®, Cutskill®, or Firepower® torch handles, welding nozzles and
multi-fl ame nozzles to ensure leak-free connections and balanced equipment.
Oxy-Fuel Apparatus
4-20
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
SECTION 5:
SETTING UP EQUIPMENT FOR WELDING
5.01 CYLINDERS
Place the oxygen and fuel gas cylinders together where they are used. Secure them properly (see
Figure 8). Chain or secure cylinders to a cylinder cart, wall, work bench, post, etc.
Figure 8: Securing the Cylinders in the Cart
CAUTION
Cylinders are highly pressurized. Always handle with care. Never allow cylinders to
be dropped, knocked over, or subjected to excessive heat. When moving cylinders,
always be certain that valve protection caps are secured in place. Place valve
protection caps where they are easily found. Replace the cap when the cylinders
are empty or not in use.
Important Safety Notes
• Always keep cylinders secured properly in a vertical position.
• Do not strike, drop, or apply heat to any cylinder or valve.
• Always keep valve protection caps in place whenever cylinders are moved or in storage,
whether cylinders are full or empty.
• Mark empty cylinders “empty” or “MT”.
• Close valves completely on empty cylinders.
• Do not use a cylinder that does not have a gas identifi cation label attached to it.
• Close valves completely prior to regulator removal.
5-210056-3260
Setting Up Equipment for Welding
CUTTING, HEATING AND WELDING GUIDE
5.02 REGULATORS
1. Carefully inspect the cylinder valve, regulator threads and mating surfaces for traces
of oil, grease, or dirt. DO NOT wipe the mating surfaces with your fi nger. Make sure the
regulator has the correct pressure rating for the cylinder being used (see Figure 9).
Figure 9: Inspecting the Cylinder and Cylinder Valve
WARNING
DO NOT use the regulator if oil, grease, or damaged parts are detected on the
regulator or the cylinder valve or if the inlet fi lter is missing or dirty (see Figure
9). Inform your gas supplier of this condition immediately. Have a qualifi ed repair
technician clean or repair the regulator.
2. Momentarily open and close the cylinder valve (commonly referred to as “cracking”).
This dislodges any loose contaminants that may be present.
CAUTION
Open the cylinder valve only slightly. If the valve is opened too much the cylinder
could tip over. When “cracking” the cylinder valve, DO NOT stand, nor have anyone
stand directly in front of the valve opening. Stand behind or to one side. Crack the
cylinder valve in a well ventilated area only. If an acetylene cylinder sprays a mist
when it is cracked, let it set for 30 minutes. Then try to crack the cylinder valve
again. If the problem persists, contact your gas supplier.
CAUTION
Use the regulator only for the gas and pressure for which it is designed. NEVER alter
a regulator for use with any other gas.
Setting Up Equipment for Welding
5-22
0056-3260
SET-UP AND SAFE OPERATING PROCEDURES
3. Before attaching the oxygen regulator to the oxygen cylinder valve, carefully inspect the
regulator for damaged threads, dirt dust, and grease, oil, or other fl ammable substances.
Remove dust and dirt with a clean cloth. Be sure the inlet swivel fi lter is clean and in
place. Attach the regulator to the cylinder valve. Tighten securely with a wrench.
4. Before attaching the fuel gas regulator to the fuel gas cylinder valve, inspect the regulator
as in step three. Tighten securely with a wrench in the direction necessary for the
particular fuel gas connection in use.
5. Connect the gas hose to the regulator outlet fi tting.
6. Before opening the cylinder valves, release the tension on the regulator adjusting screws
by turning them counterclockwise until all spring pressure is released.
Turning on the Cylinders
1. Be certain that the tension on the regulator adjusting screws has been released. Stand
so that the cylinder valve is between you and the regulator.
WARNING
Never stand, nor have anyone stand in front or behind a regulator when opening the
cylinder valve. Always stand so that the cylinder is between you and the regulator
(see Figure 10).
2. Slowly and carefully open the oxygen cylinder valve until the maximum pressure registers
on the high pressure gauge. Now, open the oxygen cylinder valve completely to seal the
valve packing.
3. Slowly open the fuel gas cylinder valve in the same manner.
CAUTION
Open the acetylene cylinder valve approximately ¾ of a turn and no more than 1½
turns. For all other fuel gases, open the fuel gas cylinder completely. Keep the cylinder
wrench, if one is required, on the cylinder valve so the cylinder may be quickly turned
off in the event an emergency situation arises.
Figure 10: Opening the Cylinder Valve
5-230056-3260
Setting Up Equipment for Welding
CUTTING, HEATING AND WELDING GUIDE
5.03 GAS HOSES
1. Connect the oxygen hose to the oxygen regulator. Tighten the connection firmly with
a wrench.
2. Adjust the oxygen regulator to allow 3-5 PSIG (21-34 kPa) to pass through the hose. Allow
oxygen to fl ow for 5-10 seconds to clear the hose of dust, dirt, or preservatives. Shut off the
oxygen fl ow.
3. Attach and clear the fuel hose in the same manner.
Important Safety Notes
• Be certain cylinder valves and regulator connections are completely free of dirt, dust, oil,
or grease.
• If oil, grease, or damage is detected on the cylinder valves, DO NOT use the cylinder. Notify
the cylinder supplier immediately.
• If oil, grease, or damage is detected on the regulator, DO NOT use the regulator. Have the
regulator cleaned or repaired by a qualifi ed repair technician.
• Never stand directly in front or behind a regulator when opening the cylinder valve. Stand
so that the cylinder valve is between you and the regulator.
• Always open the cylinder valves slowly and carefully.
• Always check for leaks on the regulator and cylinder valve connections.
WARNING
Be sure to clear hoses in a well-ventilated area. The escaping gases create conditions
for fi res and explosions.
Keep hoses clear of any falling metal, slag, or sparks.
Never allow hoses to become coated with oil, grease or dirt. This could conceal
damaged areas on the hoses.
Examine the hoses before attaching the torch handle or regulators. If any cuts, burns,
worn areas, cracks, or damaged fi ttings are found, repair or replace the hose.
5.04 TORCH HANDLE
Since cutting attachments, brazing nozzles, and heating nozzles are all connected to the torch
handle, the torch handle is probably the most frequently used item in a welding shop. Always be
sure to protect the torch handle from possible damage or misuse.
1. Inspect the torch handle head, valves, and hose connections for oil, grease, or
damaged parts.
2. Inspect the hose connections in the same manner. DO NOT use them if oil, grease, or
damage is detected.
3. Inspect the torch handle. The tapered seating surfaces in the head must be in good
condition. If dents or burned seats are present, the seat must be resurfaced. If the torch
handle is used with poor seating surfaces, backfi re may occur.
Setting Up Equipment for Welding
5-24
0056-3260
Loading...