Miller GAS EQUIP- Manual

OM-262659F
2024−05
Processes
Oxy-Fuel
Welding
Cutting
Protect yourself and
others from injury —
read, follow, and save these
important safety precautions
and operating instructions.
Warranty Information Inside
SAFETY MANUAL
Rev 2024-05
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . 1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Welding, Cutting, Brazing, Heating Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 2 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 3 − HAZARDOUS EVENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 4 − ASSOCIATED HAZARDS OF RECOMPRESSING PURE
OXYGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 5 − EQUIPMENT SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5-1. Installing Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5-2. Installing Regulators On Cylinder Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5-3. Installing Hoses On Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5-4. Installing Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5-5. Installing Flashback Arrestors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-6. Combination Torch Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-7. Installing Hoses On Torch Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-8. Installing Cutting Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-9. Installing Straight (Hand) Cutting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-10. Installing Cutting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-11. Installing Welding Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-12. Installing Multi-Flame Heating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-13. Testing The Equipment For Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 6 − WELDING TIP ADJUSTMENTS AND LIGHTING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6-1. Purging The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6-2. Lighting And Adjusting Acetylene/Oxygen Welding Tips . . . . . . . . . . . . . . 13
6-3. LP Fuel Gas/Oxygen Tips (Other Than Acetylene) . . . . . . . . . . . . . . . . . . 13
6-4. Extinguishing The Torch Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6-5. System Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 7 − MULTI-FLAME HEATING TIP ADJUSTMENT AND LIGHTING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 8 − CUTTING ATTACHMENT ADJUSTMENT AND LIGHTING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8-1. Setting Up Cutting Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8-2. Adjusting The Acetylene Cutting Tip Flame (Cutting Assembly) . . . . . . . 15
8-3. Adjusting Alternate Fuel Gas Cutting Tip Flame (Other Than Acetylene) 15
8-4. Extinguishing The Torch Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 9 − STRAIGHT (HAND) CUTTING TORCH ADJUSTMENTS AND
LIGHTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9-1. Setting Up Straight (Hand) Cutting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9-2. Adjusting Acetylene Cutting Tip Flame (Hand Torch) . . . . . . . . . . . . . . . . . 16
9-3. Adjusting Fuel Gas Cutting Tip Flame (Other Than Acetylene) . . . . . . . . 17
9-4. Extinguishing The Torch Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 1.SC12 Series Heavy-Duty Cutting Tips − Acetylene (One Piece) . . . . . . 18
Table 2.SC56 Series Heavy-Duty, Heavy-Preheat Cutting Tips − Acetylene
(One Piece) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 3. MC12 Series Medium Duty Cutting Tips − Acetylene (One Piece) . . . . 20
Table 4. SC And MC Series Special Purpose Tips For Hand Torches And Cutting
Assemblies − Acetylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 5.Heating Tips − Acetylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 6.Welding/Brazing Tips− Acetylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 7.AEffect Of Hose Diameter And Length On Flow And Pressure At Torch 24
Table 7.BEffect Of Hose Diameter And Length On Flow And Pressure At Torch 25
Table 7.CEffect Of Hose Diameter And Length On Flow And Pressure At Torch 26
Table 8.SC40 Series Heavy-Duty Cutting Tips − Propane (Two Piece) . . . . . . . . 27
Table 9.SC50 Series Heavy-Duty, Heavy-Preheat Cutting Tips −
Propane (Two Piece) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 10.SC50 Series Heavy-Duty, Heavy-Preheat Cutting Tips −
Natural Gas (Two Piece) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 11.SC46 Series Heavy-Duty Cutting Tips − Propane (One Piece) . . . . . . . 30
Table 12.SC46 Series Heavy-Duty Cutting Tips − Natural Gas (One Piece) . . . 31
Table 13.SC60 Series Heavy-Duty Cutting Tips − Propylene (Two Piece) . . . . . 32
Table 14.SC36 Series Heavy-Duty Cutting Tips − Propylene (One Piece) . . . . . 33
Table 15.SC Series Heavy-Duty Special Purpose Tips − Propane/Propylene . . 34
TABLE OF CONTENTS
Table 16.MC40 Series Medium-Duty Cutting Tips − Propane (Two Piece) . . . . . 35
Table 17.MC60 Series Medium-Duty Cutting Tips − Propylene (Two Piece) . . . . 36
Table 18.Heavy-Duty Heating Tips -Propylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Table 19.Heavy-Duty Heating Tips − Natural Gas/Propane . . . . . . . . . . . . . . . . . . 37
Table 20.Medium-Duty Heating Tips − Propane/Propylene/Natural Gas . . . . . . . 38
Table 21.Brazing Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 10 − SC900 SERIES GAS AXE − HAND CUTTING TORCH . . . . . 39
10-1. Reversing The Cutting Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION 11 − NEW YORK CITY FIRE DEPARTMENT REGULATIONS . . . . 39
WARRANTY
SECTION 1 − SAFETY PRECAUTIONS READ BEFORE USING
OXY FUEL 2024-01
Protect yourself and others from injury — read, follow, and
save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained
in the text.
Indicates a hazardous situation which, if not avoided, could
result in death or serious injury. The possible hazards are
shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means
Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and
HOT PARTS hazards. Consult
symbols and related instructions below for necessary actions to avoid
these hazards.
1-2. Welding, Cutting, Brazing, Heating Hazards
The symbols shown in this section are used throughout this
manual to call attention to and identify possible hazards.
When you see the symbol, watch out, and follow the related
instructions to avoid the hazard. The safety information given
below is only a summary of the more complete safety information found in the Principal Safety Standards. Read and follow
all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter,
the work, or the project and has received safety training to
recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
Do not use this equipment unless you are trained in its proper
use or are under competent supervision. Follow the procedures described in this manual every time you use the equipment. Failure to follow these instructions can cause fire, explosion, asphyxiation, property damage, or personal injury.
This equipment must be used in accordance with all Federal,
State, and local regulations as well as DOT (Department of
Transportation) and CGA (Compressed Gas Association) regulations. Contact your gas supplier for more information on
the proper use of compressed gases.
OM-262659 Page 1
. In this document, the phrase “welding and cutting” also refers to other oxy-fuel operations like brazing and heating.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s Manual carefully be-
fore installing, operating, or servicing equipment. Read the safety
information at the beginning of the manual and in each section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
FUMES AND GASES can be hazardous.
Welding and cutting produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
D Keep your head out of the fumes. Do not breathe the fumes.
D Ventilate the work area and/or use local forced ventilation at the
flame to remove welding and cutting fumes and gases. Some gases
(natural gas and acetylene) are lighter than air and will collect in high
areas. Other gases (propane and butane) are heavier than air and
will collect in low areas. Heavier-than-air gases are more difficult to
diffuse and are more likely to accumulate. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coatings, cleaners, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding and cutting fumes and gases can displace air and lower the oxygen level, causing injury or death. Be
sure the breathing air is safe. Test atmospheres in confined areas
for explosive and toxic gases before using oxy-fuel equipment.
D Do not weld or cut in locations near degreasing, cleaning, or
spraying operations. The heat from welding or cutting flame can
react with vapors to form highly toxic and irritating gases.
D Do not weld or cut on coated metals, such as galvanized, lead, or
cadmium-plated steel unless the coating is removed from the affected area, the area is well ventilated, and while wearing an airsupplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded or cut.
D Do not weld or cut on sealed air conditioning or refrigeration systems unless all refrigerants have been removed from the system.
OM-262659 Page 2
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use approved air-supplied
respirator.
LIGHT RAYS can burn eyes and skin.
Light rays from the welding and cutting process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
Sparks fly off from the weld.
D Wear approved face protection fitted with a proper shade of filter
lenses to protect your face and eyes from light rays and sparks
when welding, cutting, or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear welding goggles, or wear welding helmet/welding faceshield over approved goggles/safety glasses with side shields.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the welding or cutting.
D Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing such as
leather gloves, heavy shirt, cuffless trousers, high shoes, and a
cap.
WELDING AND CUTTING can cause
fire or explosion.
Welding and cutting on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from the welding or
cutting operations. The torch flame, flying sparks, hot workpiece, and
hot equipment can cause fires and burns. Check and be sure the area is
safe before doing any welding or cutting.
D Do not use this welding and cutting equipment with gases and
D
pressures other than those for which it is intended. Oxygen is not
flammable; however, the presence of pure oxygen will drastically
increase the speed and force with which burning takes place. Oxygen must never be allowed to contact grease, oil, or other petroleum-based substances; therefore, be sure there is no oil or grease
on the regulator, cylinder, valves, or equipment. Do not use petroleum-based pipe sealants. Do not use sealants on metal-to-metal
seals, such as hose and CGA cylinder connections; use
PTFE-based sealant (PTFE tape) on pipe threads. Do not use or
store near excessive heat (above 125° F/51.5° C) or open flame.
Do not refer to oxygen as air and do not use oxygen as a substitute
for compressed air. Do not use oxygen to clean clothes or work
area, for ventilation, or to operate pneumatic tools. Open oxygen
cylinder valves slowly. Be sure regulator adjusting handle is in the
full out (off) position before opening oxygen cylinder valve.
Inspect all equipment before use. Do not use damaged, defective,
or improperly adjusted welding and cutting equipment. Make sure
levers and valves work properly, threads on equipment are clean
(no grease or oil) and not deformed, gauges are intact and easy to
read, regulator is clean and free of oil or dirt, and fittings are properly sized for the cylinder. Make sure hoses are clean (no grease or
oil) and ferrules are properly installed so the fitting does not slip inside the hose. Be sure all connections are tight.
OM-262659 Page 3
D It is recommended that a reverse-flow check valve or a flashback ar-
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restor be installed between the torch handle and the regulator. Check
valves do not prevent the propagation of a flame upstream (flashback) but are designed to prevent the unintentional backflow of gases
into the cutting attachment, torch, hoses, or regulator which could
cause an explosion or fire. A flashback arrestor can be installed on the
torch handle or regulator outlet instead of a check valve. Miller flashback arrestors have a reverse flow check valve and prevent the propagation of a flame upstream. If a flashback arrestor is installed, a
check valve is not necessary. Using a flashback arrestor and a check
valve can reduce gas flow and affect torch operation. To help prevent
the reverse flow of gases, be sure the cylinders contain enough gas to
complete the work.
Understand the properties and applications of a gas, and how to
safely use a gas, before placing it in service.
Perform work only in an area with a fireproof floor (concrete). Do
not heat concrete because it can expand and explode violently.
Perform work on a fireproof surface. Use heat resistant shields to
protect nearby walls and flooring.
Do not use if grease or oil is present on equipment or if equipment is
damaged. Have equipment cleaned/repaired by a qualified person.
Do not open a cylinder valve quickly or the regulator can be damaged and cause a fire.
Do not open acetylene cylinder valve more than 1−1/2 turns. (For
all gases except acetylene, open cylinder valve fully to backseal
the cylinder valve.) Keep cylinder wrench on the cylinder for quick
shut-off.
Do not slightly open or “crack” fuel cylinder valve to blow debris
from the valve outlet. Remove the debris using nitrogen, air, or a
clean, oil-free rag.
Always purge gas from the system before lighting torch. Purge gas
in a well-ventilated area and away from flame or sparks.
Keep torch flame or sparks away from cylinder, regulator, and gas
hose.
Use only the gases recommended by the manufacturer of the
oxy-fuel equipment being used.
Never light a torch with matches or a lighter. Always use a striker.
Do not use acetylene above 15 psi (103 kPa) flowing. It is acceptable to use acetylene regulators that indicate a static pressure up
to 22 psi (151 kPa).
Do not withdraw acetylene from a cylinder at a rate exceeding 1/7
of the cylinder capacity per hour (50 SCFH for a 350 ft3 cylinder).
Maximum withdrawal rate for a half-full 100 lb propane cylinder at
70°F is 75 SCFH (2124 lph).
When required flows (SCFH) exceed the recommended withdrawal
rate from one cylinder, then additional cylinders must be manifolded to
provide safe and efficient operation.
When using liquid oxygen, tips may require greater gas volume than a
single cylinder is capable of producing. External evaporators or manifolding multiple cylinders may be necessary to supply sufficient gas
flows.
D Do not use long gas hoses or hoses with multiple connections be-
D
cause they restrict gas flow and reduce gas pressure. These conditions can cause backfires and flashbacks, and reduce equipment efficiency.
Do not use torch if you smell gas. Check oxy-fuel system for leaks
with an approved leak detection solution or leak detector. Never
test for gas leaks with a flame.
OM-262659 Page 4
D Remove all flammables within 35 ft (10.7 m) of the welding or cutD
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ting operation. If this is not possible, tightly cover them with approved covers.
Do not weld or cut where flying sparks can strike flammable
material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding and cutting sparks and hot materials from
welding and cutting can easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding or cutting on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
Do not weld or cut on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 (see Safety Standards).
Do not weld or cut where the atmosphere can contain flammable
dust, gas, or liquid vapors (such as gasoline).
Wear body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing such as
leather gloves, heavy shirt, cuffless trousers, high shoes, and a
cap.
Do not use fuel gases to clean clothes or work area.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding or cutting.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are normally part
of the welding or cutting process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, and sparks.
D Install cylinders in an upright position by securing to a stationary
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support or cylinder rack to prevent falling or tipping. Do not lay acetylene cylinders on their sides or acetone will flow out of the cylinder
and damage the equipment.
Keep cylinders away from any arc welding, cutting, or other electrical circuits.
Never drape a welding or cutting torch over a gas cylinder.
Never weld or cut on a pressurized cylinder − explosion will result.
Use only correct compressed gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and associated parts in good condition. Do not use compressed gas cylinder unless an approved gas regulator is attached to the gas valve.
Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the proper equipment, correct procedures, and sufficient number of persons to lift, move, and transport cylinders.
Store compressed gas and oxygen cylinders in separate locations.
Store empty cylinders with valves closed and caps in place.
OM-262659 Page 5
D Do not modify or repair cylinders or valves. Store leaking acetylene
D
D
cylinders outdoors in a safe area. Identify leaking cylinders and return them to the supplier.
Dispose of used disposable cylinders according to the manufacturer’s recommendations. Do not throw cylinders in fire.
Follow instructions provided by the gas supplier and on compressed gas cylinders, associated equipment, and in Compressed
Gas Association (CGA) publication P-1 listed in Safety Standards.
FLYING METAL or DIRT can injure eyes.
D Welding, cutting, chipping, wire brushing, and grinding cause
sparks and flying metal.
D Wear welding goggles, or wear welding helmet/welding face-
shield over approved goggles/safety glasses with side shields.
1-3. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.
For more information, go to www.P65Warnings.ca.gov.
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, American Welding Society standard ANSI Standard Z49.1. Website: www.aws.org.
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1. Website:
www.aws.org.
Recommended Practices for Safe Oxyfuel Gas Cutting Torch Operation,
American Welding Society Standard C4.2/C4.2M, and Recommended
Practices for Safe Oxyfuel Gas Heating Torch Operation, American
Welding Society Standard C4.3/C4.3M. Website: www.aws.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association. Website:www.cganet.com.
Acetylene, CGA Pamphlet G-1 from Compressed Gas Association.
Website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2
from Canadian Standards Association.
Website: www.csagroup.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1 from American National Standards Institute.
Website: www.safetyequipment.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA Occupational Safety and Health Standards for General Industry, Title
29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part
1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.
OSHA Important Note Regarding the ACGIH TLV, Policy Statement on
the Uses of TLVs and BEIs. Website: www.osha.gov.
Applications Manual for the Revised NIOSH Lifting Equation from the
National Institute for Occupational Safety and Health (NIOSH). Website:
www.cdc.gov/NIOSH.
OM-262659 Page 6
SECTION 2 − INTRODUCTION
Inspect all equipment before use. Do not use damaged, defective, or improperly adjusted welding and cutting equipment.
Make sure levers and valves work properly, threads on equipment are clean (no grease or oil) and not deformed, gauges are
intact and easy to read, regulator is clean and free of oil or dirt,
and fittings are properly sized for the cylinder. Make sure
hoses are clean (no grease or oil) and ferrules are properly installed so the fitting does not slip inside the hose. Be sure all
connections are tight and there are no leaks in the system.
We ask you to work like a pro − and pros weld and cut safely. Please read
and comply with the sample safety procedures outlined in this booklet
and the equipment Owner’s Manual.
SECTION 3 − HAZARDOUS EVENTS
The following events are very hazardous and can occur in any oxy-fuel
system. It is important to understand these hazards and know how to
prevent them.
Backfire: The momentary recession of the flame into the torch, potentially causing a flashback or sustained backfire. It is usually signaled by a
popping sound, after which the flame may either extinguish or reignite at
the end of the tip.
Sustained Backfire: The recession of the flame into the torch body with
continued burning characterized by an initial popping sound followed by
a squealing or hissing sound, potentially burning through inside the torch
body.
Flashback: The recession of the flame through the torch and into the
hose, regulator, and/or cylinder, potentially causing an explosion.
SECTION 4 − ASSOCIATED HAZARDS OF
RECOMPRESSING PURE OXYGEN
Open oxygen cylinder valves slowly. Opening an oxygen cylinder valve quickly can cause a fire or explosion. Be sure regulator adjusting handle is in the full out (off) position before opening an oxygen cylinder valve.
Recompressing high pressure oxygen in a low pressure cavity may create heat, resulting in combustion. For combustion to occur, oxygen, fuel,
and kindling temperatures must be present. All of these components
may be present when oxygen is recompressed by opening the tank valve
too quickly.
OM-262659 Page 7
Oxygen: High purity oxygen accelerates the rate of combustion, increases heat output, and lowers the combustible point at which various
materials will burn.
Fuel: The fuel for combustion may be the regulator itself if enough heat is
produced to reach the kindling temperature of the regulator’s components.
Kindling Temperatures: Enough heat may be generated to ignite the
regulator components by the friction created when recompressing
high-pressure oxygen. This heat is known as the heat of recompression.
If an internal fire or sustained backfire occurs (indicated by a
whistling sound or inverted flame), do the following:
D Turn off the torch oxygen valve immediately.
D Turn off the torch fuel valve.
D Turn off the oxygen cylinder valve.
D Turn off the fuel gas cylinder valve.
Do not relight the torch until the equipment has cooled to the touch and
the sustained backfire cause has been determined and corrected.
SECTION 5 − EQUIPMENT SET UP
Follow these steps to set up oxy-fuel equipment.
5-1. Installing Cylinders
1.
2.
Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Maintain a clear path from the cylinders to the work area.
Inspect equipment before use. Do not use if grease or oil is
present on equipment or if equipment is damaged. Have equipment cleaned/repaired by a qualified person.
Do not slightly open or “crack” acetylene cylinder valve to
blow debris from the valve outlet. Remove the debris using nitrogen, air, or a clean, oil-free rag.
Remove the protective cap from the cylinder valve.
For all cylinders except acetylene: Stand to one side or behind the
valve. Open the cylinder valve slightly (cracking) for an instant and
then close the valve. This will help clear the valve of any dust or dirt
that may have collected. These particles can damage regulators or
cause a fire or explosion. Direct the flow of gas away from people.
5-2. Installing Regulators On Cylinder Valves
Inspect equipment before use. Do not use if grease or oil is
present on equipment or if equipment is damaged. Have equipment cleaned/repaired by a qualified person.
Do not handle oxygen regulators with oily hands and never apply oil to any part of an oxygen regulator.
Do not use lubricant or thread tape on cylinder fittings.
Select regulators with sufficient flow capacity. Be sure there
are no restrictions that could impede gas flows (such as length
and diameter of hoses).
NOTICE − Do not use cylinder adaptors to connect regulators to cylinders. Regulators have CGA connections (manufactured to standards
OM-262659 Page 8
of the Compressed Gas Association) which allow the regulator to only be installed on the appropriate cylinder valve for the intended gas.
Pressure regulators are control devices used to reduce high pressure to
desired working pressure. There are two types of pressure regulators
used for oxy-fuel applications. One type is for use on cylinders and the
other type is used for connection to a gas piping system, or station regulator. The service temperature range for these regulators is −20° F to
140° F (−29° C – 60° C). Shown below is a cylinder regulator.
Low Pressure Gauge
High Pressure Gauge
Regulator Bonnet
Inlet (Tail Piece)
Connection
Adjusting Handle
Outlet Connection
1.
2.
3.
Examine the pressure reducing regulators that will be connected to
the cylinders. Make sure that the regulator is clean and the inlet filter
is clean and installed properly.
Connect the oxygen regulator to the cylinder valve, using the appropriate cylinder wrench to tighten the inlet nut. Connect the fuel
gas regulator to the fuel gas cylinder.
When replacing a pressure gauge, use only a UL-listed gauge.
PTFE thread tape is the only thread sealant approved for use on
oxygen regulators.
5-3. Installing Hoses On Regulators
Replace hoses at the first sign of any defects, flaws, or damage. The hoses should otherwise be replaced every four years.
Inspect hoses for damage or leaks before each operation. Do
not allow hoses to come in contact with hot metal, molten solder, or corrosive chemicals. Do not expose hoses to fluxing
agents as these agents will deteriorate the hose materials and
cause them to leak.
Do not splice or use damaged oxy-fuel hoses.
Use only industrial grade welding hose for welding, brazing, cutting, and
heating with oxy-fuel equipment. These hoses are generally color coded
green for oxygen and have a right hand threaded connection; fuel hoses
are red in color and have a left hand threaded connection with a groove
around the nut. Use grade R and RM hoses only for acetylene. T grade
hose can be used for acetylene and must be used for other fuel gases.
1. Connect the oxygen hose to the oxygen regulator and tighten firmly
with a wrench.
2. Connect the fuel hose to the fuel regulator and tighten firmly with a
wrench.
3. Make sure the regulator adjusting handles are turned counterclockwise to the off position and there is no resistance on the adjusting
handles.
5-4. Installing Check Valves
Reverse flow check valves should
be installed in the system either
on the regulator or on the torch
handle.
OM-262659 Page 9
Check valves are designed to provide some protection against the reverse flow of one gas into the hose and regulator of the other gas when
there is a sudden loss of pressure of one of the gases. Check valves do
not stop a flashback. Check valves do restrict flow. Do not use check
valves with large heating and cutting tips.
Check valves should be tested or replaced at regularly scheduled intervals as any debris may cause them to malfunction.
Check valves are designed for installation between the regulator outlet
fittings and the hoses, or between the torch butt and the hoses.
5-5. Installing Flashback Arrestors
NOTICE − When using add-on flashback arrestors, make sure the unit can
supply enough gas flow to support the tip being used. Insufficient gas flow
can cause equipment failure.
Flashback arrestors are designed to stop a flashback
from going beyond the point where they are installed.
There are several types and styles available. Flashback arrestors are recommended in all oxy-fuel welding, cutting, brazing, and heating applications. Ideally,
these units should be mounted on the welding handles.
If Smith add-on flashback arrestors are used, additional
check valves are not necessary.
5-6. Combination Torch Components
A combination torch consists of a welding handle and cutting attachment. When equipped with the proper tips, these torches are used for
welding, cutting, and heating.
Cutting Lever
Cutting Assembly
Oxygen Preheat Valve
Oxygen Valve
Handle
Fuel Gas Preheat Valve
5-7. Installing Hoses On Torch Handle
Inspect equipment before use. Do not use if grease or oil is
present on equipment or if equipment is damaged. Have equipment cleaned/repaired by a qualified person.
Torch handles are used in conjunction with welding tips, heating tips,
and cutting attachments. The illustration above shows a torch handle
with a cutting attachment.
1. Attach the green oxygen hose to the oxygen inlet fitting of the welding handle (right hand threads) and firmly tighten with a wrench. If a
check valve or flashback arrestor is being used at the torch, attach
the hose to the inlet of these devices (see Sections 5-4 and 5-5).
2. Attach the red fuel hose to the fuel inlet fitting of the welding handle
(left hand threads) and firmly tighten with a wrench. If a check valve
or flashback arrestor is being used at the torch, attach the hose to
the inlet of these devices.
5-8. Installing Cutting Attachment
Do not use cutting attachment if the o-rings are missing or
damaged.
OM-262659 Page 10
Inspect equipment before use. Do not use if grease or oil is
present on equipment or if equipment is damaged. Have equipment cleaned/repaired by a qualified person.
Cutting attachments are used in conjunction with welding handles to
perform oxy-fuel cutting of ferrous metals. See illustration of combination torch in Section 5-6.
5-9. Installing Straight (Hand) Cutting Torch
Inspect equipment before use. Do not use if grease or oil is
present on equipment or if equipment is damaged. Have equipment cleaned/repaired by a qualified person.
Cutting torches are used to cut ferrous metals using oxygen and a fuel
gas. Set-up the equipment as described in Sections 5-1 thru 5-7.
Torch Head
Oxygen Preheat Valve
Cutting Oxygen Tube
Preheat Oxygen Tube
Fuel Gas Tube
Handle
Cutting Lever
Fuel Gas Preheat Valve
5-10. Installing Cutting Tips
Acetylene Cutting Tip
Alternative Fuel Cutting Tip
Cutting tips are available in many styles and sizes depending on the
metal thickness and fuel gas being used. Refer to the tables in this
manual for tip selection and operating specifications. Prior to use, inspect cutting tips for damage and to ensure that the cutting orifice and
preheat holes are not blocked with dirt or slag. Insert tip into the torch
head and tighten the tip nut.
5-11. Installing Welding Tips
Welding tips consist of a mixer and a
copper tip. These tips are available in
different sizes to weld various metal
thicknesses. Refer to the tables in this manual for tip selection
and operating specifications.
Inspect o-rings for damage and replace if necessary. Insert the welding
tip into the torch handle by exerting light pressure on the welding tip with
a twisting motion until seated. Position the tip and hand tighten the tip nut
into the torch handle.
5-12. Installing Multi-Flame Heating Tips
Heating tips have several flame
orifices in the end. The tips consist of a mixer, heating tube,
and head, and are available for
use with several types of gas.
Refer to the tables in this manual for tip selection and operating
specifications.
OM-262659 Page 11
5-13. Testing The Equipment For Leaks
After the correct tip has been installed in the handle, cutting attachment,
or cutting torch, perform a leak test on the system before lighting the
torch. Follow this process every time the system is set-up and when a
cylinder is changed.
1.
2.
3.
4.
5.
6.
7.
Use an approved oil-free leak detection fluid to locate possible
leaks.
Do not stand in front of or behind the regulator when opening
the cylinder valve. Never open a cylinder valve suddenly as this
can damage a regulator or cause an oxygen regulator fire.
Verify that both regulator adjusting handles are turned counterclockwise to the off position.
Close both the fuel and oxygen valves on the torch handle.
While standing to the side of the regulator slowly open oxygen cylinder valve. Open the oxygen cylinder valve completely.
Adjust regulator by turning in the adjusting handle to deliver 20 psig
(138 kPa).
When using acetylene, do not open the fuel cylinder valve more
than 1/2–3/4 turn. If the cylinder has a wrench, leave it in place so
the cylinder can be quickly shut off if needed.
Adjust regulator by turning the adjusting handle clockwise to deliver
15 psig (103 kPa).
Check every connection and joint from the cylinder valve to the
torch tip with an approved leak detection solution. If leaks are detected, eliminate them before proceeding. If leaks cannot be eliminated, do not put the equipment into service until it has been repaired
or replaced.
SECTION 6 − WELDING TIP ADJUSTMENTS AND
LIGHTING INSTRUCTIONS
Inspect all equipment before use. Do not use damaged, defective, or improperly adjusted welding and cutting equipment.
Make sure levers and valves work properly, threads on equipment are clean (no grease or oil) and not deformed, gauges are
intact and easy to read, regulator is clean and free of oil or dirt,
and fittings are properly sized for the cylinder. Make sure
hoses are clean (no grease or oil). Be sure all connections are
tight and there are no leaks in the system.
Select the proper size welding tip required for the work being performed. Refer to the tables in this manual for tip selection and operating specifications.
6-1. Purging The System
1.
Always purge gas from the system before lighting torch to prevent a possible mixed-gas explosion. Purge gas in a well ventilated area and away from flame or sparks.
Purge the oxygen from the system by opening the oxygen torch
valve 1/4 turn, allowing oxygen to pass through the torch for 3–5
seconds for every 25 ft (8 m) of hose, and then closing the valve.
With the oxygen flowing, set the recommended pressure on the
oxygen regulator.
OM-262659 Page 12
2.
3.
4.
5.
Close the oxygen valve on the torch handle.
Purge the fuel gas by opening the fuel valve 1/4 turn, allowing fuel to
pass through the torch for 3–5 seconds for every 25 ft (8 m) of hose,
and then closing the valve. Set the fuel regulator while the gas is
flowing to the recommended pressure.
Close the fuel valve on the torch handle.
The system is now purged and ready for operation.
6-2. Lighting And Adjusting Acetylene/Oxygen Welding Tips
Follow the set-up instructions explained in Section 5 before lighting the
torch.
1. Purge the hoses (see Section 6-1).
2. Open the torch fuel valve 1/8 turn and ignite the acetylene using an
approved friction spark lighter.
Do not use matches or a cigarette lighter to ignite the gas.
3. Increase the acetylene gas flow until the flame is no longer producing (soot) smoke.
Failure to force a sufficient amount of fuel gas through the tip
will cause the tip to overheat and may cause a flashback or
backfire.
4. Open the torch oxygen valve until you achieve a neutral flame.
Neutral Flame
Even mixture of fuel and oxygen
6-3. LP Fuel Gas/Oxygen Tips (Other Than Acetylene)
Follow these steps for lighting and adjusting alternate fuel gas tips.
These tips require a different procedure be followed than for acetylene
tips to ensure proper performance. Follow the set-up instructions explained in Section 5 before lighting the torch.
1. Purge the hoses (see Section 6-1).
2. Open the fuel gas valve 1/8 turn and ignite the gas using an approved friction spark lighter.
Do not use matches or a cigarette lighter to ignite the gas.
3. Slowly open the torch oxygen valve until the flame is neutralized.
4. Increase the fuel gas another 1/8 turn.
5. Increase the oxygen flow until the flame is neutralized.
6. Repeat this procedure until the maximum volume of fuel is used and
the desired flame is achieved. This is important to obtain the most
efficient flame and to cool the tip during operation.
Failure to force a sufficient amount of fuel gas through the tip
will cause the tip to overheat and may cause a flashback or
backfire.
6-4. Extinguishing The Torch Flame
1.
2.
Turn torch oxygen gas valve clockwise to the closed position.
Turn the torch fuel gas valve clockwise to the closed position.
6-5. System Shut Down
1.
2.
Turn the oxygen and fuel gas cylinder valves clockwise to the
closed position.
Open the torch oxygen valves 1/2 turn and allow the gas to flow out
of the torch until both gauges indicate zero (0) pressure.
OM-262659 Page 13
3.
4.
Close the torch oxygen valve and turn the regulator adjusting handle counterclockwise to the off position.
Open the torch fuel valves 1/2 turn and allow the gas to flow out of
the torch until both gauges indicate zero (0) pressure. Close the
torch fuel valve and turn the regulator adjusting handle counterclockwise to the off position.
SECTION 7 − MULTI-FLAME HEATING TIP
ADJUSTMENT AND LIGHTING INSTRUCTIONS
Heating tips are set up and adjusted the same as welding tips. Follow the
safety and operating instructions explained in Section 6.
Be sure to force the gases through the heating tips to eliminate
the possibility of gas starvation, which can result in overheating the tip and the possibility of backfire, sustained backfire,
or flashback.
SECTION 8 − CUTTING ATTACHMENT
ADJUSTMENT AND LIGHTING INSTRUCTIONS
Cutting attachments are used in conjunction with torch handles to perform oxy-fuel cutting of ferrous metals.
8-1. Setting Up Cutting Attachment
1.
2.
3.
4.
Inspect equipment before use. Do not use if grease or oil is
present on equipment or if equipment is damaged. Have equipment cleaned/repaired by a qualified person.
Do not use cutting attachment if the o-rings are missing or
damaged.
Always purge gas from the system before lighting torch to prevent a possible mixed-gas explosion. Purge gas in a well ventilated area and away from flame or sparks.
Insert the cutting attachment into the torch handle and hand tighten
the connection nut.
Select the proper cutting tip for the application (see tip tables in this
manual).
If inserting a new cutting tip into the cutting assembly, use a wrench
to tighten tip 1/8–1/4 turn. Tips that have been set to the torch can be
hand-tightened.
Adjust the oxygen regulator to the recommended pressure setting
(from the tip table) by turning the regulator adjusting handle clockwise. Open the oxygen valve on the torch handle completely so flow
to the cutting attachment is not restricted.
OM-262659 Page 14
5.
6.
7.
Adjust the fuel regulator to the recommended pressure setting
(from the tip table) by turning in the regulator adjusting handle clockwise.
Purge the fuel gas by opening the preheat valve on the torch
handle, allowing gas to flow for 3–5 seconds for every 25 ft (8 m)
length of hose, and then closing the fuel gas valve.
Purge the oxygen by opening the preheat valve on the cutting attachment, allowing gas to flow for 3–5 seconds for every 25 ft (8 m).
length of hose, then closing the oxygen valve.
8-2. Adjusting The Acetylene Cutting Tip Flame
(Cutting Assembly)
This procedure is for use with acetylene cutting tips. Make sure the system has been set-up and purged according to Section 8-1.
1. Open the fuel valves on the torch handle 1/8 turn and light the fuel
gas using a friction lighter.
Do not use matches or a cigarette lighter to ignite the gas.
2. Continue to open the acetylene torch valve until the sooty smoke
produced by the flame completely disappears or the flame just begins to separate from the end of the tip.
3. Slowly open the preheat oxygen valve on the cutting attachment; a
long white flame will appear; this is known as the acetylene feather.
Continue to add oxygen and reduce the feather until it just disappears into the small, bright, inner cones at the end of the tip. This will
produce what is known as a neutral flame.
4. Preheat the metal by positioning the bright inner cones approximately 1/8–1/4 in. (3–6 mm) away from the steel surface.
5. When the metal turns bright red (approx.1500° F/816° C), slowly depress the cutting lever until the metal is pierced. While holding the
lever down completely, slowly move the torch in the direction to be
cut.
8-3. Adjusting Alternate Fuel Gas Cutting Tip Flame
(Other Than Acetylene)
This procedure is for use with alternate fuel gas tips such as propane,
propylene, and natural gas cutting tips. Make sure the system has been
set-up and purged as described in Section 8-1).
1. Open the fuel valves on the torch handle 1/8 turn and light the fuel
gas using a friction lighter.
Do not use matches or a cigarette lighter to ignite the gas.
2. Continue to open the torch fuel valve until the flame is about to leave
the tip.
3. Slowly open the preheat oxygen valve on the cutting attachment
until the bright preheat cones are reduced to their shortest length.
4. Continue to readjust the fuel valve until the preheat flame is about to
leave the tip.
5. Slowly open the preheat oxygen valve until the preheat cones are at
the shortest length.
6. Repeat this process until the fuel valve is nearly or completely open.
7. Preheat the metal by positioning the bright inner cones approximately 1/2–3/4 in. (13–19 mm) away from the steel surface.
8. When the metal turns bright red (approx.1500° F/816° C), slowly depress the cutting lever until the metal is pierced. While holding the
lever down completely, slowly move the torch in the direction to be
cut.
8-4. Extinguishing The Torch Flame
Follow this procedure to shut down the system when finished cutting.
OM-262659 Page 15
1.
2.
3.
4.
5.
6.
Turn the oxygen preheat valve clockwise to the closed position.
Turn the torch fuel valve clockwise to the closed position.
Turn the oxygen and fuel cylinder valves clockwise to the closed position.
Open the torch fuel valves 1/2 turn and allow the gas to flow out of
the torch until both gauges indicate zero (0) pressure. Close the
torch fuel valve and turn the fuel regulator adjusting handle counterclockwise to the off position.
Open the torch preheat oxygen valve 1/2 turn and allow the gas to
flow out of the torch until both gauges indicate zero (0) pressure.
Close the torch oxygen preheat valve. Close the oxygen valve on
the torch handle and turn the oxygen regulator adjusting handle
counterclockwise to the off position.
The system is now properly shut down.
SECTION 9 − STRAIGHT (HAND) CUTTING TORCH
ADJUSTMENTS AND LIGHTING INSTRUCTIONS
9-1. Setting Up Straight (Hand) Cutting Torch
Cutting torches are used to cut ferrous metals using oxygen and a fuel
gas. Set-up the equipment as described in Section 8.
1.
2.
3.
4.
5.
Inspect equipment before use. Do not use if grease or oil is
present on equipment or if equipment is damaged. Have equipment cleaned/repaired by a qualified person.
Do not use cutting torch if the o-rings are missing or damaged.
Always purge gas from the system before lighting torch to prevent a possible mixed-gas explosion. Purge gas in a well ventilated area and away from flame or sparks.
For larger high-volume cutting tips, certain check valve designs may restrict gas flow and cause the tips to overheat.
These high-flow tip applications require 3/8 in. (9.5 mm) or larger diameter hoses.
Select the recommended cutting tip from the tables in this manual
for the metal thickness being cut.
When inserting a new tip into the torch head, tighten with a wrench
1/8–1/4 turn. Tips that have been set to the torch head can be
hand-tightened.
Adjust the oxygen and fuel regulators to the recommended pressure settings from the tip table by turning the regulator adjusting
handle clockwise.
Purge the fuel gas by opening the preheat valve on the torch, allowing gas to flow for 3–5 seconds for every 25 ft (8 m) length of hose,
and then closing valve.
Purge the oxygen by opening the preheat valve on the torch, allowing gas to flow for 3–5 seconds for every 25 ft (8 m) length of hose,
and then closing valve.
9-2. Adjusting Acetylene Cutting Tip Flame (Hand Torch)
This procedure is for use with acetylene cutting tips. Make sure the system has been set-up and purged according to Section 9-1.
OM-262659 Page 16
1.
2.
3.
4.
5.
Open the fuel valves on the torch handle 1/8 turn and light the fuel
gas using a friction lighter.
Do not use matches or a cigarette lighter to ignite the gas.
Continue to open the acetylene torch preheat valve until the sooty
smoke produced by the flame completely disappears, or the flame
just begins to separate from the end of the tip.
Slowly open the preheat oxygen valve; a long white flame will appear. This is known as the acetylene feather. Continue to add oxygen and reduce the feather until it just disappears into the small,
bright, inner cones at the end of the tip. This will produce what is
known as a neutral flame.
Preheat the metal by positioning the bright inner cones approximately 1/8–1/4 in. (3–6 mm) away from the steel surface.
When the metal turns bright red (approx. 1500°F/816°C), slowly depress the cutting lever until the metal is pierced. Holding the lever
down completely, slowly move the torch in the direction to be cut.
9-3. Adjusting Fuel Gas Cutting Tip Flame (Other Than
Acetylene)
This procedure is for use with alternate fuel gas tips such as propane,
propylene, and natural gas cutting tips. Make sure the system has been
set-up and purged according to Section 9-1.
1. Open the fuel valves on the torch handle 1/8 turn and light the fuel
gas using a friction lighter.
Do not use matches or a cigarette lighter to ignite the gas.
2. Continue to open the torch preheat fuel valve until the flame is about
to leave the tip.
3. Slowly open the preheat oxygen valve until the bright preheat
cones are reduced to their shortest length.
4. Continue to readjust the fuel valve open until the preheat flame is
about to leave the tip.
5. Slowly open the preheat oxygen valve until the preheat cones are at
the shortest length.
6. Repeat this process until the fuel valve is nearly or completely open.
7. Preheat the metal by positioning the bright inner cones approximately 1/2–3/4 in. (13–19 mm) away from the steel surface.
8. When the metal turns bright red (approx. 1500°F/816°C), slowly depress the cutting lever until the metal is pierced. While holding the
lever down completely, slowly move torch in the direction to be cut.
9-4. Extinguishing The Torch Flame
Follow this procedure to shut down the system when finished cutting.
1. Turn the oxygen valve clockwise to the closed position.
2. Turn the torch fuel valve clockwise to the closed position.
3. Turn the oxygen and fuel cylinder valves clockwise to the closed position.
4. Open the torch fuel valves 1/2 turn and allow the gas to flow out of
the torch until both gauges indicate zero (0) pressure. Close the
torch fuel valve and turn the fuel regulator adjusting handle counterclockwise to the off position.
5. Open the torch oxygen valves 1/2 turn and allow the gas to flow out
of the torch until both gauges indicate zero (0) pressure. Close the
torch oxygen valve and turn the oxygen regulator adjusting handle
counterclockwise to the off position.
OM-262659 Page 17
OM-262659 Page 18
Table 1.
SC12 Series Heavy-Duty Cutting Tips − Acetylene (One Piece)
High gas withdrawal rates will require cylinder manifolding. Consult your gas supplier.
Tip
Number
Metal
Thickness
in.
mm
Pressure − psig
Cutting Oxygen
Preheat
Reg.
Torch
Oxygen Acetylene
Kerf
Width
Consumption − scfh
Acetylene
Oxygen
Preheat
Cutting
Preheat
SC12-00
3/16
5
20
20
10†
10
.050
24
SC12-0
1/4
6
30
30
10†
10
.055
40
SC12-0
3/8
10
35
35
10†
10
.055
50
SC12-1
1/2
13
35
35
10†
10
.080
75
SC12-1
5/8
16
40
40
10†
10
.080
85
SC12-2
3/4
19
36
35
10†
10
.095
105
SC12-2
1
25
41
40
10†
10
.095
115
SC12-2
1-1/4
32
51
50
10†
10
.095
135
SC12-3
1-1/2
38
42
40
10†
10
.100
170
SC12-3
2
51
47
45
10†
10
.100
180
SC12-4
2-1/2
64
38
35
10†
10
.125
240
SC12-4
3
76
44
40
10†
10
.125
265
SC12-4
4
102
54
50
10†
10
.125
315
SC12-5
5
127
56
50
10†
10
.150
420
SC12-5
6
152
67
60
10†
10
.150
485
SC12-5
8
203
78
70
10†
10
.150
550
SC12-6
10
254
83
70
10†
10
.230
750
SC12-6
12
305
125
90
10†
10
.230
975
† Listed pressure for 3-hose machine cutting torches only. * Minimum of one 350 cubic ft. cylinder
7
7.5
7.5
11
11
12
12
12
14
14
15
15
16
30
30
30
32
32
6.5
7
7
9.5
9.5
10.5
10.5
10.5
12
12
13
13
14
26*
26*
26*
28*
28*
Speed
IPM
26
22
20
19
17
16
14
13
12
10
9
8
7
7
6
5.5
5
4.5
Drill Size
Cutting
Preheat
Jet
68
62
62
56
56
54
54
54
51
51
45
45
45
41
41
41
32
32
75
74
74
71
71
70
70
70
68
68
62
62
62
57
57
57
57
57
Table 2.
Tip
Number
SC56 Series Heavy-Duty, Heavy-Preheat Cutting Tips − Acetylene (One Piece)
Metal
Thickness
in.
mm
Pressure − psig
Cutting Oxygen
Reg.
Torch
Preheat
Oxygen Acetylene
Kerf
Width
Consumption − scfh
Oxygen
Cutting Preheat
Acetylene
Preheat
Speed
IPM
Drill Size
Cutting
Jet
Preheat
Recm’d
No. Of
Cylinders*
OM-262659 Page 19
SC56-1
1/2
13
35
35
10†
10
.080
75
33
30
19
56
65
1
SC56-1
5/8
16
40
40
10†
10
.080
85
33
30
17
56
65
1
SC56-2
3/4
19
36
35
10†
10
.095
105
33
30
16
54
60
1
SC56-2
1
25
41
40
10†
10
.095
115
33
30
14
54
60
1
SC56-2
1-1/4
32
51
50
10†
10
.095
135
33
30
13
54
60
1
SC56-3
1-1/2
38
42
40
10†
10
.100
170
43
39
12
51
57
1
SC56-3
2
51
47
45
10†
10
.100
180
50
45
10
51
57
1
SC56-5
2-5
127
56
50
10†
10
.150
420
57
52
7
41
54
2
SC56-5
6
152
67
60
10†
10
.150
485
66
60
6
41
54
2
SC56-5
8
203
78
70
10†
10
.150
550
72
65
5.5
41
54
2
SC56-7
8–14
356
100
85
10†
10
.250
1250
110
100
4
28
54
2
SC56-9
14–20 508
110
70
14†
12
.350
2150
145
130
3
3
54
3
SC56-9
24
610
130
85
15†
13
.360
2600
175
160
2.5
3
54
4
† Listed pressure for 3-hose machine cutting torches only. Pressures shown are for 25 ft (7.6 m) or less of 3/8 in. (10mm) I.D. hose. Increase pressures if longer hose is used.
Use1/2 in. (13mm) I.D. hose when hose length exceeds100 ft (31 m).
* Cylinders required, based on 350 cubic ft. cylinder.
OM-262659 Page 20
Table 3.
Tip
Number
MC12 Series Medium Duty Cutting Tips − Acetylene (One Piece)
Metal
Thickness
Pressure − psig
in.
mm
Oxygen
Acetylene
MC12-00
1/8
3
20*
10
MC12-00
3/16
5
20*
10
MC12-0
1/4
6
35*
10
MC12-0
3/8
10
40*
10
MC12-1
1/2
13
45*
10
MC12-1
5/8
16
50*
10
MC12-2
3/4
19
50*
10
MC12-2
1
25.4
55*
10
MC12-3
1-1/2
38
55*
10
MC12-3
2
51
60*
10
MC12-4
2-1/2
64
65*
10
MC12-4
3
76
70*
10
MC12-4
4
102
65
10
MC12-5
5
127
80
10
MC12-5
6
152
90
10
* Increase pressure 10–15 psig when using AC309 cutting attachments.
Kerf
Width
.050
.050
.055
.055
.080
.080
.095
.095
.100
.100
.125
.125
.125
.150
.150
Consumption − scfh
Oxygen
Cutting
30
30
40
46
75
81
107
118
170
181
249
267
320
420
485
Preheat
7
7
7
7
9
9
11
11
12
12
14
14
15
15
15
Acetylene
Preheat
6
6
6
6
7
7
9
9
10
10
12
12
13
13
13
Drill Size
Cutting Jet
68
68
62
62
55
55
54
54
51
51
45
45
45
41
41
Preheat
75
75
75
75
74
74
71
71
70
70
70
70
70
70
70
Table 4.
OM-262659 Page 21
*
SC And MC Series Special Purpose Tips For Hand Torches And Cutting Assemblies − Acetylene
Capacity
(Width x Depth)
in.
mm
Pressure − psig
At Regulator
Oxygen
Acetylene
Tip
Number
Purpose
SC13-3
Gouging
3/8 x 1/4
10 x 6
20
SC13-5
Gouging
1/2 x 3/8
13 x 10
SC14-3
Riser
1-1/2 Rivets
SC15-2
Washing
SC17-0
SC83
Plate Or Thin
Sheet Cutting
Heating
MC13-3
Gouging
SC12-4x9
Cutting
Consumption − scfh
Drill Size
Oxygen
Acetylene
Cutting Jet
Preheat
10
151
35
50
29
59
25
10
246
50
55
38 mm Rivets
35–40
10
190
20
39
10
51
1/2 x 3/8
13 x 10
30
10
336
40
3
57
3/8
10
20
10
55
4
62
62
83,000 BTUs
N/A
15
10
58
52*
N/A
56
3/8 x 1/4
10 x 6
20
10
115
24*
60
4
102
50
10
331
14
50
29
45
2 cylinders required; based on 350 cubic ft. cylinders.
56
62
OM-262659 Page 22
Table 5.
Heating Tips − Acetylene
NOTICE When using add-on flashback arrestors, make sure the unit can supply enough gas flow to support the tip being used. Insufficient gas flow
can cause equipment failure.
Pressure − psig
Stock
Number
No. Of
Flames
Drill Size
ST602
ST603
ST605
ST610
MT603
MT605
MT610
AT605
6
6
12
12
6
6
12
6
64
56
57
54
64
56
57
64
Oxygen
15
15
15
15
15
15
15
15
Fuel Gas
15
15
15
15
15
15
15
15
Consumption − scfh
Oxygen
31
55
96
150
31
57
100
32
Fuel Gas
28
50
87
136
28
51
90
29
Average
BTU/Hr
41,160
73,500
141,120
220,500
41,160
74,970
132,300
42,630
Recommended
Number
Of Cylinders*
1
1
2
3
1
1
2
1
Overall
Length
in.
16
16
19
19
10
16
18
10
mm
406
406
483
483
254
406
457
254
. Data is based on 25 ft (7.6 m) of 1/4 in. (6 mm) I.D. hose. Pressure must be increased if hose unions, longer hose, or smaller ID hose is used. All pressure settings are flowing
pressures. Pressures shown are optimum settings for all regulators and not minimal operating pressures for torch equipment.
*
Cylinders required, based on 350 cubic ft. cylinder.
Table 6.
Tip
Number
Welding/Brazing Tips− Acetylene
Welding Range
OM-262659 Page 23
SW201
SW203
SW205
SW207
SW209
SW210
MW201
MW203
MW205
MW207
MW209
AW201
AW203
AW205
AW207
AW209
in.
1/32
5/64
1/8
3/16
3/8
1/2
1/32
5/64
1/8
3/16
3/8
Up to1/32
5/64
1/8
3/16
3/8
mm
0.7
1.9
3
5
10
13
0.7
1.9
3
5
10
0.7
1.9
3
5
10
AW210
1/2
13
Drill Size
Pressure Of Each Gas
At Regulator − psig
Consumption − scfh
71
67
57
54
49
44
71
67
57
54
49
71
67
57
54
49
10
10
10
10
10
15
10
10
10
10
10
10
10
10
10
10
2.3
3.2
6
12
23
36
2.3
3.2
6
12
23
2.3
3.2
6
12
23
44
10
36
OM-262659 Page 24
Table 7.A Effect Of Hose Diameter And Length On Flow And Pressure At Torch
Hose Diameter
in. (mm)
3/16 (5)
*
Hose Length
ft (m)
Cutting Tip
Size
Regulator
Pressure
Static − psig
Regulator
Pressure
Flowing − psig
Torch Inlet
Pressure − psig
Pressure Drop
In Hose − psig
Flow − scfh
50 (15.2)
3
50
47
37−1/2
9−1/2
169
100 (30.4)*
3
51
47
26
21
129
50 (15.2)
5
84−1/2
78
44
34
370
100 (30.4)*
5
83−1/2
78
22
56
215
50 (15.2)
7
108
100
24
76
510
100 (30.4)*
7
106−1/2
100
9
91
270
50 (15.2)
9
138−1/2
130
19−1/2
110−1/2
735
100 (30.4)*
9
136−1/2
130
7
123
405
Two 50 ft (15.2 m) lengths of hose connected together with standard hose unions.
(Continued)
Table 7.B Effect Of Hose Diameter And Length On Flow And Pressure At Torch
Hose Diameter
in. (mm)
1/4 (6)
Hose Length
ft (m)
Cutting Tip
Size
Regulator
Pressure
Static − psig
Regulator
Pressure
Flowing − psig
Torch Inlet
Pressure − psig
Pressure Drop
In Hose − psig
Flow − scfh
50 (15.2)
3
50−1/2
47
44−1/2
2−1/2
194
100 (30.4)*
3
50
47
42−1/2
4−1/2
188
50 (15.2)
5
86
78
68−1/2
9−1/2
540
100 (30.4)*
5
85
78
58−1/2
19−1/2
470
68
32
1140
49
51
870
2010
50 (15.2)
7
114
100
100 (30.4)*
7
110
100
OM-262659 Page 25
50 (15.2)
9
149−1/2
130
65
65
100 (30.4)*
9
144
130
36−1/2
93−1/2
1290
100 (30.4)**
3
50
47
36
11
164
100 (30.4)**
5
84−1/2
78
42
36
360
100 (30.4)**
7
108
100
25
75
560
100 (30.4)**
9
140
130
18
112
795
*
Two 50 ft (15.2 m) lengths of hose connected together with standard hose unions.
**
Four 25 ft (6.1 m) lengths of hose connected together with standard hose unions.
(Continued)
OM-262659 Page 26
Table 7.C Effect Of Hose Diameter And Length On Flow And Pressure At Torch
Hose Diameter
in. (mm)
3/8 (10)
*
Hose Length
ft (m)
Cutting Tip
Size
Regulator
Pressure
Static − psig
Regulator
Pressure
Flowing − psig
50 (15.2)
3
51
47
50 (15.2)
5
86
78
50 (15.2)
7
117
100
Torch Inlet
Pressure − psig
Pressure Drop
In Hose − psig
Flow − scfh
46
1
190
74−1/2
3−1/2
580
86
14
1400
50 (15.2)
9
163−1/2
130
89−1/2
40−1/2
2700
100 (30.4)*
3
51
47
46
1
198
100 (30.4)*
5
86
78
72
6
570
100 (30.4)*
7
115
100
77
23
1280
100 (30.4)*
9
155
130
75
55
2280
Two 50 ft (15.2 m) lengths of hose connected together with standard hose unions.
Table 8.
Tip
Number
SC40 Series Heavy-Duty Cutting Tips − Propane (Two Piece)
Pressure − psig
Metal
Thickness
Cutting Oxygen
in.
Reg.
mm
Torch
SC40-0
1/4
6
30
30
SC40-0
3/8
10
35
35
SC40-1
1/2
13
35
35
SC40-1
5/8
16
40
40
SC40-2
3/4
19
36
35
SC40-2
1
25
41
40
SC40-2
1-1/4
32
51
50
SC40-3
1-1/2
38
42
40
SC40-3
2
51
47
45
SC40-4
2-1/2
64
38
35
SC40-4
3
76
44
40
SC40-4
4
102
54
50
† Listed pressure for 3-hose machine cutting torches only.
Consumption − scfh
Kerf
Width
Preheat
Oxygen
Propane
10†
10†
10†
10†
10†
10†
10†
10†
10†
12†
12†
12†
10
10
10
10
10
10
10
10
10
10
10
10
.055
.055
.080
.080
.095
.095
.095
.100
.100
.125
.125
.125
Preheat
Cutting
Oxygen
Oxygen
Propane
40
50
75
85
105
115
135
170
180
240
265
315
38
38
38
38
38
38
38
38
38
65
65
65
8
8
8
8
8
8
8
8
8
15
15
15
Speed
IPM
Drill Size
Cutting
Jet
22
20
19
17
16
14
13
12
10
9
8
7
62
62
56
56
54
54
54
51
51
45
45
45
OM-262659 Page 27
OM-262659 Page 28
Table 9.
Tip
Number
SC50 Series Heavy-Duty, Heavy-Preheat Cutting Tips − Propane (Two Piece)
Pressure − psig
Metal
Thickness
Cutting Oxygen
in.
Reg.
mm
Torch
Consumption − scfh
Kerf
Width
Preheat
Oxygen
SC50-00
3/16
5
20
20
10†
SC50-0
1/4
6
30
30
10†
SC50-0
3/8
10
35
35
10†
SC50-1
1/2
13
35
35
10†
SC50-1
5/8
16
40
40
10†
SC50-2
3/4
19
36
35
10†
SC50-2
1
25
41
40
10†
SC50-2
1-1/4
32
51
50
10†
SC50-3
1-1/2
38
42
40
10†
SC50-3
2
51
47
45
10†
SC50-4
2-1/2
64
38
35
10†
SC50-4
3
76
44
40
10†
SC50-4
4
102
54
50
10†
SC50-5
5
127
56
50
10†
SC50-5
6
152
67
60
10†
SC50-5
8
203
78
70
10†
SC50-6
10
254
83
70
40†
SC50-6
12
304
125
90
40†
SC50-7
14
354
125
90
60†
SC50-8
16
406
125
90
60†
SC50-8
18
457
125
90
60†
SC50-9
20
508
125
90
60†
† Listed pressure for 3-hose machine cutting torches only.
* Cylinders required, based on 100 lb cylinders.
Propane
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
12
20
18
20
23
.050
.055
.055
.080
.080
.095
.095
.095
.100
.100
.125
.125
.125
.150
.150
.150
.230
.230
.250
.300
.340
.350
Preheat
Cutting
Oxygen
Oxygen
Propane
24
40
50
75
85
105
115
135
170
180
240
265
315
420
485
550
750
975
1250
1500
1800
2150
47
47
47
70
70
70
70
75
75
75
75
75
80
80
80
90
230
280
330
375
400
420
13
13
13
15
15
15
15
16
16
16
16
16
17
17
17
20
50
60
62
80
85
90
Speed
IPM
Drill Size
Cutting
Jet
Recm’d
No. Of
Cylinders*
26
22
20
19
17
16
14
13
12
10
9
8
7
7
6
5
5
4.5
4.0
3.5
3.5
3.0
68
62
62
56
56
54
54
54
51
51
45
45
45
41
41
41
32
32
28
17
17
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
Table 10. SC50 Series Heavy-Duty, Heavy-Preheat Cutting Tips − Natural Gas (Two Piece)
Tip
Number
Metal
Thickness
in.
mm
Pressure − psig
Cutting Oxygen
Reg.
Torch
OM-262659 Page 29
SC50-00
3/16
5
20
20
SC50-0
1/4
6
30
30
SC50-0
3/8
10
35
35
SC50-1
1/2
13
35
35
SC50-1
5/8
16
40
40
SC50-2
3/4
19
36
35
SC50-2
1
25
41
40
SC50-2
1-1/4
32
51
50
SC50-3
1-1/2
38
42
40
SC50-3
2
51
47
45
SC50-4
2-1/2
64
38
35
SC50-4
3
76
44
40
SC50-4
4
102
54
50
SC50-5
5
127
56
50
SC50-5
6
152
67
60
SC50-5
8
203
78
70
SC50-6
10
254
83
70
SC50-6
12
304
125
90
SC50-7
14
354
125
90
SC50-8
16
406
125
90
SC50-8
18
457
125
90
SC50-9
20
508
125
90
† Listed pressure for 3-hose machine cutting torches only.
Preheat
Natural
Oxygen
Gas
6†
5
6†
5
6†
5
8†
6
8†
6
8†
6
8†
6
8†
6
8†
6
8†
6
8†
6
8†
6
8†
6
8†
6
8†
6
8†
6
10†
8
15†
12
20†
16
20†
18
25†
23
25†
23
Consumption − scfh
Kerf
Width
.050
.055
.055
.080
.080
.095
.095
.095
.100
.100
.125
.125
.125
.150
.150
.150
.230
.230
.250
.300
.340
.350
Cutting
Oxygen
24
40
50
75
85
105
115
135
170
180
240
265
315
420
485
550
750
975
1250
1500
1800
2150
Preheat
Natural
Oxygen
Gas
58
36
62
38
62
38
70
40
70
40
70
40
70
40
70
40
70
40
70
40
75
45
75
45
75
45
82
50
82
50
82
50
120
75
165
100
200
120
220
135
250
150
250
150
Speed
IPM
Drill Size
Cutting
Jet
26
22
20
19
17
16
14
13
12
10
9
8
7
7
6
5
5
4.5
4
3.5
3.5
3
68
62
62
56
56
54
54
54
51
51
45
45
45
41
41
41
32
32
28
17
17
3
OM-262659 Page 30
Table 11. SC46 Series Heavy-Duty Cutting Tips − Propane (One Piece)
Tip
Number
Pressure − psig
Metal
Thickness
Cutting Oxygen
in.
Reg.
mm
Torch
SC46-2
3/4
19
36
35
SC46-2
1
25
41
40
SC46-2
1-1/4
32
51
50
SC46-4
2-1/2
64
38
35
SC46-4
3
76
44
40
SC46-4
4
102
54
50
SC46-5
5
127
56
50
SC46-5
6
152
67
60
SC46-5
8
203
78
70
SC46-6
10
254
83
70
SC46-6
12
305
125
90
† Listed pressure for 3-hose machine cutting torches only.
Consumption − scfh
Kerf
Width
Preheat
Oxygen
Propane
20†
20†
20†
20†
20†
20†
20†
20†
20†
20†
20†
10
10
10
10
10
10
10
10
10
12
12
.095
.095
.095
.125
.125
.150
.150
.150
.150
.200
.230
Cutting
Oxygen
105
115
135
240
265
315
420
485
550
750
975
Drill Size
Speed
IPM
Preheat
Oxygen
Propane
70
70
70
70
70
70
105
105
105
105
105
15
15
15
15
15
15
22
22
22
22
22
16
14
13
9
8
7
7
6
5
5
4.5
Cutting
Jet
Preheat
54
54
54
45
45
45
41
41
41
32
32
56
56
56
56
56
56
54
54
54
54
54
Table 12. SC46 Series Heavy-Duty Cutting Tips − Natural Gas (One Piece)
Tip
Number
Pressure − psig
Metal
Thickness
Cutting Oxygen
in.
Reg.
mm
Torch
Consumption − scfh
Preheat
Oxygen
SC46-2
3/4
19
36
35
20†
SC46-2
1
25
41
40
20†
SC46-2
1-1/4
32
51
50
20†
SC46-4
2-1/2
64
38
35
20†
SC46-4
3
76
44
40
20†
SC46-4
4
102
54
50
20†
SC46-5
5
127
56
50
20†
SC46-5
6
152
67
60
20†
SC46-5
8
203
78
70
20†
SC46-6
10
254
83
70
20†
SC46-6
12
305
125
90
20†
† Listed pressure for 3-hose machine cutting torches only.
Natural
Gas
10
10
10
10
10
10
10
10
10
12
12
Kerf
Width
.095
.095
.095
.125
.125
.150
.150
.150
.150
.200
.230
Drill Size
Preheat
Cutting
Oxygen
Oxygen
Nat. Gas
105
115
135
240
265
315
420
485
550
750
975
70
70
70
70
70
70
90
90
90
90
90
41
41
41
41
41
41
52
52
52
52
52
Speed
IPM
16
14
13
9
8
7
7
6
5
5
4.5
Cutting
Jet
Preheat
54
54
54
45
45
45
41
41
41
32
32
56
56
56
56
56
56
54
54
54
54
54
OM-262659 Page 31
OM-262659 Page 32
Table 13. SC60 Series Heavy-Duty Cutting Tips − Propylene (Two Piece)
Tip
Number
Metal
Thickness
in.
mm
Pressure − psig
Cutting Oxygen
Reg.
Torch
30
30
35
35
35
35
40
40
36
35
41
40
51
50
42
40
47
45
38
35
44
40
54
50
56
50
67
60
78
70
83
70
125
90
SC60-0
1/4
6
SC60-0
3/8
10
SC60-1
1/2
13
SC60-1
5/8
16
SC60-2
3/4
19
SC60-2
1
25
SC60-2
1-1/4
32
SC60-3
1-1/2
38
SC60-3
2
51
SC60-4
2-1/2
64
SC60-4
3
76
SC60-4
4
102
SC60-5
5
127
SC60-5
6
153
SC60-5
8
203
SC60-6
10
254
SC60-6
12
305
† Listed pressure for 3-hose machine cutting torches only.
Preheat
Oxygen Propylene
10†
10
10†
10
10†
10
10†
10
10†
10
10†
10
10†
10
10†
10
10†
10
12†
10
12†
10
12†
10
12†
10
12†
10
12†
10
12†
10
12†
10
Kerf
Width
.053
.055
.080
.080
.095
.095
.095
.100
.100
.125
.125
.125
.150
.150
.150
.230
.230
Consumption − scfh
Cutting
Oxygen
40
50
75
85
105
115
135
170
180
240
265
315
420
485
550
750
975
Preheat
Oxygen
Propylene
38
9
38
9
38
9
38
9
38
9
38
9
38
9
38
9
38
9
58
15
58
15
58
15
58
15
58
15
58
15
58
15
58
15
Speed
IPM
Drill Size
Cutting
Jet
22
20
19
17
16
14
13
12
10
9
8
7
7
6
5
5
4.5
62
62
56
56
54
54
54
51
51
45
45
45
41
41
41
32
32
Table 14. SC36 Series Heavy-Duty Cutting Tips − Propylene (One Piece)
Tip
Number
Pressure − psig
Metal
Thickness
Cutting Oxygen
in.
1/2
5/8
3/4
1
1-1/4
1-1/2
2
2-1/2
3
4
10
12
Reg.
35
40
36
41
51
42
47
38
44
54
83
125
mm
13
16
19
25
32
38
51
64
76
102
254
305
Torch
35
40
35
40
50
40
45
35
40
50
70
90
Consumption − scfh
Preheat
Oxygen
20†
20†
20†
20†
20†
20†
20†
20†
20†
20†
20†
20†
SC36-1
SC36-1
SC36-2
SC36-2
SC36-2
SC36-3
SC36-3
SC36-4
SC36-4
SC36-4
SC36-6
SC36-6
† Listed pressure for 3-hose machine cutting torches only.
Propylene
10
10
10
10
10
10
10
10
10
10
12
12
Kerf
Width
.080
.080
.095
.095
.095
.100
.125
.125
.125
.150
.200
.230
Cutting
Oxygen
75
85
105
115
135
170
180
240
265
315
750
975
Preheat
Oxygen
70
70
70
70
70
70
70
70
70
70
105
105
Propylene
15
15
15
15
15
15
15
15
15
15
22
22
Speed
IPM
19
17
16
14
13
12
10
9
8
7
5
4.5
Drill Size
Cutting
Jet
Preheat
56
56
54
54
54
51
51
45
45
45
32
32
56
56
56
56
56
56
56
56
56
56
54
54
OM-262659 Page 33
OM-262659 Page 34
Table 15. SC Series Heavy-Duty Special Purpose Tips − Propane/Propylene
Tip
Number
Purpose
Capacity
(Width x Depth)
in.
mm
Pressure − psig
Consumption − scfh
Fuel
Gas
Oxygen
Fuel Gas
Oxygen
Fuel Gas
Oxygen
Drill Size
Fuel Gas
Configuration
Recm’d
No. Of
Cylinders**
SC2-2
Gouging
(General)
5/16 x 1/8
8x3
Propane
60
22
389
53
53
31
Slots
1
SC2-4
Gouging
(General)
Heating
3/8 x 1/4
10 x 6
Propane
75
22
564
53
Slots
1
289,000
BTUs
3/8 x 1/4
N/A
Propane
60
25
495
125
44
28
N/A
Slots
2
10 x 6
Propane
50–60
12–18
174
31
Slots
1
3/8 x 1/4
10 x 6
Propylene
50–60
10–15
174
31
50
29
50
29
Slots
1
SC112*
SC23-3
SC23-3M
Gouging
(Heavy)
Gouging
*
Use with hand (straight) torches only. Do not use in cutting attachments.
**
Cylinders required, based on 100 lb cylinders.
Table 16. MC40 Series Medium-Duty Cutting Tips − Propane (Two Piece)
Tip
Number
Metal
Thickness
in.
mm
Pressure − psig
Oxygen
Kerf
Width
Propane
OM-262659 Page 35
MC40-00
3/16
5
30*
10
MC40-0
1/4
6
35*
10
MC40-0
3/8
10
40*
10
MC40-1
1/2
13
45*
10
MC40-1
5/8
16
50*
10
MC40-2
3/4
19
50*
10
MC40-2
1
25
55*
10
MC40-2
1-1/4
32
60*
10
MC40-3
1-1/2
38
55*
10
MC40-3
2
51
60*
10
MC40-4
2-1/2
64
65*
10
MC40-4
3
76
70*
10
MC40-4
4
102
75*
10
* Increase pressure 10–15 psig when using AC305 or AC309 cutting attachment.
.050
.055
.055
.080
.080
.095
.095
.095
.100
.100
.125
.125
.125
Consumption − scfh
Cutting
Oxygen
24
40
46
75
81
107
118
133
170
181
249
267
320
Preheat
Oxygen
35
35
35
35
35
35
35
35
35
35
35
35
35
Propane
7
7
7
7
7
7
7
7
7
7
7
7
7
Drill Size
Cutting Jet
68
62
62
55
55
54
54
54
51
51
51
51
51
OM-262659 Page 36
Table 17. MC60 Series Medium-Duty Cutting Tips − Propylene (Two Piece)
Tip
Number
Metal
Thickness
in.
MC60-0
MC60-0
MC60-1
MC60-1
MC60-2
MC60-2
MC60-2
MC60-3
MC60-3
MC60-4
MC60-4
MC60-4
*
1/4
3/8
1/2
5/8
3/4
1
1-1/4
1-1/2
2
2-1/2
3
4
mm
6
10
13
16
19
25
32
38
51
64
76
102
Pressure − psig
Oxygen
35*
40*
45*
50*
50*
55*
60*
55*
60*
65*
70*
75*
Propylene
10
10
10
10
10
10
10
10
10
10
10
10
Increase pressure 10–15 psig when using AC305 or AC309 cutting attachment.
Kerf
Width
.055
.055
.080
.080
.095
.095
.095
.100
.100
.125
.125
.125
Consumption − scfh
Cutting
Oxygen
40
46
75
81
107
118
133
170
181
249
267
320
Preheat
Oxygen
26
26
26
26
26
26
26
42
42
42
42
42
Propylene
7
7
7
7
7
7
7
11
11
11
11
11
Drill Size
Cutting Jet
62
62
55
55
54
54
54
51
51
45
45
45
Table 18. Heavy-Duty Heating Tips -Propylene
*
Pressure − psig
Stock
Number
No. Of
Flames
Uses
ST800
ST815
ST825
Fluted
Fluted
Fluted
Propylene
Propylene
Propylene
Oxygen
30–40
37–77
60–110
Fuel Gas
20–25
13–37
20–35
Consumption − scfh
Oxygen
118–138
390–655
580–1500
Fuel Gas
31–34
120–235
225–525
Average
BTU/Hr
75,000
273,000
830,000
Recm’d
No. Of
Cylinders*
1
1−2
2−5
Overall
Length
in.
15-1/2
15-1/2
31
mm
394
394
787
Head
Part No.
16317
4642
4639
Cylinders required, based on 100 lb cylinders.
Table 19. Heavy-Duty Heating Tips − Natural Gas/Propane
Stock
Number
No. Of
Flames
ST615
Fluted
OM-262659 Page 37
ST625
ST635
*
Fluted
Pressure − psig
Uses
Consumption − scfh
Average
BTU/Hr
Recm’d
No. Of
Cylinders*
Oxygen
Fuel Gas
Oxygen
Fuel Gas
Propane
23–65
10–28
225–535
70–160
244,000
1−2
Natural
Gas
18–55
10–28
175–450
96–267
155,145
N/a
Propane
50–110
17–28
480–1000
140–280
455,000
2−3
Natural
Gas
43–80
18–28
390–785
200–450
313,950
n/a
Propane
70–115
18–40
670–1580
185–480
614,195
2−5
Cylinders required, based on 100 lb cylinders.
Overall
Length
Head
Part No.
in.
mm
15-1/2
394
1495
31
787
1504
31
787
1499
OM-262659 Page 38
Table 20. Medium-Duty Heating Tips − Propane/Propylene/Natural Gas
Stock
Number
No. Of
Flames
MT800
Fluted
MT805
Fluted
MT615
*
Fluted
Uses
Pressure − psig
Consumption − scfh
Average
BTU/Hr
Fuel
Cylinders
Required*
Oxygen
Fuel Gas
Oxygen
Fuel Gas
Propylene
30–40
20–25
135–146
51–56
123,000
1
Propane
30–40
20–25
119–121
36–38
93,000
1
Propylene
50–60
20–25
242–270
120–135
280,000
1
Propane
20–60
10–25
225–535
70–160
269,000
1−2
Natural
Gas
15–50
10–25
175–450
96–267
182,000
N/a
Overall
Length
in.
mm
Head Part
No.
14
356
16317
14
356
4642
14
356
1495
Cylinders required, based on 100 lb cylinders.
Table 21. Brazing Tips
Tip
Number
MW411
Welding Range
in.
1/2–5/8
mm
13–16
Pressure − psig
Oxygen
11
Propane
11
Consumption − scfh
Oxygen
52
Propane
13
SECTION 10 − SC900 SERIES GAS AXE −
HAND CUTTING TORCH
10-1. Reversing The Cutting Lever
When reversing the high pressure seat valve assembly during this procedure, remove the components shown below and reinstall them in opposite sides of torch butt.
O-Ring (A)
Assembly (B)
When removing Assembly (B) from the torch butt, o-ring (A)
may slide off the assembly and remain lodged inside the torch
butt. This condition will cause the oxygen cutting and oxygen
preheat gases to cross-leak. Be sure to remove 0-ring and insert it with the assembly into the opposite port.
SECTION 11 − NEW YORK CITY FIRE
DEPARTMENT REGULATIONS
Torch Operations
§38-01 Issuance of City-Wide Permits for the Storage, Use and/or
Transport of Oxygen and Combustible Gases During Temporary or Emergency Torch Operations
§38-01.1 Issuance of Permits for the Storage and Use of Oxygen and
Combustible Gases for any Torch Operations during Construction, Alteration or Demolition Work
§38-02 Operators of Heating Torches Used in the Manufacture of
Jewelry
§38-03 Fire Guards During Torch Operations
§38-01 Issuance of City-Wide Permits for the Storage, Use and/or
Transport of Oxygen and Combustible Gases During Temporary or Emergency Torch Operations.
(a) Torches used in conjunction with oxygen and combustible gases
shall be of a type approved by the Fire Department, or type previously approved by the Board of Standards and Appeals.
(b) Operators of torches and required fire guards shall have Certificates of Fitness issued by the Fire Department in their possession
during torch operations.
(c) Torches shall not be used above or within 25 feet of combustible
material or construction, unless such material or construction is
protected by non-combustible shields or covers from possible
sparks or fire. All floor or wall openings within 25 feet or torch operations shall be protected in a similar manner.
OM-262659 Page 39
(d) Torches shall not be used in areas or locations wherein hazardous
gases, vapors or dust may be present.
(e) Torches shall not be used on containers formerly used for storage
of flammable liquids or gases, unless such containers have been
purged of all flammable vapors.
(f) Compressed gas cylinders shall, when in use, be properly supported and placed a safe distance from torch operations.
(g) Cylinder(s) shall, when not in use, be properly supported and
stored in a safe location protected from damage or exposure to fire.
(h) Fully charged water hose(s) or a sufficient number of water type extinguishers of adequate size shall be provided at the location and
exposed areas of the torch operations maintained and ready for immediate use by fire guards.
(i) Except as otherwise specified by the commissioner, qualified fire
guards shall be on continuous duty during torch operations. One
fire guard shall be required for each torch operator and an additional fire guard shall be provided on the floor or level below the torch
operations. Such persons shall be assigned no other duties than to
remain alert, guard against fire from sparks or transmission of heat
and ignition of combustible material or construction; also the placement and operation of fire extinguishment equipment. Fire guards
shall make an initial inspection of fire extinguishment equipment.
Fire guards shall make an initial inspection one-half hour later, for
the purpose of detecting fire. A signed inspection report shall be
filed with the person in charge of torch operations, and made available for inspection by the Fire Department.
(j) Each vehicle used by a burning contractor to transport torches and
cylinders containing oxygen and combustible gases for use during
temporary or emergency torch operations shall be inspected prior
to the issuance of a permit. Cylinders must bear stamps indicating
that they have been hydrostatically tested within the last ten years
and must be safely secured with metal brackets or chains. Legible
signs indicating that flammable materials are being carried must
appear on both sides and on the back of the vehicle. A fire extinguisher must be carried in an easily accessible position on the
vehicle.
(k) The owner, operator or person who manages or controls the
premises for the owner on which the torch operations are to be conducted shall be notified in writing by the permittee at least forty-eight
hours in advance of intended torch operations on any job locations,
and said owner or operator, or person who owns or maintains or
controls the premises, or his designated representative who shall
not be the burning contractor shall be responsible for supervising
the conduct of the operations so that they are carried out in accordance with this rule. A copy of the rule shall be furnished the owner
by the contractor at the time of notification.
(l) The permittee shall provide the owner or person in charge of
premises wherein torch operations are to be conducted with a copy
of this rule. Such owner or person in charge of premises shall be
responsible for the full compliance with such rule.
(m) Any violation of this rule shall be subject to enforcement in accordance with the provisions of §§27-4020 and 27-4254 of the Administrative Code.
(n) The Permit for any one particular job site location shall be valid for
thirty (30) days maximum; however, said permit shall remain in effect for one year with regard to its use on other job sites.
(o) City-Wide Permit shall not include the storage and use of oxygen
and combustible gases during the course of construction, alteration
OM-262659 Page 40
or demolition work. A separate permit shall be required for such
storage and use.
§38-01 Issuance of Permits for the Storage and Use of Oxygen and
Combustible Gases for any Torch Operations during Construction, Alteration or Demolition Work
(a) Torches used in conjunction with oxygen and combustible gases
shall be a type approved by the Fire Department, or type previously
approved by the Board of Standards and Appeals.
(b) Operators of torches and required fire guards shall have Certificates of Fitness issued by the Fire Department in their possession
during torch operations.
(c) Torches shall not be used above or within 25 feet of combustible
material or construction unless such material or construction is protected by non-combustible shields or covers from possible sparks
or fire. All floor or wall openings within 25 feet of torch operations
shall be protected in a similar manner.
(d) Torches shall not be used in areas or locations wherein hazardous
gases, vapors or dusts may be present.
(e) Torches shall not be used on containers formerly used for storage
of flammable liquids or gases, unless such containers have been
purged of all flammable vapors.
(f) Compressed gas cylinders shall, when in use, be properly supported and stored in a safe location protected from damage or exposure
to fire.
(g) Cylinder(s) shall, when not in use, be properly supported and
stored in a safe location protected from damage or exposure to fire.
(h) Fully charged water hose(s) or sufficient number of water type extinguishers of adequate size shall be provided at the location and
exposed areas of the torch operations maintained and ready for immediate use by fire guards.
(i) Except as otherwise specified by the commissioner, qualified fire
guards shall be on continuous duty during torch operations. One
fire guard shall be required for each torch operator and an additional fire guard shall be provided on the floor or level below the torch
operations. Such persons shall be assigned no other duties than to
remain alert, guard against fire from sparks or transmission of heat
and ignition of combustible material or construction; also the placement and operation of fire extinguishment. Fire guards shall make
an initial inspection of exposed areas one-half hour after completion of torch operations. Such inspection shall be followed up by another final inspection one-half hour later, for the purpose of detecting fire. A signed inspection report shall be filed with the person in
charge of torch operations, and made available for inspection by
the Fire Department.
(j) The owner, operator or person who manages or controls the
premises for the owner on which torch operations are to be conducted shall be notified in writing by the permittee at least forty-eight
hours in advance of intended torch operations on any job locations,
and said owner or operator, or person who owns or maintains or
controls the premises, or his designated representative who shall
not be the burning contractor shall be responsible for supervising
the conduct of the operations so that they are carried out in accordance with this rule.
(k) The permittee shall provide the owner or person in charge of
premises wherein torch operations are to be conducted with a copy
of this rule. Such owner or person in charge of premises shall be responsible for the full compliance with such rule.
OM-262659 Page 41
(l)
Any violation of this rule shall be subject to enforcement in accordance with the provisions of §§27-4020 and 27-4254 of the Administrative Code.
(m) City-Wide Permit shall not include the storage and use of oxygen
and combustible gases during the course of construction, alteration
or demolition work. A separate permit shall be required for such
storage and use.
§38-02 Operators of Heating Torches Used in the Manufacture of
Jewelry.
(a) Operators of heating torches used in the manufacture of jewelry
shall not be required to obtain individual Certificates of Fitness for
the operation of such torches.
(b) A Certificate of Fitness shall be required of a person in such occupancies, who shall be responsible for the following:
(1) Regulation of pressure and flow of oxygen and city gas to the
individual operators of heating torches:
(2) Supervision of the individual heating torch operation.
§38-03 Fire Guards During Torch Operations. A person holding a Certificate of Fitness issued by the Fire Department shall be required to act in the capacity of fire guard during torch operations in course of construction, alteration, or demolition work;
also, during temporary or emergency torch operations. Such
persons shall provide required fire extinguishing equipment at
torch operation locations; guard against fire in exposed areas,
and make a complete inspection of exposed areas for possible
fire.
Effective January 1, 2024
(For Oxy-Fuel and Pressure Regulation Equipment
with a date code of CEA or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY - Subject to the terms and conditions below, Miller
Electric Mfg. LLC, Appleton, Wisconsin, warrants to authorized distributors
that new Miller equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is shipped by
Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail
due to such defects in material or workmanship. Miller shall honor warranty
claims on warranted equipment listed below in the event of a defect within the
warranty coverage time periods listed below. Warranty time periods start on
the delivery date of the equipment to the end-user purchaser.
1. 5 Years – Parts and Labor
*
Torch Handles, Cutting Attachments, Straight Cutting Torches
and Machine Torches. The use of tips other than genuine Miller
tips voids the warranty.
2. 3 Years – Parts and Labor
*
Toughcut Outfits, Series 22, 30, 32, 35, 36, 40, 46 Regulators, and
all Flowmeters, Flow Gauges, and Flowmeter Regulators
3. 2 Years – Parts and Labor
*
Series 250, 820, and Branded Specialty Gas Regulators
4. 1 Year – Parts and Labor
OM-262659 Page 42
*
5.
Gas Axe Cutting Torches, HVAC/Purge Regulators, 3-Stage Nitrogen Low-Pressure Blanketing Regulators, Gas Savers, Gas
Mixers, and all other Oxy-Fuel Products
*
The Little Torch, Quickbraze Torch, Handi-Heet/Silver Smith
Torch
90 Days – Parts and Labor
*
Corrosive Service Regulators
Miller’s True Blue) Limited Warranty shall not apply to:
1.
Consumable components; oxy-fuel cutting, welding, and heating tips,
or parts that fail due to normal wear.
2. Items furnished by Miller, but manufactured by others. These items are
covered by the manufacturer’s warranty, if any.
3. Equipment that has been modified by any party other than Miller, or
equipment that has been improperly installed, improperly operated or
misused based upon industry standards, or equipment which has not
had reasonable and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the equipment.
4. Defects caused by accident, unauthorized repair, or improper testing.
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL AND INDUSTRIAL
USERS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT.
The exclusive remedies for warranty claims are, at Miller’s option, either: (1)
repair; or (2) replacement; or, if approved in writing by Miller, (3) the pre-approved cost of repair or replacement at an authorized Miller service station; or
(4) payment of or credit for the purchase price (less reasonable depreciation
based upon use). Products may not be returned without Miller’s written approval. Return shipment shall be at customer’s risk and expense.
The above remedies are F.O.B. Appleton, WI, or Miller’s authorized service
facility. Transportation and freight are the customer’s responsibility. TO THE
EXTENT PERMITTED BY LAW, THE REMEDIES HEREIN ARE THE SOLE
AND EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL THEORY. IN
NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS
OF PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY WARRANTY
NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY,
OR REPRESENTATION, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, ARE
EXCLUDED AND DISCLAIMED BY MILLER.
Some US states do not allow limiting the duration of an implied warranty or the
exclusion of certain damages, so the above limitations may not apply to you.
This warranty provides specific legal rights, and other rights may be available
depending on your state. In Canada, some provinces provide additional warranties or remedies, and to the extent the law prohibits their waiver, the limitations set out above may not apply. This Limited Warranty provides specific
legal rights, and other rights may be available, but may vary by province.
Mil oxy-fuel warr 2024-01
OM-262659 Page 43
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA
E2024 Miller Electric Mfg. LLC 2024−01