Concoa 65 User manual

INSTALLATION AND OPERATION INSTRUCTIONS

Certified ISO 9000

ADI 1098-P

Controls Corporation of America

1501 Harpers Road • Virginia Beach, VA 23454

To Order Call 1-800-225-0473 or 757-422-8330 • Fax 757-422-3125

www.concoa.com

Before Installing or Operating, Read and Comply with These Instructions

Gas Mizer

September 2001

Supersedes August 2000

Certified ISO 9000

Controls Corporation of America

1501 Harpers Road • Virginia Beach, VA 23454

To Order Call 1-800-225-0473 or 757-422-8330 • Fax 757-422-3125

www.concoa.com

ADI 1098-P

GENERAL SAFETY PROCEDURES

USER RESPONSIBILITY

This equipment will perform in conformity with the description contained

in this manual and accompanying label and/or inserts when installed, op-

erated, maintained and repaired in accordance with the instructions pro-

vided. This equipment must be checked periodically. Defective equip-

ment should not be used. Parts that are broken, missing, plainly worn,

distorted or contaminated, should be replaced immediately.

This equipment or any of its parts should not be altered without the prior

written approval of CONCOA. The user of this equipment shall have the

sole responsibility for any malfunction which results from improper use, faulty

maintenance, damage, improper repair or alteration by anyone other than

CONCOA or a service facility designated by CONCOA.

Should such repair or replacement become necessary, Controls Corpora-

tion of America (“CONCOA”) recommends that telephonic or written

request for service advice be made to the CONCOA Customer Service in

Virginia Beach, Virginia. PHONE: 1-800-225-0473; FAX: 1-757-422-

3125; E-MAIL: [email protected]. Please be preapred to provide the

model number and serial number of the equipment involved, in addition

to some details regarding its application.

Comply with all safety precautions given in torch instruction manual and

the following:

a. Left hand threaded connections must be on side marked FUEL GAS;

right hand threaded connections on side marked OXYGEN.

b. Test equipment for leaks regularly with an approved oxygen compat-

ible leak detection fluid.

c. Do not use equipment unless it is free from leaks.

d. Before lighting pilot light, purge lines individually to eliminate un-

wanted mixtures of fuel gas and air or oxygen.

e. Keep combustibles away from pilot light. Avoid releasing uncontrol-

lable flammable gases or vapors near the pilot light.

f. Do not use oil or oil bearing materials on or near devices through

which oxygen flows. Oil or any other combustible material can ig-

nite readily and burn vigorously in the presence of oxygen.

CUSTOMER SERVICE

Warranty Information

This equipment is sold by CONTROLS CORPORATION OF AMERICA under the

warranties set forth in the following paragraphs. Such warranties are extended only with

respect to the purchase of this equipment directly from CONTROLS CORPORATION

OF AMERICA or its Authorized Distributors as new merchandise and are extended to

the first Buyer thereof other than for the purpose of resale.

For a period of one (1) year from the date of original delivery (90 days in corrosive service)

to Buyer or to Buyer’s order, this equipment is warrantied to be free from functional

defects in materials and workmanship and to conform to the description of this equip-

ment contained in this manual and any accompanying labels and/or inserts, provided

that the same is properly operated under conditions of normal use and that regular peri-

odic maintenance and service is performed or replacements made in accordance with the

instructions provided.The foregoing warranties shall not apply if the equipment has been

repaired: other than by CONTROLS CORPORATION OF AMERICA or a desig-

nated service facility or in accordance with written instructions provided by CONTROLS

CORPORATION OF AMERICA, or altered by anyone other than CONTROLS COR-

PORATION OF AMERICA, or if the equipment has been subject to abuse, misuse,

negligence or accident.

CONTROLS CORPORATION OF AMERICA’s sole and exclusive obligation and

Buyer’s sole and exclusive remedy under the above warranties is limited to repairing or

replacing, free of charge, at CONTROLS CORPORATION OF AMERICA’s option,

the equipment or part, which is reported to its Authorized Distributor from whom pur-

chased, and which if so advised, is returned with a statement of the observed deficiency,

and proof of purchase of equipment or part not later than seven (7) days after the expira-

tion date of the applicable warranty, to the nearest designated service facility during nor-

mal business hours, transportation charges prepaid, and which upon examination, is

found not to comply with the above warranties. Return trip transportation charges for the

equipment or part shall be paid by Buyer.

CONTROLS CORPORATION OF AMERICA SHALL NOT BE OTHERWISE

LIABLE FOR ANY DAMAGES INCLUDING BUT NOT LIMITED TO: INCI-

DENTAL DAMAGES, CONSEQUENTIAL DAMAGES, OR SPECIAL DAMAGES,

WHETHER SUCH DAMAGES RESULT FROM NEGLIGENCE, BREACH OF

WARRANTY OR OTHERWISE.

THERE ARE NO EXPRESS OR IMPLIEDWARRANTIESWHICH EXTEND BE-

YOND THE WARRANTIES HEREINABOVE SET FORTH. CONTROLS COR-

PORATION OF AMERICA MAKES NO WARRANTY OF MERCHANTABIL-

ITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE

EQUIPMENT OR PARTS THEREOF.

Scope

This manual provides installation and operation information for the

CONCOA Gas Mizer.

Use

The Mizer is an accessory for inside bench production and assembly line

gas welding and heating operations. It is designed for use in the oxygen

and fuel gas supply, low pressure line of a hand welding torch. When a

hand torch is hung on the Mizer’s hanger rod, oxygen and fuel gas are shut

off.

Pilot light burner tips are not included with the Mizer, but are required

for an installation. Order them separately for MAPP®gas, propane, acety-

lene, or natural gas.

Description

The inlet side of the Gas Mizer is equipped with a fuel gas pilot light. The

inlet and outlet nipples are B size, RH for oxygen and LH for fuel gas. The

Mizer’s shut off valves can be individually adjusted by their seat adjust-

ment screws. This seat adjustment controls ignition by: LEAD for ON

and LAG for OFF.

SAFTEY

Install pressure regulators on cylinders (or pipline branch). Comply with

CONCOA manual Safe Practices in Welding & Cutting, ADE 872, and

torch and regulator instruction manuals

a. Secure the Gas Mizer on a bench or other horizontal surface, using

four mounting holes. Position the Mizer so that when the torch is

hung on the hanger, torch tip will point away from operator and

in a safe direction.

b. Connect the fuel gas hose to the inlet marked FUEL GAS and the

oxygen hose to the other inlet. Refer to the above table for hose

andfitting accessories. Turn off pilot light adjusting valve (clock-

wise).

c. Connect torch hoses to respective Mizer outlets.

d. Screw pilot light burner (for fuel gas to be used) into Mizer needle

valve securely so that is does not leak.

INSTALLATION

INTRODUCTION

IMPORTANT

Hoses for use with acetylene only - Grades R and RM . Hoses for use with

fuel gases (including acetylene) - Grade T.

NOTE

CGA G-1 5.3.3.13 To minimize the withdrawal of liquid solvent, acetylene

should be withdrawn from the cylinder at a rate not to exceed 1/10 (one-

tenth) of the capacity of the cylinder per hour during intermittent use. For

full withdrawal of the contents of the cylinder on a continous basis, the flow

rate should be no more than 1/15 (one-fifteenth) of the capacity of the cylin-

der per hour.

NOTE

Check valves prevent the reverse flow of mixed gases. Regulator Check Valves

“B” size 830 4199 Oxygen, 830 4200 Fuel. Torch Check Valves “B” size 831

4146 Oxygen, 831 4138 Fuel.

IMPORTANT

For Maximum Safety Use Flashback Arrestors

Regulator Mounted Regulator Mounted Torch Mounted

Model -78 Resettable Model 65 Model 460

801 0786 “B” Size (Oxy.) 801 0536 “B” Size (Oxy.) 801 1466 “B” Size (Oxy.)

801 0789 “B” Size (Fuel) 801 0539 “B” Size (Fuel) 801 1469 “B” Size (Fuel)

UL Listed --- Meets OSHA Requirements --- Comply with ISO 5175

OPERATION

e. Purge lines individually, pressurize, and test for leaks at valve seats,

valve stem packings, hose connections, and pilot light connections

with an approved oxygen compatible leak detection fluid.

Pilot Light

With the torch off the hanger rod, turn the pilot light adjusting needle

valve counterclockwise and immediately light the pilot with a sparklighter.

Adjust the flame with the valve until satisfactory.

Use

Use the torch as usual but when through, instead of closing the torch

valves, place the torch on the hanger rod to extinguish the flame. (Point

flame away from bench as torch is hung.) For reuse, remove torch from

hanger rod and without delay relight at pilot flame.

Pressure Settings

The Gas Mizer does not affect regulator pressure settings for the torch.

Use the same pressure settings at each regulator, as if this device were not

in the torch system.

Hanger Rod Adjustment

When placing the Mizer in operation, the hanger rod should be adjusted

so that the hand torch will shut off the fuel gas and oxygen valves with its

own weight:

a. Close the pilot valve by turning the pilot valve T-handle clockwise

until it stops. Tighten only enough to ensure a tight seal.

b. With the torch off the hanger, adjust pressures and flames.

c. When the torch is placed on the hanger rod, the flames should

shut off. If the flames to do not shut off, perform the following

steps.

d. Loosen the hanger rod adjustment screw and slide the hanger rod

and torch to a point where the valves shut off fuel gas and oxygen

supplies.

e. Tighten the hanger rod adjustment screw and turn off the fuel gas

and oxygen supplies.

f. Readjust, if necessary, the seat adjusting screws. Gases shutting

off simultaneously, flashing or popping can be eliminated by lag-

ging the fuel adjustment screw.

NOTE

The seat adjusting screw is nylon; care should be taken to avoid stripping

the threads when tightening the locknuts.

Removal From Service

a. Shut off valves upstream of regulators.

b. Open torch valves to bleed system before closing the regulator.

This will ensure regulator is drained before repressurizing.

c. Shut off regulators by turning the regulator adjusting screws coun-

terclockwise.

d. Remove Gas Mizer from system.

IMPORTANT

Send faulty equipment to a CONCOA-designated repair center for re-

pairs. Special tools and techniques are required to repair such equipment.

Personnel with experience with such equipment should perform repairs.

CAUTION

Shut off gas supplies at source before attempting inspection or service unless

leak testing with an approved oxygen compatible leak detection fluid.

General

Servicing is usually required if gas escapes from the hand torch when it is on

the hanger rod; test by hand pressure on the hanger rod.

If the torch and station outlet valves are closed, but the regulator indicates a

slow change in pressure when the torch is off the hook, the quad-ring seal in

the Mizer may be damaged. Damage to this seal will allow gas to escape past

the thrust pin seal. This condition may also be caused by a hose connection;

test with an approved oxygen compatible detection fluid.

Valve Seat Replacement

Send faulty equipment to a CONCOA-designated repair center for repairs.

CAUTION

Use only lubricants compatible with oxygen.

SERVICE

OPERATION

e. Purge lines individually, pressurize, and test for leaks at valve seats,

valve stem packings, hose connections, and pilot light connections

with an approved oxygen compatible leak detection fluid.

Pilot Light

With the torch off the hanger rod, turn the pilot light adjusting needle

valve counterclockwise and immediately light the pilot with a sparklighter.

Adjust the flame with the valve until satisfactory.

Use

Use the torch as usual but when through, instead of closing the torch

valves, place the torch on the hanger rod to extinguish the flame. (Point

flame away from bench as torch is hung.) For reuse, remove torch from

hanger rod and without delay relight at pilot flame.

Pressure Settings

The Gas Mizer does not affect regulator pressure settings for the torch.

Use the same pressure settings at each regulator, as if this device were not

in the torch system.

Hanger Rod Adjustment

When placing the Mizer in operation, the hanger rod should be adjusted

so that the hand torch will shut off the fuel gas and oxygen valves with its

own weight:

a. Close the pilot valve by turning the pilot valve T-handle clockwise

until it stops. Tighten only enough to ensure a tight seal.

b. With the torch off the hanger, adjust pressures and flames.

c. When the torch is placed on the hanger rod, the flames should

shut off. If the flames to do not shut off, perform the following

steps.

d. Loosen the hanger rod adjustment screw and slide the hanger rod

and torch to a point where the valves shut off fuel gas and oxygen

supplies.

e. Tighten the hanger rod adjustment screw and turn off the fuel gas

and oxygen supplies.

f. Readjust, if necessary, the seat adjusting screws. Gases shutting

off simultaneously, flashing or popping can be eliminated by lag-

ging the fuel adjustment screw.

NOTE

The seat adjusting screw is nylon; care should be taken to avoid stripping

the threads when tightening the locknuts.

Removal From Service

a. Shut off valves upstream of regulators.

b. Open torch valves to bleed system before closing the regulator.

This will ensure regulator is drained before repressurizing.

c. Shut off regulators by turning the regulator adjusting screws coun-

terclockwise.

d. Remove Gas Mizer from system.

IMPORTANT

Send faulty equipment to a CONCOA-designated repair center for re-

pairs. Special tools and techniques are required to repair such equipment.

Personnel with experience with such equipment should perform repairs.

CAUTION

Shut off gas supplies at source before attempting inspection or service unless

leak testing with an approved oxygen compatible leak detection fluid.

General

Servicing is usually required if gas escapes from the hand torch when it is on

the hanger rod; test by hand pressure on the hanger rod.

If the torch and station outlet valves are closed, but the regulator indicates a

slow change in pressure when the torch is off the hook, the quad-ring seal in

the Mizer may be damaged. Damage to this seal will allow gas to escape past

the thrust pin seal. This condition may also be caused by a hose connection;

test with an approved oxygen compatible detection fluid.

Valve Seat Replacement

Send faulty equipment to a CONCOA-designated repair center for repairs.

CAUTION

Use only lubricants compatible with oxygen.

SERVICE

Scope

This manual provides installation and operation information for the

CONCOA Gas Mizer.

Use

The Mizer is an accessory for inside bench production and assembly line

gas welding and heating operations. It is designed for use in the oxygen

and fuel gas supply, low pressure line of a hand welding torch. When a

hand torch is hung on the Mizer’s hanger rod, oxygen and fuel gas are shut

off.

Pilot light burner tips are not included with the Mizer, but are required

for an installation. Order them separately for MAPP®gas, propane, acety-

lene, or natural gas.

Description

The inlet side of the Gas Mizer is equipped with a fuel gas pilot light. The

inlet and outlet nipples are B size, RH for oxygen and LH for fuel gas. The

Mizer’s shut off valves can be individually adjusted by their seat adjust-

ment screws. This seat adjustment controls ignition by: LEAD for ON

and LAG for OFF.

SAFTEY

Install pressure regulators on cylinders (or pipline branch). Comply with

CONCOA manual Safe Practices in Welding & Cutting, ADE 872, and

torch and regulator instruction manuals

a. Secure the Gas Mizer on a bench or other horizontal surface, using

four mounting holes. Position the Mizer so that when the torch is

hung on the hanger, torch tip will point away from operator and

in a safe direction.

b. Connect the fuel gas hose to the inlet marked FUEL GAS and the

oxygen hose to the other inlet. Refer to the above table for hose

andfitting accessories. Turn off pilot light adjusting valve (clock-

wise).

c. Connect torch hoses to respective Mizer outlets.

d. Screw pilot light burner (for fuel gas to be used) into Mizer needle

valve securely so that is does not leak.

INSTALLATION

INTRODUCTION

IMPORTANT

Hoses for use with acetylene only - Grades R and RM . Hoses for use with

fuel gases (including acetylene) - Grade T.

NOTE

CGA G-1 5.3.3.13 To minimize the withdrawal of liquid solvent, acetylene

should be withdrawn from the cylinder at a rate not to exceed 1/10 (one-

tenth) of the capacity of the cylinder per hour during intermittent use. For

full withdrawal of the contents of the cylinder on a continous basis, the flow

rate should be no more than 1/15 (one-fifteenth) of the capacity of the cylin-

der per hour.

NOTE

Check valves prevent the reverse flow of mixed gases. Regulator Check Valves

“B” size 830 4199 Oxygen, 830 4200 Fuel. Torch Check Valves “B” size 831

4146 Oxygen, 831 4138 Fuel.

IMPORTANT

For Maximum Safety Use Flashback Arrestors

Regulator Mounted Regulator Mounted Torch Mounted

Model -78 Resettable Model 65 Model 460

801 0786 “B” Size (Oxy.) 801 0536 “B” Size (Oxy.) 801 1466 “B” Size (Oxy.)

801 0789 “B” Size (Fuel) 801 0539 “B” Size (Fuel) 801 1469 “B” Size (Fuel)

UL Listed --- Meets OSHA Requirements --- Comply with ISO 5175