Victor C Series Manual

© Thermadyne Industries, Inc., 2008 www.thermadyne.com Printed in U.S.A.
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Welding, Cutting and Heating guide
Issue Date: March 24, 2008
Set-up and Safe operating procedureS
oxy-fuel Welding equipment
Manual No: 0056-0114
English
Français
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Welding, Cutting and Heating guide
Revision: B
Welding, Cutting and Heating guide

SET-UP AND SAFE OPERATING PROCEDURES
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WARNINGS
Read and understand this entire Manual and your employer’s safety practices before
installing, operating, or servicing the equipment. While the information contained in
this Manual represents the Manufacturer’s judgment, the Manufacturer assumes no
liability for its use.
Welding, Cutting, and Heating Guide
Set-up and Safe Operating Procedures
Instruction Guide Number 0056-0114
Published by:
Thermadyne®Industries, Inc.
2800 Airport Rd.
Denton, TX. 76208
[phone]
www.victorequip.com
U.S. Customer Care: [phone]
International Customer Care: [phone]
Copyright © 2008 Thermadyne Industries, Inc. All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: March 24, 2008
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:

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SET-UP AND SAFE OPERATING PROCEDURES
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SECTION 1:
INTRODUCTION
This guide contains important information related to the safe and efficient operation of oxy-fuel
welding, cutting, and heating apparatus.
There are several potential hazards present when using oxy-fuel equipment. It is,therefore, necessary
that proper safety and operating procedures are understood prior to using such apparatus.
READ THIS BOOKLET THOROUGHLY AND CAREFULLY BEFORE ATTEMPTING TO OPERATE OXY-
FUEL WELDING, CUTTING, AND HEATING APPARATUS. A thorough understanding of the proper
safety and operating procedures will help to minimize the potential hazards involved, and add to the
efficiency and productivity of your work.
Welding, cutting, and heating operations should conform to applicable Federal, State, County or City
regulations for installation, operation, ventilation, fire prevention, and protection of personnel.
Detailed safety and operating instructions can be located within the ANSI Standard Z49.1, “Safety
in Welding and Cutting”, available from the American Welding Society, P.O. Box 351040, Miami, FL.
33135 or www.aws.org. Other publications containing safety and operating instructions are available
from the following organizations:AmericanWelding Society, (AWS) www.aws.org, Occupational Safety
and Health organization (OSHA) www.osha.gov, Compressed GasAssociation (CGA) www.cganet.com
and National Fire Protection Agency (NFPA) www.nfpa.org.
DO NOT attempt to use the apparatus unless you are trained in its proper use,or are under competent
supervision. Remember, the safest equipment, if incorrectly operated, may result in a mishap.
A system of notes, cautions and warnings emphasize important safety and operating information in
this booklet. These are as follows:
NOTE
Conveys installation, operation, or maintenance information, which is important, but
not hazardous related.
CAUTION
Indicates a potentially hazardous situation which if not avoided, may result in injury.
WARNING
Indicates a potentially hazardous situation, which, if not avoided, could result in death
or serious injury.
Introduction

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SECTION 2:
GENEral SafETy INfOrmaTION
Be sure to read and understand all safety and operating instructions provided before using this
apparatus. rETaIN THESE INSTrUCTIONS IN a rEaDIly aVaIlaBlE lOCaTION fOr fUTUrE
rEfErENCE.
The following preliminary safety checklist is the basis for further specific safety information noted
throughout this booklet.
WARNING
This product contains chemicals, including lead, or otherwise produces chemicals
known to the State of California to cause cancer, birth defects and other reproductive
harm. Wash hands after handling. (California Health & Safety Code § 25249.5 et seq.)
WARNING
DO NOT attempt to use this apparatus unless you are trained in its proper use or are under
competent supervision. For your safety, practice the safety and operating procedures
described in this guide every time you use the apparatus.Deviating from these procedures
may result in fire, explosion, property damage and/or operator injury.
If, at any time, the apparatus you are using does not perform in the usual manner, or
you have difficulty in the use of the apparatus, shut the system off and STOP using it
immediately. DO NOT use the apparatus until the problem has been corrected.
WARNING
Service or repair of apparatus should be performed by a qualified repair technician only.
Improper service, repair, or modification of the product could result in damage to the
product or injury to the operator.
NOTE
The term “Qualified Repair Technician” refers to repair personnel capable of servicing
apparatus in strict accordance with all applicable Victor “Parts & Service Bulletins” and
literature.
2.01 HOUSEkEEpING
The work area must have a fireproof floor.1.
Work benches or tables used during welding, cutting, and heating operations must have2.
fireproof tops.
Use heat resistant shields or other approved material to protect nearby surfaces from sparks3.
and hot metal.
General Safety Information

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Move all combustible material away from the work area.4.
Ventilate welding, cutting, and heating work areas adequately to prevent accumulation of5.
explosive or toxic concentrations of gases. When working with lead, lead bearing materials,
steel coated with lead paints, cadmium-coated materials or any objects containing metals
that may generate or give off toxic fumes, always ensure that suitable respiratory protection
equipment is utilized.
When welding be sure to read and understand the Material Safety Data Sheet (MSDS) for6.
the alloy being used.
Place the oxygen and fuel cylinders close to the location to where you are working.Ensure7.
the cylnders are at a safe distance from sparks or hot metal. Individually chain or otherwise
secure the cylinders to a wall, bench, post, cylinder cart, etc. to keep the cylinders upright
and secure them from falling over.
2.02 PROTECTIVE APPAREL
Protect yourself from sparks,flying slag,and flame brilliance at all times.Gas flames produce1.
infrared radiation that may have a harmful effect on the skin and especially on the eyes.
Select the appropriate goggles or mask with tempered lenses shaded 5 or darker to protect
your eyes from injury and provide good visibility of the work.
Always wear appropriate protective gloves and flame resistant clothing to protect skin and2.
clothing from sparks and slag. Keep collars, sleeves, and pockets buttoned. DO NOT roll
up sleeves or cuff pants.
Remove all flammable and readily combustible materials from your pockets,such as matches3.
and cigarette lighters.
Keep all clothing and protective apparel completely free of oil or grease.4.
Do not wear clothing that is easily ignited, such as polyester pants or shirts.5.
2.03 FIRE PREVENTION
Welding, cutting, and heating operations use fire or combustion as a basic tool. The process is very
useful when properly controlled. However, it can be extremely destructive if not performed correctly
in the proper environment.
Practice fire prevention techniques whenever oxy-fuel operations are in progress. A few simple
precautions can prevent most fires and help minimize damage in the event a fire does occur.
Keep1. ALL apparatus clean and free of grease, oil, and other flammable substances. Inspect
oxy-fuel apparatus for oil, grease, or damaged parts. DO NOT use the oxy-fuel apparatus if
oil or grease are present, or if damage is evident.
Never use oil, grease, or lubricant on or around any oxy-fuel apparatus. Even a trace of oil2.
or grease can ignite and burn violently in the presence of oxygen.
Keep flames, heat, and sparks away from cylinders, regulators, and hoses.3.
General Safety Information

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Flying sparks can travel up to a distance of 35 feet or more.Remove all combustible materials4.
away from areas where oxy-fuel operations are being performed.
Operators may not become aware of a fire starting while operating apparatus. Their vision5.
is seriously hampered by the welding goggles and dark lenses. Depending upon the
circumstances of the work location, it may be advisable to have a fire watcher to operate
an extinguisher and sound a fire alarm in case of a fire.
Keep an approved fire extinguisher of the proper size and type in the work area.6.
Inspect it regularly to ensure that it is in proper working order. Know how to use the fire
extinguisher.
Use heat resistant shields or other approved material to protect nearby surfaces, ceilings7.
and equipment from sparks and hot metal.
Only use oxy-fuel equipment with the fuel gas it was designed for.8.
After the equipment has been properly set up,open the acetylene cylinder valve approximately9.
3/4 of a turn, but NO MORE than 1-1/2 turns. Keep the cylinder wrench, if one is required,
on the cylinder valve so the cylinder may be turned off quickly if it becomes necessary.
All gases10. EXCEPT ACETYLENE: Open the fuel gas cylinder valve completely to seal the
cylinder back seal packing.
Never test for gas leaks with a flame. Use an approved leak-detector solution.11.
Never perform welding, cutting, and heating operations on a container that has held toxic12.
or combustible liquids or vapors.
Never perform welding, cutting, and heating operations in an area containing combustible13.
vapors, flammable liquids, or explosive dust.
Never perform welding, cutting, and heating operations on a closed container or vessel,14.
which may explode when heated.
Avoid operating the equipment in rooms with sprinkler systems unless there is sufficient15.
ventilation to keep the area cool.
When the work is complete, inspect the area for possible fires or smoldering materials.16.
2.04 CYLINDERS
All Government and insurance regulations relating to the storage of oxygen, acetylene and LPG
cylinders should be closely observed.
Industrial gas cylinders are made to rigid specifications and are inspected each time they are refilled
by your supplier. They are safe if properly handled.
For additional information on the safe handling of gas cylinders,contact your gas supplier or refer to the
Compressed Gas Association publication P-1, “Safe Handling of Compressed Gases in Containers”.
Keep all cylinders, empty or full, away from radiators, furnaces and other sources of heat.•
Avoid contact with electrical circuits.•
General Safety Information

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Keep oil and grease away from cylinders.•
Cylinders should be screened against direct rays from the sun.•
Protect cylinder valves from bumps and falling objects.•
Inspect the cylinder valves for damaged parts. Keep the valves clean, free from oil, grease,•
and all foreign materials.
Close cylinder valves when not in use, when empty, or when moving cylinders.•
Always be sure the cylinder valve is tightly closed before removing the regulators.•
Always replace the cylinder valve cap, if applicable, when the cylinder is not in use.•
Never allow anyone to strike an arc or tap an electrode against any cylinder.•
Never try to fill a cylinder or mix gases in a cylinder. Never draw gas from cylinders except•
through properly attached pressure regulators or equipment designed for the purpose. If
damaged, send the regulator to the supplier or qualified repair technician for repairs. Do not
tamper with or alter cylinder numbers or markings.
Never use cylinders as supports or rollers.•
When transporting cylinders with a crane, use an approved cylinder cradle only. Never use a•
“magnet” crane to move cylinders
Never lift the cylinder by its protective cap.•
If you are unable to make a gas-tight seal between the cylinder valve and a regulator nipple,•
check to see if the connection nut is tight. If so, check the regulator inlet connection for
damage. If the cylinder valve is damaged, remove the cylinder from service and notify the
gas supplier.
Never insert washers of lead or other material between the regulator and cylinder valve. Never•
use oil or grease on the connections.
NEVER• use compressed gas cylinders without a pressure reducing regulator attached to the
cylinder valve.
Never drag cylinders or roll them on the bottom edge, use a suitable cylinder cart.•
Never transport gas cylinders inside a passenger vehicle. Only transport gas cylinders in•
a suitable ventilated service vehicle. See CGA PS-7, “CGA Position statement on the Safe
Transportation of Cylinders in Passenger Vehicles”.
Use only standard cylinder keys to open cylinder valves, never extend the length of these•
keys under any circumstances. If valves cannot be opened by hand, do not use a hammer or
a wrench; notify the supplier.
Leave the cylinder key in position when fuel gas cylinder valves are open.•
Some cylinder valves, most notably acetylene cylinder valves, may require adjustment of the•
valve packing. Consult your gas supplier for the proper method of adjusting the packing. DO
NOT use the cylinder if the packing is leaking.
General Safety Information

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WARNING
Cylinders are highly pressurized. Handle with care. Serious accidents can result from
improper handling or misuse of compressed gas cylinders. DO NOT drop the cylinder,
knock it over, expose it to excessive heat, flames or sparks. DO NOT strike a cylinder
in any manner.
Figure 1: Thermadyne Safety Duck
General Safety Information

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SECTION 3:
INDUSTRIAL GASES
CAUTION
Fuel Gases may be toxic. Contact your gas supplier for the appropriate Material Safety
Data Sheet (MSDS) for each gas you use. The Hazardous Materials Regulations of the
Department of Transportation (DOT) regulates the transportation of industrial gases and
the cylinders used to transport them. Disposal of fuel gases may also be controlled.
Contact your local or state Department of Labor for further information.
3.01 OXYGEN
Gaseous chemical element, symbol: O; it is of great interest because it is the essential element in the
respiratory processes of most living cells and in COMBUSTION PROCESSES. It is the most abundant
element in the Earth’s crust. Nearly one fifth (in volume) of the air is oxygen.
Oxygen can be separated from air by fractionated liquefaction and distillation. One of the main
applications for oxygen is melting, and the refining and manufacture of steel and other metals.
Oxygen is required to support any burning process. It is, therefore, combined with a “fuel” gas to
produce the desired operating flame. Oxygen itself is not flammable. However, the presence of pure
oxygen will dramatically accelerate the burning process. Oxygen can easily turn a small spark into
a roaring flame or explosion.
WARNING
Never allow oxygen to contact grease, oil, or other flammable substances. Although
oxygen by itself will not burn, these substances become highly explosive and may ignite
and burn rapidly when supported by pure oxygen. Oil or grease combined with oxygen
may ignite or even explode without the presence of excessive heat or flame.
Oxygen is ordinarily supplied in standard drawn steel cylinders. The 244-cubic foot cylinder is the
most commonly used. Smaller and larger sizes are available. Full oxygen cylinders are normally
pressurized in excess of 2000 pounds per square inch.Determine oxygen cylinder contents by reading
the inlet pressure gauge on the regulator when in use. For example, half the full cylinder pressure
rating indicates half the volume (c/f) of oxygen remaining. The maximum fill pressure should always
be stamped on the cylinder.
Due to the high pressure under which oxygen is contained, cylinders must always be handled with
great care. THE POTENTIALLY VIOLENT REACTION OF OIL,GREASE,OR ALL OTHER CONTAMINANTS
IN THE PRESENCE OF OXYGEN CANNOT BE OVERSTRESSED. SERIOUS INJURY OR DEATH MAY
EASILY RESULT IF OXYGEN IS USED AS A SUBSTITUTE FOR COMPRESSED AIR. Oxygen should
never be referred to as “air”.
Industrial Gases

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WARNING
NEVER USE OXYGEN:
In pneumatic tools•
In oil pre-heating burners•
To start internal combustion engines•
To blow out pipelines•
To dust off clothing or work area•
To create pressure•
For ventilation•
In short, under no circumstances use oxygen as a substitute for compressed air or
other gases. Use oxygen only for appropriate oxy-fuel cutting, heating and welding
applications
Oxygen Valve Outlet and Regulator Inlet Connections
CGA 540 up to 3000 PSIG•
CGA 577 up to 4000 PSIG•
CGA 701 up to 5500 PSIG•
3.02 ACETYLENE
Acetylene is a compound of carbon and hydrogen (C2H2). It is a versatile industrial fuel gas used in cutting,
heating, welding, brazing, soldering, flame hardening, metallizing, and stress relieving applications. It is
produced when calcium carbide is submerged in water or from petrochemical processes.The acetylene gas
produced is then compressed into cylinders or fed into piping systems.Acetylene becomes unstable when
compressed in its gaseous state above 15 PSIG.Therefore,it cannot be stored in a“hollow”cylinder under
high pressure the way oxygen, for example,is stored.Acetylene cylinders are filled with a porous material
(calcium-silicate) creating, in effect, a “solid” as opposed to a “hollow” cylinder.The porous filling is then
saturatedwithliquid acetone.Whenacetyleneispumped intothe cylinder,itisabsorbedbythe liquidacetone
throughout the porous filling.It is held in a stable condition (see Figure 2). Filling acetylene cylinders is a
delicate process requiring special equipment and training.Acetylene cylinders must,therefore,be refilled
only by authorized gas distributors. Acetylene cylinders MUST NEVER be transfilled.
Industrial Gases

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POROUS FILLER: (calcium-sicilate) 8% - 10%
The filler, which completely occupies the steel shell, is
90% - 92% composed of millions of interconnected pores.
ACETONE: 42%
Acetone is equal to 42% of the internal volume, and is
dispersed throughout the filler.
ACETYLENE GAS: 36%
The acetylene gas is uniformly absorbed by the acetone.
The resulting mixture occupies 78% of the internal volume.
RESERVE VOLUME AT 70˚ F: 10% - 12%
Since acetone and acetylene gas will expand as temperature
rises, a safety reserve must be present even at 150˚ F.
dwg-00377
Figure 2: Acetylene Cylinder Interior
Acetylene Cylinders
All acetylene cylinders are fitted with fusible plugs.These are designed to vent the cylinder contents
in the event of an unsafe condition arising in the cylinder that could be due to any number of reasons,
such as overheating from either incorrect operating techniques, faulty equipment, or in conjunction
with excessive temperature. In the event of a cylinder safety device malfunctioning, remove the
cylinder from service, place the cylinder in a well ventilated area, preferably outdoors, and notify the
supplier immediately.
Commonly Available Acetylene Cylinder Capacities
Cubic Feet
10 130 330
40 190 360
60 225 390
75 290 850
100 300
Acetylene cylinders used in the U.S.A. must conform to DOT 8 and 8 AL specifications.
Industrial Gases

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Specifications
SAFETY
Shock sensitivity Unstable over 15 PSIG
outside of cylinder
Explosive limits in oxygen (%) 3.0-93
Explosive limits in air (%) 2.5-80
Maximum allowable use pressure 15 PSIG
Tendency to backfire Considerable
Toxicity Low
Maximum Withdrawal Rate 1/7 of cylinder
contents per hour
COMBUSTION PROPERTIES
Neutral flame temperature (°F) 5720
Burning velocity in oxygen (ft. - sec.) 22.7
Primary flame (BTU / cu. ft.) 507
Secondary flame (BTU \ cu. ft.) 963
Total heat (BTU / cu. ft.) 1470
Total heating value (BTU / lb.) 21,600
Auto ignition temperature (°F) 763 - 824
VALVE OUTLET AND REGULATOR INLET CONNECTIONS
Standard connection CGA 510•
Alternate standard connection CGA 300•
Small valve series (10 cu. ft. cylinder) CGA 200•
Small valve series (40 cu. ft. cylinder) CGA 520•
*All values are approximations*
If more detailed specifications are required, contact your fuel gas supplier for the specific properties
of the fuel gas.
3.03 NATURAL GAS AND PROPANE
Natural gas is available throughout most areas of the U.S.A. and Canada. Physical properties vary
according to the geographical location. Methane is a colorless, odorless gas and is the principal
Industrial Gases

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component of natural gas, a mixture containing about 75% methane (CH4), 15% ethane (C2H6), and
5% other hydrocarbons, such as propane (C3H8) and butane (C4H10).
Propane (C3H8) is a non-renewable fossil fuel, like the natural gas and oil it is produced from. It is
known in popular terms as LPG (Liquefied Petroleum Gas). Similar to natural gas (methane), propane
is colorless and odorless. Although propane is nontoxic and odorless, foul-smelling mercaptan is
added to it to make gas leaks easy to detect.
Liquid Petroleum (LP) gases were discovered in 1912 when an American scientist,Dr.Walter Snelling,
discovered that these gases could be changed into liquids and stored under moderate pressure. The
LP-gas industry got its start shortly before World War I when a problem in the natural gas distribution
process popped up.A section of the pipeline in one natural gas field ran under a cold stream, and the
coldness led to a lot of liquids building up in the pipeline, sometimes to the point of blocking the entire
pipeline. Soon, engineers figured out a solution: facilities were built to cool and compress natural gas,
and to separate the gases that could be turned into liquids (including propane and butane).
Both natural gas and propane are used as industrial fuel gases for flame cutting, scarfing, heating,
flame hardening, stress relieving, brazing, and soldering.
Natural Gas and Propane Cylinders
Natural gas is transported by pipeline to most installations that use natural gas as a fuel gas. Natural
gas / Methane is authorized for shipment in a non-liquefied compressed gas cylinder under DOT
regulations.
Propane is available in on-site bulk storage tanks. It is also obtainable in 5 - 420 lb. cylinders.
Specifications
SAFETY
Natural Gas Propane
Shock sensitivity Stable Stable
Explosive limits in oxygen (%) 5.0-59 2.4-57
Explosive limits in air (%) 5.0-15 2.1-9.5
Maximum allowable use pressure Varies Cylinder (120 PSIG @ 70°F)
Tendency to backfire Slight Slight
Toxicity Low Low
Industrial Gases

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COMBUSTION PROPERTIES
Natural Gas Propane
Neutral flame temperature (°F) 4600 4579
Burning velocity in oxygen (ft. / sec.) 15.2 12.2
Primary flame (BTU / cu. ft.) 55 295
Secondary flame (BTU / cu. ft.) 995 2,268
Total heat (BTU / cu. ft.) 1,050 2,563
Total heating value [after vaporization] (BTU / lb.) 24,800 21,600
Auto ignition temperature (°F) 999 874
VALVE OUTLET AND REGULATOR INLET CONNECTION
Natural Gas By Pipeline
Methane CGA 350
Methane (5500 Max. PSIG) CGA 695
Propane CGA 510
*All values are approximations*
If more detailed specifications are required, contact your fuel gas supplier for the specific properties
of the fuel gas.
3.04 PROPYLENE AND PROPYLENE-BASED FUEL GASES
Propylene,also known by its IUPAC name propene,is an organic compound having the chemical formula
C3H6. It is the second simplest member of the alkene class of hydrocarbons, ethylene (ethene) being
the simplest.At room temperature and pressure, propylene is a gas. It is colorless, highly flammable,
and has an odor similar to garlic.
Propylene is found in coal gas and can be synthesized by cracking petroleum.
In newer designs, cracking takes place using a very active zeolite-based catalyst in a short-contact
time vertical or upward sloped pipe called the “riser”. Pre-heated feed is sprayed into the base of the
riser via feed nozzles where it contacts extremely hot fluidized catalyst at 1230 to 1400 °F (665 to
760 °C).The hot catalyst vaporizes the feed and catalyzes the cracking reactions that break down the
high molecular weight oil into lighter components, including LPG, gasoline, and diesel.The catalyst-
hydrocarbon mixture flows upward through the riser for just a few seconds and then the mixture is
separated via cyclones.The catalyst-free hydrocarbons are routed to a main fractionator for separation
into fuel gas, LPG, gasoline, light cycle oils used in diesel and jet fuel, and heavy fuel oil.
These gases are industrial fuel gases used for flame cutting, scarfing, heating, flame hardening,
stress relieving, brazing and soldering. They may also be used in certain applications for welding
cast iron and aluminum.
Propylene and Propylene-Based Fuel Gas Cylinders
Available in on-site bulk storage tanks. Also available in portable 30 lb. cylinders, and larger 60-70
lb. and 100-110 lb. cylinders.
Industrial Gases

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Specifications
SAFETY
Shock sensitivity Stable
Explosive limits in oxygen (%) 2.0-57
Explosive limits in air (%) 2.0-10
Maximum allowable use pressure Cylinder
(135 PSIG @ 70°F)
Tendency to backfire Moderate
Toxicity Low
COMBUSTION PROPERTIES
Neutral flame temperature (°F) 5240
Burning velocity in oxygen (ft. / sec.) 15.0
Primary flame (BTU / cu. ft.) 403
Secondary flame (BTU / cu. ft.) 1969
Total heat (BTU / cu. ft.) 2372
Total heating value [after vaporization] (BTU / lb.) 20,000
Auto ignition temperature (°F) 896
VALVE OUTLET AND REGULATOR INLET CONNECTION
CGA 510-.885” - 14 NGO-LH-INT (POL Outlet)
*All values are approximations*
If more detailed specifications are required, contact your fuel gas supplier for the specific properties
of the fuel gas.
3.05 FUEL GASES WITH NATURAL GAS OR PROPANE BASE
PLUS LIQUID HYDROCARBON ADDITIVES
These fuel gases consist of a natural gas or propane base which is enriched by a liquid hydrocarbon
additive. The liquid hydrocarbon additive is usually a low-boiling point, petroleum ether fraction of
n-pentane and / or iso-pentane. N-pentane has a heating value of approximately 4,249 BTU/cu.ft.
Pentane added to natural gas will show a greater percentage increase in heating value, as the BTU
heat value of natural gas is approximately 1050 BTU/cu.ft.This is not meant to imply that all the fuel
gases listed above use n-pentane or iso-pentane as the liquid hydrocarbon additive.
The physical and combustion properties of these fuel gases vary according to the percentage of
additives added to the base of natural gas or propane. Use the general specifications for natural gas
and propane as listed in the preceding pages as a guide only. Contact your fuel gas supplier for the
specific properties of the fuel gas if more detailed specifications are required.
Industrial Gases

SET-UP AND SAFE OPERATING PROCEDURES
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SECTION 4:
OXY-FUEL APPARATUS
Typical oxy-fuel workstations normally include the following items, each designed to perform a
specific function:
Oxygen and fuel supply• Cutting attachment and tip(s)•
Regulators• Welding nozzle(s)•
Hose• Heating nozzle(s)•
Torch Handle• Operator safety equipment•
4.01 OXYGEN AND FUEL SUPPLY
There are two types of workstations, portable and stationary. The portable station is usually supplied
by cylinders mounted on a cart.The stationary units are supplied by piping or manifold systems (see
Figure 3). The stationary system restricts the operator to the length of hose attached to the torch
handle.
CAUTION
Always be aware of the gases in use at the station. Use only the type of apparatus
designed for use with those gases.
4.02 REGULATORS
Oxygen and fuel pressure regulators are attached to the cylinders or piping outlets to reduce high
cylinder or supply pressures to suitable lower working pressures for oxy-fuel applications. The basic
external features of a regulator are as shown in Figure 3. Figure 3 also shows: CGA inlet connection
with filter, pressure adjusting screw, inlet gauge, delivery gauge, outlet connection, and relief valve
(where provided).
INLET GAUGEDELIVERY GAUGE DELIVERY GAUGE
RELIEF VALVE
OUTLET CONNECTION OUTLET CONNECTIONADJUSTING SCREW
CGA INLET CONNECTION
FILTER
(INSIDE
NIPPLE)
dwg-00378
Figure 3: Regulator Features
Oxy-fuel Apparatus

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WARNING
Always keep the regulator free of oil,grease and other flammable substances.Never use
oil or grease on the regulator, cylinder or manifold connection. Only use the regulator
for the gas and pressure for which it was designed. NEVER alter a regulator for use
with any other gas.
Inlet Connection
Regulators are attached to the cylinders or piping outlets by their“inlet connections.”Inlet connections
must have a clean filter. All inlet connections conform to specifications and standards set by the
Compressed Gas Association (CGA) and are marked with an identifying CGA number. CGA numbers
identify the cylinder valve and gas service for which that inlet connection is designed. Examples: CGA
510 has been designated for standard fuel gas cylinder connections such as acetylene, propylene/
propylene-based fuel gases, MAPP®and propane. CGA 540 connections are designated for oxygen
service only. Fuel gas inlet connections usually have left-hand threads. Those with left-hand threads
also have a “V” notch around the inlet nut to further designate the connection for fuel gas service.
All oxygen connections have right-hand threads.
Pressure Adjusting Screw
The regulator adjusting screw controls the delivery pressure of the gas to the hose. As previously
stated, the regulator’s function is to reduce high supply pressures to a suitable working pressure
range. When the adjusting screw is turned clockwise, the regulator allows gases to flow through the
regulator to the hoses and to the torch. The threaded adjusting screw applies mechanical force to a
spring and diaphragm which controls a pressure valve in the regulator. If the adjusting screw is turned
fully counterclockwise, tension on the spring is released and the regulator normally does not allow
the gas to flow. The regulator adjusting screw is not intended as a “shut off” mechanism.
Pressure Gauges
The inlet pressure gauge indicates the cylinder or supply pressure entering the regulator.The delivery
pressure gauge indicates the delivery pressure from the regulator to the hose.All gauges are precision
instruments; handle with care.
Outlet Connections
Gas hoses are attached to the regulator outlet connections. Most fuel gas regulators have left-hand
threaded outlet connections to mate with the left-hand hose connections and have a “V” notch around
the outlet connection to further designate the connection for fuel gas service.Oxygen regulators have
right-hand threaded outlet connections to mate with the right-hand hose connections.
Relief Valve (where provided)
Internal or external relief valves are designed to protect the low pressure side of the high pressure
regulator from damage due to an inadvertent high pressure surge.
WARNING
DO NOT tamper with the relief valve or remove it from the regulator. Relief valves are
not intended to protect downstream equipment from high pressures.
Oxy-fuel Apparatus