The symbols shown below are used throughout this manual D Remove any combustibles, such as a butane lighter or matches,.
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TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS – READ BEFORE USING1 .1-1.Symbol Usage1 ..1-2.Oxy-Fuel Welding, Cutting, Brazing, Heating Hazards1 .1-3.California Proposition 65 Warnings6 1-4.Principal Safety Standards6 .SECTION 2 INTRODUCTION7 .SECTION 3 HAZARDOUS EVENTS7 .SECTION 4 HAZARDS OF RECOMPRESSING PURE OXYGEN7 .SECTION 5 THE TORCH SYSTEM8 ..5-1.Torch8 .5-2.Gases8 .5-3.Tips8 5-4.Repairs/Replacement Of Hose8 SECTION 6 FREQUENTLY ASKED QUESTIONS9 ..SECTION 7 USING TORCH WITH DISPOSABLE-TYPE CYLINDERS10 .7-1.Disposable Compressed Gas Cylinders11 .7-2.Installing Regulators On Cylinders Models 239-499B And 239-500B11 ..7-3.Installing Hoses11 7-4.Activating The System12 7-5.Purging The System12 ..7-6.Testing The Equipment For Leaks12 7-7.Selecting And Installing A Tip12 .7-8.Lighting Procedures (When Using Disposable Cylinders)12 .7-9.Extinguishing The Torch Flame13 ..7-10.Shutting Down The System13 ..7-11.Bleeding The System13 .SECTION 8 USING TORCH WITH HIGH PRESSURE CYLINDERS13 .8-1.Industrial-Type Cylinder Information13 .8-2.Installing Regulators14 ..8-3.Installing Hoses14 8-4.Activating The Regulators14 .8-5.Adjusting Regulator Pressures And Purging The Hoses15 ..8-6.Testing The Equipment For Leaks15 8-7.Selecting And Installing A Tip16 .8-8.Lighting /Adjusting Torch When Using Acetylene Or Hydrogen Fuel 16 8-9.Lighting And Adjusting Torch When Using Alternate Fuel Gases17 .8-10.Extinguishing The Torch Flame And Securing Equipment17 .8-11.Shutting Down The System17 ..8-12.Bleeding The System Of Gases17 .SECTION 9 HOSE REPLACEMENT18 9-1.Removing Old Hose18 9-2.Installing New Hose18 SECTION 10 REGULATORS19 SECTION 11 TECHNICAL DATA20 11-1.Tip Specifications20 ..11-2.Fuel Gas And Flame Characteristics21 11-3.Flame And Heat Placement BTU Output Per Cubic Ft Of Fuel Burned 21 .11-4.Cylinder Valve Identification For Regulator Selection21 ..SECTION 12 ACCESSORIES22 WARRANTY
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OM-263357 Page 1SECTION 1 SAFETY PRECAUTIONS -READ BEFORE USINGOXY FUEL 2015-09Protect yourself and others from injury Š read, follow, and save these important safety precautions and operating in- structions.1-1.Symbol Usage DANGER! Indicates a hazardous situation which, if notavoided, will result in death or serious injury. The possiblehazards are shown in the adjoining symbols or explainedin the text.Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible haz- ards 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! W atch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoidthe hazards. 1-2.Welding, Cutting, Brazing, Heating Hazards The symbols shown below 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 Safety Standards listed in Section 1-4. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, andrepair this equipment. During operation, keep everybody, especially children, away. Do not use this equipment unless you are trained in its properuse or are under competent supervision. Follow the proced- ures described in this booklet every time you use the equip-ment. Failure to follow these instructions can cause fire, ex- plosion, 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) reg-ulations. Contact your gas supplier for more information on the proper use of compressed gases. In this document, the phrase ﬁwelding and cuttingﬂ also refers to oth- er oxy-fuel operations like brazing and heating.
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OM-263357 Page 2READ INSTRUCTIONS. Read and follow all labels and the Owner™s Manual carefully be- fore installing, operating, or servicing equipment. Read the safetyinformation at the beginning of the manual and in each section.Use only genuine replacement parts from the manufacturer. Perform installation, maintenance, and service according to the Owner™s Manuals, industry standards, and national, state, and local codes. HOT PARTS can burn. Do not touch hot parts bare handed.Allow cooling period before working on equipment.To handle hot parts, use proper tools and/or wear heavy, insu- lated 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. Keep your head out of the fumes. Do not breathe the fumes.If inside, ventilate the area and/or use local forced ventilation at the flame to remove welding and cutting fumes and gases. Some gases (natural gas a nd acetylene) are lighter than air and will col-lect in high areas. Other gases (propane and butane) are heavier than air and will collect in low areas. Heavier-than-air gases aremore difficult to diffuse and are more likely to accumulate. The recommended way to determine adequate ventilation is to sam- ple for the composition and quality of fumes and gases which per-sonnel are exposed. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Safety Data Sheets (SDSs) and the manufacturer™s instructions for adhesives, coatings, cleaners, consumables, coatings, cleaners, degreasers, fluxes, and met-als.Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch-person nearby. Welding and cutting fumes and gases can dis- place air and lower the oxygen level, causing injury or death. Besure the breathing air is safe. T est atmospheres in confined areasfor explosive and toxic gases before using oxy-fuel equipment. Do not weld or cut in locations near degreasing, cleaning, or spraying operations. The heat from welding or cutting flame canreact with vapors to form highly toxic and irritating gases. Do not weld or cut on coated metals, such as galvanized, lead, or cadmium-plated steel unless the coating is removed from the af-fected area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded or cut. Do not weld or cut on sealed air conditioning or refrigeration sys- tems unless all refrigerants have been removed from the system.
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OM-263357 Page 3Shut off compressed gas supply when not in use. Always ventilate confined spaces or use approved air-suppliedrespirator. BUILDUP OF GAS can injure or kill.Light rays from the welding and cutting process produce intense visibleand invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. 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). Wear welding goggles, or wear welding helmet/welding face- shield over approved goggles/safety glasses with side shields. Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the welding or cutting.Wear body protection made from durable, flame resistant mate-rial (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.LIGHT RAYS can burn eyes and skin. 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. WELDING AND CUTTING can causefire or explosion.Do not use this welding and cutting equipment with gases and pressures other than those for which it is intended. Oxygen is notflammable; however, the presence of pure oxygen will drastically increase the speed and force with which burning takes place. Oxy-gen must never be allowed to contact grease, oil, or other petro- leum-based substances; therefore, be sure there is no oil or greaseon the regulator, cylinder, valves, or equipment. Do not use petro-leum-based pipe sealants. 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 oper- ate 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 toread, regulator is clean and free of oil or dirt, and fittings are prop-erly sized for the cylinder. Make sure hoses are clean (no grease oroil) and ferrules are properly installed so the fitting does not slip in-side the hose. Be sure all connections are tight.
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OM-263357 Page 4It is recommended that a reverse-flow check valve or a flashback ar- restor be installed between the torch handle and the regulator. Check valves do not prevent the propagation of a flame upstream (flash- back) 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 instead of a check valve. Miller flashback arrestors have a reverse flow check valve and prevent the propagation of a flame up- stream. If a flashback arrestor is installed, a check valve is not neces- sary. 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.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 toprotect 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 per- son.Do not open a cylinder valve quickly or the regulator can be dam- aged and cause a fire. Do not open acetylene cylinder valve more than 3/4 turn. (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 ﬁcrackﬂ 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 gasin a well-ventilated area and away from flame or sparks. Keep torch flame or sparks away from cylinder, regulator , and gashose.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 accept- able to use acetylene regulators that indicate a static pressure up to 22 psi (151 kPa).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. Remove all flammables within 35 ft (10.7 m) of the welding or cut-ting operation. If this is not possible, tightly cover them with ap- proved 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 open-ings 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 weld or cut on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they areproperly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards). Do not weld or cut where the atmosphere can contain flammable dust, gas, or liquid vapors (such as gasoline).
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OM-263357 Page 61-3.California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-4.Principal Safety Standards Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).Safe Practices for the Preparation of Containers and Piping for W eldingand Cutting, American W elding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184,website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Com- bustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184,website: www.global.ihs.com). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Acetylene, CGA Pamphlet G-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, from American National Standards Institute,25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- site: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.) OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, andPart 1926, Subpart J, from U.S. Government Printing Office, Superinten-dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Of ficesŠphonefor Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation , The Na-tional Institute for Occupational Safety and Health (NIOSH), 1600 CliftonRd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). Recommended Practices for Safe Oxyfuel Gas Cutting T orch OperationC4.2/C4.2M, and Recommended Practices for Safe Oxyfuel Gas Heat-ing Torch Operation C4.3/C4.3M from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
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OM-263357 Page 7SECTION 2 INTRODUCTIONInspect all equipment before use. Do not use damaged, defect-ive, or improperly adjusted welding and cutting equipment. Make sure levers and valves work properly, threads on equip- ment are clean (no grease or oil) and not deformed, gauges areintact 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 in-stalled so the fitting does not slip inside the hose. Be sure allconnections are tight and there are no leaks in the system.This booklet offers basic information regarding the Little Torch. Given reasonable care, the torch will provide trouble-free use for many years.SECTION 3 HAZARDOUS EVENTSThe 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 return of the flame into the torch, usually accompanied bya popping sound. The flame may be extinguished or it may re-appear at the tip end. Sustained Backfire: The return of the flame into the torch that contin-ues to burn inside the torch with a hissing or squealing sound. Flashback: The return of a flame into and through the torch or into the hose. In some instances it can reach the regulator and even enter the cylin- der. This is generally caused by the mixing of the oxygen and fuel gas in the system. This is a very d angerous situation that can cause an explosion any- where in the system. This is why purging is so important (Section 7-5 or 8-5). SECTION 4 ASSOCIATED HAZARDS OF RECOMPRESSING PURE OXYGENOpen oxygen cylinder valves slowly. Opening an oxygen cylin- der valve quickly can cause a fire or explosion. Be sure regula- tor adjusting handle is in the full out (off) position before open- ing an oxygen cylinder valve. Recompressing high pressure oxygen in a low pressure cavity may cre-ate 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. Oxygen: High purity oxygen accelerates the rate of combustion, in-creases heat output, and lowers the combustible point at which variousmaterials will burn.
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OM-263357 Page 8Fuel: The fuel for combustion may be the regulator itself if enough heat isproduced to reach the kindling temperature of the regulator™s compo- nents.Kindling Temperatures: Enough heat may be generated to ignite theregulator components by the friction created when recompressing high-pressure oxygen. This heat is known as the heat of recompression.If an internal fire or flashback occurs (indicated by a whistling sound or inverted flame), do the following: Turn off the torch oxygen valve immediately. Turn off the torch fuel valve. Turn off the oxygen cylinder valve. Turn off the fuel gas cylinder valve. Do not relight the torch until the equipment has cooled to the touch and the flashback cause has been determined and corrected. SECTION 5 THE TORCH SYSTEM 5-1.Torch The torch is designed to meet the requirements of industry for a small, lightweight torch to fusion weld, braze, heat, and solder materials rang-ing from 3/16 in. (5 mm) metal to ultra-fine wires. The six tips available provide a wide range of flame sizes and the versatility to perform manydifferent tasks. Lightweight construction and highly flexible hose providepinpoint welding with maximum control.5-2.Gases The torch uses oxygen and these commonly available pressurized fuel gases: acetylene, hydrogen, propane, propylene, or natural gas. The smallest tip (size 2) can only be used satisfactorily with acetylene and hydrogen fuel gases. NOTICE When using natural gas, a minimum of 1 psig (6.9 kPa) is re-quired at the torch. Higher pressures are necessary for use with meltingtips.5-3.Tips There are six tips available for the torch. Because of their extraordinarilysmall orifices, tip sizes 2 and 3 are fitted with a synthetic sapphire to en-sure accurate gas flow. There are also two different heating tips avail- able, one tip is for use with acetylene or hydrogen and another tip is de- signed for propane or natural gas. Refer to the pressure recommendation chart provided in this booklet for the tips being used.5-4.Repairs/Replacement Of Hose Replace hoses at the first sign of any defects, flaws, or dam-age. The hoses should otherwise be replaced every four years.Inspect hoses for damage or leaks before each operation. Donot allow hoses to come in contact with hot metal, molten sol- der, or corrosive chemicals. Do not expose hoses to fluxing agents as these agents will deteriorate the hose materials andcause them to leak. Use an approved oil-free leak detection fluid to locate possible leaks.
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OM-263357 Page 9Use only industrial grade hose. Grade T hose is acceptable for all fuel gases. Grade R hose is for acetylene only. The torch hose is of a special material designed to be compatible with thevarious fuel gases. The maximum length of hose used should not exceed 12 ft (3.7 m). The hose may be attached to standard welding gas hoses 3/16 in. or larger diameter with special brass fittings if the gas cylindersmust be located a further distance from the torch. The brass B-type fit- tings for connecting the hoses can be purchased from most welding equipment dealers. For your protection, use only genuine Smith Equipment hose and re- placement parts. Smith Equipment replacement hoses come with stepŒbyŒstep replacement instructions and a tool for securing the brassferrules over the hose ends. Repairs and replacement parts are available through your authorized Smith Equipment distributor. Find a dealer at www.smithequipment.com.SECTION 6 FREQUENTLY ASKED QUESTIONS How do I replace the torch hose?StepŒbyŒstep instructions, a ferrule (brass hose retainer band), and fer-ule replacement tool accompany all replacement hose assemblies. What are the part numbers for replacement hose assemblies?Oxygen1325418Fuel Gas 1325438Hose Pair1325448Why is it hard to light size 1 and size 2 tips or keep them lit?This condition is typically due to excessive gas pressures. A maximum ofjust 2 psig (13. 7 kPa) outlet pressure is recommended for both gases and the use of an open flame makes lighting the tiny flames much easier. Does the torch require adaptors to fit cylinder regulators? For most regulators the answer is no. The hose assemblies have stan-dard size B, 9/16 in. welding hose-type connections and will attach to most industrial welding gas regulators. Can the orifices in the torch tips be cleaned? If the orifices are obstructed by flux, the tips can often be cleaned by boil- ing them in water for about 10 minutes. Other methods used to clean dirty tips involve the use of a jeweler™s type steam cleaner or an ultrasonic cleaner. What fuel gases will work with the torch?The torch may be operated with most commercially used welding gasesincluding acetylene, propane, hydrogen, propylene, and butane. It mayalso be used with city gas (natural gas) at a minimum pressure of 1 psig(6.9 kPa) at the torch. NOTICE Most city gas lines only produce 1/4Œ1/2 psig (1.7Œ3.4 kPa).What fuel gas should I use with the torch?Most operators use either acetylene or propane. However both gases of-fer specific advantages and disadvantages. Acetylene produces a very
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