F-15-602

INSTRUCTIONS for January, 2000

Hy-Tec 21 HEAVY-DUTY
WELDING AND CUTTING OUTFITS
Standard, CGA 510 ...................................... P/N 22243P
Deluxe, CGA 510 ......................................... P/N 22244P

Standard Outfits Include:

315C Welding Torch .................................... P/N Q315 R-36-15-510 Acetylene Regulator ..................... P/N 21184
CA2460 Cutting Attachment ....................... P/N QCA2460 OR
1-101 Series Cutting Nozzle ....................... P/N Q-1-101-1 R-36-15-300 Acetylene Regulator .................... P/N 21314
W-Series Welding Head .............................. P/N QW-1 R-36-75-540 Oxygen Regulator ......................... P/N 21185
.............................. P/N QW-3

Deluxe Outfits Include in Addition to Standard Outfit Items:

1/4" X 25' B-B Hose ..................................... P/N 999468

Goggles ........................................................ P/N 17862
Friction Lighter ............................................ P/N 790F34

If you desire to extend the range of this outfit, other welding heads (thin gauge to 1" thick steel) and cutting nozzle (1/8" to 8" thick
steel) are available for attachment to the 315C welding torch and CA2460 cutting attachment (see tables).
Table 1 - Specifications
315C Welding Torch CA2460 Cutting Attachment (90 deg. head)
P/N Q315C P/N QCA2460
Welding Range ............................................ Thin Gauge to 1-in. Cutting Range using acetylene .................................. up to 8-in.
Length .................................................................................. 9-in. Length .......................................................................... 10-1/2-in.
Weight ............................................................................... 18 oz. Weight ............................................................................... 32 oz.
Torch-Hose Connections ... Oxy (9/16" - 18RH) "B" Connection Cutting Nozzles ...................................................... 1-101 Series
.... F.G. (9/16" - 18LH) "B" Connection

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe prac-
tices for oxy-fuel gas equipment, we urge you to read our booklet “Precautions and Safe Practices for Gas Welding, Cutting and
Heating” Form 2035. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install
or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these
instructions, contact your supplier for further information.

The welding torch handle, cutting attachment and regulators covered by these instructions are listed by Underwriter’s Laborato-
ries only when used in combination with welding tips, cutting nozzles and parts manufactured by ESAB Welding & Cutting
Products to the specifications on file with Underwriter’s Laboratories, Inc. and when they are used in the gas service for which
they are designed and listed. The use of other welding tips, nozzles and parts voids the manufacturer’s warranty.

For packing purposes, the pressure-adjusting screw of the regulator may be either turned in or packed separately. If installed in
regulator, back out screw (turn counterclockwise) until it turns freely. If packed separately, install the screw in the regulator cap
and turn it in (clockwise) only one or two turns.

Be sure this information reaches the operator.

You can get extra copies through your supplier.
 SAFETY PRECAUTIONS

3. Refer to ANSI/ASC Standard Z49.1 listed below for specific

ventilation recommendations.
These Safety Precautions are for your protection. They sum-
marize precautionary information from the references listed EQUIPMENT MAINTENANCE - Faulty or improp-
in Additional Safety Information section. Before performing any erly maintained equipment, such as torches, hoses
installation or operating procedures, be sure to read and fol- and regulators, can result in poor work, but even
low the safety precautions listed below as well as all other more important, it can cause injury or death
manuals, material safety data sheets, labels, etc. Failure to ob- through fires. Therefore:
serve Safety Precautions can result in injury or death. 1. Always have qualified personnel perform the installation,
troubleshooting, and maintenance work. Do not operate or
PROTECT YOURSELF AND OTHERS - Some repair any equipment unless you are qualified to do so.
welding, cutting and gouging processes are 2. Keep all oxy-fuel equipment free of grease or oil. Grease, oil,
noisy and require ear protection. Hot metal can and other similar combustible materials, when ignited, can burn
cause skin burns and heat rays may injure eyes. violently in the presence of oxygen.
Training in the proper use of the processes and 3. Do not abuse any equipment or accessories. Keep equipment
equipment is essential to prevent accidents. away from heat and wet conditions, oil or grease, corrosive
Also: atmospheres and inclement weather.
1. Always wear safety glasses with side shields in any work area, 4. Keep all safety devices in position and in good repair.
even if welding helmets, face shields, or goggles are also re- 5. Use equipment for its intended purpose. Do not modify it in
quired. any manner.
2. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt,
cuffless trousers, high-topped shoes, and a welding helmet or GAS CYLINDER HANDLING - Gas cylinders, if
cap for hair protection, to protect against hot sparks and hot mishandled, can rupture or explode violently.
metal. A flameproof apron may also be desirable as protection Sudden rupture of a cylinder, valve or relief de-
against radiated heat and sparks. vice can injure or kill you. Therefore:
3. Hot sparks or metal can lodge in rolled up sleeves, trousers
cuffs, or pockets. Sleeves and collars should be kept buttoned, 1. Use the proper gas for the process and use the proper pres-
and open pockets eliminated from the front of clothing. sure reducing regulator designed to operate from the com-
4. Protect other personnel from hot sparks with a suitable non- pressed gas cylinder. Do not use adaptors to mount the regu-
flammable partition or curtains. lator on the cylinder. Maintain hoses and fittings in good con-
5. Use goggles over safety glasses when chipping slag or grind- dition. Follow manufacturer’s operating instructions for mount-
ing. Chipped slag may be hot and can travel considerable dis- ing the regulator to the gas cylinder.
tances. Bystanders should also wear goggles over safety 2. Always secure cylinders in an upright position by chain or strap
glasses. to suitable hand trucks, benches, walls, post, or racks. Never
secure cylinders to work tables or fixtures where they may
become part of an electrical circuit.
FIRES AND EXPLOSIONS - Heat from a flame can 3. When not in use, keep cylinder valves closed. Have the valve
act as an ignition source. Hot slag or sparks can protection cap in place on top of the cylinder if no regulators is
also cause fires or explosions. Therefore: installed. Secure and move cylinders by using suitable hand
trucks. Avoid rough handling of cylinders.
1. Remove all combustible materials well away from the work 4. Locate cylinders away from heat, sparks, or flame of a weld-
area or completely cover the materials with a protective non- ing, cutting, or gouging operation. Never strike an arc on a
flammable covering. Combustible materials include wood, cylinder.
cloth, sawdust, liquid and gas fuels, solvents, paints and coat- 5. For additional information, refer to CGA Standard P-1, “Pre-
ings, paper, etc. cautions for Safe Handling of Compressed Gases in Cylin-
2. Hot sparks or hot metal can fall through cracks or crevices in ders:, which is available from the Compressed Gas Associa-
floors or wall openings and cause a hidden smoldering fire on tion, 1235 Jefferson Davis Highway, Arlington, VA 22202.
the floor below. Make certain that such openings are protected
from hot sparks and metal. ADDITIONAL SAFETY INFORMATION - For more in-
3. Do not weld, cut, or perform any other hot work on materials, formation on safe practices for oxy-fuel welding and
containers, or piping until it has been completely cleaned so cutting equipment, ask your distributor for a copy
that no substances on the material can produce flammable or of “Precautions and Safe Practices for Gas Weld-
toxic vapors. Do not do hot work on closed containers. They ing, Cutting, and Heating”, Form 2035. Gas appara-
may explode. tus safety guidelines are also available on video cas-
4. Have fire extinguishing equipment handy for instant use, such settes from your distributor.
as a garden hose, a pail of water or sand, or portable fire
extinguisher. Be sure you are trained in its use. The following publications, which are available from the American
5. After completing operations, inspect the work area to be sure Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are
that there are no hot sparks or hot metal which could cause a recommended to you:
later fire. Use fire watchers when necessary. 1. ANSI/AWS Z49.1 - “Safety in Welding and Cutting”.
6. For additional information, refer to NFPA Standard 51B, “Fire 2. AWS F4.1 - “Recommended Safe Practices for the Prepara-
Prevention in Use of Cutting and Welding Processes”, which tion for Welding and Cutting of Containers and Piping That
is available from the National Fire Protection Association, Have Held Hazardous Substances”/
Batterymarch Park, Quincy, MA 02269. 3. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

FUMES AND GASES - Fumes and gases, par-

ticularly in confined spaces, can cause dis- This symbol appearing in this manual means
comfort or injury. Do not breathe fumes or Attention! Be Alert! Your safety is involved.
gases from welding or cutting, Therefore:
Used to call attention to immediate hazards
1. Always provide adequate ventilation in the work area by natu- which, if not avoided, will result in immediate,
ral or mechanical ventilation means. Do not weld, cut, or gouge serious personal injury or loss of life.
on materials such as galvanized steel, stainless steel, copper,
zinc, lead, beryllium, or cadmium unless positive mechanical
ventilation is provided. Do not breathe fumes and gases from Used to call attention to potential hazards
these materials. which could result in personal injury or loss of
2. If you develop momentary eye, nose, or throat irritation while life.
operating, this is an indication that ventilation is not adequate.
Stop work at once and take necessary steps to improve venti- Used to call attention to hazards which could
lation in the work area. Do not continue to operate if physical result in minor personal injury.
discomfort persists.
2 SP-GA 7/97
OPERATING INSTRUCTIONS TESTING FOR LEAKS

CONNECTING Every welding and cutting outfit should be thoroughly

1. Attach regulators to the oxygen and fuel gas cylin- tested for leaks after it is first hooked up, and at regular
ders. Follow all instructions supplied with your regu- intervals thereafter. After all connections have been
lators. made, make sure both valves on the torch handle are
2. Attach oxygen and fuel gas hoses (see Note 1 in closed. Then turn in the regulator pressure-adjusting
Operating Data section on pg. 4 for recommended screws clockwise until the oxygen delivery-pressure
hose sizes) to the regulators and to the torch handle gauge registers 50 psi, the fuel gas delivery-pressure
after making sure all metal seating surfaces are gauge registers 10 psi. Using Leak Test Solution suit-
clean. Tighten all connection nuts with a wrench. able for oxygen service, such as P/N 998771 (8 oz. con-
3. Using Welding or Heating Head: Remove weld- tainer), check for leaks at the cylinder valves, the cylin-
ing head connection nut from torch handle. Insert der-to-regulator connections, the regulator-to-hose con-
welding head into handle using slight back and forth nections, and the hose-to-torch connections. If bubbling
twisting motion as you push. Slip connection nut over at any point indicates leakage, tighten the connection. If
the head and hand-tighten to handle. this does not stop the leakage, close the appropriate
cylinder valve, open the torch valve to remove all pres-
Using Cutting Attachment: Set the welding head sure from the line, and finally release the regulator pres-
connection nut aside and insert the cutting attach- sure-adjusting screw by turning it counterclockwise. Then
ment to the torch handle in the same manner as the break the leaky connections, wipe metal seating sur-
welding head. Remove nozzle nut and insert cutting faces with a clean, dry cloth, and examine them for nicks
nozzle into the cutting attachment head. Slip nut over and scratches. Remake the connection(s) and retest.
the nozzle and tighten with a wrench. Do not try to light the torch until you are satisfied that all
4. Check all valve packing nuts for tightness. connections are gas tight.

LIGHTING & FLAME ADJUSTMENT

Flashbacks can cause serious burns. CAUTION: Use friction lighter for lighting torch. Do NOT
Be sure gas flow is sufficient for head or nozzle size. use a match. Use of a match can seriously
Adjust regulators for proper psig pressures. burn your hand.
Adjust throttle valves properly.
Keep torch in good repair. Welding or Heating Head
DO NOT throttle back gases to use large head or nozzle 1. Open fuel gas valve about 1/2 turn and light the gas
on thin material. at the tip.
2. Slowly close the fuel gas valve until the yellow flame
ADJUSTING GAS PRESSURES just starts to throw off smoke.
3. Open oxygen valve slowly until you have a neutral
Fuel Gas: With oxygen valve closed, open the fuel gas flame.
valve on the torch handle about one turn. Turn in the 4. If harsher or softer flame is desired, readjust the
pressure adjusting screw on the fuel gas regulator until two valves.
its delivery-pressure gauge indicates the desired pres-
sure (refer to operating charts on page 5). Then imme- NOTE: When operating with a very soft flame, the weld-
diately close the torch fuel gas valve. ing head will tend to heat up and transfer some
of this heat back to the torch handle. This may
Oxygen, Using Welding or Heating Head: Open the create some discomfort to the operator.
torch oxygen valve at least 1-1/2 turns. Adjust oxygen
pressure at the regulator to the desired pressure (refer Cutting Attachment
to charts) and then close the torch oxygen valve. 1. Open the acetylene valve on the torch handle about
Oxygen, Using Cutting Attachment: Open the torch 1/2 turn, and light the gas at the nozzle.
oxygen valve WIDE and leave the preheat oxygen valve 2. Slowly close the acetylene throttle valve until the
on the cutting attachment closed. Depress the cutting yellow flame just starts to throw off black smoke.
oxygen valve lever on the cutting attachment. Adjust the 3. Slowly open preheat oxygen valve on cutting attach-
oxygen pressure at the regulator to the desired pres- ment until neutral flames are obtained.
sure (refer to chart). Shut off the oxygen flow by releas- 4. Finally, open the cutting oxygen valve by depress-
ing the cutting oxygen valve lever only. ing lever and readjust the neutral flames by turning
preheat oxygen valve.

3
The flame now has the proper strength for any cutting cur repeatedly, shut off the torch. Check the ‘O’-ring seals
job. With this flame, acetylene is being consumed eco- between the welding head or cutting attachment and the
nomically and the cutting attachment will be operating handle, and the nozzle seats (if cutting). Readjust oper-
at best resistance to flashback. If greater preheat flame ating pressure and relight.
temperature is desired for faster starts or piercing, open
the cutting oxygen valve and adjust the preheat oxygen Flashback: Under certain circumstances, the flame may
valve until the flame inner cones shorten about 10 per- not ‘pop’ out (backfire) but instead burn back inside the
cent and become sharply pointed. torch with shrill hissing or squeal. This is called a ‘flash-
back’. A flashback should never occur if (1) the equip-
SHUTTING OFF ment is in good condition; (2) preheat ports on cutting
nozzles or welding tips are cleaned frequently; (3) oper-
Close the fuel gas valve first, then the oxygen valve ating pressures are correct; and (4) throttle valves are
whether you are using a welding head or cutting attach- adjusted properly. Should a flashback occur, IMMEDI-
ment. However, if the cutting attachment is to be relighted ATELY shut off the torch. Allow it to cool off for at least a
within a half-hour, you may close the preheat oxygen minute. Then check your nozzle or tip, gas pressures,
valve on the attachment instead of the oxygen valve on readjust regulators if necessary, and relight the torch. If
the torch handle. flashback recurs, send the torch handle and welding
head or cutting attachment to your distributor for repair.
If operations are to be stopped for a half-hour or more,
you should release all pressure from regulators. To do IMPORTANT OPERATING NOTES
this, first close both cylinder valves. Then open the torch
valves. Finally, back out the regulator pressure-adjust- 1. Pressures given in the charts are measured at the
ing screws until they turn freely. regulator using 25-ft. long hoses (1/4-in. I.D. up
through size No. 4 welding/heating head or for cut-
OPERATING PRECAUTIONS ting up to 3-in. thick steel; 3/8-in. I.D. for larger heads
or cutting nozzles). If longer hoses re required, only
Flow: There must be proper flow of gases for safe op- 3/8-in. I.D. hoses should be used and pressure drop
eration and full performance. This requires the following between regulator and torch should be considered.
three conditions: (1) the regulators that determine the Use test gauge adaptors to check for proper pres-
inlet pressure to the hoses must be set to the correct sure at torch if using long hose length, or if there are
pressure: (2) the hoses and their connectors must have doubts about the adequacy of gas flows. Do NOT
adequate capacity for the job (hoses that are too long, use hose line check valves when operating No. 5
too small or have connectors with small passageways and larger heads.
can cause problems); and (3) the throttle valves on the 2. Correct pressure and flow must be maintained for
torch must be adjusted with the procedure shown in these proper operation of a welding or heating head. If a
instructions. tip is “starved” due to insufficient flow of fuel gas,
the tip may overheat and cause backfire or flash-
Note: Items (1) and (2) can be checked by measuring back.
the gas pressures at the torch. Gauge adaptors
are available for this purpose. An acetylene cylinder has a limited capacity for de-
livering fuel to the tip; therefore, it is extremely im-
Backfire: Improper operation of the torch or cutting at- portant to manifold 2 or more cylinders when oper-
tachment may cause the flame to go out with a loud ating larger heads to assure adequate supply of fuel
‘pop’. (If you are welding, the flame will often reignite gas to the tip. The rate of withdrawal depends on
instantly). Such a backfire may be caused by contact of type of fuel gas cylinder size, the contents remain-
tip or nozzle with the work, by spatter from the work, by ing, and the outside temperature. Check with your
the use of incorrect gas pressure, or by leakage at the fuel gas supplier for recommended withdrawal rate
cutting nozzle seats due to dirt or nicks on seats or to a information.
loose nozzle nut. After a backfire, you can normally re- 3. The tables show average values based on typical
light the flames immediately. However, if backfires oc- conditions. The type and quality of steel, its surface
condition, and purity of oxygen, etc., will always have
a bearing on the end results.

4
 Tip

Mixer

Part # QW Complete Assembly

Tip Selection & Recommended Working Pressure of Regulators

Oxygen Pressure Acetylene Pressure

Complete Assembly Tip Only Mixer Only Metal Thickness Tip Size P.S.I.G. P.S.I.G.
Part Number Part Number Part Number Min. Max. Min. Max.
QW-000 QET-000 QUM-2 1/64" - 1/32" 000 3 5 3 5
QW-00 QET-00 QUM-2 1/32" - 3/64" 00 3 5 3 5
QW-0 QET-0 QUM-2 3/64" - 5/64" 0 3 5 3 5
QW-1* QET-1 QUM-2 5/64" - 3/32" 1 3 5 3 5
QW-2 QET-2 QUM-2 3/32" - 1/8" 2 3 5 3 5
QW-3* QET-3 QUM-4 1/8" - 3/16" 3 4 7 3 6
QW-4 QET-4 QUM-4 3/16" - 1/4" 4 5 10 4 7
QW-5 QET-5 QUM-6 1/4" - 1/2" 5 6 12 5 8
QW-6 QET-6 QUM-6 1/2" - 3/4" 6 7 14 6 9
*Supplied with Hy-Tec 21 Heavy-Duty Outfit.

5
 OXY-ACETYLENE CUTTING TIP CHART

Oxygen Acetylene
Cutter Tip Metal Thickness Nozzle Size Pressure (P.S.I.G.) Pressure (P.S.I.G.)
Part Number Min. Max. Min. Max.
Q1-101-000 1/8" 000 20 25 3 5
Q1-101-00 1/4" 00 20 25 3 5
Q1-101-0 1/2" 0 30 35 3 5
Q1-101-1* 3/4" 1 30 35 3 5
Q1-101-2 1-1/2" 2 35 45 3 7
Q1-101-3 2-1/2" 3 40 50 4 10
Q1-101-4 3 4 40 50 5 10
Q1-101-5 5 5 45 55 5 13
Q1-101-6 8 6 45 55 7 14
*Supplied with Hy-Tec 21 Heavy-Duty Outfit.

OXY-ACETYLENE MULTI-FLAME HEATING NOZZLES

Complete Acetylene Oxygen Acetylene Cubic Oxygen Cubic

Assembly Tip Size Pressure Range Pressure Range Feet Per Hour Feet Per Hour
Part Number P.S.I.G. P.S.I.G. Min. Max. Min. Max.
QMFA-6 6 8 - 11 10 - 14 14 40 15 44
QMFA-8 8 10 - 14 18 - 28 30 80 33 88

6
MAINTENANCE

For all repairs, send the apparatus to ESAB Remanufacturing Center, 411 S. Ebenezer Road, Florence, SC 29501.
Improperly repaired apparatus is hazardous.

Part # Q1-101

CA2460 Welding Torch 90° Head - QCA2460

Replacement - Welding Torch and Cutting Attachment Assemblies

Part # QMFA

315C Cutting Attachment 90° Head - Q315C

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F-15-602 1/2000 Printed in U.S.A.