ESAB W-24R Welding Torch Troubleshooting instruction

Brand: ESAB

Model: W-24R Welding Torch

Type: Troubleshooting instruction

INSTRUCTIONS for

F-3119-S

June 2009

W-24R WELDING TORCH

P/N 10A48

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera-

tion and safe practices for oxy-fuel gas equipment, we urge you to read ESAB booklet “Precautions and Safe

Practices for Gas Welding, Cutting and Heating,” Form 2035. Do NOT permit untrained persons to operate this

equipment. DO NOT attempt to operate this equipment until you have read and fully understand these instruc-

tions. If you do not fully understand these instructions, contact your supplier for further information.

The welding torches covered by these instructions are listed by Third Party Listed only when used in combina-

tion with tips and parts manufactured to ESAB Welding & Cutting Products to the specications on le with

Third Party Listed, and when they are used in the gas service for which they are designed and listed. The use

of other parts that cause damage or failure to the equipment will voids the manufacturer’s warranty.

SPECIFICATIONS

Welding Range ............................ Thin gauge to over 1-in.

Heating Range.............................1 to 250 cfh acetylene

Length................................................................... 8-1/4-in.

Weight .........................................................................1 lb.

Torch-Hose Connections ........ ORS Oxy - 41/64—18 fem.

ORS F.G. - 41/64—18 LH fem.

 Equivalent to approximately 1400 to 37,000 Btu/hr.

Acetylene and other fuel gases may be used.

OPERATING INSTRUCTIONS

CONNECTING

1. Attach regulators to the oxygen and acetylene

cylinders. Follow all instructions supplied with your

regulators.

2. Attach oxygen and acetylene hoses to the regu-

lators and to the torch handle, after making sure

all metal seating surfaces are clean. Tighten all

connection nuts with a wrench.

3. Attach welding or heating head to the torch handle.

Tighten the connection nut with a wrench, but use

only slight force, since the threads have a low pitch

and excessive force may distort them.

4. Check throttle valve packing nuts for tightness.

Flashbacks can cause serious burns.

Be sure gas ow is sufcient for head or nozzle

size. Adjust regulators for proper psig pressures.

Adjust throttle valves properly. Keep torch in good

repair. DO NOT throttle back gases to use large

head or nozzle on thin material.

ADJUSTING GAS PRESSURES

Medium-Pressure Fuel Gas: Open the torch fuel gas

valve one-half turn. Turn in the pressure-adjusting

screw on the fuel gas regulator until delivery-pressure

gauge indicates a pressure of 5 psi. IMMEDIATELY

close the acetylene valve.

Low-Pressure Acetylene: Open the shut-off valve

at the station.

Oxygen: Open the torch oxygen valve at least one

full turn. Turn in the pressure-adjusting screw on the

oxygen regulator until its delivery-pressure gauge

indicates the desired pressure. (See table on pg. 4.)

Close the oxygen valve.

Be sure this information reaches the operator.

You can get extra copies through your supplier.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

SAVE THESE INSTRUCTIONS!

IMPORTANT SAFEGUARDS

When using Oxy-Fuel Gas Torches, basic safety precautions should always be followed:

Never use Acetylene gas at a pressure over 15 psig.a.

Never use damaged equipment.b.

Never use oil or grease on or around Oxygen equipment.c.

Never use Oxygen or fuel gas to blow dirt or dust o clothing or equipment.d.

Never light a torch with matches or a lighter. Always use a striker.e.

Always wear the proper welding goggles, gloves and clothing when operating Oxy-Acetylene equipment. f.

Pants should not have cus.

Do not carry lighters, matches or other ammable objects in pockets when welding or cutting.g.

Always be aware of others around you when using a torch.h.

Be careful not to let welding hoses come into contact with torch ame or sparks from cutting.i.

SAVE THESE INSTRUCTIONS.j.

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

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 the manufacturer or a ser-

vice facility designated by the manufacturer.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the prin-

ciples of operation and safe practices for gas welding and cutting equipment, we urge you to read

our booklet, “Precautions and Safe Practices for Gas Welding, Cutting, and Heating,” Form F- 2 0 3 5 .

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. Be

sure to read the Safety Precautions before installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

READ AND UNDERSTAND INSTRUCTION MANUAL BEFORE INSTALLING

OR OPERATING. PROTECT YOURSELF AND OTHERS!

�





























 





 









 





 



 













 









 







 









 





 





 















 











 









 



4. WARNING: This product, when used for welding or

cutting, 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 �25249.5 et seq.)











 





 





 





 

 











 











 







 







 





 



























 

 





 

Means immediate hazards which, if not avoided,

will result in immediate, serious personal in-

jury or loss of life.

Means potential hazards which could result in

personal injury or loss of life.

Means hazards which could result in minor

personal injury.

MEANING OF SYMBOLS - As used throughout

this manual: Means Attention! Be Alert! Your

safety is involved.



SAFETY PRECAUTIONS

FG-2 (104 lb. cyl.) Propane (100 lb. cyl.)

Head Min. No. of Min. No. Of

Size Flowrate Cyl. Req’d* Flowrate Cyl. Req’d**

70 43 1 40 1

100 62 1 58 1

150 93 1 86 2

200 124 2 116 2

250 - - 144 3

* Based on max. continuous withdrawal rate of 110 cfh for 104 lb. cylin-

der, 1/2 full @ 70° F.

** Based on max. continuous withdrawal rate of 65 cfh for 100 lb. cylinder,

1/2 full @ 70° F.

Withdrawal rate will increase with wind velocity and intermittent usage;

reduce with lower temperature.

LIGHTING AND FLAME ADJUSTMENT

1. Open the torch oxygen valve one-quarter of a turn.

2. Open the torch fuel gas valve one-half turn (two full turns

if low-pressure acetylene is being used) and light the gas

at the tip with a friction lighter. DO NOT USE A MATCH.

Use of a match can seriously burn your hand.

3. Open the oxygen valve wide and adjust the fuel gas

valve to secure the desired ame. If a softer ame is

desired, reduce the oxygen ow by throttling the oxygen

valve and then readjust the fuel gas valve.

NOTE: Whenoperatingwithaverysoftame,thewelding

headwilltendtoheatupandtransfersomeofthis

heat to the torch handle. This may create some

discomforttotheoperator.

SHUTTING OFF

Close the fuel gas valve rst, then the oxygen valve.

If operations are to be stopped for a half-hour or more, all

pressure should be released from the torch, hoses, and

regulators by doing the following:

1. Close each cylinder or station valve.

2. Open torch valves.

3. After relieving the gases, back out the pressure-adjusting

screw of each regulator and close the torch valves.

IMPORTANT OPERATING NOTES

1. Do not attempt to operate head size 100 or larger from

a low-pressure acetylene supply.

2. Head size number on each welding and heating head

indicates the rated acetylene ow capacity in cubic feet/

hour (cfh). For example, No. 55A requires about 55 cfh

of acetylene at normal operating pressure. However, on

heating heads designed for other fuel gases, the size

indicates the approximate equivalent heating capacity

in terms of acetylene ow. For example, No. 100A and

No. 100FG provide the same average heating output

(147,000 Btu/hr) but No. 100FG head really requires

about 62 cfh of FG-2, 57 cfh of propane, or 147 cfh of

natural gas.

For consumption purposes, the following are the oxygen/

fuel gas ratios normally required for welding and heat-

ing:

1.1 to 1.5 cfh oxygen/1.0 cfh acetylene

3.2 to 3.6 cfh oxygen/1.0 cfh FG-2

3.5 to 4.5 cfh oxygen/1.0 cfh propane

1.7 to 2.0 cfh oxygen/1.0 cfh natural gas

PRECAUTIONS - NO. 55 and LARGER HEADS

Large welding and heating heads (No. 55 and above) require

high ow of oxygen and fuel gas for proper operation. Failure

to follow the following precautions can result in serious

overheating, ashback, and possible operator injury.

1. Read and understand the operating instructions packed

with your torch as well as these precautions before light-

ing up the welding or heating head.

2. Always operate with oxygen and fuel gas pressures

given in the tables.

3. Do NOT use hose line reverse ow check valves when

using No. 100 or larger welding or heating head.

4. Use 3/8-in. I.D. hoses when using No. 5 or larger welding

or heating head.

5. Do NOT use whip hose, hose splices, nor hose nipples

smaller than 1/4-in. I.D. (“B”-size).

6. If using hose lengths greater than 25-ft., or if there is

any doubt about the adequacy of gas ows, use an

oxygen test gauge adaptor (P/N 07X17) and either the

acetylene (P/N 262510) or fuel gas (P/N 639422) test

gauge adaptor while the torch is operating to make sure

that the recommended operating pressures are available

at the torch inlet.

7. Manifold two or more fuel gas cylinders to assure ad-

equate supply of fuel gas. The tables show the number

of commonly used cylinders recommended for manifold-

ing when using larger heads. If using other cylinders

or gases, check with your fuel gas supplier for recom-

mended withdrawal rate information.

8. In the event of a ashback, immediately close both oxy-

gen and fuel gas valves on the torch (preferably oxygen

valve rst). For greater protection, install 1/4-turn quick

shutoff valve (P/N 999306) on the torch oxygen hose

connection.

Acetylene

Head Flowrate, Min. No. of Cylinders Requires*

Size cfh WK Cyl (300 cf) WTL Cyl. (390 cf)

55 55 2 1

70 70 2 2

100 100 3 2

150 150 4 3

200 200 5 4

250 250 6 5

* Based on that max. hourly owrate should not exceed

1/7 of cylinder capacity at 70° F. Example: 1/7 (300 cf

WK cyl.) = 43 cfh max.

9. If the inner cone of the ame appears too short (less

than 1/4-in.), you are lacking fuel gas and the head will

tend to overheat. Recheck the above precaution with

your set up.

10. Do not bring the head too close to the work. Maintain a

distance of at least 1/4-in. between tip and work.

RECOMMENDED HOSE SIZES

Oxygen, Acetylene (medium-pressure) and Natural Gas

(at pipeline pressures over 5 psig): With head sizes 4-30,

1/4-in. or 3/8-in. I.D. With head sizes 55 and larger, 3/8-in

I.D. Acetylene (low-pressure) and Natural Gas (at pipeline

pressure below 5 psi): With head sizes 4-70, 3/8-in. I.D.

hose. Head sizes 100-250, 1/2-in. I.D. hose. Do not use

over 25 feet of hose.

TESTING FOR LEAKS

Every welding and cutting outt should be thoroughly tested

for leads after it is rst hooked up, and at regular intervals

thereafter. After all connections have been made, make

sure both valves on the torch handle are closed. Then turn

in the regulator pressure-adjusting screw until the oxygen

deliver-pressure gauge registers 50 psi, the acetylene

delivery-pressure gauge registers 10 psi. Using Leak Test

Solution suitable for oxygen service, such as P/N 998771

(8 oz. container), check for leaks at the cylinder valves. The

cylinder-to-regulator connections, the regulator-to-hose con-

nections, and the hose-to-torch connections. If bubbling at

any point indicates leakage, tighten the connection. If this

does not stop the leakage, close appropriate cylinder valve,

open the torch valve to remove all pressure from the line,

and nally release the regulator pressure-adjusting screw

by turning it counterclockwise. Then break the leaky con-

nection, wipe metal seating surfaces with a clean, dry cloth,

and examine them for nicks and scratches. Remake the

connection(s) and retest. Do not try to light the torch until

you are satised that all connections are gas-tight.

After lighting the torch, and adjusting the ames, use leak

test solution to check for leakage at all torch valves, and at

the connection between the torch handle and the welding

head or cutting attachment.

Table 1 - Single-Flame Acetylene Welding Heads

Replacement Parts Cleaning Drill

Welding Head Metal Oxy. (Size No.) TipExtension

Assembly Thickness Press Tip Mixer for for (Accessory)

Size† Part No. in. psi Tip Nut Tube Injector Tip Injector Length Part No.

4A 639974 1/32-1/16 7-8 639684 16Z26 01Z06 64 79  

6A 639975 1/16-3/32 8-20 639685 16Z27 01Z07 58 77  

9A 639976 3/32-1/8 10-24 639686 639870 16Z28 01Z08 55 75  

12A 17271 1/8-3/16 11-25 17266 16Z29 01Z09 54 73  

15A 639977 3/16-1/4 11-26 639687 16Z30 01Z10 53 71  

30A 639978 1/4-1/2 18-29 17261 998847 16Z32 01Z12 44 65

50A 639979 1/2-3/4 25-39 998060 639969 639971 01Z14 33 59 12-in. 19X42

70A 639981 3/4-1 22-30 998061 639969 639972 01Z15 30 67

100A 11X71 45-55 998062 33A59 16Z54 01Z21 25 56 15-in. 19X43

150A 11X73 Heating 50-60 64Z22 33A58 16Z56 01Z23 17 54 18-in. 19X44

250A 11X75 70-80 12Z80 33A63 16Z58 01Z25 1/4-in. 52 21-in. 19X45

† See Important Operating Notes on page 3.

Acetylene pressure is 1/2 to 5 psi.

OPERATING PRECAUTIONS

Flow: There must be proper ow of gases for safe operation

and full performance. This requires the following three condi-

tions: (1) the regulators that determine the inlet pressure to

the hoses must be set to the correct pressure; (2) the hoses

and their connectors must have adequate capacity for the

job (hoses that are too long, too small or have connectors

with small passageways can cause problems); and (3) the

throttle valves on the torch must be adjusted with the pro-

cedure shown in these instructions.

Note: Items(1)and(2)canbecheckedbymeasuringthe

gas pressures at the torch. Gauge adaptors are

availableforthispurpose.

Backre: Improper operation of the torch may cause the

ame to go out with a loud “pop”. Such a backre may be

caused by contact of the tip with the work, spatter from the

tip, or by attempting to operate with too small a ame. After

a backre, you can normally relight the ame immediately. If

backres occur repeatedly, shut off the torch. Then reopen

the oxygen valve, check for correct oxygen pressure, and

test for leakage at the welding head connection nut and tip

connection nut. If there is leakage at either point, correct it

(by tightening the tip, or cleaning the seating surfaces on the

injector and in the torch body) before resuming work.

Flashback: Under certain circumstances, the ame may not

“pop” out (backre) but instead burn back inside the torch

with a shrill hissing or squeal. This is called a “ashback”. A

ashback should never occur if (1) the equipment is in good

condition; (2) preheat ports on cutting nozzles or welding

tips are cleaned frequently; (3) operating pressures are cor-

rect; and (4) throttle valves are adjusted properly. Should a

ashback occur, IMMEDIATELY shut off the torch. Allow it to

cool off for at least a minute. Then check your nozzle or tip,

gas pressure, readjust regulators if necessary, and relight the

torch. If ashback recurs, send the torch handle and welding

head or cutting attachment to your distributor for repair.

MAINTENANCE INSTRUCTIONS

For all repairs other than those covered below, send

the apparatus to your welding equipment distributor

or to ESAB’s Remanufacturing Center, Ebenezer Road,

Florence, SC 29501. Improperly repaired apparatus is

hazardous.

Torch Valves: Leakage around either throttle valve can

usually be corrected by tightening the packing nut slightly. If

it cannot be corrected, replace throttle valve assembly.

If either valve fails to shut off completely, remove the throttle

valve assembly from torch and wipe the ball seat on the end

of the stem with a clean cloth. Then reinstall the valve and

tighten it heavily several times. If this does not eliminate

leakage, try a new throttle valve assembly. If then the valve

does not shut off completely, send the torch handle to a repair

station for reseating of the body.

Tip Cleaning: If a welding tip produces a distorted, irregular

ame, clean the tip with an OXWELD tip cleaner, or the cor-

rect size twist drill (see table on page 4). Do not attempt to

clean with any other type of tool. When using cleaning drills,

push the drill straight in and out; do not twist.

Injector Cleaning: The relatively small central oxygen ori-

ce in an injector may become partially clogged with small

particles conveyed in the oxygen stream or carbon particles

produced by backres. To clean or replace an injector, re-

move it from the mixer tube (after removing the connection

nut retaining ring and sliding the nut forward) by grasping it

with a pair of pliers between the seating surfaces and pulling

it straight out with steady force. Take great care not to mar

the injector seats or O-rings with the pliers. Clean the central

(oxygen) orice with the correct size twist drill (see table on

page 4). Use no other tools. Replace O-rings if damaged or

worn. Replace the injector if its rear seats are marred. When

reinstalling injector, be sure to push it in until its retaining

O-ring is rmly seated in the mixer tube.

Complete Pressure, Avg. Replacement Parts

Head Assembly psig Heat Tip Extension Tip

Fuel No. of Output Tip Tip Mixer Injector Head Retain. (Accessory) Cleaning

Size† Part No. Oxy. Gas Flames Btu/hr. Assy. Stem Nut Tube or Mixer Nut Ring Length P/N Drill Size

For Oxy-Acetylene Use

100 O-A 999842 55-60 1/2-5 12 147,000 998799 998793 33A59 16Z54 01Z21 998596 37A41 15-in. 19X43 57

200 O-A 999844 15-20 9-12 16 294,000 998800 998794  998830 998832 999910 998553 18-in. 998790 54

For Oxy-Fuel Gas FG-2, propane, natural gas etc.

100 O-FG 999843 50-70 1/2-5 8 148,000 999227 998793 33A59 16Z54 01Z99 998596 37A41 15-in. 19X43 49

200 O-FG 999845 30-55 6-11 21 297,000 999230 998794  998830 998832 999910 998553 18-in. 998790 52

Table 2 - Rosebud Style Multiame Heating Heads

† See Important Operating Notes on page 3.

 Requires extension coupling 998838.

IMPORTANT: P/N 998832 is a mixer; not an injector for low fuel gas pressure. Be sure to use operating pressures as given, using lower pressure can overheat

the tip and cause torch to ashback.













�



A. CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST

Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:

Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:

Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST

Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS:

Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST

Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST

Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4462

Hours: 7:30 AM to 5:00 PM EST

visit us on the web at http://www.esabna.com

The ESAB web site oers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

ESAB W-24R Welding Torch Troubleshooting instruction

ESAB W-24R Welding Torch Troubleshooting instruction

ESAB W-24R Welding Torch Troubleshooting instruction

Related papers

Other documents