ESAB W-17 Welding Torch Troubleshooting instruction

Brand: ESAB

Model: W-17 Welding Torch

Type: Troubleshooting instruction

INSTRUCTIONS for

F-4644-N

June 2009

W-17 Welding Torch

P/N 4250

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

and safe practices 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 covered by these instructions is listed by Third Party Listed only when used in combination with

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

Party Listed, and when they are used in the gas services for which they are designed and listed. The use of other

parts that cause damage or failure to the equipment will void the manufacturer’s warranty.

SPECIFICATIONS

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

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

Length ................................................................ 7-1/2-in.

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

Torch-Hose Connections .................Oxy - 9/16 - 18 fem.

F.G. - 9/16 - 18 LH fem.

* Equivalent to approximately 1400 to 370,000 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.

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 throt-

tling 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.

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!

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



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

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

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

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



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

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

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

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

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

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

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

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

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



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

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

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

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

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

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

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

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

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



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

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

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

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



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



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

IMPORTANT OPERATING NOTES

1. Do not attempt to operate heads size 100 or larger

from a low-pressure acetylene supply (less than 5

psig).

2. Head size number of each welding and heating head

indicates the rated acetylene 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 equiva-

lent 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 heating:

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 op-

eration. 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 lighting 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. 55 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 pres-

sures are available at the torch inlet.

7. Manifold two or more fuel gas cylinders to assure

adequate supply of fuel gas. The tables show the

number of commonly used cylinders recommended

for manifolding when using larger heads. If using

other cylinders or gases, check with your fuel gas

supplier for recommended withdrawal rate informa-

tion.

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

oxygen and fuel gas valves on the torch (preferably

oxygen valve rst). For greater protection, install

1/4-turn quick shut off valve (P/N 999306) on the

torch oxygen hose connection.

Acetylene

Head Flowrate, Min. No. of Cylinders Required*

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.

FG-2 (104 Ib. cyl.) Propane (100 Ib. 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 Ib. cylinder,

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.

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. Main-

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

work.

RECOMMENDED HOSE SIZES

Oxygen, Acetylene (medium-pressure) and Natural

Gas (at pipeline pressure 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 pipe-

line pressure below 5 psi): With head sizes 4-70,

3/8-in. I.D. hose. Head sizes 100-250, 1/2-in. hose.

Do not use over 25 feet of hose.

Heating Head Operating Replacement Parts Tip Injector Tip Extensions

Assembly Pressure Cleaning Cleaning (Accessory)

Fuel Tip Tip Mixer No. of Drill Drill

Size Part No. Oxygen Gas Ass’y Stem Nut Tube Injector Holes Size Size Length Part No.

For Acetylene Use

55 O-A 998819 35-40 1/2-5 998797 998792 639969 639971 01Z14 9 61 59 12-in. 19X42

70 O-A 998820 45-50 1/2-5 998798 998792 639969 639972 01Z15 9 57 57 12-in. 19X42

100 O-A 998821 55-60 1/2-5 998799 998793 33A59 16Z54 01Z21 13 57 56 15-in. 19X43

200 O-A 998822 15-20 9-12

 998800 998794  998830 998832 16 54 47 18-in. 998790

250 O-A 998823 20-25 12-14

 998827 998826  998831 998832 16 53 47 21-in. 998825

For Fuel Gases Other Than Acetylene (FG-2, propane, natural gas, etc.)

70 O-FG 999232 40-45 1/2-5 999224 998792 639969 639972 01Z23 8 51 54 12-in. 19X42

100 O-FG 999233 50-70 1/2-5 999227 998793 33A59 16Z54 01Z99 8 52 56 15-in. 19X43

200 O-FG 999234 30-55 6-11

 999230 998794  998830 998832 21 52 47 18-in. 998790

Welding and Heating Head Parts

Table 1 - Single-Flame Acetylene Welding Heads

Welding Replacement Parts Cleaning Drill Tip

Head Oxygen (Size No.) Extension

Assembly Metal Thickness Pressure Tip Mixer for for (Accessory)

Size

 Part No. In. mm. psi Tip Nut Tube Injector Tip Injector Length Part No.

4A 639865 1/32-1/16 0.8-1.6 7-18 639684 16Z26 01Z06 64 79

6A 639866 1/16-3/32 1.6-2.4 8-20 639685 16Z27 01Z07 58 77

9A 639867 3/32-1/8 2.4-3.2 10-24 639686 639870 16Z28 01Z08 55 75

12A 17270 1/8-3/16 3.2-4.8 10-25 17266 16Z29 01Z09 53 73

15A 639868 3/16-1/4 4.8-6 11-26 639687 16Z30 01Z10 53 71

30A 639869 1/4-1/2 6-13 18-29 17261 998847 16Z32 01Z12 45 65

55A 998101 1/2-3/4 13-19 25-39 998060 639969 639971 01Z14 33 59 12-in. 19X42

70A 998102 3/4-1 19-25 22-30 998061 639969 639972 01Z15 30 57

100A 10X03 45-55 998062 33A59 16Z54 01Z21 25 56 15-in. 19X43

150A 10X05 Heating 50-60 64Z22 33A58 16Z56 01Z23 17 54 18-in. 19X44

250A 10X07 70-80 12Z80 33A63 16Z58 01Z25 1/4-in. 52 21-in. 19X45

Table 2 - Standard Multiame Heads

Heating Head Replacement Parts Tip Cleaning Injector Tip Extensions

Assembly Oxygen Cleaning (Accessory)

Pressure Tip Mixer No. of Drill Drilll

Size

 Part No. psi Tip Nut Tube Injector Holes Size Size Length Part No.

For Acetylene Use

70A 998047 40-45 998071 639969 639972 01Z15 7 56 57 12-in. 19X42

100A 11X22 55-60 998072 33A59 16Z54 01Z21 8 55 56 15-in. 19X43

150A 11X24 60-65 998073 33A58 16Z56 01Z23 12 55 54 18-in. 19X44

250A 11X26 75-80 12Y44 33A63 16Z58 01Z25 12 55 52 21-in. 19X45

For FG-2 Use

70 FG 998038 33-70 998078 639969 639972 01Z25 7 54 52 12-in. 19X42

100 FG-2 998281 34-88 998079 33A59 16Z54 01Z25 8 48 52 15-in. 19X43

150 FG-2 998265 32-70 998036 33A58 16Z56 998286 12 48 46 18-in. 19X44

For Fuel Gases Other Than Acetylene & FG-2

70 FG 998038 33-70 998078 639969 639972 01Z25 7 54 52 12-in. 19X42

100 FG 11X32 45-55 998079 33A59 16Z54 01Z21 8 48 56 15-in. 19X43

150 FG 11X34 50-60 998036 33A58 16Z56 01Z23 12 48 54 18-in. 19X44

250 FG 11X36 70-80 12Y60 33A63 16Z58 01Z99 20 48 50 21-in. 19X45

Table 3 -Rosebud-Style Multiame Heating Heads

Size indicates approximate acetylene ow rate in cu. ft./hr (cfh) at normal operating pressure. See Important Operating Notes on pg. 3.

 Acetylene pressure is 1/2 to 5 psi.

See Important Operating Notes on pg. 3.

 Fuel Gas pressure is 1/2 to 5 psi.

See Important Operating Notes on pg. 3. This stainless steel extension requires coupling 998838 for 200 size; 998839 for 250 size.

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

†

TESTING FOR LEAKS

Every welding and cutting outt should be thoroughly

tested for leaks 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 delivery-pressure gauge reg-

isters 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 connec-

tions, and the hose-to-torch connections. If bubbling

at any point indicates leakage, tighten the connection.

If this does not stop the leakage, close the appropri-

ate 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 connection, 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.

OPERATING PRECAUTIONS

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

eration and full performance. This requires the following

three conditions: (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 procedure 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 correct; 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 at-

tachment to ESAB Remanufacturing Center or 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 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, ir-

regular ame, clean the tip with an OXWELD tip cleaner,

or the correct 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 relative 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, remove 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.

PARTS INFORMATION

All parts which can be replaced without breaking soldered or brazed joints are illustrated and listed below. When or-

dering parts, please give both part number and description (including size where appropriate). Parts may be ordered

from your welding equipment distributor or from ESAB Welding & Cutting Products, Customer Service Department,

Florence, SC.

W-17 Welding Torch Handle .......................P/N 4250

*O-rings included with Injector. **Except rosebud head assemblies 998822, 998823, 998234 use head nut 998787 and retaining ring 998553.

NOTE: If you are having problems inserting the above heads (injector with 3 O-rings) into an old torch handle

made prior to 1978, have the torch handle reseated by an authorized distributor repair service.

THROTTLE VALVE ASSEMBLY (OXY.) - 54A82

THROTTLE VALVE ASSEMBLY (F.G.) - 54A91

See

Note

STEM (ROSEBUD HEAD)

(See Table 3)

TIP (ROSEBUD

HEAD) (See Table 3)

TIP (STD.

MF HEAD)

(See Table 2)

TIP

(WELD HEAD)

(See Table 1)

TIP NUT

(See Tables)

RING

37A41

(For All

Heads**)

HEAD NUT

36Z09

(For All

Heads**)

MIXER TUBE

(See Tables)

INJECTOR

(See Tables)

*O-RING

14K10

2064104

86W51

NOTE: Apply X-pando Compound (7358-5950) on stem threads before assembly.

TIP NUT

HEAD NUT - 36Z09

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

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ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

ESAB W-17 Welding Torch Troubleshooting instruction

ESAB W-17 Welding Torch Troubleshooting instruction

ESAB W-17 Welding Torch Troubleshooting instruction

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