SAFETY AND OPERATION MANUAL Congratulations on purchasing the GASPONY®1 Portable Welding/Cutting Outfit! This manual is designed to help you get the most out of your GASPONY®1. CAREFULLY REVIEW ALL SAFETY INFORMATION. Adherence to proper safety practices protects you from potential hazards on the worksite. Installation and operation are quick and easy. Instructions for setup and use are included in this manual. Warranty and service information are also provided.
TABLE OF CONTENTS SECTION 1 – SAFETY INFORMATION ................................................................... 2 SECTION 2 – GLOSSARY OF TERMS ...................................................................... 4 SECTION 3 – CONTENTS ........................................................................................... 5 SECTION 4 – OXY-FUEL APPARATUS ................................................................... 6 4.1 Compressed Gas Cylinders .............................................
SECTION 1 – SAFETY INFORMATION WARNING: READ BEFORE USING – AVOID INJURY TO YOURSELF AND OTHERS WARNING: Only qualified persons should install, operate, maintain, and repair this unit. WARNING: Keep other people, especially children, away during operation. FIRE PREVENTION - Oxy-fuel gas apparatus uses fire or combustion as a basic tool. This process must be controlled or it can be extremely destructive. • The work area must have a fireproof floor.
• • • Extra precaution should be used while operating in confined areas. Ensure that breathing air is safe. Welding/cutting fumes and gases displace air and lower the oxygen level causing injury or death. Use an approved air-supplied respirator when needed. Avoid use in locations with potential for high concentrations of chemical vapors. Remove all coatings from the work pieces. Coatings can give off toxic fumes if welded or cut.
• • • • • • NEVER weld or cut a pressurized cylinder. Identify your application and only use correct gas cylinders, regulators, hoses and fittings. Keep all well maintained and replace as needed. NEVER face valve outlet when opening. ALWAYS keep protective cap over the valve when cylinder is not in use. Cylinders require specialized equipment or cylinder tote to move and position safely. Read and comply with instructions from Compressed Gas Association (CGA) publication P-1.
SECTION 3 – CONTENTS Parts List: 1. Acetylene Cylinder, 10 cu. ft. 2. Oxygen Cylinder, 20 cu. ft. 3. CGA200 Light Duty Acetylene Regulator, 30 psig 4. CGA540 Light Duty Oxygen Regulator, 100 psig 5. Medium Duty Torch Handle (Compatible with Victor Technologies) 6. Medium Duty Cutting Attachment (Compatible with Victor Technologies) 7. Cutting Tip: style 3-101, size #0 8. Welding Tip: style W-1, size #2 9. Striker 10. Tip Cleaner w/ 12 tips 11. Twin R-Grade Gas Hose 12. Welding Safety Glasses 13. Tote 14.
SECTION 4 – OXY-FUEL APPARATUS 4.1 Compressed Gas Cylinders The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases used for welding and cutting operations. Cylinders are highly pressurized. Serious accidents may result from improper handling or misuse. DO NOT drop or knock over a cylinder. DO NOT expose a cylinder to excessive heat, flames or sparks. DO NOT bang cylinders together.
4.2 Regulators Pressure regulators, when attached to cylinder valves, reduce high cylinder pressure to a low working pressure for welding and cutting applications. Regulators must always be used for the gas and pressure for which they are designed. NEVER adapt or alter a regulator for use with another gas. Figure 2 1. Familiarize yourself with all regulator parts. (See Figure 2) 2. Inspect the regulator. Remove dust and dirt with a clean cloth. DO NOT use the regulator if grease, oil or damage is present.
4.3 Gas Hoses An R-Grade twin hose is included in this kit. R-Grade is suitable for use with oxygen and acetylene gas. DO NOT USE WITH PETROLEUM BASED GASES. The hose is color coded green for Oxygen and red for Acetylene. 1. Examine the hose for cuts, burns and damaged fittings before use. Replace hose before use if any of these defects are present. 2. Connect the hose to the regulators and tighten with a wrench. 3.
SECTION 5 – WELDING & CUTTING OPERATIONS 5.1 Welding Procedure Follow the below procedures before performing welding operations. 1. Inspect the torch handle for dust, dirt, grease, oil or damage. Remove dust and dirt with a clean cloth. If grease, oil or damage are present, DO NOT use and replace or have a qualified repair technician fix the handle. 2. Inspect the welding tip for dust, dirt, grease, oil or damage. Remove dust and dirt with a clean cloth.
7. Insert the cutting tip into the cutting attachment and tighten securely with a wrench. 8. Open the oxygen control valve on the torch handle completely. 9. Open the oxygen control valve on the cutting attachment and depress the oxygen cutting lever. Adjust the oxygen regulator to a delivery pressure suitable for the tip type and size. See Cutting Tip Chart in Section 6. 10. Release the oxygen cutting lever and close the oxygen control valve on the cutting attachment. 11.
5. (When using the cutting attachment, skip to step 8) When using the Welding Tip, Open the oxygen valve slowly. A bright inner cone will appear in the flame. Continue to adjust the oxygen valve until the edges of the flame disappear and a sharp inner cone is visible. The resulting flame is a “Neutral Flame.” 6. To increase the flame, open the torch control valves or slightly increase the regulator operating pressure. DO NOT reduce the flame setting. This will cause the tip to overheat and BACKFIRE.
5.5 Proper Shutoff Procedures When the Welding or Cutting Procedure is complete, follow this procedure. 1. Close the oxygen control valve on the torch handle. 2. Close the fuel control valve on the torch handle. 3. Close both cylinder valves. 4. Open the oxygen control valve on the torch handle to release remaining pressure. 5. Turn the pressure adjusting screw on the oxygen regulator clockwise until it spins freely. 6. Close the oxygen control valve on the torch handle. 7.
SECTION 6 – OPERATIONAL DATA & TIP CHARTS Operational Data – Using 3/8” I.D. Hose – 100 ft. in length or less. Gas Acetylene Oxygen Maximum Pressure 15 psig 150 psig Maximum Capacity Welding: 3”, Cutting: 8” Welding: 3”, Cutting: 8” Welding Tip Chart – Using 3/8” I.D. Hose on Mild Steel Acetylene Pressure (psig) Oxygen Pressure (psig) Tip Size 000 00 0 1 2 3 4 Metal Drill Size Thickness Up to 1/32" 1/16" ‐ 3/64" 1/32" ‐ 5/64" 3/64" ‐ 3/32" 1/16" ‐ 1/8" 1/8" ‐ 3/16" 3/16" ‐ 1/4" 75 (.022) 70 (.
SECTION 7 – WARRANTY INFORMATION LIMITED WARRANTY - GASPONY®1 - LIMITED 1 YEAR / 90 DAY WARRANTY STATEMENT OF LIMITED WARRANTY. THOROUGHBRED INDUSTRIAL CYLINDER EXCHANGE MAKES EVERY EFFORT TO ENSURE THAT ITS PRODUCTS MEET HIGH QUALITY STANDARDS AND THE FOLLOWING TO THE ORIGINAL END USER (PURCHASER): NINETY (90) DAYS, WELDING TIP SEAT, HOSE, STRIKER, TIP CLEANER AND GOGGLES ARE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP . THIS DOES NOT APPLY TO CONSUMABLE PARTS: WELDING TIP AND CUTTING TIP.
