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Unimag Uni-flame Instruction Manual

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GAS WELDING / FLAME CUTTING
AND GOUGING KIT
Instruction manual

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Summary of Contents for Unimag Uni-flame

  • Page 1 GAS WELDING / FLAME CUTTING AND GOUGING KIT Instruction manual...

  • Page 2: General Safety Information

    AS4603 This manual refers to safety measures that must be adhered to for safe operation of your Uni-Flame gas cutting and welding equipment. Please read and understand these warnings and instructions before use. Failure to do so could result in serious injury or death.
  • Page 3 INSTRUCTION MANUAL FOR UNI-FLAME GAS WELDING, FLAME CUTTING AND GOUGING KIT CHART 1 The properties of these and other commonly used gases are listed in the table below. Property Oxygen Acetylene LP Gas (O2) (C2H2) (C3H8) Note 1 Density relative to air 1.103...
  • Page 4 General Your Uni-Flame gas welding and cutting equipment is designed to be used by gases delivered to the point of use from porta- ble compressed gas cylinders. In all cases, gas supplies may be subject to statutory or regulatory provisions. Many Australian Standards cover the subject.
  • Page 5 INSTRUCTION MANUAL FOR UNI-FLAME GAS WELDING, FLAME CUTTING AND GOUGING KIT Cylinder Types and General Care Cylinders used for oxygen, acetylene, LPG, are in effect thin walled highly pressurised vessels. Due to the presence of gases under pressure, full or partially filled cylinders can cause serious injury or damage should they rupture.
  • Page 6 "cracking" as serious injuries can occur. Make sure the Uni-Flame pressure regulator is suitable for the gas and pressure in the cylinder and that its inlet connection is the same thread as that in the cylinder valve. Fuel gas connections have left handed threads. Never force any connection that does not fit.

  • Page 7: Hoses And Fittings

    These must be as specified in AS 1335, of an appropriate type, securely made and leak tight. Wire should never be used to fasten hose to fittings. Oxygen fittings have right hand threaded nuts, fuel gases left hand thread nuts. Use only Uni-Flame gas hoses and connectors when replacement is required.
  • Page 8 Never test for leaks with a flame. Tips, nozzles and their attachment fittings Uni-Flame Tips and nozzles are well identified and carry information relating to their use such as size, recommended gas pressures and plate thickness to be cut. Uni-Flame Tips and cutting nozzles appropriate to the particular fuel gas should be used.
  • Page 9 Uni-Flame gas welding and cutting kits are therefore supplied with four IBEDA flashback arrestors that comply to AS4603. Two pieces to suit the torch end and two pieces to suit the regulator end for optimum protection. The Uni-Flame gas welding and cutting kit must not be operated without the four flashback arrestors being installed.
  • Page 10 Your Uni-Flame gas welding and cutting kit comprises many components. It is important for safe operation that replacement parts purchased in the future are genuine Uni-Flame parts or parts that are compatible and suitable for use with Uni-Flame gas equipment.
  • Page 11 Equipment Inspection and Maintenance Inspection and Maintenance Inspection and maintenance should be carried out on a routine basis for all items of Uni-flame gas and cutting equipment. Guidance on inspection and maintenance for the equipment are described in Charts 4 and 5.
  • Page 12 INSTRUCTION MANUAL FOR UNI-FLAME GAS WELDING, FLAME CUTTING AND GOUGING KIT FLASHBACK is the return of flame through the blowpipe into the hoses and even the regulators. Depending on its severity, it may also reach the acetylene cylinder, causing heating and decomposition of the contents.
  • Page 13 INSTRUCTION MANUAL FOR UNI-FLAME GAS WELDING, FLAME CUTTING AND GOUGING KIT Acetylene Cylinder Overheating Acetylene cylinders may become hot either through flashback or due to accidental heating (e.g. contact with hot objects, fires). To prevent serious accidents, the following procedure should be carried out immediately overheating is noted: Shut cylinder valve quickly and have the supplier notified as soon as practicable.
  • Page 14 INSTRUCTION MANUAL FOR UNI-FLAME GAS WELDING, FLAME CUTTING AND GOUGING KIT CHART 4 GUIDANCE ON EQUIPMENT MAINTENANCE EQUIPMENT WEEKLY 1 AS NOMINATED 2 REFURBISHMENT OR REPLACEMENT INTERVALS 3 Visual examination to determine Six monthly: Manufacturer or supplier 1. REGULATORS (including...
  • Page 15 INSTRUCTION MANUAL FOR UNI-FLAME GAS WELDING, FLAME CUTTING AND GOUGING KIT CHART 5 SAFE PROCEDURES FOR SETTING UP AND CLOSING DOWN GAS WELDING, HEATING AND CUTTING EQUIPMENT STEP ACTION COMMENT 1 SETTING UP 1.1 Equipment connection 1 Check that all equipment, equipment...
  • Page 16 INSTRUCTION MANUAL FOR UNI-FLAME GAS WELDING, FLAME CUTTING AND GOUGING KIT 12 Once all leaks have been corrected, re-open cylinder valve slowly. 13 Repeat the procedure (steps 9 tp 12) for the fuel gas. 14 If the valve is not handwheel operated,...
  • Page 17 Set up procedure for oxy acetylene kit 1. Secure both oxygen and 2 - 2a. Stand to one side and crack both oxygen and acetylene cylinders to acetylene cylinders on approved clear any foreign material that may interfere with seating or clog orifices carry stand or trolley.
  • Page 18 Set up procedure for oxy acetylene kit 4. Connect approved IBEDA flash arrestors (AS4603 supplied) and tighten with appropriate spanner to regulators. Note: These are colour coded and are thread orientated. 5. Attach gas hoses to flash arrestor on regulators using appropriate spanner.
  • Page 19 Set up procedure for oxy acetylene kit Before opening cylinder valves with regulators attached, ENSURE that regulator control knobs are fully wound in the ANTI-CLOCKWISE position. 6a. SLOWLY open the cylinder valves so that high pressure gauge needle moves up gradually and check for leaks. Note: never open cylinder valves suddenly as the in rush of high-pressure gases can damage the regulator components and void your warranty.
  • Page 20 Set up procedure for oxy acetylene kit 7. Holding the gas hose away from body and any ignition source, slowly turn CLOCK WISE the oxygen regulator control knob to achieve a small gas flow to purge any foreign material from tubing. When hose and regulators have been cleared return regulator control knob to the fully ANTI CLOCK WISE position.
  • Page 21 Set up procedure for oxy acetylene cutting 1. Follow the set up procedure steps 1 to 9 ensure that the heating control valve is aligned with control valves on handle 2. Fit the cutting attachment into the blowpipe handle, and ensure that the heating control valve is aligned with control valves on handle tighten by hand.
  • Page 22 Set up procedure for oxy acetylene cutting 1. Open the acetylene fuel control valve on blowpipe, turn regulator control knob CLOCK-WISE to obtain correct set pressure required (Refer to refer to manufactures chart) (Chart 2) then close the control valve at the blowpipe. 2.
  • Page 23 Set up procedure for oxy acetylene cutting Oxygen-Acetylene flame settings (as viewed through cutting goggles) Inner Inner Inner Inner 3-6 mm 3-6 mm Cones Cones Cones Cones Secondary Faint flicker Cone just disappears Oxygen Stream Outer Outer Outer Outer Cone Cone Cone Cone...
  • Page 24 Set up procedure for oxy acetylene welding 1. Follow the set up procedure steps 1 to 9 2. Fit mixer to the blowpipe handle and tighten by hand 3. Install appropriate welding tip (refer to manufactures chart (Chart 3) for tip size and set pressures for procedure to be preformed) 4.
  • Page 25 Lighting procedure for oxy acetylene welding 1. Open the blowpipe fuel control valve and turn the acetylene regulator control knob CLOCK-WISE until the correct pressure is obtained on the delivery gauge then close the fuel control valve at blowpipe. Repeat this procedure for the oxygen gas. (Refer to refer to manufactures chart (Chart 2) for correct settings for tip size) 2.
  • Page 26 INSTRUCTION MANUAL Disclaimer: While the above information is provided in good faith, Welding Guns Of Australia Pty Ltd and the Welding Technology Institute of Australia do not warrant the accuracy of information provided nor assume any legal responsibility for it or for any damage which may result from reliance on or use of it or from any negligence of Welding Guns Of Australia Pty Ltd and Welding Technology Institute of Australia or other person/s with respect to it.