Gas Equipment

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Gas Equipment | Afrox Product Reference Manual

10 | Gas Equipment

| Gas Equipment

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Gas Equipment

Afrox Product Reference Manual

Section 10 - Gas Equipment

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Afrox Range

3

Oxy-Fuel Cutting, Welding & Heating Processes

3

Industrial Regulators & Flowmeters

10

Saffire® 916 Multi-Stage Regulators

18

Regulator Spares, Fittings & Attachments

19

Torches & Attachments

21

Nozzles

30

Flashback Arrestors & Quick Release Couplings

38

Gas Hoses & Fittings

43

Gas Equipment Accessories

46

PortaPak®

48

Gas Welding & Cutting Outfits

50

Sievert® Equipment

52

Gas Cutting Machines

58

IBEDA

62

Flashback Arrestors & Quick Release Couplings

62

Transarc Gas Equipment

67

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Gas Equipment

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Afrox Range Oxy-Fuel Cutting, Welding & Heating Processes Gas Welding Combustion can only take place if three conditions are satisfied. There must be a fuel. A fuel is a material that burns or combusts with oxygen to release energy. The hot gases produced by combustion form a flame. Most, but not all, fuels are hydrocarbons. Oxygen must be present. Oxygen is a chemical element with which most chemical compounds will combine in an exothermic reaction.

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Gas Equipment | Afrox Product Reference Manual

where the remaining by-products of the initial combustion burn with oxygen from the atmosphere. Here the reactions are: 2CO + O2 ≥ 2CO22H2 + O2 ≥ 2H2O These outside two zones form what is termed the secondary zone or outer envelope. Flame Types

Ignition is required for the fuel/oxidant mixture to ignite and produce a flame. The source of ignition may be a pilot flame, an electrical spark, a hot spot or a sudden pressure change. In the process of combustion, ignition causes a fuel to react with oxygen.

Although the neutral flame is the most commonly used for gas welding, two other flame types – oxidising flame and carburising flame – are used for different applications.

The products of complete combustion, in the case of hydrocarbon fuels, are oxides such as carbon dioxide and water, and a large amount of energy in the form of heat and light.

In the neutral flame, the primary zone is sharp and clearly defined.

Neutral Flame

When oxygen and a fuel gas are burned together at the end of a nozzle, a flame is created and it is this flame that is used to melt both the parent and filler material. Of all the fuel gases available, acetylene is the most widely used because of its higher flame temperature and the ease at which the flame can be set. When equal quantities of acetylene and oxygen are burned, a neutral flame is created and this has two visibly distinct zones within it. In actual fact, there are more than two zones within a neutral flame – there are four. Looking from the nozzle, the first zone is an unburned mixture of oxygen and acetylene. No combustion takes place here because the gases are effectively at room temperature and there is no source of heat. On the edge of this inner zone is a bright blue-white stationary combustion zone where burning takes place. The reaction within this area can be defined by the equation: C2H2 + O2 ≥ 2CO + H2

The neutral flame is used for gas welding: Carbon and alloy steels Stainless steel Cast iron Copper. Oxidising Flame As the name suggests, in an oxidising flame an excess of oxygen is present. This produces a much shorter, brighter secondary zone. The oxidising flame is also noisier than the other two flame types.

The outside of this zone is the hottest point of the flame. These two zones form what is called the primary zone or primary cone of the flame.

The oxidising flame is primarily used for gas welding brass. Carburising Flame Schematic of the gas welding flame

Further out from the primary zone is the reducing zone. Very little combustion takes place in this zone, as most of the oxygen available was consumed in the previous zone.The outside zone is

The carburising flame is created by having a small excess amount of acetylene present in the flame. This flame is clearly distinguished by a small ‘feather’ of acetylene at the end of the primary zone.

Afrox Product Reference Manual



| Gas Equipment

Mismatch of colour between parent metal and the bronze welded deposit.

Braze welded joints Fillet joints The excess of acetylene in the flame adds carbon into the weld pool and is used predominantly for hardfacing applications.

Lap joint

Application

No fusion of the joint edges

The application of gas welding is wide and various, both in terms of the thickness range and the materials that can be welded with it. It can also be used to weld in all positions as long as the operator has the skill required to carry out the task.

Pronounced build-up of the filler metal.

The industries that use gas welding are varied. The relatively low cost equipment and its flexibility mean that every engineering workshop is likely to have a system on site. Of these systems, oxy-acetylene is by far the most common because it is the only gas combination that can be used to weld all materials. Gas welding has also become a favourite with the home DIY hobbyist, again because of its flexibility.

The Oxy-Fuel Welding Process Welding Welding is using a flame to melt the plate and add filler. Welding (fusion welding) takes place when a flame is used to heat the edges of the joint to melting temperature. When the metal is in a molten state, the edges flow together. The addition of the welding rod may be required, depending on the type of joint being welded.

Butt joint

Brazing Brazing is the adhesion of one plate to another without melting at temperatures above 450°C but below the melting point of the base metal. The filler material to form the union is non-ferrous. Features of brazing

Filler metal in a thin film (0,0254 – 0,0085 mm) between two or more tightly fitted pieces of base metal Often referred to as silver brazing or silver soldering Fast metal joining is achieved because:

• Brazing rod has the lowest achievable melting point, which can lead to capillary action • Whole joint is raised to the correct temperature (in contrast with localised heat applied in welding) • Brazing rod flows by capillary action along joint edges and through to the reverse side of the joint. Braze joints

Braze Welding

Fillet joints

Brazing and braze welding take place at temperatures above 450°C, but below the melting point of the base metal.

Lap joints

Braze welding happens when the edges of the joint to be welded are heated sufficiently to melt the braze welding rod, which then flows onto the joint edges, producing a fillet in the joint. The parent metal does not melt. The process is one of adhesion. An advantage of braze welding is reduced distortion because of the lower temperatures.

Butt joints – not suitable for brazing. Fluxes in brazing Fluxes clean the metal surface. When fluxes are used to clean the surface chemically, the parent metal does not melt. The cleaning permits a good bond between the parent metal and the brazing welding rod when brazing:

The filler material is an alloy of copper and zinc and may also contain other elements such as silicon, nickel or manganese.

Mild steel

A flux, either coated on or contained within the rod, must chemically clean the surface of the parent metal during heating.

Cast iron

The edges of the joint to be welded are heated sufficiently to melt the braze welding rod which then flows on to the joint edges. The parent metal does not melt. Comparisons Advantages of braze welding: Less distortion because of lower heat input Faster welding speeds because of lower heat input. Disadvantages Weakness of joint at high temperatures

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Stainless steel

Copper. Removal of fluxes Removal of fluxes after brazing is important when using aluminium, as the flux residues are very corrosive to aluminium. Flux not needed When using the copper phosphor brazing rod to braze with copper, a flux is not needed. Soldering Soldering is also adhesion at a lower temperature. Filler metal or solder alloy with a melting temperature of less than 450°C

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is used. The filler metal wets the parent metal, spreads, makes contact with the joint opening and is drawn into the joint by capillary action. Filler metals in soldering Soldering is another type of adhesion process Filler metal or solder alloy with a melting temperature of 100 mm. Safety Features Dust inlet filter promoting longer life Non-return valve preventing dangerous gas mixtures Flame arrestor preventing flashbacks Thermal cut-off valve prevents excessive temperatures. IBEDA High Flow Flashback Arrestor with Thermal Cut-Off Valve Description

Gas

Maximum Air Flow (L/H)

Maximum Pressure (kPa) O2

Da

LPG

H2

Inlet Thread

Outlet Thread

Item Number

DG 91 N

Fuel

54 700

-

150

500

400

9/16" UNF LH

9/16" UNF LH

W236009

DG 91 N

O2

54 700

2 000

-

-

-

9/16" UNF RH

9/16" UNF RH

W236010

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Gas Equipment | Afrox Product Reference Manual IBEDA High Flow Flashback Arrestor with Thermal Cut-Off Valve and Resettable Pressure Gas Cut-Off Valve This safety device can be used for Welding up to 30 mm Flame cutting up to 500 mm Heating >100 mm. Safety Features Dust inlet filter promoting longer life Non-return valve preventing dangerous gas mixtures Flame arrestor preventing flashbacks Thermal cut-off valve prevents excessive temperatures

Resettable pressure sensitive gas cut-off valve stops gas flow (Model DS2000).

IBEDA High Flow Flashback Arrestor with Thermal Cut-Off Valve and Resettable Pressure Gas Cut-Off Valve Description

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Gas

Maximum Air Flow (L/H)

Maximum Pressure (kPa) O2

Da

LPG

H2

Inlet Thread

Outlet Thread

Item Number

DS 2000

Fuel

54 700

-

150

500

400

9/16" UNF LH

9/16" UNF LH

W236037

DS 2000

O2

54 700

2 000

-

-

-

9/16" UNF RH

9/16" UNF RH

W236038

Inlet Connection

Outlet Thread

Item Number

Torch Mounted Flashback Arrestors IBEDA Standard Flashback Arrestor This safety device can be used for Welding up to 30 mm Flame cutting up to 200 mm Heating up to 50 mm.



Safety Features Dust inlet filter promoting longer life Non-return valve preventing dangerous gas mixtures Flame arrestor preventing flashbacks.

IBEDA Standard Flashback Arrestor Description

Gas

Maximum Air Flow (L/H)

Maximum Pressure (kPa) O2

Da

LPG

H2

GT

Fuel

26 300

-

150

500

350

Ø Hose 8 mm

9/16" UNF LH

W236021

GT

O2

26 300

2 000

-

-

-

Ø Hose 8 mm

9/16" UNF RH

W236022

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Afrox Product Reference Manual

| Gas Equipment

Gas Equipment

IBEDA Standard Flashback Arrestor for Profile Machine Torches

64

This safety device can be used for Welding up to 30 mm Flame cutting up to 300 mm Heating up to 50 mm. Safety Features Dust inlet filter promoting longer life Non-return valve preventing dangerous gas mixtures Flame arrestor preventing flashbacks.

IBEDA Standard Flashback Arrestor for Profile Machine Torches Description

Gas

Maximum Air Flow (L/H)

Maximum Pressure (kPa) O2

Da

LPG

H2

Inlet Thread

Outlet Thread

Item Number

GG

Fuel

26 300

-

150

500

350

9/16” UNF LH

9/16” UNF LH

W236017

GG

O2

26 300

2 000

-

-

-

9/16” UNF RH

9/16” UNF RH

W236018

IBEDA High Flow Flashback Arrestor This safety device can be used for Welding up to 30 mm Flame cutting up to 500 mm Heating up to 100 mm.

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Safety Features Dust inlet filter promoting longer life Non-return valve preventing dangerous gas mixtures Flame arrestor preventing flashbacks.





IBEDA High Flow Flashback Arrestor Description

Gas

Maximum Air Flow (L/H)

Maximum Pressure (kPa) O2

Da

LPG

H2

Inlet Thread

Outlet Thread

Item Number

DG 91 UA

Fuel

54 700

-

150

500

400

9/16” UNF LH

9/16" UNF LH

W236013

DG 91 UA

O2

54 700

2 000

-

-

-

9/16” UNF RH

9/16" UNF RH

W236014

Gas Equipment

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Gas Equipment | Afrox Product Reference Manual

Regulator Mounted Flashback Arrestors & Quick Release Couplings IBEDA Standard Flashback Arrestor with Quick Release Couplings This safety device can be used for Welding up to 30 mm Flame cutting up to 200 mm Heating up to 50 mm.



IBEDA Standard Flashback Arrestor with Quick Release Couplings Description

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Gas

Maximum Air Flow (L/H)

Maximum Pressure (kPa) O2

Da

LPG

H2

Inlet Thread

Outlet Connection

Item Number

DGN-K + N2

Fuel

32 600

-

150

500

350

9/16” UNF LH

Ø Hose 8 mm W236088

DGN-K + N2

O2

32 600

2 000

-

-

-

9/16” UNF RH

Ø Hose 8 mm W236089

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Afrox Product Reference Manual

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Gas Equipment

Torch Mounted Flashback Arrestors & Quick Release Couplings

66

IBEDA Standard Flashback Arrestor with Quick Release Coupling This safety device can be used for Welding up to 30 mm Flame cutting up to 200 mm Heating up to 50 mm. Safety Features Dust inlet filter promoting longer life Non-return valve preventing dangerous gas mixtures Flame arrestor preventing flashbacks Thermal cut-off valve prevents excessive temperatures Automatic gas cut-off when disconnecting Double ‘O’-ring seal Coloured marking of coupling and pin No mixing of gas connections through different coding of pins.

IBEDA Standard Flashback Arrestor Description

Gas

Maximum Air Flow (L/H)

Maximum Pressure (kPa) O2

Da

LPG

H2

Inlet Connection

Outlet Thread

Item Number

NKST + N1

Fuel

22 100

-

150

500

350

Ø Hose 8 mm

9/16" UNF LH

W236086

NKST + N1

O2

22 100

2 000

-

-

-

Ø Hose 8 mm

9/16" UNF RH

W236087

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Gas Equipment | Afrox Product Reference Manual

Transarc Gas Equipment The Transarc NM250 cutting torch is a versatile, well-balanced torch capable of cutting steel up to 270 mm thick. The torch provides excellent flame control and exceptional handling for all industrial cutting applications.

A B

C

1 year conditional warranty ISO 5172 TÜV certified

Transarc NM250 cutting torches feature nozzle mixing technology for added safety and for protecting the torch and operator from accidental backfires. They can be used with acetylene or LPG, depending on the type of nozzle fitted.

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A

Nozzle mixing helps contain backfires in the nozzle, protecting the torch from downtime and providing added operator safety

B

Custom angle head design allows for proficient and rapid nozzle change

C

Large forged head provides unmatched durability and reduces warping for extended service

D

Three-tube construction keeps gases separate, allowing gas mixing only in the nozzle for added operator safety

E

Solid lever for added durability

F

Fully silver-brazed joints, thick-walled stainless steel tubes and solid brass forged head and tail result in robustness and lower maintenance costs

G

Easy-grip valves give you full control over your cutting flame

H

Heavy duty cast handle for positive grip, comfort and control

I

Colour coded control knobs to improve operator productivity and safety

D

E H

I F G

Afrox Product Reference Manual

Transarc Heavy Duty Torch

Cutting Nozzles

| Gas Equipment

Transarc Torch

Transarc 3 Seat Oxy-Acetylene A-NM6 Cutting Nozzle W005027 (0,8) W005028 (1,2) W005029 (1,6) W005034 (2,0) W005035 (2,4) W005036 (3,2)

Transarc 3 Seat A-NM6 Acetylene Cutting Nozzle

Transarc 3 Seat Oxy-LPG P-NM Cutting Nozzle W010044 (0,8) W010045 (1,2) W010046 (1,6) W010047 (2,0) W010048 (2,4) W010049 (3,2)

Transarc 3 Seat LPG P-NM Cutting Nozzle

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Transarc Medium Duty Cutting Attachment W005846

Transarc Medium Duty Shank W005844

Transarc Heavy Duty Cutting Torch W005843

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Transarc Standard Flow Torch End Oxygen FBA TM35 W012042

Transarc Standard Flow Torch End Fuel FBA TM35 W012041

Transarc Flashback Arrestors Transarc Standard Flow Torch End Fuel FBA TM35 W012042

Transarc Standard Flow Torch End Oxygen FBA TM35 W012041

Gas Equipment

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Gas Equipment | Afrox Product Reference Manual

Transarc Welding Nozzles*

Size 13,0 5,0 mm W005105

Transarc Medium Duty Mixer

Transarc Medium Duty Shank

Transarc Medium Duty Shank W005844

Transarc Medium Duty Mixer W005845

Size 10,0 4,0 mm W005104

Size 7,0 3,2 mm W005103

Size 5,0 2,6 mm W005102

Size 3,0 2,0 mm W005101

10 Size 2,0 1,2 mm W005100

Size 1,0 0,9 mm W005099

For Your Safety: Use flashback arrestors on both ends (regulator and torch).

Transarc Flashback Arrestors Transarc Standard Flow Torch End Fuel FBA TM35 W012042

Transarc Standard Flow Torch End Oxygen FBA TM35 W012041

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Afrox Product Reference Manual

| Gas Equipment

Gas Equipment

Transarc Regulator Series

70

The Transarc series comprises a range of versatile pressure regulators designed to offer a safe and reliable product. The range is ISO 2503 TÜV certified and each regulator has been designed to provide optimum flow control utilising Afrox’s patented Quadflow encapsulated valve technology. The product has been designed to the latest and most stringent regulatory standards to offer an extended product life. Features 3rd generation Quadflow technology encapsulated valve 62 mm gauges colour-coded for ease of use and setting Full technical and back up service from Afrox 1 year conditional warranty.

Afrox Transarc Single-Stage Regulator Model

Description

Gas Type

Delivery Pressure

Inlet Connection

Outlet Connection

Max Inlet Pressure

Item Number

S6000 AGS 150

Single-stage general-purpose regulator for welding, cutting and heating

Acetylene

0 - 150 kPa

5/8” LH

3/8” LH

2 750 kPa

W003858

S6000 OGS 600

Single-stage medium outlet pressure regulator for medium duty welding and cutting

Oxygen

0 - 600 kPa

5/8” RH

3/8” RH

30 000 kPa

W003859

S6000 LGS 400

Single-stage 400 kPa Handigas (LPG) regulator suitable for the full range of Afrox LPG nozzles

Handigas (LPG)

0 - 400 kPa

5/8” LH

3/8” LH

2 000 kPa

W003612

Transarc Cartridge and Automatic Arrestors Afrox Transarc Cartridge & Automatic Arrestors Model

Gas

Inlet Connection

Outlet Connection

Description

Item Number

Transarc TM35

Fuel Gas

8 mm Hose

3/8” BSP

NM250 Torch Mount

W012042

Transarc TM35

Oxygen

8 mm Hose

3/8” BSP

Type 2 Torch Mount

W012041

Transarc RM35

Fuel Gas

8 mm Hose

3/8” BSP

Regulator Mount

W012037

Transarc RM35

Oxygen

8 mm Hose

3/8” BSP

Regulator Mount

W012036

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Gas Equipment | Afrox Product Reference Manual

Transarc Cutting Nozzles Transarc Acetylene Hand Cutting – A-NM6 Gas Consumptions Nozzle Size

Material Thickness (mm)

Oxygen Pressure (kPa)

Acetylene Pressure (kPa)

Cutting Speed (mm/min)

Oxygen Cutting (kg/h)

Oxygen Heating (kg/h)

Acetylene Heating (kg/h)

0,8

3-6

150

15

500 - 850

1,13

0,41 0,69

0,31 0,52

W005027

2,45

0,49 0,82

0,37 0,62

W005028

5,37

0,56 1,06

0,44 0,76

W005029

6,23

0,60 1,06

0,49 0,76

W005029

0,49 0,76

W005029

1,2 1,6 1,6

6 - 12

200

12 - 25

15

250

25 - 50

440 - 700

15

300

300 - 610

20

230 - 400

Item Number

1,6

50 - 75

350

30

180 - 300

7,03

0,76 1,06

2,0

75 - 100

300

30

180 - 250

9,55

0,76 1,17

0,56 0,87

W005034

2,4

100 - 150

300

30

150 - 180

13,92

1,17 1,62

0,87 1,20

W005035

3,2

150 - 250

450

35

100 - 125

29,84

1,65 2,06

1,23 1,54

W005036

34,48

1,88 2,42

1,39 2,00

W005036

3,2

250 - 300

550

35

90 - 125

Transarc LPG Cutting – P-NM Gas Consumptions

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Nozzle Size

Material Thickness (mm)

Cutting Speed (mm/min)

Cutting Oxy- Heating Oxy- LPG gen Pressure gen Pressure Pressure (kPa) (kPa) (kPa)

Oxygen Cutting (kg/h)

Oxygen Heating (kg/h)

LPG Heating (kg/h)

Item Number

0,8

3-6

460

150

30

20

1,13

1,8

0,67

W010044

1,2

6 - 12

400

200

35

20

2,62

2,0

0,91

W010045

1,6

12 - 25

300

300

35

20

5,3

2,0

0,91

W010046

1,6

25 - 50

220

300

40

30

5,3

2,3

0,91

W010046

1,6

50 - 75

160

350

50

35

6,1

2,5

1,0

W010046

2,0

75 - 100

155

350

70

40

10,4

3,1

1,3

W010047

2,4

100 - 150

140

400

70

40

16,4

3,5

1,4

W010048

3,2

150 - 250

100

560

100

50

35,6

4,5

1,8

W010049

3,2

250 - 300

90

560

100

60

35,6

4,5

1,8

W010049

Type 2 torch, maximum cutting thickness is 75 mm.

Afrox Product Reference Manual

| Gas Equipment

Transarc Welding/Brazing Tips Transarc Medium Duty Welding & Brazing Tips Gas Consumptions Nozzle Size

Material Thickness (mm)

Nozzle Length (mm)

Oxygen Pressure (kPa)

Acetylene Pressure (kPa)

Oxygen (kg/h)

Acetylene (kg/h)

Item Number

1

0,9

140

15

15

0,04 0,06

0,03 0,05

W005099

2

1,2

140

15

15

0,07 0,15

0,06 0,11

W005100

0,09 0,16

W005101

3

2,0

140

15

15

0,11 0,21

5

2,6

140

15

15

0,21 0,25

0,16 0,19

W005102

7

3,2

185

15

15

0,28 0,38

0,22 0,28

W005103

10

4,0

185

20

20

0,41 0,47

0,31 0,35

W005104

13

5,0

185

30

30

0,54 0,66

0,40 0,50

W005105

0,56 0,62

W005106

18

6,5

290

40

40

0,62 0,83

35

10

290

60

60

1,45 1,49

1,08 1,11

W005107

1,39 1,48

W005108

1,70 2,01

W005109

45

13

345

60

60

1,88 1,99

55

19

345

60

60

2,29 2,71

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10 Transarc Gas Hoses

Picture shown with optional hose connections

Picture shown with optional hose connections

Transarc Gas Hoses Description

Size

Item Number

Transarc Acetylene Hose

8 mm (30 m lengths)

W002607

Transarc Oxygen Hose

8 mm (30 m lengths)

W002608

Transarc LPG Hose

8 mm (per metre)

W002606