torch@petrogen.com |1-877-888-6724 |719-596-1175 |Fax: 719-596-4721 |P.O. Box 75610, Colorado Springs, CO 80970
Petrogen
Petrogen

P: 719-596-1175 | E: torch@petrogen.com

ONLINE RESOURCE

Whether you wish to see a live demo of our liquid fuel cutting torch systems, or would like to brush up on the components and maintenance of your current Petrogen system, our Live Online Training resource makes it easier than ever to get the information you need.

  • All Petrogen online trainings are complimentary and do not require you to create an account or login. At the conclusion of our trainings we do invite feed back that we may use to improve the experience for future participants.

TO PARTICIPATE:

  1. First contact us at torch@petrogen.com or at 1-877-88-TORCH (877-888-6724) to schedule a spot between Monday - Friday, 9 a.m. - 4 p.m. (Mountain time).
  2. Ten minutes before your scheduled time a Petrogen trainer will call to confirm your spot, and ask you to visit this page to access the below live feed (requires high speed Internet).
  3. At the time of your scheduled spot the Petrogen trainer will call back to initiate the training. He will remain on the phone to verbally walk you through the training while an operator demonstrates the training on the live feed.
  • If you would like to allow multiple people to follow along in the training, call on a phone that has suitable speaker-phone capabilities.
  • We also conference call separate lines at your request.


Petrogen's Live Feed for Training and Demos

Feed Tips:

  • Hover over the feed for play/pause and full screen options.
  • Clicking the feed will open a new tab, opening the feed in the LiveStream website.
  • There will be no sound through the feed. Call in or use the live chat to comunicate.

Petrogen Breach Lab Training Classes

Up-Coming Petrogen Breach Lab (PBL) Class Schedule


Description Date Price Book
Core Training TBD TBD Closed
Intermediate Training TBD TBD Closed
Avanced Training TBD TBD Closed

Training classes range from basic cutting to advanced technical breaching. Classes will be held at the Petrogen Breach Lab (PBL). Custom classes are currently available by appointment, so don't hesitate to contact us.

Petrogen also offers Mobile Training Teams (MTT). With the MTT, a trainer or trainers will come out to your facility and give operators a specialized training based on their cutting operations. We recommend one trainer per four students. This ensures trainees get the most out of the instruction.


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Section 1 - System Components

Sections:


1. FULL SYSTEM

* Hover over the circled letters to learn more.

Complete Petrogen System
2. LIQUID FUEL TORCH

* Hover over the circled letters to learn more.

Petrogen Torch Componenets
3. LIQUID FUEL TANK

* Hover over the circled letters to learn more.

Petrogen Liquid Fuel Tank Components
4. OXYGEN BOTTLE

* Hover over the circled letters to learn more.

Oxygen Bottle Components

Every Petrogen package also includes a Standard Spare Parts Kit, Standard Tool Kit and 8" Adjustable Crescent Wrench for assembly, maintenance and repair.


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Section 2 - SYSTEM ASSEMBLY

Sections:


1. SYSTEM COMPONENT CHECK

Before assembling your system or after prolonged storage, check that all components are present, serviceable, and undamaged. It is also best practice to check system components for serviceability before each use. If there is any question as to whether or not a part is in good working order, please contact Petrogen Customer Service at 877-888-6724.



2. TORCH ASSEMBLY

For Multi-Fuel Adapter assembly Click here.


  1. Slide Tip Nut over chosen Tip. Place Tip’s seating surface into Torch Head.
  2. Tip Installation

  3. Tighten the Tip Nut in a clockwise manner using an Adjustable Wrench. DO NOT OVERTIGHTEN.
  4. Tip Installation

  5. Attach the Oxygen Flashback Arrestor (found in the Standard Spare Parts Kit) to the Torch’s Oxygen Hose Connector (labeled OXY). Use an Adjustable Wrench to snug the Oxygen Flashback Arrestor to the Torch.

  6. Oxygen Flashback Arrestor Installation

3. PACKING NUT CHECK

Use the included Packing Nut Wrench found in the Standard Tool Kit to check the following packing nuts for snugness:

  1. Pre-Heat Oxygen Valve Packing Nut - located under the Pre-Heat Oxygen Knob on the Torch.
  2. Preheat Oxygen Knob Packing Nut

  3. Fuel Control Valve Packing Nut - located under the Fuel Control Knob on the Torch.
  4. Fuel Control Knob Packing Nut

With the Adjustable Wrench, check:

  1. Fuel Valve Packing Nut- located under the Fuel Valve on the Liquid Fuel Tank.
  2. Shut-Off Valve Packing Nut

The packing nuts should be snug at all times to ensure proper valve seal. If desired, knob tension can be adjusted by increasing the tightness of the packing nuts.


NOTE: These three fittings should be checked:

  1. As part of initial assembly of new systems
  2. During routine maintenance
  3. If any weeping or leaking is observed

4. OXYGEN REGULATOR & OXYGEN HOSE
  1. Inspect the regulator inlet and oxygen bottle valve port for debris. Ensure the oxygen valve is clear by briefly opening (crack open) the oxygen bottle, allowing oxygen to expel any debris.
  2. Clearing the Oxygen Valve

    WARNING: Any debris between the regulator and oxygen valve can create combustion inside the regulator which may violently exit through the regulator gauges.

  3. Connect the oxygen regulator to the oxygen bottle valve. Snug the fitting with an adjustable wrench.
  4. Attach one end of the green Oxygen Hose to the Oxygen Flashback Arrestor on the Torch and the other end to the Regulator. Snug both fittings with an adjustable wrench (All Oxygen fittings have a standard right hand thread and cannot be confused with fuel fittings which have a left hand thread).

5. OXYGEN HOSE PRESSURIZATION

It is best practice to pressurize the oxygen line before the fuel line. Maintaining positive pressure throughout the oxygen system safeguards the oxygen line against fuel contamination. If fuel is allowed to enter the Oxygen Hose, a flashback may occur. Purging the Torch before light up further protects the operator against oxygen line flashback.

  1. When opening the Oxygen Bottle Valve, ALWAYS FACE AWAY FROM THE GAUGES. Open the valve slowly and fully.

6. OXYGEN PRESSURE SETTINGS
  1. The oxygen pressure setting is based on the Tip size selected. Each Tip has a specified range of acceptable oxygen pressure. Begin with the lower pressure indicated and increase the pressure if necessary. Using incorrect oxygen pressure will greatly affect performance and consumption though it will not create a hazard.
  2. The gauge on the left indicates the amount of pressure being delivered to the Torch. The gauge on the right indicates the amount of pressure inside the Oxygen Bottle.
  3. To increase the amount of pressure delivered to the torch, turn the Regulator Control Valve clockwise. To decrease the amount of pressure delivered to the torch, turn the Regulator Control Valve counterclockwise while depressing the High Pressure Oxygen Trigger on the Torch.

STANDARD TIP SELECTION CHART

TIP SIZE INCHES FUEL - PSI OXYGEN - PSI
0, 0HH 0 - ¼ 10 - 20 12 - 17
1, 81, HH1 ¼ - 1 10 - 20 17 - 25
2, HH2 1 - 2 10 - 20 25 - 35
3, 83, HH3 2 - 4 10 - 20 35 - 40
4, HH4 4 - 6 10 - 20 40 - 50
5, HH5 6 - 8 14 - 20 50 - 60
6, HH6 8 - 10 16 - 20 70 - 80
7 10 - 12 18 - 20 80 - 100
8 10 - 14 20 120+
L HEATING 18 - 20 100

METRIC TIP SELECTION CHART

TIP SIZE MILLIMETER FUEL - KPA OXYGEN - KPA
0, 0HH 0 - 7 70 - 140 80 - 120
1, 81, HH1 70 - 140 70 - 20 120 - 180
2, HH2 25 - 50 70 - 140 180 - 250
3, 83, HH3 50 - 100 80 - 140 250 - 280
4, HH4 100 - 150 80 - 140 280 - 350
5, HH5 150 - 200 100 - 140 350 - 420
6, HH6 200 - 250 110 - 140 490 - 560
7 250 - 300 130 - 140 560 - 700
8 300 - 350 140 80+
L HEATING 130 - 140 700

7. LIQUID FUEL TANK FILLING
  1. Select Fuel
  2. For best performance, use clean fresh fuel. If the only fuel available is old or fouled the system can still be operated without damage.

    • Fuels suitable for use include gasoline of any grade, white gas, camping fuel, and stabilized (tool or small engine) fuels. When using the Multi-Fuel Adapter, diesel, biodiesel, kerosene, Jet-A, JP-8, JP-5 and JP-24 can be used.
  3. Remove Filler Cap from the Fuel Tank
  4. If there is pressure in the Fuel Tank, open the cap slowly until you hear the pressure venting through the machined groove in the cap body. Let the tank completely vent its pressure before removing the cap completely.

  5. Fill the Fuel Tank to specified level
  6. It is important to fill your Fuel Tank to the specified level. This leaves the optimum amount of air space in the Fuel Tank for proper pressurization. Overfilling the Fuel Tank will cause the pressure to fall rapidly. Underfilling the Fuel Tank will require excessive pumping to obtain optimum pressure.

    • Place the Fuel Tank on the ground to avoid static discharge while fueling.
    • Fill the Fuel Tank directly from a fuel pump OR from an approved fuel container.
      • 2.5 Gallon Fuel Tank (Standard): Fill to 2 gallon Weld Line, indicated by the welded seam on the upper half of the tank.
      • 2 Quart Fuel Tank (PCS.): Fill with 1.5 quarts.
      Petrogen's Liquid Fuel Tank Filling
  7. Replace the Filler Cap and secure it snugly by hand.

8. LIQUID FUEL TANK PRESSURIZATION
  1. Pump the Fuel Tank to the pressure specified for your system (If your system requires 50 or 100 psi, this will be indicated on the Filler Cap).
    • Standard Systems: 20 psi
    • Multi-Fuel Adaptor Systems: 50 psi
    • Underwater System: 100 psi

    Pumping a standard 2.5 gallon Fuel Tank should require between 80 and 100 plunges to reach 20 psi. The standard 2 quart Fuel Tank should require between 15 to 25 plunges to reach 20 psi.

    • During cutting operations, ensure the Fuel Tank pressure remains above 10 psi. When the Fuel Tank pressure reaches 10 psi, re-pressurize the Fuel Tank to 20 psi. This will ensure the fastest activation of the Fast Flow Check Valve.
  2. All Petrogen pressure vessels are fitted with an automatic pressure relief valve inside the Filler Cap. Do not attempt to adjust or modify the pressure relief valve. If you believe the valve has been tampered with, return the Filler Cap assembly to Petrogen for re-calibration.
  3. NOTE: Tampering with the tank pressure relief valve voids the warranty for the entire system.

  4. When conducting overhead cutting in excess of 30 feet, it may be necessary to compensate by increasing the fuel tank pressure. This may require a Filler Cap with a higher activation setting. If this type of cutting is common it is recommended that operators install the tank Automatic Pressure Kit (Part #2349), which uses an external compressed Air Carry Tank (Part #2370), eliminating the need for hand pumping. Contact Petrogen Customer Support for more details.

9. LIQUID FUEL LINE PURGE

Purging the fuel line eliminates air bubbles. If air bubbles are left in the Fuel Hose, the flame may go out during the first minutes of operation. Purging the line may take up to 2 minutes per 25 feet of hose.

  1. Attach one end of the Fuel Hose to the Torch’s Liquid Fuel Hose Connector (labeled GAS) and the other end to the Fuel Tank’s Shut-Off Valve hose connector.
    • Snug both fittings with an Adjustable Wrench. All Fuel Hose fittings have a left hand tightening thread identified with a hash mark to indicate counter-clockwise tightening.
  2. Slowly turn the Fuel Tank’s Shut-Off Valve 1/4 turn allowing fuel to flow out of the tank into the hose.
    • Opening the Shut-Off Valve too quickly will activate the Fast Flow Check Valve, stopping fuel flow. If this happens, fuel will not leave the tank and cutting will not be possible. To reset the valve, close the Fuel Valve on the tank fully, and tap the top of the knob. Slowly re-open the knob 1/4 turn.
  3. Hold the Torch above the Fuel Tank and oscillate/agitate the Fuel Hose to speed the movement of the fuel through the Fuel Hose and help eliminate air bubbles.
  4. Open the Fuel Control Knob on the Torch.
    • This step is necessary to allow air in the fuel line to escape.
    • Be prepared for a small amount of fuel (approximately 1-2 Tbsp) to come out of the torch tip while the air is purging. Use a metal can or other approved fuel container to catch the fuel.
  5. Close the Fuel Control Knob on the Torch
  6. Once the line is purged, completely open the Shut-Off Valve on the Fuel Tank. The Shut-Off Valve should remain completely open during operation.

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Section 3 - LIGHT UP

Sections:


1. SAFETY CHECKS

CHECK YOURSELF & YOUR TEAM

  • Wear the correct protective equipment for the job
  • Know how the material you are cutting reacts to heat

CHECK YOUR ENVIRONMENT

  • Know what is beneath, beside and above your cut
  • Aggressively look for hidden hazards
  • Never cut into, or near anything you are not sure of

CHECK YOUR EQUIPMENT

  • CHECK that all fittings are snug
  • Store and transport your system safely
  • Before light up, PURGE the system by depressing the High Pressure Oxygen Trigger

* The above safety checks are recommended practice when preexisting policies have not been set.


2. LIGHT UP
  1. PREP THE SPARK STRIKER
  2. Ensure that your spark striker is engaging the flint and creating adequate sparks before beginning the light up process. Doing so will prevent excess fuel from being lost.

  3. CONTROL SURFACES
  4. Liquid fuel cutting torch's three control surfacesThere are three control surfaces to activate on the Petrogen Torch when performing light up.

    1. PRE-HEAT OXYGEN KNOB -
      Turn counterclockwise to open the valve and clockwise to close the valve.
    2. HIGH PRESSURE OXYGEN TRIGGER -
      Depress trigger to release the flow of high pressure oxygen. Release the trigger to cease the oxygen flow.
    3. FUEL CONTROL KNOB -
      Turn counterclockwise to open the valve and clockwise to close the valve.

  5. LIGHT UP PROCEDURE
  6. The recommended light up sequence (1/2 turn - Purge - 1/2 turn), creates a suitable preheat mixture for light up and also helps to protect from oxygen flashback.

    (when using a Multi-Fuel Adapter: 1/2 turn – purge – 1 full turn)


    1. Pre-Heat Oxygen Knob - Open precisely 1/2 turn (use the '+,-' decals to execute a precise turn).
    2. If using tips 6, 7, or 8 open 1/4 turn.


      Petrogen start up - Half Turn
    3. High Pressure Oxygen Trigger - Purge by fully depressing for 3 to 5 seconds.

    4. Petrogen start up - Purge
    5. Fuel Control Knob - Open precisely 1/2 turn (use the '+,-' decals to execute a precise turn).
    6. When using a Multi-Fuel Adapter open the Torch Fuel Control Knob (3) precisely 1 full turn)


      Petrogen start up - Half Turn
  7. LIGHTING THE TORCH
  8. When lighting the Torch, strike the sparker directly at the tip. Striking sparks too far away will slow or even prevent ignition.


  9. WARM UP IMPORTANT
  10. Tip to Material Warm UpAfter ignition, rest the Tip directly on the steel at a 45 degree angle for 5 to 10 seconds. The reflected heat will bring the Tip to its operating temperature allowing the fuel to fully vaporize inside the Tip. Make no flame adjustments during this period. Failing to allow the Tip to fully heat will prevent proper flame adjustment. As the Tip warms, the yellow and orange in the flame will disappear.

    Increase efficiency by warming the Tip on the cut line, effectively preheating the metal while bringing the Tip to cutting temperature.


  11. FINAL ADJUSTMENTS
  12. With the Tip still touching the steel, use the Fuel Control Knob to make the final adjustment. When using the recommended light-up setting (1/2 turn oxygen / 1/2 turn fuel), the preheat flame will be slightly rich. Using the Fuel Control Knob, adjust the flame so that the preheat jets slightly oscillate. See below flame illustrations or flame adjustment card for visual reference.


  • The Petrogen preheat flame should look and sound more aggressive than the flames of compressed gas cutting torches. Running the Torch with a rich flame setting is critical to unlocking the performance of the system. Running the torch with a lean (wispy) setting will overheat the head, reduce performance and increase maintenance and repair.

  • A rich setting allows more liquid fuel to enter the head of the torch. The natural cooling effect created by the liquid fuel evaporation protects the Mixer and Tip against overheating. Additionally, the liquid fuel rapidly increases in volume as it expands into a gas, creating a greater oxy/fuel velocity as it leaves the Tip, ultimately driving more BTUs into the steel.


LEAN RICH/CORRECT TOO RICH
  • Not enough fuel
  • No canopy
  • Hissing sound
  • Flame about to separate from tip
  • Balanced flame
  • Desired Setting
  • Canopy
  • Roaring sound
  • Dark blue core 3/16" (4 mm)
  • Too much fuel
  • Canopy
  • Wavering blue core
  • Large streaks of yellow
Liquid fuel flame variations

3. SHUT DOWN
    Petrogen Shut Down
  1. First, close the Fuel Control Knob on the Torch (1) by turning it clockwise, fully. Do not over tighten.
  2. Purge the torch by depressing the High Pressure Oxygen Trigger (2) for 3 to 5 seconds.
  3. Close the Pre-Heat Oxygen Valve (3) by turning it clockwise fully. Again, do not over tighten.

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Section 4 - STORAGE

Sections:


Refer to the American Welding Society Safety in Welding, Cutting and Allied Processes (ANSI Z49.1:2012) publication and local regulations for detailed storage and transportation guidelines.


NORMAL SHUTDOWN

After the Torch is shutdown, close the Tank Fuel Valve. Close the Oxygen Bottle Valve at the source bottle. Relieve the pressure in the oxygen line by depressing the High Pressure Oxygen Trigger. To return to cutting operations, first open the Oxygen Bottle Valve on the source tank and then open the Tank Fuel Valve.


STORAGE SHUTDOWN
  1. Before the last cut of the day, close the fuel shutoff valve. During the last cut the pressure in the fuel line will be relieved, reducing spillage during disassembly.Perform the steps listed in “Regular Use Shutdown”. Disconnect the oxygen hose from the torch and oxygen regulator.

  2. Remove the oxygen regulator from the oxygen bottle.

  3. Install the transport safety cap onto the oxygen bottle and secure the bottle in an approved storage area. Unscrew the fuel tank filler cap until the sound of escaping air can be heard.

  4. Once the pressure has been completely relieved, remove the cap completely.

  5. Remove the fuel line from the fuel tank and place the hose end into the fuel tank. This is easiest when done with two people. Hold the torch above the level of the fuel tank and open the fuel control knob on the torch eliminating any vacuum which might keep fuel in the line or torch.

  6. Working from the torch to the tank push any remaining fuel out of the hose by holding the line above the fuel tank. Repeat this until no fuel drains from the hose into the tank.

  7. Remove the torch from the fuel line and allow both to fully air dry. (NEVER STORE ANY OXY/FUEL SYSTEM IN AN AIRTIGHT CONTAINER OR COMPARTMENT. FLAMMABLE FUMES MAY COLLECT AND EXPLODE.)

  8. Drain the contents of the fuel tank into an approved storage container. If no container is available the Petrogen fuel tank is a UL tested, ASME code pressure vessel which meets or exceeds the requirements for flammable liquids storage containers in most areas.

Prolonged storage of fuel in the Fuel Tank or Torch will not damage the equipment. However, over time fuel will degrade and lose volatility. If the quality of the fuel has degraded to a point where performance is adversely affected, replace the fuel in the tank and lines. Remove old fuel and oily buildup by flushing the Fuel Hose using a ratio of one cup of fresh fuel per 25 feet of hose. Generally fuel will remain effective for 2-3 months when stored in the system. Fuel stabilizing additives may be used to extend fuel life.


READY LEVELS
  • Ready 1
  • Ready 1 should be used when cutting operations must be initiated in the shortest amount of time. Primed and ready for use, this is the highest level of readiness.
    Common usage: During daily operations, Rescue/Military Vehicles In Service.

    • Fuel tank full and pressurized
    • Fuel in line
    • Fuel and oxygen hoses connected and secure
    • Fuel and oxygen off at the Torch
    • Fuel and oxygen off at the bottles

    • PCS/SAR systems include Oxygen Valve protection. The Regulator may remain attached at all times including during transport.
    • Standard Systems do not include additional Oxygen Valve protection and Regulators should be disconnected from the oxygen tank during vehicle transport.

  • Ready 2
  • Ready 2 is a safe way to store and transport the Petrogen System when use is intermittent. Keep in mind that it will be necessary to pressurize the fuel tank and prime the fuel line before cutting.

    • Fuel in tank NOT UNDER PRESSURE
    • Fuel line empty
    • Fuel and oxygen hoses connected and secure
    • Fuel and oxygen off at the torch
    • Fuel and oxygen off at the bottles
    • Regulator disconnected and safely stored

    • PCS/SAR systems include Oxygen Valve protection. The Regulator may remain attached at all times including during transport.
    • Standard Systems do not include additional Oxygen Valve protection and Regulators should be disconnected from the oxygen tank during vehicle transport.

  • Ready 3
  • Ready 3 is the appropriate way to store the Petrogen System for prolonged periods.

    • Fuel tank empty and not under pressure
    • Fuel line empty
    • Regulator disconnected and safely stored
    • Oxygen bottle turned off and stored with transport safety cap installed
    • Fuel and oxygen hoses disconnected

The above storage procedures are recommendations and may be modified to fit established SOP’s.


AFTER EXTENDED STORAGE CHECKS
  • PACKING NUTS -
  • Check to ensure the system's three Packing Nuts are snug.

    1. Pre-Heat Oxygen packing (Torch)
    2. Fuel Control packing (Torch)
    3. Fuel Valve packing (Liquid Fuel Tank)

  • OXYGEN FLASHBACK ARRESTOR -
  • Check to ensure the Oxygen Flashback Arrestor is assembled to the torch should it have been removed for storage.


  • LEATHER PUMP CUP -
  • If little resistance is felt while pumping the Liquid Fuel Tank you may need to oil or replace the Leather Pump Cup located on the Pump Shaft.


  • FILLER CAP GASKET -
  • If pressure will not build in the Liquid Fuel Tank, check that the Filler Cap Gasket is in tact.


  • FUEL -
  • Fuel stored in the Liquid Fuel Tank and/or fuel hose longer than three months, without a stabilizer will become stale and may reduce performance. Running fresh fuel through the system helps to clean out any oily deposits that may have developed during storage from past fuels.


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Section 5 - CUTTING INSTRUCTION

Sections:


CUTTING BASICS

KEYS TO SUCCESS

Performing clean, fast cuts requires practice. Make the following habits a standard part of cutting operations to greatly increase productivity and reduce the learning curve of the operator.


  1. Take the time to find a stable, comfortable position
  2. Use what's available to rest or stabilize the torch and or the operators hand
  3. Use small, smooth movements
  4. Use one consistent speed of travel throughout the cut
  5. Pay extra attention at the beginning of the cut to ensure that the flame has completely penetrated the material before proceeding.
  6. If at any time sparks or molten material exits the cut from a direction other than directly from the bottom of the material, examine the area, as the flame may not be fully penetrating the steel.

TORCH POSITION

Take time to analyze the precise path the cut will follow before lighting the torch. This path is called the Cut Line. Identify and mark the cut line with soap stone or chalk. This will result in a smoother and thus faster cut.


Determining your Cut

Position the preheat flame so that half of the flame is on the steel and the other half runs down the leading edge of the steel.


Keep the torch perpendicular to the face of the steel while cutting (Fig. 20). This directs all of the energy of the preheat flame and high pressure oxygen jet directly into the steel, maximizing cutting efficiency and controlling hot material as it exits the cut.


Positioning the Cutting Torch

INTRODUCING HIGH PRESSURE OXYGEN

Once the steel becomes molten, depress the High Pressure Oxygen Trigger smoothly and fully. If ignition is lost, release the trigger and allow the preheat flame to bring the steel back to a molten temperature.


ASSESS THE CUT

It is best to assess and fix mistakes as they occur rather than waiting to the end of the cut and attempting to remember where they happened. The best indicator that the cut is not completely penetrating the steel is when the sparks move sideways rather than straight from the bottom of the cut. Any time this is observed, evaluate the area and do what is necessary to fix any problem.



STEEL IS THE FUEL

The BTUs generated by the burning steel produce the majority of the overall energy released in the cutting precess. The preheat flame is simply the catalysis for ignition. When faced with difficult cutting scenarios, consider how the burning steel can be used to ignite layers beneath it. This is essential knowledge when cutting through air gaps, layers or difficult shapes because it is the contribution of BTUs from the burning steel that allow these operations to be possible. To learn more refer to VDOT.



FAILED CUT

In the event that the steel does not fully separate after the cut is complete, you may need to go back and retrace a portion of the cut. Take the following actions:


  1. Look down through the kerf to determine the point of attachment. Tapping the metal may help to identify the snag.
  2. Identify a point above or below the snag where the cut clearly penetrates completely through the material.
  3. Begin a new cut with the intention of cutting around the snag at the bottom.

Retracing a Failed Cut

NOTE: A common operator mistake is holding the Tip in the middle of the kerf (the gap were steel was removed), and depressing the High Pressure Oxygen Trigger in an attempt to burn or dislodge metal or slag which is holding the cut together.

When only a small bridge of material exists, the fastest technique may be to begin a new cut adjacent to the bridge, allowing the molten steel from the cut to flow down and eliminate the snag. If there is substantial material holding the cut together it is advisable to make a new cut directly parallel to the original cut. It is important to move into the material deep enough to engage fresh steel. Generally 1/4 inch is sufficient.


Common causes for a cutting pass to fail include moving too quickly, stopping slightly short leaving a web on the bottom end, not using the appropriate tip size, or incorrect oxygen pressure for the Tip size.


ADVANCED CUTTING

V-CUT

The V-Cut is a very subtle technique used to grab added steel from the top most layer of a stack to fuel the layers beneath. This added back and forth “V” motion is useful in situations when there is a significant buildup of debris between layers or there is difficulty achieving penetration through all layers.


Lazy W Technique

HOLE PUNCHING

Place the preheat flame in the location of the desired hole. Maintain a 1/4 inch coupling distance and observe beneath the preheat flame for a molten puddle to form. Once a molten puddle has formed and begins to drip (spider out) perform the following three actions simultaneously.


  1. Smoothly engage the High Pressure Oxygen Trigger fully
  2. Increasing the coupling distance (1/4 to 1/2 inch)
  3. Move the torch head (1/4 to 1/2 inch) left, right or back

Punching Holes

The movement of the torch head will create a small trench which molten material and expanding gases will follow. The material will travel in the opposite direction of the movement of the torch. For example, to direct the material to the left, move the torch head right. Don’t push the torch forward as this will direct the material toward the operator.


Once a hole has been pierced through the steel, the operator may enlarge the hole by keeping the High Pressure Oxygen Trigger depressed and moving the Torch in an outward spiral.


When this technique is performed properly, little or no popping will occur and the tip will be protected from overheating because the heat is directed away. Failure to use a proper hole punching technique may result in overheating the head of the torch or melting the Tip. Indications that this has occurred include: the Tip Nut becoming loose, and leaking around the Tip Nut due to melted O-rings on the Mixer(see Mixer Repair).


CUTTING LAYERS

If the layers are exposed, preheat the cut line and down the side of the material where the cut will be initiated before beginning the cut. If the layers are not exposed, begin by punching a hole. Once the top-most layer becomes molten, depress the High Pressure Oxygen Trigger smoothly and fully, allowing the heat generated from the top layers to ignite the bottom layers before moving deeper into the cut. (see below).


When proceeding into the cut, executing the small, controlled ‘V’ pattern will make penetrating the bottom layers much easier. Once through all layers, proceed with the cut normally, using the ‘V-Cut’ technique whenever needed.


Watch the material as it leaves the bottom of the cut. If it does not exit directly from the bottom, as it would when cutting a solid piece, then the cut is probably not penetrating all of the layers.


Cutting Layered Material with Petrogen

NOTE: When cutting layers, it is generally necessary to increase one tip size over the cutting chart recommendation for the solid equivalent of the cut thickness.


CUTTING GAPS

Use the same techniques described in layer cutting. Preheat the cut line and down the side of the material where the cut will be initiated before beginning the cut. Once the top-most surface becomes molten, depress the High Pressure Oxygen Trigger. Maintain this position until the heat from the burning of the top layers has passed through the air gap and ignited the layer(s) below. As you move into the cut, make the “V” motion to increase the heat of the cut. Watch the material as it leaves the bottom of the cut. If it does not exit directly from the bottom as it would when cutting a solid piece, then the cut is probably not penetrating all of the layers.


Cutting Gapped Material with Petrogen

DRIVE TECHNIQUE

If there is a significant buildup of debris between the layers or there is difficulty achieving penetration through all layers, it may be necessary to increase the forward speed of the cut and increase the size of the ‘V’ until complete penetration is achieved. This technique will increase the heat significantly, allowing for deeper penetration. Note that there may be uncut layers at the start of the cut when using this technique.


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Section 6 - Maintenance

Sections:


The Petrogen system requires very little day-to-day maintenance when operated properly. Most problems occur as a result of using a flame adjustment that is too lean (too much oxygen and not enough fuel). As described in Run It Rich, using a slightly rich flame adjustment eliminates this problem and significantly enhances overall performance.


1. TIP MAINTENANCE

Perform Tip maintenance when preheating performance and/or cut cleanliness has been noticeably reduced.


* A cleaner Tip will produce a cleaner cut. Clean the preheat flutes to produce a more consistent preheat flame. Clean the high pressure oxygen center hole to improve cut edge quality. Though cleaning the preheat flutes will produce a more stable flame, cleaning the high pressure oxygen center hole directly affects cut edge quality by enhancing laminar flow of the oxygen jet.


Petrogen Torch Tip Assembly

Tip Removal

Using an adjustable wrench, loosen the Tip Nut by turning it counterclockwise. Remove the Tip Nut and Tip from the head of the torch, being careful not to drop the tip core.


Note: To cool a hot Tip before removal, take the following actions. Briefly open the torch fuel control valve. The evaporating fuel will quickly cool the Tip to room temperature. Once the fuel exiting the Tip becomes a liquid immediately close the fuel valve.


Liquid Fuel Tip Cleaning

A. Tip Drill Set (Part #4018)

Used to clear debris from the high pressure oxygen center hole, as shown in figure 32. The nine drills in the set correspond to the nine Tip sizes. The brass brush can be used to clean the Tip core flutes as well as remove slag from around the high pressure oxygen center hole.


B. Tip Reamer (Part # 4012)

Used to remove deposits from the slot inside of the tip shell.


C. Two Part Tip Brush (Part #4013)

Used to remove slag from the Tip shell and the flutes of the Tip core. DO NOT use this brush or any abrasives on the seating surface of the Tip core where it mates with the Mixer inside the Torch Head


2. PACKING NUT MAINTENANCE

Packing Nut maintenance should be performed regularly between uses or if valve leaking/weeping is observed.


Use the included Packing Nut Wrench found in the Standard Tool Kit to check the following packing nuts for snugness:

  1. Pre-Heat Oxygen Packing Nut - located under the Pre-Heat Oxygen Knob (Torch).
  2. Fuel Control Packing Nut - located under the Fuel Control Knob (Torch).

With the Adjustable Wrench, check:

  1. Fuel Valve Packing Nut - located under the Fuel Valve (Liquid Fuel Tank).

The packing nuts should be snug at all times to ensure proper valve seal. If desired, knob tension can be adjusted by increasing the tightness of the packing nuts.


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Section 7 - TROUBLESHOOTS

Sections:


1. LIFETIME WARRANTY

Any Petrogen product found to be defective in materials or craftsmanship will be repaired or replaced at no charge during the warranty period (25 Years). Petrogen may require the product to be returned to the factory for examination. Return transportation charges will be at the customer’s expense; replacement transportation charges will be at Petrogen’s expense.


The “Petrogen Warranty” will be considered void if the product has been subject to misuse, negligence, accident, misapplication, modification, used with other than OEM components, or repaired by unauthorized personnel.


Please do not hesitate to contact Petrogen for assistance.


2. DIFFICULTY LIGHTING THE TORCH

3. FUEL LEAKS

4. OXYGEN LEAKS
  • Tip
  • PRE-HEAT OXYGEN KNOB
  • OXYGEN HOSE/TORCH OXYGEN HOSE CONNECTOR
    • Remove the Oxygen Hose and clean the threads and mating surfaces
  • OXYGEN HOSE/REGULATOR
    • Remove the Oxygen Hose and clean the threads and mating surfaces
  • REGULATOR/OXYGEN BOTTLE VALVE
    • Use a plastic brush to clean the threads of the Regulator Valve Connector and the threads of the Oxygen Bottle Valve (*Never use liquids or abrasives to clean this connection)
    • Carefully ispect the components for debris before reassembling

5. FUEL TANK PRESSURE

6. POPPING
  • Loosen and retighten the Tip Nut
  • Inspect the seating surfaces of the Tip and replace the Tip if necessary

7. FLICKERING OR UNSTABLE FLAME

TROUBLESHOOTING THE TORCH

* Hover over the circled letters to learn more.

Troubleshooting the Petrogen Liquid Fuel Torch
TROUBLESHOOTING THE LIQUID FUEL TANK

* Hover over the circled letters to learn more.

Troubleshooting the Petrogen Liquid Fuel Tank

For further advice, Live Online Training or repair information contact us at 1-877-88-TORCH (6724) or at torch@petrogen.com.


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Section 8 - Repairs

Sections:


1. FUEL STREAM CHECK

If little or no fuel exits the Tip when the Fuel Tank and Torch valves are open, perform the following test to determine the location of the restriction.


NOTE: Because the problem may be an accidental activation of the Fast Flow Check Valve, reset the valve before beginning the test.


NOTE: Safety Glasses are required safety equipment for the Fuel Stream Check.


  • Perform this test with the Oxygen Bottle Valve open and the Oxygen Hose pressurized. (This will protect the oxygen system from fuel contamination during the test.)
  • Begin the test with the Torch Fuel Control Knob and Pre-Heat Oxygen Knob closed.

  1. Remove the Tip and Mixer from the head of the Torch.

  2. In a well lit area, look straight down into the head of the Torch.

  3. Open the Fuel Control Knob on the Torch and look for a small focused stream of liquid fuel to enter the head of the Torch.
  4. Fuel Stream Check

  5. Close the Fuel Control Knob.

  6. If the stream is present, fuel is passing through the system normally and the restriction is after the head of the Torch. Take the following action. Replace the Wick (Part #1802) located on the Mixer.
    • Replace the Wick (Part #1802) located on the Mixer.
    • Replace the Tip.
    • Reinstall the Mixer and Tip into the head of the Torch.

  7. Perform the following Special Purge before continuing. Press the High Pressure Oxygen Trigger and open the Pre-Heat Oxygen Knob simultaneously. Keep both valves open until fuel no longer exits the tip.

NOTE: Avoid pressing the High Pressure Oxygen Trigger when performing the test as this may blow fuel into the face of the operator.


2. MIXER REPAIR

The Mixer is located inside the Torch Head. Its function is to mix oxygen and liquid fuel to supply the pre-heat flame.


Liquid Fuel Torch Mixer Assembly

The Mixer does not require regular maintenance, however it may require attention if any of the following problems is encountered.


Fuel leaks from between the Torch Head and Tip Nut

  • Replace Small and/or Large O-ring(s)

Popping occurs

  • Clean the Tip and/or Mixer seating surfaces

Dying flame or no fuel flow to the Tip

  • Replace Mixer Wick
  • See fuel stream test

NOTE: Running the Torch with a rich fuel setting will keep both the Tip and the head of the torch cool, preventing damage to the Mixer O-rings and Wick.


MIXER REMOVAL:

Mixer Removal

  • Using the Adjustable Wrench (Part #6022), remove the Tip Nut and Tip from the Torch Head. Be careful not to drop the tip core when removing the tip.

  • The Mixer sits directly beneath the tip inside the head of the Torch. Slide the Jackscrew (Part #4016), which can be found in the Tool Kit, into the center hole of the Mixer and turn it clockwise. Keep turning the Jack Screw until the Mixer is pulled from it’s position in the head.

O-RING & WICK REPLACEMENT:

  • Remove the damaged O-rings and replace them with the provided spares from the Standard Spare Parts Kit (Part #4002). There is one large and one small O-ring. Sometimes damage to the O-rings is not obvious. Overheating can reduce the elasticity of the O-ring, keeping it from forming a complete seal inside the head of the torch.

  • Remove the damaged Wick and replace it with the provided spare from the Spare Parts Kit. A Damaged Wick will have a brown “cooked” appearance. Severe overheating can fuse the centered bronze, reducing fuel flow into the Mixer.

MIXER INSTALLATION:

Mixer Installation
  • To install the Mixer, place it small side down into the Torch Head (Fig. 37 A), and push it into position by hand

  • Replace the Tip and Tip Nut.

  • Tightening the Tip Nut will complete the Mixer seating process.

  • Following the initial tightening of the Tip Nut to seat the mixer, loosen and re-tighten the Tip Nut to ensure the Tip is properly seated into the Torch Head.

Do not overtighten the Tip Nut. Doing so will lead to premature wear of the Torch Head.


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3. HIGH PRESSURE OXYGEN VALVE REPAIR

Located under the High Pressure Oxygen Trigger, The High Pressure Oxygen Valve regulates the flow of high pressure oxygen through the torch.


Liquid Fuel Torch High Pressure Oxygen Valve Assmebly

Perform valve maintenance if the torch exhibits the following behavior.


Oxygen leaks from the Tip center hole while the Pre-Heat Oxygen Knob is fully closed and High Pressure Oxygen Trigger is disengaged.

  • Replace High Pressure Oxygen Valve
  • Replace High Pressure Oxygen Valve Internal O-ring

HIGH PRESSURE OXYGEN VALVE REMOVAL:

High Pressure Oxygen Valve Removal
  • Shut off the oxygen supply to the Torch by closing the Oxygen Bottle Valve and depressing the High Pressure Oxygen Trigger on the torch.

  • Use the Adjustable Wrench to remove the Lever Nut (Part #1403) from the Lever Assembly (Part #1401).

  • Use a Flat Head Screwdriver to remove the Lever Screw (Part #1404) from the Lever and center body of the Torch.

  • Using the Packing Nut Wrench (Part #4011), provided in the Standard Tool Kit (Part #4003), place the wrench over the exposed hex nut on the top of the High Pressure Oxygen Valve and turn it counter clockwise to remove it.

  • Install the spare High Pressure Oxygen Valve found in the spare parts kit. To repair the valve proceed to the next step.

HIGH PRESSURE OXYGEN VALVE DISASSEMBLY:

High Pressure Oxygen Valve Disassembly
  • Place the Packing Nut Wrench over the High Pressure Oxygen Valve Nut. Using a Flat Head Screwdriver, turn the head of the High Pressure Oxygen Valve Stem counterclockwise.

  • Remove the High Pressure Oxygen Valve Stem from the High Pressure Oxygen Valve. The Nut and Spring will then be released from the assembly. The Bushing and Internal O-ring will remain inside the High Pressure Oxygen Valve Body until gently pushed out.

O-RING REPAIR

  • Remove the damaged O-ring.

  • Replace the damaged O-ring with a spare found in the Spare Parts Kit.

  • If the High Pressure Oxygen Valve Stem O-ring is damaged take the following action.
    • Slide the High Pressure Oxygen Valve Internal O-ring Installation Tool (Part #4017) provided in the Standard Parts Kit (Part #4002), over the High Pressure Oxygen Valve Stem (A.). The tool allows the replacement O-ring to be rolled into position on the High Pressure Oxygen Valve Stem (B.). Once the O-Ring is in place simply remove the High Pressure Oxygen Valve Stem from the tool (C.).

High Pressure Oxygen Valve O-Ring Repair

HIGH PRESSURE OXYGEN VALVE ASSEMBLY:

High Pressure Oxygen Valve Assembly
  1. Insert the O-ring and Bushing into the Valve Body with the O-ring facing down.

  2. Hold the Bushing in place using the Spring.

  3. While holding the assembly together, slide the Spring into the Nut.

  4. Push the Valve Body down so that the spring is compressed and the nut slides into the Valve Body.

  5. NOTE: It may be necessary to rotate the Nut slightly so that it aligns properly with the Valve Body


  6. With the spring compressed, slide the Valve Stem through the Valve Body and screw it into the Nut on the opposite side.

  7. Use the Packing Nut Wrench to hold the Nut and tighten the Valve Stem with a flat head screwdriver until it is snug.

HIGH PRESSURE OXYGEN VALVE INSTALLATION:

High Pressure Oxygen Valve Installation

  • Inspect the High Pressure Oxygen Valve hole in the Torch Centerbody to ensure it is free of debris.

  • Insert the High Pressure Oxygen Valve into the hole in the Centerbody with the Nut facing up.

  • Use the provided Packing Nut Wrench to tighten the High Pressure Oxygen Valve in the Centerbody.

  • Replace the Lever, Screw and Nut.

NOTE: Place one drop of thread lock on the threads of the Lever Nut.


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4. PUMP ASSEMBLY REPAIR

Located on the Fuel Tank, the Pump Assembly is comprised of two assemblies: the Pump Cylinder Assembly and the Pump Shaft Assembly.


Complete Pump Assembly

Perform Pump Assembly maintenance if the following behaviors are observed.


No resistance is felt when Pumping

  • Lubricate and/or replace the Leather Pump Cup

Tank pressure does not build when pumping

  • Lubricate and/or replace the Leather Pump Cup
  • Tighten Filler Cap
  • Add fuel

Pump Handle raises by itself


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PUMP SHAFT ASSEMBLY REPAIR

REMOVING THE PUMP SHAFT ASSEMBY:

Complete Pump Assembly

  • Unscrew the Pump Shaft Screw Cap from the pump cylinder.

  • Pull the pump shaft out from the cylinder.

  • Inspect the Leather Pump Cup.
    • The Pump Cup should be well lubricated and moist to the touch.

LEATHER PUMP CUP LUBRICATION:

  • If the Leather Pump Cup is dry to the touch, lubricate it with a medium viscosity oil.

  • Firearm lubricants have proven to be ideal, however heavier lubricants like motor oil and lighter aerosol lubricants may also be used.

LEATHER PUMP CUP REPLACEMENT:

Complete Pump Assembly
  • Use the Adjustable Wrench to remove the Pump Shaft Nut located under the Leather Pump Cup.

  • Remove the Lock Washer and the old Leather Pump Cup.

  • Replace the old pump cup with the provided spare located in the Spare Parts Kit (Part #4002).

  • Replace the Lock Washer and Pump Shaft Nut, tightening the nut until it is snug.

PUMP SHAFT INSTALLATION:

  • Splay the Leather Pump Cup open to increase the tension against the wall of the Pump Cylinder ( this will increase efficiency while pumping).

  • Place one edge of the Leather Pump Cup into the Pump Cylinder.

  • Using a twisting motion, squeeze the Leather Pump Cup into the Pump Cylinder.

  • Push the Pump Handle to the bottom of the Pump Cylinder and screw the Pump Shaft Screw Cap back to the Pump Cylinder.

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PUMP CYLINDER ASSEMBLY REPAIR

If the Pump Handle is pushed up by the pressure in the Fuel Tank, or if fuel is observed leaking from the Pump Assembly, please contact Petrogen directly to process a warranty repair. If the unit must be repaired in the field, take the following steps.


REMOVING THE PUMP CYLINDER ASSEMBLY:

Complete Pump Assembly
  • Discharge the tank pressure by opening the Filler Cap until the sound of escaping air can no longer be heard.

  • Do not remove the Filler Cap completely until the Fuel Tank pressure has reached “0”.

  • Remove the Pump Shaft as described in “REMOVING THE PUMP SHAFT ASSEMBLY”.

  • Hold the Fuel Tank securely and, using a large adjustable wrench, unscrew and remove the Pump Cylinder Assembly.

PUMP CHECK SEAL REPLACEMENT:

Complete Pump Assembly
  • Use the Adjustable Wrench to unscrew the Pump Check Valve Nut from the cylinder.

  • Remove the Pump Check Valve Seal, Seal Retainer, and Spring.

  • Replace the Check Valve Seal with the spare located in the Spare Parts Kit (Part #4002).

ASSEMBLING THE PUMP CYLINDER:

Complete Pump Assembly
  • Place the Spring, Retainer and Seal back into the Nut.

  • Place the Lock Washer over the threaded nipple and screw the Nut back onto the pump cylinder tightening it snugly with the Adjustable Wrench.

PUMP CYLINDER INSTALLATION:

Complete Pump Assembly
  • Clean the threads of the Pump Cylinder and Fuel Tank making sure that no PTFE tape or dirt remains.

  • Make two complete wraps of the Pump Cylinder threads with new Teflon tape.

  • Place the Pump Cylinder back into the Fuel Tank, and tighten it with the Adjustable Wrench.

  • Reinstall the Pump Shaft as described in “PUMP SHAFT INSTALLATION”.

  • Pressurize the tank and then perform a leak test using soapy water.

  • If the tank leaks, tighten the fitting further.

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