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INSTRUCTIONS FOR USE AND MAINTENANCE
8. MANAGING FAULTS
Problem
Cause
• Damaged gaskets (10)
Gas leak
• Incorrect or damaged connections
• Damaged pipes
Gas flow insufficient
• No gas in cylinders
or absent
• Incorrect or damaged connections
• Reducers or handgrip taps not working
• Insufficient gas in cylinders
Irregular or
• Reducers defective
insufficient flame
• Handgrip taps defective
• Brass tip (12) defective or obstructed
HOW TO GAS WELD WITH TURBO SET 90/110
With gas welding always work methodically : before starting a
weld ensure that the parent metal in the weld area is cleaned and
free from grease, oil, paint, rust and scale. Make sure that you have
a good supply of gas and filler metals and welding flux suitable
for the job. Before applying heat to the parts, make sure that they
are properly positioned and locked to remain in the correct ali-
gnment.
Once the joint is complete, you will need to clean it, as residues
of flux (when present) can weaken it if they are not completely
removed.The flame power depends on the size of the tip used,
and these vary depending on the thickness, melting point and
thermo-conductivity of the materials.
TURBO SET 90 and 110 have a choice of 5 tips. The power is mea-
sured according to the number of litres of combustible gas consu-
med per minute with a duly regulated flame. Too lower pressure
gives too short cone, which may cause a lack of weld penetration
and fusion, it can also cause frequent back firing. On the other
hand too higher pressure can give a long cone and cause overhe-
ating and a lack of control of the molten metal.
12
Solution
• Replace the gaskets on the reducers.
• Check the connections of the reducers on the cylinders and the
closures of the handgrip taps.
• Replace equipment or contact the supplier
• Replace the cylinders
• Check that the reducers are completely screwed onto the
cylinders.
• Replace equipment or contact the supplier
• Replace the cylinders.
• Replace equipment or contact the supplier
• Replace equipment or contact the supplier
• Dismantle the tip and make sure that the passageways are free
(clean or replace)
Three different types of flame can be made via varying propor-
tions of gas:
1- The carburizing flame
This is a flame in which an excess of fuel gas is burning, i.e. com-
bustion is incomplete and unconsumed carbon is present. This
kind of flame is generally not good for welding steel as the un-
consumed carbon could be introduced to the weld and create a
hard embrittled weld.
2 - The neutral flame
When the oxygen supply to the torch is increased by means of the
corresponding supply knob (8), the flame contracts and the white
cone becomes more clearly defined, taking on a precise rounded
shape. At this stage approx equal quantities of fuel gas and oxy-
gen are being used and combustion is complete. The flame is now
neutral and this type of flame is the one most extensively used
for welding.
3- The oxidising flame
A further increase in oxygen will produce the oxidising flame, in
which there is more oxygen than is required for complete combu-
stion. In this case excessive sparking will occur.
1
A BACK FIRE can often occur if:
- the gas pressure is too low
- touching the plate or weld pool
- loose nozzle
- over heating
- a metal particle gets into the nozzle.
2
The fault can normally be rectified with no damage.
3
N.B. Some of the details in the illustrations may differ from those of
the appliance supplied. This company reserves the right to modify
the product without prior warning.
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