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Operating manual
Please use the products only as intended by Air Liquide
and only if you are familiar with their use and observe the
General Operating Instruction for Acetylene, Welding
and Cutting Equipment and Safety Precautions. Should
there be any uncertainties as to the use of the product,
before using request further special Air Liquide product
information or talk with an Air Liquide specialist.
This operating manual is intended to enable the OPTAL 90
to be used safely and as specified. Reading and following
the operating manual helps prevent risks and downtime,
increasing the reliability and life of the equipment and
guaranteeing the quality of our product throughout the
entire period it is used, under the best safety conditions
possible.
Not following the instructions, or altering the product can
lead to serious accidents or injuries. Air Liquide cannot
be held liable in the event of improper use.
The operating manual must always be available close to
hand.
1. Basic safety instructions
1.1 Obligation of the operator
The operator is obliged only to allow people who are
familiar with the basic safety at work and accident pre-
vention regulations and have permanent access to these
regulations, have read and understood the safety chapter
in this operating manual, are trained and instructed on
the use of the equipment to work on gas welding torches.
The safety- conscious working of the staff is to be checked
at regular intervals. The competence of staff in fitting,
starting up and operating are to be clearly established.
Staff being trained must only work on pressurised equip-
ment under the supervision of someone experienced. All
safety and risk instructions are always to be kept an a
readable form.
1.2 Warranty and liability
Our „General Sales and Supply Conditions" are strictly
applicable. There shall be no claim under warranty or for
liability in the event of injury or material damage, if it is
due to one or more of the following:
• Use of the equipment not as specified.
• Improper fitting, starting up, operating and maintaining
of the equipment.
• Operating the equipment with faulty safety equipment
or safety and protective equipment that is not properly
applied or not operational.
• Not following the instructions in the operating manual
on starting up and maintenance.
• Unauthorised alteration to the structure of the pressurised
equipment.
• Use seals from others or non-original seals.
• Insufficient inspection of equipment, fitting and sealing
parts subject to wear.
• Repairs not properly carried out.
• Exceeding or undercutting the values indicated in the
table during operation.
• Catastrophes due to the effect of foreign bodies and
force majeure.
1.3 Obligation of staff
Everyone entrusted to work with gas welding equipment
is obliged to observe the fundamental regulations on
safety at work and accident prevention before starting
work, and to make themselves familiar with the safety
regulations with respect to the type of gas used.
1.4 Organisational measures
The required personal protective equipment is to provided
by the operator. All safety equipment is to be inspected
regularly. In the event of lack of oxygen or high concentration
of pollutants, regardless of the surrounding atmosphere,
breathing apparatus is required.
1.5 Protective equipment
Before each commissioning of gas welding equipment,
all the safety equipment must be properly applied and
operational. Protective devices and safety equipment
must only be removed after the equipment has been
shut down.
1.6 Safety measures in normal operation
Before igniting the gas welding equipment, ensure that
nobody can be put at risk by starting up the equipment.
1.7 Risks from pressure energy
Depressurise parts of the system to be opened and
pressure lines before starting repair work. Due to external
effects such as high temperatures, heat radiation, impact
etc. gas cylinders or pressurised parts of the system may
heat up or burst. Take appropriate precautionary and
safety measures.
1.8 Laws and regulations,
which are to be considered:
• Safety data sheet of each specific gas type
• Employee protection law ASchG
• Work equipment directive (AM-VO) BGBL. II.
Nr. 164/2000 igF
• General operating instructions for acetylene welding
and cutting equipment according to § 26 para. 4 of
the AM-VO.
2. Description
2.1 Description of the construction
Combined welding and cutting torches consist of a
handle with adjustment valves and various attachments.
These attachments are selected according to the relevant
application and connected with the handle to the ready-to-
use torches.
2.2 Description of the mixing system symbols
in accordance with EN ISO 5172 are shown on the mixing
system:
= Injector mixer for fuel gas (injector-type torch)
= Mixer without injector-type effect
(gas and compressed air torch)
= Injector mixer secured against backflow of gas
(injector- type torch)
3. Use
3.1 Use as directed
• OPTAL attachments must only be used for gas welding
procedures. Depending on attachment, they are used
for welding, flamecutting, heating, brazing, scarfing
and residual heating. See tables for performance data.
• Different fuel gases can be used for the various gas
welding procedures. Welding: acetylene Scarfing (steel)/
residual heating: acetylene Oxygen cutting/heating/
brazing: acetylene, propane, natural gas, hydrogen,
methyl acetylene- propadine mixture
• Only fuel gases for which the relevant torch attachment
and cutting nozzle is labelled must be used.
O ... Oxygen A ... Acetylene
P ... Propane, butane or LPG M ... Natural gas
H ... Hydrogen
Y ... Methylacetylene-propadine mixture D ... Compressed air
F ... For more than one fuel gas
• If an attachment can be used for more than one fuel
gas, it has all the code letters of these gases on it.
Apart from that, some pieces of equipment may be
labelled with the code letter „F". The operating data
contain details on the fuel gases which can be used for
these parts.
• The relevant fuel gas is mixed with oxygen in the torch
attachment. For the heating or brazing procedure,
compressed air is also used. This is only possible if the
torch attachment is labelled for compressed air.
• The optional use of different fuel gases with the same
cutting attachment (gas mixing) is only allowed if the
mixture of the fuel gases is done with oxygen or air in the
cutting nozzle (gas mixing nozzle II). When doing so,
the gas type label of the cutting nozzle must be observed.
• Combined torches must only be used for procedures
for which the relevant torch attachment is provided.
• Use as directed also includes following all the instruc-
tions in the operating manual and keeping to servicing
and maintenance work.
Important safety instruction: Each gas welding equip-
ment requires a defined gas quantity for safe operation.
If the gas quantity is not available, there is a risk of
flashback. Follow the consumption quantities in the
table of the relevant attachment or nozzle. The gas
supply type is to be adapted to the consumption quantity
as needed (e.g. cylinder bundle). Please note the maxi-
mum capacity (depending on temperature and time) of
the different cylinder sizes! In case of any doubts,
contact the supplier of the gas welding equipment or
the gas supplier.
3.2 Use not as directed
• For example, it is not permitted to weld with the cutting
torch or cut with the welding torch.
• Working of non-metallic materials is only allowed with
the heating torch. If there is any doubt, consult the
manufacturer.
• The torches must not be used for decanting gases or
for releasing work.
• The torches are not suitable for the use of gases in
liquid phase.
4. Safety requirements
4.1 Working area
• Ensure that the working area is kept free of dust and dirt.
• Remove inflammable material.
• When gas-welding ensure that welding sparks, falling
material or dripping molten metal does not come into
contact with inflammable material.
• Moreover, ensure that neither the hot workpiece nor
the welding flame can set fire to any objects in the vicinity.
• Provide for sufficient ventilation.
• A non-flammable, heat-resistant glove must always
be available in the working area in accordance with
AM-VO (Austrian Working Equipment Regulation).
• Consult the local fire protection authorities if there is any
uncertainty as to whether the working area is suitable
for gas welding or flame cutting.
• Wear suitable personal protective equipment and eye
protection (welding goggles).
• There is a risk of explosion when welding or cutting
containers holding inflammable liquids.
4.2 Gas cylinders
• Gas cylinders are to be handled with great care and must
not be subjected to any impacts or other mechanical
jolting.
• Gas cylinders must be secured against falling over.
• Storage areas for gas cylinders should be provided
with a clearly visible instruction that in case of fire the
gas cylinders are to be taken to a safe place.
• Tested safety equipment is to be used both on the
oxygen and the fuel gas pressure- reducer to prevent
back flow of gas, flashback or backfiring from getting
into the pressure -reducing valve or in the cylinders.
• An ignited torch must not be hung on the pressure
reducer or placed so that the flame directly reaches the
gas cylinders.
• In emergency situations, cylinder valves are to be shut
off immediately.
• No adapter must be used between the gas cylinder valve
and the cylinder pressure- reducer.
4.3 Oxygen
• Even small quantities of oil or grease may lead to an
explosive fire in the presence of oxygen. Therefore, the
equipment parts must not be lubricated.
• Oxygen must not be used for ventilation or releasing.
RISK OF EXPLOSION! An oil stain on clothing may
catch fire when combined with oxygen.
4.4 Acetylene
• Acetylene is a combustible gas with a distinct smell.
When it is mixed with air, it can ignite or explode. Ensure
everything is leaktight.
• Acetylene is lighter than air
• An acetylene cylinder must, under no circumstances,
be subjected to high heat (max. 50°C).
• Acetylene cylinders must only be used in an upright
position.
• Using individual acetylene cylinders in a lying position
is permitted when the cylinder valve is at least 40 cm
higher than the cylinder stand.
4.5 Propane
• Propane is a combustible gas with a distinct smell.
When it is mixed with air, it can ignite or explode.
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