Worthington Bernzomatic WK5500OX

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08/19/16

INSTRUCTION MANUAL

Trigger-Start Torches

Models: WK5500OX

 DANGER

EXTREMELY FLAMMABLE GASES USED WITH TORCH.

FIRE/EXPLOSION HAZARD. CARBON MONOXIDE HAZARD

This oxygen brazing and cutting torch is unlike most hand held torches.

It is designed to be used simultaneously with an oxygen cylinder and a

MAP-Pro™ or propane cylinder. The use of an oxygen cylinder results in

the torch ﬂame burning at much higher temperatures as it would without an

oxygen cylinder. Do not use this torch until you become thoroughly familiar

with its proper use and potential hazards. In particular, you must not attempt

to ignite the torch while oxygen is ﬂowing to the torch. Further, when turning

the torch off ALWAYS TURN OFF THE OXYGEN BEFORE TURNING OFF THE FUEL GAS. Turning off the fuel gas while oxygen is still

ﬂowing could result in a ﬂash back and an explosion.

Read and follow the instructions and warnings in this manual. Familiarize yourself with the torch before lighting and using.

Review instructions and warnings periodically to maintain awareness. Do not try to operate before reading instructions and

without being thoroughly familiar with this torch’s use and potential hazards.

Failure to comply with these instructions and warnings may result in damage to property, serious personal injury, or death.

 WARNING

• While the Oxygen-MAP-Pro

™

Torch is not a commercial oxygen torch, it produces ﬂame temperatures up to 5300°F.

This is much hotter than the ﬂame of a standard propane torch. These extremely high temperatures can cause serious

personal injury or damage to the metal you are working on if not handled carefully and correctly.

• Never point the torch toward the cylinders or let the ﬂame deﬂect to heat the cylinder in any manner.

• Do not permit grease or oil to be placed on or come in contact with any portion of the torch, hoses or cylinders,

particularly the oxygen cylinder, oxygen connection, oxygen regulator or oxygen hose as oxygen can cause the grease

or oil to burn in an uncontrolled manner.

• Keep torch out of reach of children and anyone who has not read instructions. Do not point torch towards face, other

persons or ﬂammable objects. Never attempt to use torch as a cigarette lighter.

• Disconnect cylinders when not in use.

Materials used in the construction of this device may contain brass (which may contain lead), a chemical known to the

State of California to cause birth defects or other reproductive harm.

Combustion by-products produced when using this device contain chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

ENG DANGER INCENDIE EXPLOSION FUMES

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Summary

DANGER: Flammable Gases and Hazards

WARNING: Material and Combustion Hazards

High Temperature and Handling Precautions

Precautions for high temperatures, cylinder handling, and keeping the torch away from children and flammable objects.

General Operational Safety Warnings

Safe Operation and Environmental Guidelines

Guidelines for safe operation including ventilation, handling materials, and outdoor use.

Operational Warnings

Flame and Hose Integrity

Warnings regarding flame length, mixing tube temperature, and hose condition during operation.

Maintenance and Inspection

Hose Care and Inspection

Instructions for maintaining hoses, ensuring they are dry, clean, and free from damage.

Assembly Procedures

Steps for assembling the torch, including attaching hoses and securing cylinders.

Lighting and Operation

Leak Testing

Procedure for testing connections for gas leaks using soapy water before ignition.

Ignition and Flame Adjustment

Steps for lighting the torch, adjusting the flame, and safety during ignition.

Shut Off and Storage

Instructions for safely turning off the torch and storing cylinders and equipment.

Particular Applications

Soldering;Heat Treating Flame

Guidance on setting the flame for soldering and heat treating applications.

Welding;Brazing Flame

Instructions for adjusting the flame for welding and brazing tasks.

Cutting Flame

Procedure for setting the flame for cutting metal, including safety notes.

Trouble Shooting

No Flame;Unacceptable Flame

Steps to diagnose and resolve issues when no acceptable flame can be obtained.

Rod Sticking Issues

Solutions for problems where brazing or welding rods stick to the metal.

Torch Not Welding

Troubleshooting steps for when the torch fails to perform welding tasks.

This document describes the Bernzomatic Trigger-Start Torches, specifically models WK55000X, which are designed for various applications including soldering, heat treating, welding, brazing, and cutting. These torches utilize extremely flammable gases and operate with both an oxygen cylinder and a MAP-Pro™ or propane cylinder, enabling higher flame temperatures than standard propane torches.

Function Description:

The Bernzomatic Trigger-Start Torch is a hand-held device that produces a high-temperature flame for various metalworking tasks. Unlike typical hand-held torches, it integrates the use of an oxygen cylinder to achieve significantly hotter flames, reaching up to 5300°F. This enhanced heat capability allows for more demanding applications such as welding and cutting, in addition to standard soldering, heat treating, and brazing. The torch is designed for simultaneous operation with both fuel gas and oxygen, requiring careful handling and adherence to safety protocols due to the high temperatures and flammable gases involved.

Important Technical Specifications:

Flame Temperature: Up to 5300°F when used with oxygen.
Fuel Compatibility: MAP-Pro™ or propane cylinders, in conjunction with an oxygen cylinder.
Flame Length (Soldering/Heat Treating): Approximately 7 to 9 inches.
Flame Length (Welding/Brazing - Inner Blue Flame): Approximately 1½ inches.
Flame Length (Cutting - Inner Blue Flame): Approximately 5/16 inches.
Oxygen Cylinder Duration (Welding/Brazing): Approximately 18-25 minutes for a full cylinder.
Oxygen Cylinder Duration (Cutting): Approximately 8-12 minutes for a full cylinder.
Minimum Flame Length for Operation: Not less than 1½ inches to prevent overheating of the mixing tube.

Usage Features:

Trigger-Start Ignition: Designed for easy ignition, though specific instructions emphasize using a spark lighter and opening the fuel valve slowly.
Dual Gas Operation: Requires both a fuel gas (MAP-Pro™ or propane) and an oxygen cylinder for optimal performance and higher temperatures.
Adjustable Flame: The torch allows for adjustment of both fuel and oxygen flow to achieve different flame characteristics suitable for various applications:
- Soldering/Heat Treating Flame: Characterized by a yellow flame 7-9 inches long, with the yellow portion in contact with the torch tip.
- Welding/Brazing Flame: Features an inner blue flame approximately 1½ inches long at the tip, achieved by slowly increasing oxygen flow from the soldering flame.
- Cutting Flame: Achieved by further increasing fuel and then oxygen flow, resulting in an inner blue flame of about 5/16 inches, which is the hottest part and should be in contact with the metal for cutting.
Cylinder Stand: A stand is provided to secure both cylinders during operation, preventing accidental tip-over and potential hazards like liquid fuel entering the hose.
Safety Protocols: Emphasizes critical safety measures:
- Always turn off oxygen before fuel gas to prevent flashback and explosion.
- Never ignite the torch while oxygen is flowing.
- Do not point the torch towards cylinders, other persons, or flammable objects.
- Do not use the torch as a cigarette lighter.
- Disconnect cylinders when not in use.
- Always wear safety glasses and protective gloves.
- Work in well-ventilated areas to avoid fumes from fluxes, lead-based paint, cadmium plating, and galvanized metal.
- Be aware of radiant energy and wear appropriate lens shades (e.g., 3-4 for brazing/light cutting, 4-5 for medium cutting/light welding, 5-8 for heavy cutting/medium-heavy welding).
- Never leave the torch unattended when lit.
- Always have a fire extinguisher and water nearby.
- Not recommended for industrial or commercial use.

Maintenance Features:

Hose Care: Hoses must be kept dry, free of debris, caustic chemicals, oil, grease, and gasoline. Avoid pinching, twisting, puncturing, pulling, tugging, or placing hoses near heat or flame.
Hose Inspection: Prior to each use, inspect hoses for tears, cuts, frays, or other signs of deterioration. Damaged hoses must not be used.
Tip Inspection: Visually ensure the torch tip is open and unobstructed. A blocked or deformed tip can damage the oxygen regulation system and cause leaks.
Leak Testing: Before ignition, always check all joints and couplings with soapy water. Bubbles indicate a gas leak, and the torch must be repaired before use. Never use a flame to check for leaks.
Troubleshooting: The manual provides guidance for common issues such as "No Flame/Cannot Obtain Acceptable Flame" and "Brazing or Welding Rods Stick to the Metal and Fail to Flow Properly," including steps to check for blockages, gas flow, and leaks.
Storage: Store the torch and cylinders separately and out of reach of children. Do not store them inside a vehicle.
Disconnection: When not in use, disconnect cylinders from the hoses. Turn off oxygen valve first, then fuel valve, then bleed hoses by re-opening valves before disconnecting.