SOP-EQ-035 Rev 2 — Victor VCM-200 Portable Flame Cutting Machine — Safe Operation (UA46 115V, acetylene, 10-ft track)

Equipment: Victor VCM-200 Portable Flame Cutting Machine (EQ-035)

Location:

Approved by: Marty Howe, Welding Instructor

Approval date: 2026-05-25

Linked records: HA-EQ-035 · · TR-EQ-035

Standards basis: OHSA s.25 (general duty); O.Reg 851 s.24 (machine safety), s.42 (electrical), s.79 (compressed gas), s.85 (lockout — multiple energy sources), s.105 (PPE); CSA W117.2 Section 5 (oxy-fuel cutting safety, gas hoses, regulators), Section 6 (flashback prevention), Section 11 (fire prevention in cutting operations); CSA Z460-13 (cord/plug + gas-supply LOTO — dual-energy isolation); CSA Z94.3 (eye/face — shade requirement for cutting); CSA Z94.2 (hearing); CGA E-9 (flashback arrestors); CGA P-1 (cylinder safe handling); NFPA 51 / NFPA 51B (hot work — UA46 shop functions as designated hot work area per shop policy); manufacturer manual Victor VCM-200 Series Operating & Instruction Manual / Parts List (UL listed).

Machine Specs

Specification	Value
Manufacturer	Victor (Thermadyne / ESAB)
Model (UA46 variant)	VCM-200 standard (NOT VCM-200HT high-temp, NOT VCM-200HS high-speed)
Drive	Constant-speed AC induction motor with cone disk variable speed drive
Cutting speed range	1 to 60 ipm (infinitely variable)
Voltage	115V AC, 60 Hz (UL Listed)
Direction control	FWD-OFF-REV toggle switch (operable from either end)
Clutch	DRIVE / FREE lever (allows free machine movement on track)
Torch mount	Single torch (UA46) — 32-pitch pinion torch holder with angle scale for bevel/chamfer
Track	~10-ft total at UA46 (6-ft section + extension); straight cuts only
Circle cutting	Capable with radius rod (4-96" diameter) — NOT used at UA46
Fuel gas (UA46)	Acetylene
Typical regulator pressures	O2 ~30 psi cutting / Acetylene ~5-7 psi (NEVER exceed 15 psi acetylene)
Energy sources to control	Electric (cord-and-plug 115V) AND gas (O2 + acetylene cylinders)

⚠ Danger VCM-200 will NOT detect end of track or workpiece — UNATTENDED operation risks the machine falling from elevated work (manufacturer-warned). Hose snag during travel can tip the machine (UA46-observed). NEVER walk away during operation. Stay with the machine through the full cut.

PPE Required

⊙ Cutting goggles with Shade 5 lens (CSA Z94.3 / ANSI Z87.1) — MANDATORY for oxy-acetylene flame work

⊙ Welding/cutting gloves — leather, gauntlet style

⊙ CSA Z94.2 hearing protection (motor + cutting jet noise)

⊙ Cutting jacket or leather apron (slag spatter protection)

⊙ CSA Z195 Grade 1 safety footwear with metatarsal guard (hot slag drop hazard)

Pre-Use Inspection

Confirm cord intact, three-prong grounded plug; verify 115V circuit available at work location
Inspect oxygen and acetylene hoses for cuts, kinks, oil contamination, or loose fittings
Confirm flashback arrestors installed at BOTH regulator outlets (oxygen + acetylene)
Verify oxygen and acetylene cylinders chained/secured upright; regulators in good condition
Set track on workpiece — verify track is straight, level, and extends at least 6" beyond intended cut start AND end
Place machine on track with clutch in FREE position; verify machine slides smoothly along full track length
Engage clutch to DRIVE; confirm FWD-OFF-REV switch is at OFF and SPEED knob at minimum
Clear combustibles within 35 ft of cutting zone; confirm fire extinguisher in place; fire watch arranged if required

Operation

Pre-Operation Setup

Position track on workpiece; track must be straight, level, and EXTEND BEYOND both ends of intended cut
Place machine on track with clutch lever in FREE position; push machine end-to-end to verify free travel
Install correct cutting tip in torch per material/thickness chart; verify tip is clean and undamaged
Connect oxygen hose to outer manifold ports, acetylene hose to center port; leak-test all connections with soapy water (NEVER flame test)
Open cylinder valves slowly: oxygen FIRST (full turn back from open), then acetylene (NOT MORE than 1.5 turns open — leave wrench on valve)
Set regulator pressures per cutting tip chart (typical: O2 ~30 psi, acetylene ~5-7 psi — DO NOT exceed 15 psi acetylene)
Plug cord into 115V outlet; verify FWD-OFF-REV at OFF, SPEED knob at minimum, clutch at DRIVE

Lighting & Adjusting the Torch

Open acetylene valve on torch 1/4 turn; ignite IMMEDIATELY with friction striker (NEVER lighter, match, or torch-to-torch)
Increase acetylene flow until flame stops smoking and pulls slightly away from tip
Slowly open oxygen valve until NEUTRAL flame achieved — inner cone sharply defined, no feather, no excess oxygen sound
Press cutting lever (high-pressure oxygen jet); verify cutting jet is straight and centered through preheat flames
If cutting jet disturbs preheat flames, release lever and re-adjust preheat flames; re-test
Release cutting lever — flame should return to neutral preheat without changes
Position torch over cut start point; torch tip 1/16" to 1/8" above workpiece

Cutting Speed & Direction Reference

VCM-200 cutting speed range: 1 to 60 ipm (infinitely variable). Speed indicator calibrated for straight-line cuts. Use the slowest practical speed for material thickness — too fast leaves slag, too slow over-melts the top edge.

Material thickness	Typical speed range (ipm)	Notes
1/8" mild steel	20-24 ipm	Light, clean cut — use small tip (00 or 0)
1/4" mild steel	16-20 ipm	Standard demo cut at UA46 (tip 1)
3/8" mild steel	13-16 ipm	Tip 1 or 2
1/2" mild steel	10-13 ipm	Tip 2
3/4" mild steel	8-10 ipm	Tip 3; preheat fully before drop-down
1" mild steel	6-8 ipm	Tip 3; consider single torch — multiple passes if dual

Direction control: FWD-OFF-REV toggle switch next to power cord. Dual SPEED knobs (one each end) allow operation from either end. UA46 scope: Straight-line cuts only — no circle cutting (radius rod not in UA46 stock).

Performing the Cut

Press cutting lever to start kerf at workpiece edge (or pre-drilled pilot hole); wait for full penetration through material
With cut penetrating, IMMEDIATELY engage FWD-OFF-REV to desired direction; machine travels at set speed
STAY WITH MACHINE THROUGHOUT CUT — do not walk away; monitor for hose snag risks at machine path
Watch cut quality: clean kerf = correct speed; top-edge melting = too slow; slag at bottom = too fast (adjust SPEED knob during cut)
As machine approaches END of track or workpiece edge, release cutting lever FIRST
Set FWD-OFF-REV to OFF; machine stops at current position
Close ACETYLENE valve on torch FIRST, then oxygen valve (correct shutdown order — prevents reverse-flow into acetylene)

Prohibitions

NEVER operate without operator qualification confirmed (instructor sign-off interim; TR_Register entry future)
NEVER use oil or grease on ANY oxygen connection, regulator, valve, or fitting — oxygen + oil = explosion
NEVER use a cracked, deformed, or out-of-test cylinder

Emergency Stop

Emergency Response SEQUENCE MATTERS — gas first, then motor, then power: (1) CLOSE the cutting oxygen valve on the torch — stops the cut immediately. (2) CLOSE the preheat oxygen valve. (3) CLOSE the acetylene valve on the torch. (4) STOP the travel motor — set DRIVE/FREE lever to FREE or flip the on/off switch. (5) Once travel stopped, close cylinder valves at the cylinders (oxygen first, then acetylene). (6) If electrical emergency: unplug the power cord at the wall outlet. DO NOT shut off the motor before stopping gas flow. DO NOT shut off cylinder valves while flames are still active at the torch. For flashback: close acetylene valve at torch IMMEDIATELY, then oxygen valve at torch, then cylinder valves. Manufacturer-installed check valves at the torch are the engineering controls for gas-side emergencies. Manufacturer warning: VCM-200 does NOT detect end of track or workpiece — operator must monitor travel path actively to prevent tractor falling off elevated surfaces.

Scenario	Immediate response	Notify
FLASHBACK (flame retreats into torch or hose with popping/whistling)	CLOSE ACETYLENE VALVE IMMEDIATELY, then close oxygen valve; do NOT relight; tag torch out of service pending inspection	Instructor immediately
Backfire (single sharp pop, flame extinguishes)	Close acetylene then oxygen on torch; allow tip to cool; check tip for clog or contact damage; relight ONLY after tip cleared	Instructor
Machine falls off track end / workpiece edge	Power off (FWD-OFF-REV); do NOT approach until movement stops; close gas cylinder valves before inspecting	Instructor + first aid if struck
Hose tip-over (machine tips from hose snag during travel)	Power off IMMEDIATELY; close gas cylinder valves at source; do NOT right machine until verified gas is OFF	Instructor
Cylinder valve fails / uncontrolled gas leak	EVACUATE work area; ventilate space; close cylinder valve from safe distance if possible; do NOT relight any flames near area	Instructor + 911 if leak uncontrolled
Operator clothing ignites from sparks/spatter	STOP-DROP-ROLL; smother with fire blanket; do NOT use water near energized machine	Instructor + 911 + first aid
Cord damage during operation	Do not touch machine; power off at wall breaker	Instructor immediately

Power Isolation

Cord-and-Plug Control Before servicing, cleaning, or accessory change — unplug the unit and maintain exclusive control of the plug. Per CSA Z460-20 cl. 4.3.5.

Set FWD-OFF-REV to OFF; unplug power cord at outlet
Close oxygen and acetylene cylinder valves AT THE CYLINDER (not just torch); bleed both regulators to zero
Apply personal lock+tag at electrical plug AND verify gas pressure at zero before service >5 min (per CSA Z460-20 cl. 4.3.5)

Post-Use

Set FWD-OFF-REV to OFF; unplug power cord at outlet
Close cylinder valves: oxygen first, then acetylene; bleed both regulators to ZERO
Disconnect hoses from manifold if cylinders to be moved; cap fittings against debris
Wipe machine clean of slag and debris; inspect cutting tip for clogs, wear, damage
Coil hoses neatly; inspect along full length for damage; tag for service if damage found
Return machine to designated storage; secure cylinders upright with chain

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ELIM

Cannot eliminate; oxy-fuel track cutting is the equipment's purpose. Substitute plasma cutting (SOP-PROC-PLASMA-001) where plate thickness, material, and cut-edge quality permit. Mechanical cutting (saws — Baxter Verticut, cold-cut) substitutes for straight cuts within machine capacity.

SUB

Within oxy-fuel cutting category, the VCM-200 substitutes for handheld torch cutting on long straight cuts. Sibling unit Koike IK-12 (SOP-EQ-011) is the alternate track cutter at UA46. VCM-200HS variant (5-120 ipm speed range) is a substitution upgrade considered for future faster production cutting.

ENG

Manufacturer-installed check valves at torch (flashback control); rail-mounted tractor eliminates handheld torch hazards; grounded three-prong cord (115V single-phase); cone disk drive with automatic wear adjusting mechanism; balanced design with integral carrying handle; cylinder station chains (SOP-PROC-CYLINDER-001); regulator-controlled pressure (manufacturer max specs — 20-45 psi cutting oxygen standard tip range); 10-ft straight track constrains travel path.

ADM

Operator qualification — instructor sign-off required (interim; TR_Register reference for future); pre-use leak test of all gas connections (soap-and-water); rail clearance check before motor engagement (NO body parts, NO hoses crossing travel path — hose snagging causes tractor tip-over); hose routing rule (behind and elevated relative to travel direction); end-of-track monitoring required (manufacturer warns unit does not auto-detect end of track or workpiece — tractor will run off if unattended); UA46 shop is designated hot work area (no per-cut permit, no fire watch required by shop policy); shutdown sequence enforced (gas → motor → power); standard tips only (102-series acetylene); cross-reference SOP-PROC-CYLINDER-001 for cylinder handling; cross-reference SOP-EQ-011 (Koike IK-12) as sibling track cutter.

PPE

CSA Z94.3 cutting goggles or welding helmet with appropriate shade — STUDENT-SUPPLIED at UA46; shade compatibility is student responsibility (shade 5 for tips up to size 0, shade 6 for sizes 1-2, shade 7 for sizes 3-4 per ANSI Z49.1 / CSA W117.2 cl. 7); fire-resistant clothing (FR cotton or leather); leather gauntlet gloves; CSA Z94.2 hearing protection; CSA Z195 Grade 1 footwear; cotton or leather (NEVER synthetic — melts) clothing; head covering for any reach-in work; respiratory protection consideration for galvanized or coated plate (zinc fume hazard).

Before you sign off on this machine

On the next page you will confirm you have:

Read this entire SOP
Received instructor demonstration of the procedure
Demonstrated competent operation to the trainer
Understood the prohibitions and the emergency stop
Had the opportunity to ask questions

If you are unsure about any step or any control on this machine, stop and ask the instructor before you sign off.

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SOP-EQ-035

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