Brazing kit MICRO (brazing and cutting)

1. INTRODUCTION.
The present operation manual for the DONMET 994 MICRO kit covers the setting-up procedures, work procedures, maintenance check and maintenance procedures, storage and transportation instructions and other data relevant to the its proper handling.
Gas welders with a rank of at least 3 are allowed to work with the kit.

2. GENERAL INFORMATION.
Scope of delivery for order № 994.000.00

* Pressure regulator MICRO DM with thread М12х1 can fit oxygen 1L cylinders produced by «Oxyturbo», «Providus», «Castolin Eutectic». If you intend to use cylinders produced by Kemper please order the kit with a pressure regulator MICRO DM with thread M10x1 №055.000.01.
Spare parts (upon request) are mentioned in paragraph 3.1 of the manual for cutting torch “DONMET” 132-07 P

3. DESCRIPTION AND OPERATION
DONMET 994 MICRO kit (Order №994.000.00) is designed for manual oxy-gas parting cutting (severing) of sheet and rolled metal of low-carbon steel up to 20mm thick. After replacing the cutting torch tip, it can be used for brazing, eating and other kinds of gas-flame treatment of ferrous and non-ferrous metals and their alloys.
Consumables:
Bottled oxygen (cylinder features: diameter~71mm; V=930ml; P=110bar; thread М12х1 dx.) (based on a CASTOLIN cylinder – orig. 730240 OX;)
Bottled propane/MAPP (cylinder features: diameter ~75mm; V=1l; W=400gr; thread 7~16” 28 UNEF);
The technical characteristics of the kit are featured in the manual for cutting torch “DONMET” 132-07 P.
The kit consists of the following units:
– cart for cylinders;
– manual oxy-gas cutting torch “DONMET” 132-07P including:
– pressure regulator MICRO DM (055.00.000);
– adapter 7/16” 28 UNEF (962.500.00);
– hose OXYGEN ISO EN 559 2MPa 3,2 mm; L=1,5 m (blue)
– hose PROPANE ISO EN 559 2MPa 3,2 mm; L=1,5 m (orange)
Adapter 7/16” 28 UNEF is designed for feeding the required amount of gas (propane/MAPP) to the cutting torch inlet. The flow rate can influence how smoothly the flow of propane is adjusted when working with a torch tip.
Oxygen pressure regulator MICRO DM is designed for setting the required oxygen pressure at the cutting torch inlet. Maximum working pressure is 2,5 kgf/сm2 which is controlled with a pressure gauge at the regulator.
Cart for cylinders is a device that combines the basic components of the kit into one compact unit and ensures its convenient transportation. ,
Low-pressure cutting torch “DONMET”132P MICRO is designed for manual oxy-gas parting cutting (severing) of sheet and rolled metal of low-carbon steel up to 20mm thick.
The cutting torch consists of a shank assembly and a tip. There are two tips included in the delivery set – one for cutting and one for brazing (welding).
The shank consists of a preheating oxygen valve, a gas fuel valve, a cutting oxygen valve, a body and a handle. The shank is designed for adjusting oxygen and gas fuel consumption before they are fed into the tip mixing chamber.
Tip (for cutting) consists of a mixer, two tubes (one inside the other), a head, a cutting nozzle and a preheating nozzle. The mixture is supplied through the internal tube. The cutting oxygen is supplied through a gap between the tubes.
Tip (for brazing) consists of a mixer, a tube for supplying the mixture into the nozzle and a nozzle for brazing (welding). Do not open the cutting oxygen valve when using the brazing tip.
Rubber-fabric hoses are designed for supplying the energy carriers from the cylinder to the cutting torch (torch).

4. OPERATING INSTRUCTIONS
4.1 Setting-up procedures
Before putting the torch into operation make sure it functions properly and check:
a) tightness of hose connections, all detachable and soldered joints;
b) suction (inflow) in the gas fuel channel.
Make sure the pressing screw at the pressure regulator MICRO DM is unscrewed, and that the valve at the adapter is closed. Make sure all the valves at the cutting torch are closed.
Put the cylinders into the seats and screw the regulator MICRO DM at the oxygen cylinder and the adapter at the gas fuel cylinder. Make sure there are no leakages. To avoid mistakes during tightening, the threads at the cylinders are the same.
Precautions.
1. The cylinders are to be replaced in well—ventilated areas, preferably outside, away from inflammable materials (substances), burning hot heat sources, away from people and animals.
2. Make sure the cylinders are empty before you replace them.
Be careful – the weight of an empty cylinder is almost the same as a full one.
3. Do not use cylinders if the sealings at attachments are damaged or lost.
4. Make sure the hoses are leakproof and intact.
4.2 Setting-up.
Turn the oxygen cylinder pressing screw clockwise (see pic. 1 on p. 8) to build up working pressure to 2,5 kgf/cm2. The pressure value is controlled with a pressure gauge.
Open the shut-off valve at the adapter.
At the cutting torch open the oxygen valve 1/10 of the way and gas fuel valve 1/5 of the way, ignite the gas mixture. Adjust a proper flame with the cutting torch valves.
Turn of the gas supply in reverse order: gas fuel first, oxygen next.
In case of continuous claps or a backfire, immediately close the gas fuel valve, then the oxygen valve and let the cutting torch cool down.
After a backfire purge and blow out the mixing device and the nozzles, tighten the nozzles and the nuts, check the cutting torch hermeticity.
To replace the tip unscrew the union nut at the shank, replace the tip (the torch tip is included in the delivery set) and tighten the nut.
To increase the product service life it is recommended to perform maintenance works once in three months.
Checkups must be conducted for:
– connection tightness,
– suction in the gas fuel connection unit (injection),
– burning with a cutting oxygen flame jet with checking the sealings at the pressure regulator and the adapter.
Precautions.
Use the cylinders only in vertical position.
Do not operate the kit in confined spaces and in basements of buildings. The area should be well-ventilated.
Do not leave the kit unattended.
Do not leave a working cutting torch unattended.
Do not use thick lubricants or oil on parts in contact with oxygen.
Replace the cutting torch shank in case of wear or damage to the shut-off valves in a timely manner.
Do not allow the hoses to be twisted, ruptured or overheated.

5. MAINTENANCE
Maintenance and servicing operations should be recorded in a maintenance register according to the form below:

Actions when detecting a gas leakage (a gas odour):

• put out the flame immediately;
• take the kit outside, to a well-ventilated area; check the sealings at joints between the cylinders and the pressure regulator and adapter by applying a 4% soap solution. The leakage becomes evident with appearance and growth of bubbles and foam where the soap solution is applied;
• in case the sealing is worn out replace it for a spare included in the delivery set;
• keep the cutting torch clean, on a regular basis purge the nozzles from deposit and metal splashes with an emery cloth or a small file Purge the torch tip (for brazing and welding) with compressed air. Do not use needles or pins for cleaning the tip orifices as it changes the diameter and shape of the orifices which causes claps during operation and distortion of the flame core shape.

6. STORAGE AND TRANSPORTATION
The kit and its components can be transported by any means of transport with due regard for the regulations applicable for that transport mode.
Transportation and handling conditions of the kit and its components in terms of the impact of environmental climatic factors for land cargo in group C. During transportation and storage the cylinders should be kept in vertical position. Do not ever place the cylinders horizontally. Protect the cylinders from sunlight, do not expose them to temperatures over 50°C. Store the cylinders in dry, cool and well-ventilated areas.
Transportation conditions: any transport mode (except sea). If the kit is not operated for a long time or during transportation, detach the regulator and adapter from the cylinders. This will keep the cylinders content intact and prevent even the slightest leakages.

7. MANUFACTURER’S WARRANTY
The manufacturer guarantees the kit compliance with the requirements of design documentation К18.009-994.00.000, ISO 5172 subject to the consumer’s due regard for the service, transportation and storage instructions.
The kit design complies with the requirements of current standards and regulations of technical and fire safety, occupational safety and health as well as industrial sanitation in terms of operation and maintenance.
Warranty period is 12 months from the date of commissioning but no more than 24 months from the delivery date.
Production year is indicated at the cutting torch shank under the pads.
DONMET plant performs warranty repair works, i.e. free defect elimination within the warranty period.

Free warranty repair is not performed if:

1. the product was not used in accordance with the operating instructions (p. 4) and technical specification requirements (p. 3);
2. the product was misused or used negligently resulting in mechanical or other damages;
3. the cutting torch design was tampered with. The warranty does not cover spare parts.

8. TEST CERTIFICATE
The kit complies with the requirements of design documentation К18.009-994.00.000. The kit has been tested and proven fit for service.