INSTALLATION & OPERATING INSTRUCTIONS FOR THE DS300 BRAZING HEARTH FLAMEFAST (UK) LIMITED

Transcription

1 INSTALLATION & OPERATING INSTRUCTIONS FOR THE DS300 BRAZING HEARTH FLAMEFAST (UK) LIMITED Unit 2. Labtec Street. Swinton. Manchester M27 8SE Telephone Fax

2 INSTALLATION & OPERATION DS300 BRAZING HEARTH DS300 BRAZING HEARTH The DS300 Brazing Hearth is supplied complete with one RF80 Brazing Torch. FUME EXTRACTION Wherever hot metals equipment is fitted, a fume extraction system is recommended to remove unwanted heat and fumes. VARIVAC EXTRACTION The Flamefast Varivac fume extraction systems is recommended for this application. 1

3 WILL IT FIT? Allow room around the unit. Place 1 metre from any side walls and 20-30cm from the rear wall. 720mm 1192mm 810mm 585mm GAS INLET 1/2in B.S.P. THREAD 10mm DIA. HOLES FOR BOLTING TO FLOOR 595mm 150mm HOW MUCH GAS? The DS300 Brazing Hearth uses Natural, Propane/Butane or Towns Gas. Heat input is approximately 80,000 Btu/hr. (25kw). APPROXIMATE GAS CAPACITY Natural Gas 80ft. 3 /h 2.26m. 3 /h Propane/Butane 4lbs./h 1.8kg./h GAS PRESSURE It is important that the Hearth is supplied with the correct gas pressure. You must fit a fixed (not variable) pressure regulator - see your gas supplier. GAS PRESSURE Natural Gas 8in WG 20mbar Propane 14in WG 35mbar Butane 11in WG 28mbar Towns Gas 6in WG 15mbar FIXED PRESSURE REGULATOR VALVE BUTANE 2

4 GAS INSTALLATION The gas inlet pipe is 1 /2 in BSP/NPT thread and should be fitted with a union and isolating valve. BACK OF HEARTH UNION ISOLATING VALVE OPERATIONAL PROCEDURE 1 - Make sure the torch valve(s) are in the closed position. 2 - Switch on both the gas and electrics to the unit. 3 - Press the green start button. 4 - The amber neon will indicate that a gas soundness test is being applied. If the unit is sound, after approximately 30 secs the green neon will illuminate. 5 - Hold the brazing torch to the cage containing the ignition electrode. Press the ignition button on the fascia. When the torch ignites release the ignition button. GREEN NEON TORCH VALVE CLOSED GREEN START BUTTON IGNITION CAGE IMPORTANT IF THE AMBER LIGHT GOES OUT IMMEDIATELY AND THE BLOWER STARTS, THE SYSTEM MAY HAVE HELD PRESSURE FROM A PREVIOUS OPERATION. TO CHECK, STOP THE UNIT BY PRESSING THE STOP BUTTON. WITH THE UNIT SHUT DOWN, OPEN THE TORCH VALVE AND RESTART. THE AMBER NEON SHOULD REMAIN ILLUMINATED. BLOWER STARTS BUT GREEN NEON DOES NOT ILLUMINATE. THE BLOWER IS NOT SUPPLYING ENOUGH AIR. CHECK THE BLOWER FILTER. AMBER NEON IGNITION BUTTON RED STOP BUTTON 3

5 FAILURE TO START A - If gas is not present or has low pressure, the DS300 will not start or will shut down during operation. B - If the amber light does not go out the system has not purged. TORCH VALVE Check that the torch is turned off. Check the gas connections and the torch for gas escapes. Do this while the amber neon is on. 5 - To Shut Down turn the torch valve anti clockwise and press the red stop button. RED STOP BUTTON OPERATING HINTS 1 - Where possible work to be brazed should be surrounded by material to reflect and radiate heat. It also helps to raise any flat work on small supports to get even heat distribution. A revolving brazing table can be used. FLAME GAPS TO ALLOW BURNT GAS TO ESCAPE PLATES TO BE BRAZED SUPPORT RODS OR WIRE 4

6 2 - Always start heating with the largest possible flame. Do not have the flame too near. 50c.m. FOR LARGEST FLAME 50 c.m. 3 - As soon as Brazing temperature is reached - turn the torch valve anti-clockwise to obtain a sharp pointed flame. Then apply the brazing rod. 4 - A softer flame (Ideal for annealing) can be obtained by depressing the torch choke button. 5 - The Flamefast heating torch can also be used for heating work for hardening and tempering. TORCH VALVE CHOKE BUTTON 5

7 OPERATION & MAINTENANCE RF80 BRAZING TORCHES RF80 BRAZING TORCHES OPERATION For optimum performance regulate the flame size by turning the single control valve. CONTROL VALVE MAINTENANCE The only maintenance normally required is lubrication of the valve plug every six months. Use a suitable valve grease, such as Rocol M23660, sparingly as it is important to keep valve ports clean. LUBRICATE 6

8 ELECTRICAL DS300 BRAZING HEARTH 220 / 240 volt - 50 cycles 240 watts 1 - Remove the four screws and cover of the connection Box - make sure isolating switch is off. 2 - Connect to terminals 1 - Live 2 - Neutral 3 - Earth in isolating box. 3 - Terminals 4 Earth 5 Neutral and 6 Live are only for connection to the extraction unit. CONNECTING BOX WITH FOUR SCREWS Replace cover on connection Box. 7

9 NUMBERS INDICATE TERMINAL BLOCK CONNECTOR NUMBERS 10 MAIN SOLENOID VALE N L BYPASS SOLENOID VALE N L 3 GAS PRESSURE SWITCH E COM NO NC EARTH TO FRONT COVER EXTRACTION NEUTRAL OUT LIVE OUT L N BLOWER FAN FEED IN NEUTRAL LIVE A2 A START STOP AMBER NEON MICRO SWITCH EARTH TO SPARK IGNITOR GREEN NEON 6 E COM NO NC 1 ELECTRICAL WIRING DIAGRAM DS300 BRAZING HEARTH HT TRANSFORMER TYPE ZA E 5 Kv 8

10 ANNUAL SERVICING AND TESTING JANUARY 2006 Flamefast offers an Annual Inspection and Service of your hot metal equipment. We will service it to ensure it is working safely and correctly and provide a full written report on the safety and operational condition of your equipment. The Annual Fee for this service is per Room of equipment plus VAT. It is mandatory under the Control of Substances Hazardous to Health (COSHH) Regulations that each extract system is tested at least once every 14 months. To assist the employer to comply with this statutory requirement Flamefast will carry out full tests and provide a report on the performance of any extract system in your Hot Metal and Woodworking areas. The fee for the first fan in each area s extract system is plus VAT. Second and subsequent fans in any area are each plus VAT. Please note:- these prices are correct at the date of this publication. Prices are subject to change with time. 9