Brazing set DONMET MICRO (brazing and cutting)

Small and lightweight portable brazing set for heating, brazing, soldering, and plumbing ferrous and non-ferrous metals. It works with propane and oxygen. The brazing torch set also comes with a cutting tip for gas-cutting steel and ferrous metals. The flame temperature is about 2400°C. So it allows to make professional brazing of all metals and alloys, especially copper and copper alloys, which are often joined by brazing.

A portable set has an optimal size and weight, which makes it convenient for transportation and storage. And It can easily be brought into any building and to any floor without much effort.

The brazing set must be completed with cylinders (are not included in the delivery set):

1. Disposable oxygen cylinder – (110-165bar)
2. Disposable propane cylinder – 600ml (330g)

 Operating time while brazing:

– oxygen disposable cylinder – up to 1,5 hours
– propane disposable cylinder-up to 8 hours

Operating time while cutting:

– oxygen disposable cylinder – up to 1,5 minutes.
– propane disposable cylinder – up to 1 hour.

“DONMET 994 MICRO” delivery set № 994.000.00

* Pressure regulator MICRO DM with thread М12х1 can fit oxygen 1L cylinders produced by «Oxyturbo», «Providus», and «Castolin Eutectic».  And 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

 DESCRIPTION AND OPERATION of the brazing set DONMET MICRO

Brazing set DONMET 994 MICRO (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, heating, and other kinds of gas-flame treatment of ferrous and non-ferrous metals and their alloys.

Consumables parts of the brazing set (are not included in the delivery set):

1. Bottled oxygen (cylinder features: diameter~71mm; V=930ml; P=110bar; thread М12х1 dx.) (based on a CASTOLIN cylinder – Orig. 730240 OX;)
2. Bottled propane/MAPP (cylinder features: diameter ~75mm; V=1l; W=400gr; thread 7~16” 28 UNEF);

The set 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.
The oxygen pressure regulator MICRO DM is designed for setting the required oxygen pressure at the cutting torch inlet. The maximum working pressure is 2,5 bar 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).

OPERATING INSTRUCTIONS for brazing set DONMET MICRO

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. Then make sure all the valves at the cutting torch are closed. After this put the cylinders into the seats and screw the regulator MICRO DM at the oxygen cylinder and the adapter at the gas fuel cylinder. Next 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, and away from people and animals.
2. Make sure the cylinders are empty before you replace them. But 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.
 

Oxygen and propane pressure regulators settings:

Turn the oxygen cylinder pressing the screw clockwise to build up working pressure to 2,5 bar. The pressure value is controlled with a pressure gauge.
Open the shut-off valve at the adapter.

Oxy propane torch settings:

At the torch shank open the oxygen valve 1/10 of the way and the gas fuel valve 1/5 of the way, and ignite the gas mixture. Then adjust a proper flame with the cutting torch valves. And 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, and 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 of the brazing set 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:

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.

Actions when detecting a gas leakage (a gas odor) during operating the brazing set:

• put out the flame immediately;
• take the kit outside, to a well-ventilated area; check the sealings at the joints between the cylinders and the pressure regulator and adapter by applying a 4% soap solution. The leakage becomes evident with the appearance and growth of bubbles and foam where the soap solution is applied;
• in case the sealing is worn out replace it with a spare included in the delivery set;
• keep the cutting torch clean, and 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.

Warranty period

The warranty period is 12 months from the date of commissioning but no more than 24 months from the delivery date.
The 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.

List of works performed with the brazing set DONMET MICRO:

1. Precise straight cutting of rolled sheet metal
2. Precise contour cutting of marked-out sheet profile
3. Cutting in enclosed volumes and confined spaces
4. Parting cutting of sheet metal
5. Cutting of profile iron – pipes/channel bars/angle pieces/double-T pieces
6. Cutting of steel reinforcement
7. Cutting of rusted bolts, load pins, and couplings when conducting repair works
8. Cutting when repairing car bodies in hard-to-reach places
9. Cutting when dismantling small metal structures (fences, enclosures, etc.)
10. Cutting holes in pipes of various sections and sheet metal
11. Cutting when using small-volume cylinders or portable gas kits
12. Heating products before forging
13. Heating products before bending (strip, pipe)
14. Heating products for subsequent hardening
15. Bearing heating before removal from the shaft
16. Flame leveling of sheet metal
17. Heating of “stuck” threaded connections for unscrewing
18. Heating of elements during the creation of metal sculptural compositions (design)
19. Heating elements during the creation of forged products ий
20. Local heating of the product surface
21. Soldering copper pipes during the installation of heating / underfloor heating systems
22. Soldering electrical cables
23. High-temperature soldering of ferrous and non-ferrous metal parts
24. Soldering of thin-walled ferrous metal tanks
25. Soldering of thin-walled aluminum tanks
26. Soldering of copper tracks during installation of multi-zone air conditioning systems VRF and VRV
27. Soldering copper or brass pipes to dilute oxygen and combustible gases
28. Non-ferrous metal smelting
29. Burning the paint-and-lacquer coating from metal surfaces
30. Burning soot from kitchen utensils
31. Supplied as part of portable gas kits
32. Calcination of parts
33. Scorching of wood to give it a vintage look
34. Warming up frozen locks, taps, water pipes thawing ice, etc.
35. Warm-up/calcination / heat treatment of welding seams
36. Quick lighting the fire
37. Fire marking
38. Heating before milling
39. Heating before surfacing
40. Surface heating during spray coating
41. Cleaning the metal surface of the scale and other contaminants
42. Metal surface tinning