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for oxy-fuel metal cutting

Operation manual

PG23.009-971.00.000-04 OM

Ukraine 2024

                                                                                   TABLE OF CONTENTS                                 Page

Introduction……………………………………………………………………………………………………………………..4

1. Description and work…………………………………………………………………………………………………….4

1.1 Purpose of the product …………………………………………………………………………………………4

1.2 Characteristics (properties)…………………………………………………………………………………….4

1.3 Product set …………………………………………………………………………………………………………5

1.4 Operation of the kit………………………………………………………………………………………………6

1.4.1 Preparation for work ………………………………………………………………………………………….6

1.4.2 Preparing the tank…………………………………………………………………………………………….6

1.4.3 Preparing the cutting torch………………………………………………………………………………….6

1.4.4 Torch ignition…………………………………………………………………………………………………..6

1.4.5 Flame control…………………………………………………………………………………………………..7

1.4.6 Metal cutting……………………………………………………………………………………………………7

1.4.7 Closing after completion of work………………………………………………………………………….7

1.5 IMPORTANT INFORMATION……………………………………………………………………………..7

1.6 Marking……………………………………………………………………………………………………………8

2. Description and operation of components…………………………………………….………………………..9

2.1 Oxygen regulator RO-200-2 DM ……………………………………………………………………………9

2.2 Flashback arrestor ……………………………………………………………………………………………..9

2.3 Tank ……………………………………………………………………………………………………………….10

2.4 Tank body ……………………………………………………………………………………………………….11

2.5 Tank control unit ……………………………………………………………………………………………….11

2.6 Pump ……………………………………………………………………………………………………………….12

2.7 Filler cap with pressure relief valve ……………………………………………………………………..13

2.8 Cutting torch “DONMET” 185 “TRIDENT” series………………………………………………….14

2.9 Handle assembly ………………………………………………………………………………………………14

2.10 Cutting nozzle, preheating nozzle, head assembly …………………………………………………16

2.10.1 Preheating nozzle…………………………………………………………………………………………..16

2.10.2 Cutting nozzle ………………………………………………………………………………………………17

2.11 Rubber hoses …………………………………………………………………………………………………..18

3. Preparing the kit for use …………………………..………………………………………………………....……..18

3.1 Safety measures when preparing the kit for use ……………………………………………………….18

3.2 Scope and sequence of external inspection of the kit products ……………………………………19

3.3 Preparation of the workplace………………………………………………………………………………..19

3.4 Rules for checking the readiness of the kit for operation and the inspection procedur…….19

3.4.1 Before starting gas-flame operations …………………………………………………………………..19

3.4.2 Connection to the source of oxygen and liquid fuel supply………………………………………20

3.4.3 Checking the tightness of the connection points on the oxygen line of the kit …………….20

3.5 Preparing the torch for operation ………………………………………………………………………….20

3.5.1 Checking the injection. …………………………………………………………………………………..20

3.5.2 Checking the operation and tightness of the cutting oxygen valve ……………………………20

3.5.3 Checking the functionality of the spool in the flashback arrestor ……………………………..21

4. Actions in case of equipment failures …………………………………………………………………………..21

4.1 Causes of continuous pops and flashbacks ……………………………………………………………..21

4.2 Actions to take in case of continuous pops or flashback …………………………………………..22

4.3 List of possible malfunctions ………………………………………………………………………………22

5. Technological part ………………………………………………………………………………….….26

5.1 Features of cutting …………………………………………………………………………………………….26

5.2 Oxygen pressure ………………………………………………………………………………………………26

5.3 Oxygen purity ………………………………………………………………………………………………….26

5.4 Cutting oxygen consumption ………………………………………………………………………………27

5.5 Cutting speed …………………………………………………………………………………………………..27

5.6 Power of the heating flame …………………………………………………………………………………27

5.7 Cutting width …………………………………………………………………………………………………..27

5.8 Guidelines for cutting technique ………………………………………………………………………….28

5.9 Cutting torch – workpiece distance ………………………………………………………………………28

6. Service and maintenance  ……………………………………………………………………………..28

6.1 Frequency of inspection ……………………………………………………………………………………..28

6.2 Requirements for the composition and qualifications of the service personnel………………28

7. Routine service of the kit and its component. General instructions ……………………29

8. Storage, transportation and packaging …………………………………………………………..29

9. Manufacturer’s warranty…………………………………………………………………………..29

Parts list for the cutting torch DONMET 185 “TRIDENT” series……………………………………..30

Parts list for the liquid fuel tank DG-08-1DM……………………………………………………………….32

INTRODUCTION

This operating manual is intended for the kit No. 3 for oxy-fuel metal cutting, its preparation for operation, operating procedure, checking its technical condition, maintenance, storage and transportation rules and other information necessary for its proper operation.

Before using the kit No. 3, it is necessary to study the information contained in this manual, the information contained in the operating documents of the component parts, and get acquainted directly with the design of the kit and its components.

Required level of special training of the operating personnel

The kit may be operated by persons not younger than 18 years of age who have studied its structure, have admission to work independently on gas-welding equipment and have undergone safety training.

1. Description and operation

1.1. Purpose of the product

Kit No. 3 for oxy-fuel metal cutting (Order No. 971.000.04) is intended for oxy-fuel cutting of low-carbon and low-alloy steels in the presence of an oxygen source (oxygen line, manifold or cylinder) using liquid fuel: basic version – for diesel fuel; optional – for gasoline (change of cutting and preheating nozzles requires).

1.2. Characteristics (properties)

Consumables:

Technical oxygen gas               

Diesel fuel                                                                            

Gasoline (optional)

Oxygen pressure regulator RO-200-2 DM:

Maximum throughput, m³/h                                                                                                                      50,0

Maximum gas inlet pressure, bar                                                                                                    200

Maximum working pressure, bar                                                                                                                                 10

Weight, no more than, kg                                                                                                                                           1,2

Inlet connection                                                                                                     W21,7x 1/14’’

Outlet connection                                                                                                    G3/8  Dy6/9

Fuel tank:

Tank capacity, l                                                                                                                                                         8

Fuel volume, not more than, l                                                                                  6

Fuel consumption, kg/hour                                                                                     0,85-1,7

Working pressure in the tank, bar                                                                           0.5-3.0

Thread on the outlet connection of the tank control unit                                        9/16 LH

Tank weight, kg                                                                                                      4.5

Liquid fuel cutting torch “DONMET” 185 “TRIDENT” series

Metal thickness to be cut, mm                                                                                                                                8-300

Energy consumption:

Oxygen, m³/h                                                                                         3.4-30

Diesel fuel, kg/h                                                                                                                       0.85-1.7

Gasoline, kg/h                                                                                                                          0.9-1.8

Operating weight of the cutting torch, kg no more than                                             1.1

Length of the cutting torch, mm                                                                                                                                                550

Thread in the cutting torch head:                                                                                                                  G3/8

Thread on the cutting torch inlet connections:

for oxygen                                                                                                                            9/16

for fuel                                                                                                                                 9/16 LH

Inner diameter of the hoses to be connected, mm                                                                              6
1.3. Product set

 The kit consists of the following main components:

Fig.1 – Kit No. 3 for oxy-fuel metal cutting

1 – Liquid fuel cutting torch “DONMET” 185 “TRIDENT” series

2 – Oxygen pressure regulator RO-200-2 DM

3 – Liquid fuel tank DG-08-1 DM.

4 – Flashback arrestor “DONMET” 950 (Included in the cutting torch).

5 – Oxygen hose WP 20 bar – ISO 3821 – 2023, L=10 m, Dn = 6 mm (1/4”).

6 – Fuel hose WP 20 bar – SAE J30 R6, L=10 m, Dn = 6 mm (1/4”).

7 – Pump.

8 – Valve of the control unit.

9 – Pressure gauge 6 bar.

10 – Safety valve.

11 – Cutting oxygen lever.

12 – Heating oxygen valve.

13 – Fuel valve.

1.4. Operation of the kit

The space where the kit №3 will be placed must be provided with fire extinguishing equipment.

1.4.1. Preparation for work

Preparation for work (please look at the Fig. 1):

• connect the pressure regulator item 2 to the oxygen cylinder;
• connect to the cutting torch pos. 1 the oxygen flashback arrestor(FA) pos. 4 (thread 9/16);
• connect the hose pos. 5 (blue or green) to the pressure regulator pos. 2 and to the FA pos. 4 (thread 9/16);
• connect the hose pos. 6 (red) to the tank pos. 3 and to the fuel inlet connection of the cutting torch pos. 1 (thread 9/16LH);
• tighten all threaded connections with a key;
•  tightly screw the valves of the cutting torch.

1.4.2. Tank preparation

Fill the tank with fuel (no more than 6 liters).

Create an air pressure of about 1 bar in the tank using the pump pos. 7 (look at the pressure gauge pos.9). The pressure drops as the cutting torch cuts. When the pressure drops to 0.7 bar, pump it up again to 1 bar. The pressure 0.7 bar in the fuel tank is necessary for the shut-off valve to work.

At a pressure higher than 3 bar, the safety valve pos. 10 will release an excess air into the atmosphere.

Structure of the pressure control unit – see Fig. 15. p.33.

Fill the fuel hose with liquid fuel. Slowly, about 1 turn, open the valve pos. 8 on the control unit of the tank. After 30 seconds, open valve 8 fully. If liquid fuel is blocked by the dump valve, close the valve, tap the tank on the ground and repeat the procedure.

1.4. 3. Preparation of the cutting torch

Select the cutting nozzle and oxygen pressure from the cutting chart in the cutting torch manual. Slowly and fully open the valve of the oxygen cylinder. Set the required pressure on the oxygen regulator, pos. 2.

Fill the oxygen line by pressing the cutting oxygen lever pos.11 for 5 seconds. Failure to do so could create the conditions for a backlash.

WARNING! Fully open the preheating oxygen valve pos. 12. During operation, the heating oxygen valve is not adjusted. It is very important to set the oxygen pressure according to table 1 in the cutting torches manual.

1.4.4. Ignition of the cutting torch

Open the liquid fuel valve pos. 13 of the cutting torch until light mist appears. If liquid drips from the cutting torch, reduce the liquid supply.

Purge the oxygen line again by opening the cutting valve for 5 seconds.

Ignite the cutting torch by using a lighter to create a spark close to the tip and on one side.

When the torch ignites, do not attempt to adjust the flame, but immediately press the tip of the torch against the steel surface at a slight angle to heat the nozzle. The minimum time to enter the mode is achieved by heating the preheating nozzle with a heating flame reflected from an obstacle (from a corner, from a board, from any refractory barrier so that the heating flame contacts the side walls of the preheating nozzle). After heating, the temperature is maintained automatically.

1.4.5. Flame regulation

After the disappearance of yellow flashes in the flame, the composition of the mixture should be finally adjusted with the start of cutting oxygen. Adjust the fuel valve so that yellow flashes of unvaporized fuel do not appear in the flame when the cutting oxygen is turned on. WARNING! Avoid burning inside the preheating nozzle of the flame core during the final adjustment of the cutting torch, this leads to its overheating. A correctly adjusted core of the heating flame protrudes 5-7 mm relative to the end of the preheating nozzle (for cutting nozzle No. 1, the flame core protrudes by 3-5 mm).

1.4.6. Metal cutting

Heat the cutting point into the metal until the steel turns a bright red-orange.

Press the cutting oxygen lever pos. 11 and cut the metal.

1.4.7. Closing after completion of works

After cutting, turn off the cutting torch by first closing the liquid fuel supply valve, and then, after 5-10 seconds, the heating oxygen supply valve in order to prevent the formation of soot on the nozzle.

Important for your safety.

After stopping work and during interruptions in work, the cutting torch must be placed or suspended with a mandatory tilt towards the head to prevent liquid fuel from flowing into the oxygen channels.

WARNING! The preheating nozzle is a composite monobloc product in which two parts are screwed and soldered together. To remove tarry deposits inside the preheating nozzle, it must be removed from the cutting torch and then heated with a torch flame to a red color. At the same time, the heating temperature should not be higher than the melting point of the solder. Allow the nozzle to cool, then blow the channels inside the nozzle with a compressed air, or tap the end (from the cut side) against a wooden surface.

In the process of operation, do not allow leakage in the places of connection of the head with the preheating and cutting nozzles. Check the tightness of all connections, if necessary, tighten the connections and eliminate leaks.

1.5. Important information

* Fill the DG-08-1 DM tank with fresh fuel from the gas station.

Fuel from other tanks is often old and/or contaminated, which can result in a yellow flame.

If the preheating flame is yellow:

1. The nozzle may be too cold. Heat the nozzle by pressing it against the steel.

2. The flame may be too saturated with fuel. Increase the amount of oxygen or decrease the amount of fuel.

3. The flame may be too big. Reduce the dark blue flame core to 3-4mm.

4. A new fuel hose contains an oily residue from the manufacturing process which causes the flame to burn yellow.

5. Fuel may be contaminated with oils. Fill the tank with new, fresh fuel.

6. Oxygen supply may be insufficient.

If the flame goes out while cutting:

There may still be gas burning inside the tip. Stop burning by quickly closing the preheating oxygen valve and then just as quickly opening it again. Ignite the cutting torch again. If this is not done quickly, you can damage the cutting nozzle or the sealing ring near the handle.

If the cutting and preheating nozzles are loose:

When the cutting torch head is exposed to a very hot environment, the heat can expand the brass in the cutting torch head so that the thread will loosen from the thread of the preheating or cutting nozzle.

A sign that the cutting nozzle has come loose is that you will hear micro-pops at a rate of 1 to 5 pops per second.

When the preheating nozzle is released, the flame may burn in the gap between the nozzle and the head. This leads to their overheating or burning. Do not allow the nozzle to loosen and the flame to burn in the gap between the nozzle and the head.

Do not tighten the preheating nozzle when the cutting torch head is hot. Tightening a hot nozzle on hot brass can lead to deformation of both the head and the preheating nozzle.

Cool the head before tightening.

If you are running on gasoline, the head can be quickly cooled by closing the gasoline and oxygen valves, and then opening only the gasoline supply valve. The hot nozzle will instantly vaporize the gasoline and cool it down. When the vapor turns into a mist, the head will cool and the nozzle can be tightened.

You can cut from a greater distance from the nozzle to the metal:

You can get away from the slag and heat build-up that is created thanks to the long contact distance of the liquid fuel flame. To continue cutting the torch ”DONMET” 185 no need to be exactly 10-12 mm away from the steel, as other cutting torches do. Keep the nozzle away from hot spots to extend the life of the nozzle and prevent the cutting torch head from overheating.

You can immerse the tip in mud, sand, water, etc.:

The flame may go out, but it will never rekindle. The flame is very strong because the fuel in the nozzle expands as it changes from liquid to vapor.

Guarantees of your safety:

1. Cutting torch ”DONMET” 185 cannot cause flashback in the fuel line. Liquid fuel does not burn without access to air.

2. Any leakage will leave a wet spot that will be visible and can be quickly removed.

3. If you cut the hose with liquid fuel, the shut-off valve in the control unit of the tank will block the fuel supply.

1.6. Marking

Kit No. 3 for oxy-fuel metal cutting has markings of the constituent parts:

• Cutting torch for manual oxy-fuel cutting type ”DONMET” 185 “TRIDENT” series: – the cutting torch type and trademark of the DONMET plant are marked on the cutting torch handle.
• The number of the nozzle and the type of fuel are marked on the cutting nozzle of the cutting torch.
• On the handwheels of the valves there is a recognizable color of blue for the oxygen valve, red for the liquid fuel valve.
• The tank bears the trademark of the DONMET plant and a sign prohibiting the use of oxygen to create pressure in the tank.
•  Oxygen pressure regulator RO-200-2 DM: – the trademark of the DONMET plant and the brand of the regulator are indicated on the body.

Transport marking is not provided.

2. Description and operation of components

2.1. Oxygen pressure regulator RO-200-2 DM

Oxygen pressure regulator RO-200-2 DM is designed to reduce the pressure of oxygen coming from the cylinder and set the working pressure before entering the cutting torch.

The pressure regulator is designed for a maximum gas input pressure of 200 bar, and a maximum working pressure of 10 bar.

The pressure regulator, Fig. 2, is attached to the cylinder with a nut with a W21.7x 1/14” thread. Oxygen, after passing through filters 17 and 3, enters the high-pressure chamber. During rotation of the adjusting screw 7, the force of the setting spring 14 is transmitted through the pressure disk, membrane 5 and pusher 10 to the reducing valve 2. The valve 2, moving, opens the passage for oxygen through the gap formed between the valve and the valve seat 9 into the working pressure chamber. The reduction of oxygen pressure in the pressure regulator occurs by one-stage expansion of it while passing through the gap between the seat 9 and the reducing valve 2. Clockwise rotation of adjusting screw 7 increases working pressure while counterclockwise rotation decreases it. If the working pressure accede 16 bar or in case of malfunction the safety valve 6 will operate.

A pressure gauge 15 shows an inlet (high) pressure and a pressure gauge 16 shows an outlet (low) pressure of oxygen from the pressure regulator (installed in the range from 2.5 to 10.0 bar by operator).

 The pressure regulator is marked RO-200-2 DM.

Fig. 2 – Oxygen pressure regulator RO-200-2 DM.

1 – body assembly; 2 – pressure reducing valve; 3 – filter; 4 – cap assembly; 5 – diaphragm assembly; 6 – safety valve; 7 – adjusting screw; 8 – reducing spring; 9 – seat; 10 – pusher; 11 – breather; 12 – gasket; 13 – locking nut; 14 – setting g spring; 15 – high pressure gauge; 16 – low pressure gauge; 17 – filter element EF-2; 18 – nipple; 19 – nut.

2.2. Flashback arrestor

Flashback arrestor, Fig.3, is designed to protect the

the hose from rupture and ignition in case of flashback.

Working principle: Oxygen is supplied to the inner cavity of the valve body 10 under pressure and, overcoming the force of the spring 5, moves the spool 3 with the seal 4. Passing through the holes of the spool 3 and the flame arrestor 1, oxygen enters through the channels of the nipple 8 into the oxygen connection of the cutting torch. When a flashback occurs, the explosive wave passes through the flame arrestor 1 and, acting on the end surface of the spool 3, presses it against the housing seat 10. The gas supply to the consumer is instantly stopped. Extinguishing the flame occurs in the pores of the flame arrestor.

WARNING: in the case of damage of a flashback arrestor due to the thermal effect of flashback and its failure, send the valve to a specialized workshop for repair or replacement.

An oxygen flashback occurs when fuel enters the oxygen line when the torch is not operating and the operator forgets to purge the oxygen line before igniting the torch. Blowing the oxygen line is a mandatory procedure for all torches of all manufacturers. However, accidents can happen, and a flashback arrestor valve is a useful device to increase your safety.

2.3. The Tank

The TankFig. 4. is a device that combines the constituent parts of the tank into one compact structure and is intended for transportation, storage and supply of liquid fuel under a specified pressure to the liquid-fuel cutting torches during separate cutting of metals.

The tank includes: tank body 1; pump 2; tank control unit with pressure gauge 3; filler cap with safety valve 4.

 Working principle: Before starting work, fill the tanks with liquid fuel in a volume of no more than 6 liters. To do this, remove filler cap 4 and pour fuel into the tank through the filler neck. Install cap 4 on the neck and tightly tighten with a wrench. To create the working pressure of 07-1.5 bar inside the tank make reciprocating movements with the pump handle of pump 2. You can monitor the working pressure value at the pressure gauge of control unit 3.

Fill the tank to about 5 cm from the top. If the tank is completely full, there will be no room left for the air that is needed to create pressure.

2.4. Tank body

Tank body Fig. 5 is a hollow welded structure. In the upper cover of the tank body there are: fuel filler neck 1; neck (in the center of the lid) for installing the pump 2; union of the control unit 3 and a handle for carrying the tank 4.

In the lower cover of the tank body, there is a base 5 to add stability to the body.

2.5. Tank control unit

The control unit is designed to supply liquid fuel to the cutting torch, control the amount of working pressure and quickly stop the fuel supply in the event of a rupture of the hose through which fuel is supplied to the torch. The control unit fig.6 includes: body of the control unit 1, shut-off valve 2, pressure gauge 3, valve. 4, fuel intake tube with filter 5, outlet connection 6 and one-way nut 7 to connect the unit to the tank body.

Working principle:

The control unit of the tank is installed from the very beginning on the tank union 3, Fig. 5. and fixed with a nut 7. The design of the unit allows you to orient the connector at the outlet 6 in any position convenient for the user. After opening the valve 4, the fuel through the intake 5 under the pressure of the air created by the pump begins to flow into the cavity of the body 1. Under the action of the fluid flow, the ball 2 (acting as a shut-off valve) moves up. In case of quick opening of the valve 4, the ball 2 will block the output of fuel from the connection 6 into the hose. Therefore, the valve 4 must be opened smoothly, taking your time, so that the fuel, flowing around the ball, can fill the hose without triggering the shut-off valve. If the valve is opened quickly, there will be a distinct metallic click as the fast-acting ball check shut-off valve snaps into place and shuts off the fuel supply. If this happens, close the fuel valve, lightly tap the tank on the ground and try again. The function of the shut-off check valve is to shut off the fuel supply if the fuel line is accidentally cut. Valve 4 must ALWAYS be fully open for proper operation. If you suspect that the check valve is not working, do not use the tank until the entire assembly has been replaced. At the end of intake 5, inside the tank, there is a filter that protects against dirty fuel entering the hose.

To control working pressure of the liquid fuel created by the pump there is a pressure gauge 3. The pressure gauge scale range from 0 to 6.0 bar (0.6 MPa). The pressure in the tank should not fall below 0.7 bar. When the pressure is higher than 3 bar, the safety valve is activated, see Fig. 4, and excess air is released into the atmosphere.

2.6. The pump

The pump in Fig. 7 is designed to create working pressure inside the tank.

Working principle:

To create working pressure in the tank, rod 2 with a handle must make reciprocating movements. During the movement of the rod to the left (see Fig. 7), the rubber ring 10 is pressed against the wall with holes for piston 4, and air from the left part of the bulb 1 moves through them to the right part of the bulb. With further movement of the rod to the right, the ring 10 is pressed against the wall of the piston without holes and the air in the right part of the bulb begins to compress. When the pressure of the compressed air in the bulb exceeds the force of the spring 7 of the non-return valve, a portion of the air enters the tank. If the tank is filled with fuel to ¾ of its volume, 40 reciprocating movements are required to create a working pressure of 1.5 bar.

When rod 2 moves to the right, a new portion of air from the atmosphere enters the left side of the bulb through the annular gap between cap 3 and rod 2.

The buffer 13 prevents the impact of the nut 12 against the bottom of the bulb 1, and the small buffer 9 softens the impact of the piston 4 against the end of the cap 3.

Gasket 8 ensures tightness of the tank neck with the pump through the M42x2 threaded connection.

The check valve allows air to move only from the pump to the tank. It prevents the replenishment of air and агуд in the pump bulb. However, dirt in the fuel or dirt flowing from the outer surface of the pump bulb can interfere with the seal and require replacement of the sealing element of the valve 5.

A leaky seal becomes apparent when the pump handle rises vigorously under pressure, or if gasoline is seen leaking past the pump rod.

2.7. Filler cap with a pressure relief valve

Cap 1 Fig. 8. is designed to be installed on the neck of the tank. A pressure relief valve 2 is installed on the cap and tightened with a gasket 3. Gasket 4 seals cap 1 and the tank neck.

The purpose of the pressure relief valve is to relieve pressure from the tank after completion of work and when the working pressure exceeds 3 bar.

To release the pressure after completion of work, pull the valve stem by the ring.

When the working pressure in the tank exceeds 3 bar, the valve stem will start to move, supplementing the spring force, and the excess pressure will be released into the atmosphere through the side openings in the valve body. The valve will close automatically when the pressure drops below 3 bar.

Warning: after servicing of pressure relief valve, check for leaks and operation at a pressure of no more than 3 bar. The working pressure of valve should not exceed the scale range of pressure gauge of control unit (6 bar).

2.8. Cutting torch “DONMET” 185  “TRIDENT” series

The cutting torch DONMET 185 “TRIDENT” series  Fig. 9. is designed for manual separation cutting of low-carbon steels. The cutting torch is based on heating the metal to the ignition temperature and then burning it in an oxygen stream.

Oxygen is supplied to the torch from the pressure regulator via a Dn 6 hose (Oxygen hose WP 20 bar – ISO 3821). The hose, which is pre-attached to nipple 12, is connected to the cutting torch inlet connection 9/16 with a 9/16 threaded nut. After valve 5, the oxygen is divided into two streams. One stream through the valve 5 goes through the annular gap between the oxygen collector 2 and the fuel collector 1 to the mixer 15, where it is mixed with the fuel. The second flow through the valve 7, the cutting oxygen tube 4 and the head 10 goes to the central channel of the cutting nozzle 8.

Liquid fuel is supplied from the tank through the Dn 6 hose (Fuel hose WP 20 bar – SAE J30 R6). The hose is connected to the 9/16LH connection with nut 13 with 9/16LH thread. Then the liquid fuel through the valve 6 goes through the fuel collector tube 1 to the mixer 15, where it is mixed with oxygen.

The combustible mixture formed in the mixer 15 is directed into the slotted gap between the cutting nozzle 8 and the preheating nozzle 9. It burns out of the nozzle, forming a heating flame.

2.9. Handle assembly

The handle assembly is the basic element of the cutting torch, to which rubber-fabric hoses are

attached on one side, and on the other- see Fig. 1 – the cutting oxygen tube, the fuel collector, the

oxygen collector and the head assembly with nozzles are connected.

Handle assembly, see Fig. 10, consists of a soldered handle 1, on which there are a heating oxygen valve, 3, a liquid fuel valve 4, a cutting oxygen valve 2 with a lever 5 and overhead handles. The purpose of the valves is to regulate the consumption of energy carriers.

The spindles of the valves 3 and 4 should rotate easily. But if you can rotate them too easy there is a possibility of leakage. In that case you should tight the packing nut 7 with a wrench. And if it’s too hard to rotate the spindles you should untighten the packing nut 7.
2.10. Cutting nozzles, preheating nozzles, head assembly 

 The cutting nozzle pos. 2 and the preheating nozzle pos. 3 are screwed into the head of the cutting torch tip pos. 1, where they are sealed metal by metal.

A combustible mixture enters the slit gap formed between the cutting and preheating nozzles, which, going beyond the nozzles, burns, forming a heating flame. The power of the heating flame is regulated by the fuel valve and the working pressure of oxygen. The working pressure of oxygen is selected according to the table in the manual of the cutting torch ”DONMET” 185.

The central oxygen channel of the cutting nozzle serves to form and direct a cutting jet of oxygen. With the cutting oxygen valve fully open, the guaranteed maximum flow is provided by the diameter of the central channel of the cutting nozzle. The preheating nozzle is a composite monoblock product in which two parts are screwed and soldered together.

 If necessary, to remove resinous deposits inside the preheating nozzle, it must be removed from the cutting torch and then heated with a burner flame to a red color. At the same time, the heating temperature should not be higher than the melting point of the solder. Allow the nozzle to cool, then blow the channels inside the nozzle with air. In the process of operation, do not allow leakage in the places of connection of the head with the cutting and preheating nozzles.

2.10.1. Preheating nozzle

 Preheating nozzle for diesel fuel, see Fig. 12, is a monobloc construction of two parts (nozzle base 1 and nozzle (heater 2), soldered together. At the same time, a threaded gap ”A” is formed between parts 1 and 2, in which heating and evaporation of liquid fuel in the composition of the aerosol mixture obtained in the mixer 15 takes place, look at the Fig. 12.

Aerosol mixture through holes C with diameter D1enters the chamber in front of the hole d and further through the slotted grooves on the cutting nozzle enters the pre-chamber ”B”, where it is ignited by an external source.

During the combustion of the mixture in the pre-chamber ”B”, heat is transferred to the walls of the pre-chamber, which, thanks to the monoblock design, is transferred to the entire preheating nozzle.

The next cold portion of the aerosol (oxygen + liquid fuel), hitting the heated walls of the threaded gap, heats up, and the liquid fuel changes from a liquid to a vapor state. When the fuel is completely evaporated, the mixture at the exit from the nozzle has a blue color. When a balance is reached between the amount of liquid fuel and the degree of heating of the preheating nozzle, there will be no yellow flashes of non-evaporated fuel in the flame.

The degree of heating of the nozzle is controlled by the depth ”H” of the pre-chamber ”B”. It should be taken into account that the heating of the preheating nozzle is affected by convective heat coming from the metal cutting zone. The value ”H” is chosen in such a way that if the value of the oxygen pressure at the entrance to the cutting torch is observed (for diesel see table 1.1 of the manual of the cutting torch ”DONMET” 185 “TRIDENT” series or page 18 of this manual), the flame will burn stably, evenly and safely.

The face of the hexagon of the nozzle is marked ”1D” or ”2D”, where the number means the number of the preheating nozzle, and the letter means the type of liquid fuel – diesel.

For gasoline (petroleum) there will be a different preheating nozzle with other designation: – ”Petrol”. Technical specifications see in table 1 of the manual of the cutting torch ”DONMET” 185 “TRIDENT” series or table 1.2 page 18 of this manual.

With the preheating nozzle ”1D” you must use cutting nozzles ”1” to ”5”, and with the preheating nozzle ”2D” you must use the cutting nozzle ”6”.

2.10.2. Cutting nozzle.

Cutting nozzle for diesel fuel, see Fig. 13, made of copper and is attached to the head of the cutting torch with an M8 thread, and with slots it is connected to the preheating nozzle, see Fig. 11.

The nozzle flat is marked from ”1” to ”6”.

Each number of the cutting nozzle corresponds to the number of grooves, their depth, as well as the diameter of the central channel.

Each number of the cutting nozzle corresponds to its oxygen pressure at the entrance to the cutting torch, see table 1.1. It is for this reason that the heating oxygen valve must be fully opened. This makes it possible to set the guaranteed maximum amount of liquid fuel consumption and its complete evaporation in combination with the dosed consumption of heating oxygen for the number of the cutting nozzle used. You will always be able to correctly adjust the flame, adjusting its composition only with the liquid fuel valve.

For gasoline (petroleum) there will be a different cutting nozzle with other designation. Technical specifications see in table 1 of the manual of the cutting torch ”DONMET” 185 “TRIDENT” series or table 1.2 page 18 of this manual.

Technical specifications for diesel fuel                                                                   Table 1.1

Technical specifications for gasoline (optional)                                                          Table 1.2

2.11. Rubber hoses

”Oxygen hose WP 20 bar – ISO 3821, Dn = 6 mm (1/4″)” is used to supply oxygen from the regulator to the cutting torch. Hose length L=10 m.                                              

To supply fuel from the tank to the cutting torch, an oil- and gasoline-resistant hose ”Fuel hose WP 20 bar – SAE J30 R6, Dn = 6 mm (1/4″)” is used. Hose length L=10 m                              

NOTE: Residues from the manufacturing process may remain in the new fuel hose. The fuel coming from this hose will be yellow and very oily. Light the flame of the cutting torch for about 5-10 minutes until the fuel becomes clear and the flame becomes normal. The length of the hose requires more time to clean.

3. Preparation of the kit for use

3.1. Safety measures during the preparation of the kit for work

The manufacturer delivers the products included in the kit in assembled form and checks their performance before shipment. In case of violation of operational restrictions and careless transportation, the product may fail.

It is forbidden to use compressed oxygen to create pressure in the tank. It is explosive.

The use of personal protective equipment for hearing, vision and breathing is mandatory.

Persons no younger than 18 years of age who have studied its structure, have permission to work independently and have undergone safety training when working with gas-flame equipment are allowed to work with a cutting torch.

It is prohibited:

– start work without first checking the tightness and operability of the component parts of the kit;

– carry out work in case of violation of mechanical strength and leakage of hoses and connections;

– use cutting torch hoses not for their intended purpose (for other types of gases);

– carry out processing of the design of the cutting torch and tank for liquid fuel;

– work in oiled clothes, use oiled rags and tools;

– to work without overalls, special shoes, individual hearing and eye protection;

– work in the absence of fire extinguishing means at workplaces;

When preparing and using the kit, observe the safety requirements of the country of the intended use.

3.2. The scope and sequence of the external inspection of the products of the kit

Perform an external inspection of the equipment:

• The end of the preheating nozzle on the cutting torch should not have dents or other mechanical damages;
• The products included in the kit must not have mechanical damage that impairs their performance;
• Places of threaded and soldered joints must not have visible damage after transportation;
• Hoses should not have cuts and other mechanical damage received during transportation that violates their integrity;
• The threaded surfaces of the union nuts and the spherical surfaces of the nipples on the hoses must not have dents or scratches;
• The open threaded and conical surfaces of the connecting unions on the cutting torch and the tank must not have scratches and dents;
• The spindles of the valves on the cutting torch and the tank should rotate easily, should not have mechanical damage that impairs their efficiency (for example, the spindle was bent during transportation or the valve handwheel was broken).

3.3. Workplace preparation

• The workplace must be organized in accordance with safety and occupational hygiene requirements for gas-flame processing.
• Before starting gas-flame work, inspect the workplace, remove unnecessary objects that interfere with work, and flammable materials.
• When working in temporary places, fix the oxygen cylinder in a special stand or on a cart, and in the summer protect it from heating by the sun’s rays.
• Install the tank on a flat surface to prevent it from tipping over. Place the tank at least 5 meters away from the work area so that the carver can keep an eye on it while cutting, and the oxygen tank no closer than 5 meters from the liquid fuel tank.
• Perform gas-flame works at a distance of at least 10 meters from mobile generators and groups of gas cylinders; 5 m – from individual cylinders with a capacity of more than 5 liters and tanks with liquid fuel; 3 m – from gas pipelines and gas separation stations during manual work.
• If sparks are directed towards the source of gas supply, install metal screens or shields to protect against sparks or flame heat.
• In case of working from oxygen pipelines, safety shutters or flashback arrestors should be installed at the sampling points.
• During gas-flame work outdoors in rainy, snowy weather and in windy weather, protect the workplace from the effects of precipitation and wind.

3.4. Rules for checking the readiness of the set for work and the inspection procedure

3.4.1. Before starting gas-flame works, check:

• Correct supply of oxygen and fuel to the cutting torch;
• Airtight connection of hoses to the cutting torch, regulators, safety devices and other equipment;
• Serviceability of the tank and cutting torch;
• Mobility of the spool in the flashback arrestor;
• The presence of rarefaction (suction) in the nozzle for liquid fuel on the cutting torch.

3.4.2. Connection to the supply source of oxygen and liquid fuel

Install a 9/16 threaded nut and nipple on one end of the oxygen hose, and a combo nipple Dn6/9 and G3/8 threaded nut on the other end. To do this, use a nipple with a nut attached to the inlet connection of the cutting torch (thread 9/16) and a nipple with a nut attached to the outlet connection of the pressure regulator (thread G3/8).

Before connecting the oxygen pressure regulator to the cylinder (or valve of the gas separation station), the cutting torch must:

•  inspect the connection of the cylinder and the union nut of the regulator. Make sure that the mating threaded surfaces are in good condition. Bruises, dents or any mechanical damage on sealing and threaded surfaces is not allowed;
•  make sure there are no traces of oils and greases;
•  make sure of the presence and serviceability of the sealing gasket and filter in the input connector of the regulator;
•  check the tightness of the supply hoses in their places.

Install the RO-200-2 DM regulator on the oxygen cylinder, and install the fire safety valve on the cutting torch inlet connection. Connect the oxygen hose included in the delivery set to the outlet connector of the regulator. Connect the second end of the hose to the inlet connection on the flashback arrestor (thread 9/16). Tighten the union nut at the point of connection of the regulator to the cylinder and the nut at the point of connection of the ends of the oxygen hose.

At the end of the hose for liquid fuel, install nipples and nuts with a 9/16LH thread. Connect the fuel hose included in the delivery set to the outlet connection of the tank control unit (thread 9/16LH). Connect the second end of the hose to the inlet connection on the cutting torch (thread 9/16LH, the connection has an annular groove on the hexagon). Tighten the union nuts at the connection points of the ends of the hose.

In the places where the hoses are connected to the nipple, install a crimp clamp for reliable fixation of the hose when the hose will be under pressure.

3.4.3. Checking the tightness of the connection points on the oxygen line of the kit

Initial position – the valves on the cutting torch are closed.

Set the oxygen pressure on the RO-200-2 DM oxygen regulator depending on the thickness of the cut, see table 1 page 18.

Apply a soapy solution in the places where the oxygen hose is connected to the regulator, the cutting torch and the flashback arrestor, and in the place where the regulator is connected to the cylinder connection. The appearance of gas bubbles in places of threaded connections and on the ends of the hose is not allowed.

3.5. Preparing the cutting torch for work

3.5.1. Injection check

Initial position – the valves on the cutting torch are closed, only the oxygen hose is connected to the cutting torch, the inlet connection for liquid fuel is free.

Set the oxygen pressure on the RO-200-2 DM oxygen regulator depending on the cutting thickness, see table 1 page 18. Fully open the liquid fuel valve, and then fully open the heating oxygen valve. The presence of rarefaction (air suction) can be determined by holding a finger to the liquid fuel inlet connection (thread 9/16LH). The finger should be attracted to the end of the connection. The absence of suction indicates a malfunction of the equipment. Only after the presence of suction has been established, it will be possible to attach a hose for liquid fuel to the cutting torch.

3.5.2. Checking the operation and tightness of the cutting oxygen valve

Check the operability of the cutting oxygen valve. To do this, press the cutting oxygen valve lever on the cutting torch 2-3 times. The piston of the valve should moove easily, without rubbing or jamming.

Check the tightness of the cutting oxygen valve by applying a soapy solution to the end surface of the cutting nozzle (item 2, Fig. 11) or by dipping the end of the preheating nozzle into a vessel with water. Closing the valve is considered airtight if air bubbles do not appear and continue to grow in the place of soaping (or in the water). After checking the tightness, blow the channels with oxygen for 2-3 seconds to remove residual moisture.

3.5.3. Checking the functionality of the spool in the flashback arrestor

The flashback arrestor (fire safety valve, see Fig.3 page 10) is installed on the fitting for oxygen of the cutting torch (thread 9/16). Before connecting the oxygen hose to it, the mobility of the spool 3 must be checked. To do this, use a match or a wire to press and release the spool located in the central channel of the valve body 10 for 3-4 times.

Eligibility criteria: after each push, the spool should return to its original position freely without jamming or distortion.

In case of non-compliance with the eligibility criteria, establish and eliminate the reasons for the non-compliance. If disassembly of the valve is required to eliminate the causes of non-compliance, contact a specialized workshop or the manufacturer.

A reminder: it is forbidden to disassemble and assemble the valve yourself, since it is simply impossible to check its flame retardant properties after assembly without a special stand.

4. Actions in case of equipment failures

In case of failure of the components of the set, shut off the supply of energy carriers, check the correctness of the assembly and the tightness of the connection of the component parts of the set. Identified inconsistencies should be eliminated, inspections should be repeated in accordance with the requirements of section 2, and if the inspection results are positive, work should be continued.

Equipment failures include the failure of parts and assemblies in the set of products, as well as the appearance of pops and flashbacks during gas cutting operations.

4.1. Causes of continuous pops and flashbacks:

• Loose cutting nozzle. The mixture enters the central channel and during its combustion frequent continuous pops occur.
• Overheated preheating nozzle

Reasons:

– Exposure to reflected flame or incorrect flame setting. In an overheated nozzle, the vapor-oxygen mixture can spontaneously ignite.

– Mass sticking of slag on the preheating nozzle worsens heat exchange.

– There is no tightness in the place where the preheating nozzle joins the head. An additional flame burns at the point of leakage, which overheats the nozzle.

• Liquid fuel got into the oxygen channels:

Reasons:

• Incorrect position of the cutting torch head during work breaks.
• Poorly tightened union nut on the cutting torch barrel, due to which the fluoroplastic ring 14, see Fig. 9, does not ensure the tightness of the connection and fuel can flow into the oxygen channels.
• Clogging of the internal channels of the preheating nozzle with layers of sooty deposits.

Carbon accumulation – carbon can accumulate inside the preheating nozzle, like in a car carburetor. This carbon is formed from fuel that has not completely burned, which is the result of a flame that is too saturated for a long time. If the nozzle is not cleaned periodically, this carbon builds up in the threaded clearance of the outer nozzle and eventually creates additional problems that can destroy the nozzle.

Until you become familiar with the carbon deposition rate of your particular cutting torch, it is wise to check the nozzle once or twice a week. If you neglect this maintenance, you may lose the nozzle.

Remove soot from the surface of nozzles in a timely manner. To dissolve tarry deposits, use solvent (acetone or other) and after dissolving process rinse the nozzle with water. Be sure that water flows from threaded end to cutting edge to remove dirt. Other method – heat the nozzle with a torch flame. To do this, it must be removed from the cutting torch and then heated with a burner flame to a red color.

Importantly! The heating temperature should not be higher than the melting temperature of the solder. If you see that solder from solid becomes liquid – stop heating immediately.

Allow the nozzle to cool, then blow the channels inside the nozzle with a compressed air, or tap the end (from the cut side) against a wooden surface.

In the process of operation, do not allow leakage in the places of connection of the head with the external and cutting nozzles. Check the tightness of all connections, if necessary, tighten the connections and eliminate leaks.

4.2. Actions to take in case of continuous pops or flashback:

Quickly close the liquid fuel valve;

Close the heating oxygen valve;

Cool the cutting torch head;

Remove the preheating and cutting nozzles from the cutting torch, check their integrity (especially in the places of contact with the head), clean and blow them out;

Check the integrity of the connection points of the head with the nozzles.

Install the nozzles in the head of the cutting torch, ensuring tightness in the places of contact with the head.

Open the cutting oxygen valve and the heating oxygen valve for 5-7 seconds and blow out the channels to prevent fuel from getting into them.

Tighten the union nut on the cutting torch handle. If necessary, replace the fluoroplastic ring 14 cm. Fig. 9.

Check the oxygen pressure and fuel pressure in the tank.

If after cleaning the flashbacks and pops are repeated, stop working, and send the cutting torch to a specialized repair workshop to eliminate deviations found during operation.

4.3. List of possible malfunctions in the process of using the kit by appointment and recommendations for their elimination

Table 2

5. Technological part

5.1. Features of cutting

The main factor of the oxygen cutting process is the jet of cutting oxygen.

The characteristic of the cutting jet depends on:

• oxygen pressure in front of the nozzle (primarily);
• oxygen consumption per unit of time;
• the size and shape of the cutting oxygen channels in the nozzle.
• cutting torch movement speed (cutting speed).

5.2. Oxygen pressure

The higher the oxygen pressure in front of the cutting torch, given the thickness of the steel being cut and the diameter of the cutting oxygen channel, the more oxygen flows through the central channel of the cutting nozzle and comes into contact with the surface of the steel being cut per unit of time, and the better (up to a certain limit ) conditions for metal oxidation. When the oxygen pressure increases, the cutting speed increases while maintaining the quality of the cut surface.

However, the relationship between these values is not linear, which is explained by the following circumstances:

• first, with an increase in oxygen pressure, oxygen consumption through the incision increases and, therefore, its useless removal.
• secondly, with an increase of oxygen pressure (at a constant outlet cross-section of the nozzle), the diameter of the oxygen jet after exiting the central channel of the cutting nozzle increases, and therefore the width of the cut, as a result of which the amount of metal removed from the cut increases.

5.3. Purity of oxygen

The most common impurities of oxygen are nitrogen, argon and water vapor. The highest concentration of impurities occurs near the surface of the metal. As the oxygen jet penetrates deep into the metal, the activity of the oxidation reaction decreases, and to compensate for the harmful effect of reduced oxygen purity, the cutting speed must be reduced. The fewer impurities contained in oxygen, the higher the cutting speed. According to ISO 2046, the release of technical gaseous oxygen of three grades is provided: 1st grade with a purity of 99.7%; 2nd grade with a purity of 99.5%; 3rd grade with a purity of 99.2%. The lower the oxygen purity, the more hard-to-separate slag sticks to the lower edge of the cut.

5.4. Consumption of cutting oxygen

The amount of oxygen required to oxidize the metal being cut and the flux is determined by the amount of burned metal and flux. Theoretically, the oxidation of 1 kg of iron requires 0.29-0.38 m³ of oxygen, depending on whether the iron is completely oxidized into FeO or Fe₃O₄. The consumption of cutting oxygen, as well as its pressure, are determined by the thickness of the metal being cut, the purity of oxygen and the cutting speed. Observe the values of oxygen pressures specified in the technical characteristics of the cutting torch.

5.5. Cutting speed

A stable cutting process and good surface quality of the cutting edges (without significant lagging and slagging of the cutting surface) is achieved only if the cutting torch is moved along the cutting line in accordance with the rate of oxidation of the metal according to the thickness of the sheet being cut. If the speed is too low (other things being equal), the cutting edges melt; if the speed is too high, there is a significant lag behind the cutting line, sections of the metal remain uncut to the end and the cutting process is disrupted. The cutting speed is directly dependent on the purity of oxygen.

5.6. The power of the heating flame

In the process of cutting steel, the heat released by the heating flame must be transferred to the metal being cut.

If the power of the heating flame is low, the heating of the metal at the time of cutting will be insufficient, and the cutting will not take place or will not proceed stably.

The power of the heating flame, set for cutting steel of a given thickness, should ensure rapid heating of the steel at the beginning of cutting.

5.7. Cutting width

The width of the cut depends on many factors, the main of which are:

• metal thickness;
• the size of the cutting oxygen channel used for it in the nozzle;
• the speed at which the cutting torch is moved.

Cuts made by manual cutting torches are always wider than machine cuts. This is due to insufficiently uniform movement of the cutting torch during manual cutting.

5.8. Guidelines for cutting techniques

Starting cutting from the edge, the nozzle is placed perpendicular to the surface so that it is above the sheet being cut. After heating some volume of metal to a temperature close to the melting point, the cutting torch is moved back so that the central channel of the cutting oxygen is only partially above the edge. After the metal burning process is established throughout the thickness, the movement of the cutting torch relative to the metal should be uniform. The more uniform the movement of the cutting torch, the cleaner the cut and the higher the cutting speed that can be used.

The cutting speed should be such that it is consistent with the power of the heating flame. Increasing the oxygen pressure makes it possible to increase the cutting speed, while the width of the cut near the bottom edge is greatly expanded.

For high-quality cutting, the amount of ”lag” should be no more than 10% of the thickness of the cut steel.

After cutting, the cutting torch should be stopped at the exit due to the existing lag and cut the lower part of the sheet.

Cutting of stacked metal sheets: to cut a stacked sheets, the starting edges should be aligned as evenly as possible, and the ignition should take place along the entire length of the stack before attempting to move deep into the cut. After complete ignition, cutting occurs at almost the same speed as when cutting a solid piece of steel.

Cutting air gaps: the torch has the ability to bridge multiple gaps up to 20mm each and even larger single gaps. Measure the height of the folded plate and select the next larger nozzle number.

Punching holes: oxygen pressure is critical when punching holes. The oxygen pressure must be sufficient to blow the slag back through the top until the hole is punched through.

Punching deeper holes requires a tip at least one size larger than normal, as well as higher oxygen pressure. The problem grows rapidly as the depth of the hole increases. Too much oxygen can cool the steel to the point where ignition is lost.

Procedure for punching a hole: When cutting metal thinner than 20 mm heat the cutting point on a metal until bright yellow with preheating flame (approximately 1200˚C), than press cutting oxygen lever to full opening of the cutting oxygen valve and finish the procedure. When cutting metal thicker than 20 mm heat the cutting point on a metal until bright yellow with preheating flame (approximately 1200˚C), wait till you see some of the steel starting to melt and some sparks appeared, than slightly press the cutting oxygen lever, tilting the torch head by 10-15 degrees. This action prevents slag ejection towards the nozzle. When the metal has melted to half its thickness, press the lever fully and return the head to perpendicular position and finish the procedure. If you see that the slag is actively rising to the nozzle, raise the torch higher from the metal surface. Do not allow slag to enter the opening of the nozzle.

5.9. Cutting torch-product distance

During cutting, the carver must be in a comfortable position from which it is possible to adjust and monitor the speed of movement of the cutting torch, as well as the distance between the nozzle and the metal being cut.

In the process of cutting, the distance between the end of the nozzle and the surface of the metal to be cut should be 10-12 mm. The specified distances may vary because the flame has a long contact distance. The nozzle can be raised high above the surface of the steel and still continue to cut through the steel.

6. Service and maintenance 

6.1. Periodicity of inspection

Kit No. 3 and its components must be regularly inspected.

Valves should be inspected before the start of each shift for gas/fuel leaks and other defects.

The manometers on the pressure regulator and control unit should be checked before the start of each shift to ensure that there is no external damage and that the arrow is in the 0 (zero) position.

Pressure regulator should checked for tightness, self-flow, pressure drop, flow capacity, safety valve operation – once every three months in specialized workshops and be repaired and degreased (if necessary).

Pressure regulator should be checked for damage and wear of connecting threads, for tightness and tightness of reducing unit – every week.

Filter of pressure regulator should be cleaned and washed with technical ethyl alcohol (if necessary).

Inspect rubber fabric hoses and remove (if necessary) defective places, check for tightness with compressed air or nitrogen at a pressure of 10 bar, check for strength with a hydraulic pressure of 30 bar – once every three months.

Replaceable parts (if they are included in the delivery set) – conduct an external inspection before using each unit of the set.

Flashback arrestor should be checked on the mobility of the spool after each flashback.

If you suspect that the flashback arrestor failed, replace it with a new one, and send the old one to the manufacturer or a company that has the equipment for the appropriate inspection.

6.2. Requirements for the composition and qualifications of service personnel

For the operation and maintenance of the set, a cutter and a service technician are needed. The work of one person who has the appropriate rank and work skills is allowed.

Persons at least 18 years of age who have undergone appropriate training, instruction and knowledge verification of safety requirements in accordance with current regulatory and technical documents and have the appropriate certificate are allowed to perform maintenance work on the set.

Re-instruction and verification of knowledge on safety techniques and industrial sanitation are carried out in accordance with current regulations with a note in the journal.

7. Routine service of the kit and its component. General instructions

The design of the kit is made in such a way that malfunctions can occur only in case of improper handling of it and its parts, therefore special repair documentation is not provided for delivery. Current repairs are performed in case of failure of component parts or to eliminate defects discovered as a result of inspection. Repair is possible for all component parts and details of the product, except for pressure gauges, pressure regulators and flashback arrestors. If it is necessary to repair pressure gauges, pressure regulators and flashback arrestors, you should contact the manufacturer directly or to specialized workshops that have permission to repair them. For all other parts and details, use assembly and metalwork methods, soldering, restoration of parts by mechanical processing. The personnel performing metalworking, soldering operations and mechanical processing must have a nessesery qualification.

8. Storage, transportation and packaging

The kitt and its components can be transported by any type of transport in compliance with the rules in force during this type of transportation.

The kit does not contain parts with a limited shelf life. The shelf life of the kit is no more than one year.

Technical and accompanying documentation must be wrapped in branded wrapping paper or placed in a polyethylene film bag. Replaceable mouthpieces (if provided by the order) must be hermetically packed in polyethylene film.

Packaging of entire kit No. 3 for oxy-liquid metal cutting is not provided.

9. Manufacturer’s warranty

The manufacturer guarantees the compliance of the products included in kit No. 3 with the requirements of the design documentation.

The kit meets the requirements of the current norms and rules of technical and fire safety, labor protection and industrial sanitation in terms of operation and repair, provided that the user observes the rules of operation, transportation and storage.

The warranty period is 12 months from the day of commissioning, but not more than 24 months from the day of delivery.

Warranties for individual parts of the kit are in the manuals for those parts.

Pats list of the cutting torch ”DONMET” 185 “TRIDENT” SERIES

 (look at the Fig. 14)

Fig. 14 – Diagram of the parts of the cutting torch ”DONMET” 185 “TRIDENT” series

List of parts of the tank for liquid fuel DG-08-1 DM (look at the Fig. 15)

Fig. 15 – Diagram of the parts of the tank for liquid fuel DG-08-1 DM