Technical Data - Oxyturbo TurboSet 90 Instrucciones De Uso

Instructions for use and
GB
maintenance
HOW TO GAS WELD WITH TURBO SET
90/110
With gas welding always work methodically : before starting a weld ensure
that the parent metal in the weld area is cleaned and free from grease,
oil, paint, rust and scale. Ensure you've a good supply of gases and filler
materials and flux's suitable for the job.
Before applying heat to the parts, make sure they are properly-positioned
and braced to remain in proper alignment. Once you've complete your
joint, it will need to be cleaned, as Flux residues are chemically corrosive
and may weaken the joint if not completely removed.
The power of the flame is governed by the size of tip used and these vary
according to thickness, melting points and heat conductivity. The TURBO
SET 90 and 110 have five size nozzles available.
The power is measured by the number of litres per minute of fuel gas that
is consumable with a perfect flame. Too lower pressure gives too short
cone, which may cause a lack of weld penetration and fusion, it can also
cause frequent back firing. On the other hand too higher pressure can
give a long cone and cause overheating and a lack of control of the molten
metal.
Three different types of flame can be made via varying proportions of gas:
THE CARBURIZING FLAME
This is a flame in which an excess of fuel gas is burning, i.e. combustion
is incomplete and unconsumed carbon is present. This kind of flame is
generally not good for welding steel as the unconsumed carbon could be
introduced to the weld and create a hard embrittled weld.
THE NEUTRAL FLAME
As the supply of oxygen to the torch is increased, the flame contacts and
the white cone become more clearly defined, assuming a definite rounded
shape. At this stage approx equal quantities of fuel gas and oxygen are
being used and combustion is complete. The flame is now neutral and this
type of flame is the one most extensively used for welding.
THE OXIDISING FLAME
A further increase in oxygen will produce the oxidising flame, in which
there is more oxygen than is required for complete combustion. In this
case excessive sparking will occur.
A BACK FIRE can often occur if :
- the gas pressure is too low
- touching the plate or weld pool
- loose nozzle
- over heating
- a metal particle gets into the nozzle.
The fault can normally be rectified with no damage.
i
CAUTION
Read the following instructions carefully before using the TURBO
SET and keep them for future reference. The instructions supply all
the information necessary for correct use of the appliance to avoid
danger and damage.
OXYTURBO is not responsible for any damage occuring due to
incorrect use of the appliance, or to modifications made to it.
PARTS LIST
TURBO SET 90 115050 115051
TURBO SET 110 131090.MP 131091.MP
1. Oxygen cylinder 1 lt 110 bar
M12x1 right 480300
M11x1 left 480301
2. Maxy Gas cartridge 483200
2. Map//Pro 400g cylinder 483580
3. Trolley for bottles
4. Squares for blocking
5. Oxygen pressure reducer Mignon 220500 220501
with fashback arrestors
6a. Gas pressure reducer Mignon 223515
with fashback arrestors
6b. Gas valve 7/16 with fashback arrestors 201500
7. Handgrip with inserted arrestors with two functions for oxygen and
gas
8. Adjusting knob for oxygen on the torch
9. Adjusting knob for gas on the torch
10. Seal gasket
11a. Oxygen hose with connections
11b. Gas hose with connections
12 80lt nozzle
13 Lance
14. Lighter 101000
15. Multipurpose wrench 102000
16. Star with 4 nozzles 110730.ESP
17. Brass welding rods 101500.01
18. Goggles 100000
19. Microset (optional) 110650
20.
Adapter for micro - needles
21. Micro - needles

TECHNICAL DATA

TURBO SET 90 115050
Max. operating temperature 3000°C - 5432°F
TURBO SET 110 131090.MP
Max. operating temperature 3100°C - 5612°F
Gas consumption
(normal regulation with a 80 lt nozzle): 92 g/h
End. of the oxygen cylinder 0,30 h
End. of the Maxy Gas cartridge 3,30 h
Endurance of the Map//Pro cylinder 4,30 h
1. GAS SUPPLY
The TURBO SET is fuelled with an oxygen cylinder (T-PED approval π 0036)
and with a 7/16" Maxy Gas cartridge (complying with EN 417: 2003) or
Map//Pro cylinder (complying with EN 12205:2001 T-Ped homologation
nr. 0035 2008/7).
We recommend using the OXYTURBO cylinders and cartridges.
ATTENTION: the oxygen cylinders and the gas cartridges of TURBO
SET are not rechargeable.
i
CAUTIONS
- The use of other cylinders or cartridges may be dangerous
- Do not connect cylinders or cartridges before you have read the
instruction on them.
2. PUTTING INTO SERVICE
2.1 INSERTING OR CHANGING CYLINDERS OR CARTRIDGES
- Put the two squares (4) on the trolley for bottles in correspondence
with the relevant cylinder or the gas cartridge.
- Insert the cylinder or the cartridge into their housing passing the
valves through the hole of the squares.
- Block the squares screwing manually the wingsnuts on the screws.
- Make sure that the adjusting knobs on the pressure reducers Mignon
and on the gas valve (5, 6a and 6b) and on the torch (8 and 9) are
closed (for Mignon : clockwise = open, anticlockwise = close; for gas
tap : clockwise = close, anticlockwise = open).
- Screw the oxygen and gas pressure reducers and the gas valve on
the relevant cylinders and cartridge without forcing to much, paying
attention that there are no leaks.
- The threads are diversified to avoid mistakes in coupling cylinders to
oxygen and gas pressure reducer Mignon and cartridge to gas valve.
16
i
CAUTIONS
- Changing or inserting cylinders or cartridge must be performed
in a well ventilated area, preferably outdoors and away from
inflammable materials or substances, from glowing sources of
heat (such as naked flames, lit cigarettes, electrical rings, etc.)
and far away from persons and animals.
- Make sure the cylinder or the cartridge is empty before changing
it. Do not let you be deceived by the weight of the oxygen
cylinder, because it is the same also when the cylinder is empty.
- Do not use the TURBO SET if the gaskets (10) are damaged or
missing.
- Control that the oxygen and gas hoses with connections (11a and
11b) are not damaged.
- To protect the environment, dispose of the cylinder and of the
cartridge in a safe place and preferably in a recycling bin.
3. INSTRUCTION FOR USE
Place before using lance and nozzle as in fig.2 and make sure the nut is
blocked.
3.1 SWITCHING ON
- Make sure the adjusting knobs of the torch are closed (8 and 9).
- Open the oxygen pressure reducer Mignon (5) and the gas Mignon/
valve (6a and 6b).
- Kindle using the special lighter (14) paying attention to keep the
flame stucked to the soldering nozzle. If the flame tends to come off
the nozzle, close a little the gas valve.
115051
- Open the adjusting knob for oxygen on the torch (8) to obtain a
sparkling flame.
131091.MP
- Adjust the flame operating on the adjusting knobs to have a dart with
shape and dimensions like those of picture 2.
3.2 SWITCHING OFF
- Close first the gas cartridge pressure reducer/valve (6a and 6b).
- Close the oxygen pressure reducer (5).
- Let the flame estinguish till the hoses are empty.
- Close the knobs of the nozzle (8 and 9).
3.3 MICRO-SOLDERING (optional)
- Unscrew the lance (13) using the multipurpose wrench (15).
- Place the adaptor (20) on the torch (picture 3).
- Tighten the nut in depth without forcing.
- Put the desired micro-needle (21) on the adaptor.
i
CAUTIONS
- Always use the kit with cylinder and cartridge in vertical position
or the gas liquid phase could damage the hoses.
- Do not work in a narrow place.
- The TURBO SET must be used in a well-ventilated area, away
from inflammable materials or substances. Fire hazard!
- It is absolutely prohibited to grease any part of the kit.
- Do not leave the TURBO SET unattended when lit.
- Do not put down the lit torch.
- Work on a non-inflammable base.
- During welding works wear goggles (20) and gauntlets.
- Do not use grease or oil on the parts in contact with oxygen.
- Wear clothes suitable to the type of work to be accomplished and
do and do not wear clothes
- Attention! Avoid breathing welding fumes.
- Replace immediatly the hoses with connections (11a and 11b) in
case of abrasions, deterioration or other imperfections.
- Avoid torsions, tears and overheatings of the hoses (11a and
11b).
- During use, parts of the TURBO SET can reach high temperatures.
After the switching off let the hoses empty and let the kit
become cool before putting it away.
- it is dangerous to use damaged or incorrectly functioning
equipment.
- In case of gas delivery problems, check if there is gas in the
cylinder and in the cartridge (1 and 2). If so, the problem could be
resolved by cleaning the nozzle (see 5.4).
- It is absolutely prohibited to make any mechanical intervention
on any component of the equipment.
- In case the TURBO SET should not be used for a long time or in
case of transport by a motor vehicle, unscrew the cylinders and
the cartridges from the respective oxygen pressure reducer and gas
pressure reducer/valve. This will let you have the greatest guarantee
to find the content of the cylinder and of the cartridges intact
even much time later, avoiding the possibility of little and almost
imperceptible leaks, even though all their valves are provided with
guaranteed seal.
- Put away the TURBO SET in a protective packaging (if possible in the
original one) and keep it in a cool, dry and well ventilated place.
i
For TURBO SETS with cylinders and cartridges inserted :
- Make the storage and the transport with the cylinders and the
cartridges in vertical position, NEVER lying.
- Protect from sunlight.
- Do not expose to temperatures higher than 50°C.
- Keep out of the reach of children.
5. MAINTENANCE
- Do not carry out maintenance or repairs, other than the following.
- Use only original OXYTURBO spare parts and accessories.
- Spare parts are available from your retailer.
- In case of failures which cannot be repaired following these
instructions, take your TURBO SET back to the retailer.
5.1 GAS LEAKS
- If your appliance leaks gas (gas smell) take it outdoors immediatly to
a well ventilated area, away from inflammable sources where the seal
can be checked (see 5.2).
5.2 CHECKING THE SEAL
- To check the seal of the TURBO SET, work outdoors and do not use
a flame: use special detectors (Gascontrol cod. 405020) or soapy
water.
- Spray the detector on the area to be checked.
- Gas leaks are detected by the formation of bubbles or foam.
5.3 CHANGING THE GASKET
- Remove the worn gasket from its seat (10).
- Insert the new gasket into the seat by pushing its edges down with a
flat screwdriver, paying attention not to damage it.
5.4 NOZZLE CHANGING AND CLEANING.
- Unscrew the nozzle (12) with the special wrench (15).
- Clean the nozzle blowing into the hole with compressed air.
- Screw the choosen nozzle (16) on the lance (13).
- Check the seal (see 5.2).
i
- Execute this intervention when the nozzle is cold.
- Do not use needles or pins to clean the nozzle, because any
damage you may cause to the appliance could make the TURBO
SET dangerous.
- If the blockage cannot be removed, substitute the nozzle.
dirty with grease.
N.B. : Some of the details in the illustrations may differ from those of
the appliance supplied. This company reserves the right to modify the
product without prior warning.
17
4. STORAGE
CAUTIONS
CAUTIONS