BossWeld BRAZEN 3000 Bedienungsanleitung
PORTABLE BRAZING
AND HEATING KIT
MANUAL
BRAZEN 3000 G
GAS
2
3
INDEX PAGE
GENERAL SAFETY INFORMATION 5 3
PHYSICAL AND SAFETY PROPERTIES OF GASES 6
GAS SUPPLY 7
SAFETY 8-9
CYLINDER STORAGE, NOZZLE CHART 10
PERSONAL PROTECTIVE EQUIPMENT 11
BOX CONTENTS 12
SETUP AND LIGHTING PROCEDURE 13-15
SHUT DOWN PROCEDURE 16
WARNINGS & MAINTENANCE 17
WARRANTY 18
CONSUMABLES 19
4
BOSSWELD GAS WELDING EQUIPMENT
Dear customer,
Thank you for your purchase of our BOSSWELD BRAZEN 3000 portable
brazing & heating kit. The BOSSWELD range of gas welding and cutting
equipment has been rigorously tested by independent laboratories and
conforms to the following Australian Standards for gas welding and cutting
processes:
Small heating and brazing kits currently are not covered under the scope of
an existing Australian standard (DEC 2018), however the Brazen 3000 kit meets
the requirements of the European Standard.
EN 1326 - 1996 Gas welding equipment
- small Kits for brazing and welding
BOSSWELD strives to meet all relevant Australian Standards. Should there
be change to existing or creation of new Australian Standards, BOSSWELD
will endeavor to ensure that all products and services comply with those
standards.
This manual refers to safety measures that must be adhered to for the safe
operation of your BOSSWELD BRAZEN 3000 equipment. Please read and
understand these warnings and instructions before use. Failure to do so
could result in serious injury or death. BOSSWELD brazing and heating
equipment should only be used by operators who are properly trained and
qualied in the safe use of this type of equipment.
5
GENERAL SAFETY INFORMATION
Safety consideration for both the operator and surroundings must be given to
the heat source produced by mixing compressed oxygen with a fuel gas and
igniting the resulting mixture. When using these processes, particular safety
considerations apply with respect to:
a) Do not leave the Brazen 3000 torch unattended when lit, or put it down
b) Burns from ames, hot objects, malfunctioning hand-held equipment,
molten particles, etc.
c) Explosions from mixed gas concentrations created by fuel gas leakage
from cylinders,
d) Fire caused by ignition of ammable materials, leakage of fuel gases,
contact with hot slag, poor condition of welding equipment, etc. (Plant,
building, ship and bush res have occurred)
e) Use welding goggles when using the Brazen 3000 kit.
d) Do not breath welding fumes
e) Violent rupture or explosion of components due to pressurisation beyond
their designed working pressures
f) Asphyxiation due to the displacement of atmospheric, breathable air by
inert or toxic gases. For example, leakages in conned spaces or lack of
oxygen resulting from excessive rusting in conned spaces
g) Radiation damage (to eyes principally and other exposed surfaces)
h) Fumes originating from the particular materials being welded and heating
6
PHYSICAL AND SAFETY PROPERTIES OF GASES
a) DO NOT use oxygen to refresh air. There is often a temptation to use
oxygen to ‘sweeten’ air whilst welding or cutting operations are being
carried out in conned spaces. Large amounts of oxygen can be released
locally in a short time from gas cylinders under pressure. In one situation
where this was done, hot work in the form of ame cutting was carried out
with a subsequent ignition of worker’s clothes and fatal burns.
b) TAKE CARE in conned spaces. Do not leave blowpipes or hoses
connected to the supply gases within conned spaces overnight or during
work breaks. Slow leaks can result in very hazardous situations, with
possible re and explosion on re-ignition of the blowpipe.
c) VENTILATE conned spaces. In ame cutting not all of the oxygen
released from the cutting nozzle is necessarily used in cutting. In conned
spaces this may result in a dangerous increase in oxygen content in the air,
pointing to the need for adequate ventilation in such situations.
d) DO NOT use oxygen as a substitute for compressed air. There are
many examples of this situation where oxygen has been used, such as in
cleaning, resulting in serious and fatal accidents due to re or explosion from
spontaneous ignition. NEVER use oxygen to start engines, drive air tools
etc.
e) DO NOT use oxygen or compressed air to dust off clothes. Clothes
can become readily ammable and even self-igniting through oxygen
enrichment.
f) DO NOT kink pressure hosing. Kinking or nipping hose to interrupt gas
ows or whilst changing torches is a very dangerous practice. Gas can still
bleed through the system, or more seriously, escape rapidly should the hose
rupture or the operator lose their grip.
g) The oxygen cylinder once it is empty can devalued and the cylinder
recycled at a scrap metal merchant.
DO NOT USE BRAZEN 3000 IF THE RUBBER O-RING IS MISSING
OR DAMAGED IN THE REGULATORS
7
GAS SUPPLY
General
Your BOSSWELD gas welding and cutting equipment is designed to be used
by gases delivered to the point of use from portable compressed gas cylinders.
In all cases, gas supplies may be subject to statutory or regulatory provisions.
Many Australian Standards cover the subject.
a) The Brazen 3000 is fueled with Oxygen and Mapp gas cylinders, Cylinders
are generally obtained from gas suppliers.
b) Do not tamper with the markings or colour coding of cylinders. Do not use
non colour coded cylinders or those without safety and information labels.
c) The Oxygen and Mapp gas cylinders are not rellable.
d) Gas should only be used for the particular intended purpose, e.g. never
use oxygen for cleaning (dusting), or to provide ventilation or to support
breathing
e) Gases should only be identied by their correct name so as to avoid
dangerous confusion or misunderstanding.
f) Valve seats and outlets should be protected by keeping all kinds of dirt
and contamination away from cylinders, especially during connection
and disconnection. Grit, loose bers and other dirt may lodge in
connectors or valve seats causing leaks or may be picked up by high
velocity gas streams, causing hot spots in regulators, potentially resulting
in ignition. Organic matter such as oil, grease and hydrocarbon liquids
which may ignite spontaneously in high pressure oxygen is another hazard
to regulators and other downstream equipment.
g) Do not tamper with safety devices.
DO NOT CONNECT CYLINDERS BEFORE YOU HAVE READ THIS
MANUAL IN FULL AND UNDERSTAND IT.
THE BRAZEN 3000 OXYGEN BOTTLE CONNECTION ONLY
CONNECTS TO M12x1 THREAD.
THE BRAZEN 3000 MAP-PRO CONNECTION IS CGA 600.
8
SAFETY
The regulators supplied ensure a low and constant ow and pressure. Inspect
all parts of the equipment for wear or loose connection before use. If you have
a leaking hose or connection, close all valves regulators and torch handles, and
ensure you ventilate the area you are working in. and remove this equipment
from and ammable sources. Do not attempt to x any damaged parts contact
your nearest Bossweld service agent or Bossweld directly.
• Always make sure the ame is fully extinguish after use before place the
torch on any surface.
• Check hoses for kinks or bends.
• Keep ame away from cylinders, regulators, hoses and other persons.
• Only use this product in a well ventilated space - never use in a conned
area.
• Make sure the cylinder holder is on a at surface - do not drag the cylinders
or cylinder holder by the hoses.
• Ensure the work area is clean and remove all ammable objects and re
hazards.
• Always wear the appropriate PPE equipment when operating this equipment.
IN CASE OF FIRE
• In the event of a re, if it is safe to do close the oxygen valve, this should
extinguish the ame and also if safe close the fuel valve and remove the
equipment from the area.
• Extinguish the re with the appropriate equipment only if it is safe to do so.
• If you are unable to turn of the valves or extinguish the re leave the area,
warn any other persons in the area and contact emergency services
- Phone 000.
9
SAFETY SAFETY
TIP REPLACEMENT
Make sure you use the tool supplied and that tips are installed straight as not to
wear the thread, this can result in a leak.
• Ensure tip has cooled after use before replacing.
• Do not over tighten
• Ensure tip is clean and dry before installing and is not blocked.
CYLINDER REPLACEMENT
• Make sure the regulator is completely shut off before removing it from the
cylinder., Always check condition of the seal in the regulator before replacing
on a new cylinder
• Unscrew the empty cylinder and replace with a new one.
• Dispose of empty cylinder at your local recycling center
- NEVER incinerate empty cylinder.
- Do NOT puncture.
10
Storage
In the case where the Brazen 3000 should not be used for a long time or
when requiring transport by a motor vehicle, unscrew the cylinders from
the regulators, This will ensure that the contents of the cylinder will remain
contained and prevent leaks. Do not expose cylinders to a temperature higher
than 50ºC.
- Always transport in a well ventilated vehicle never transport in a closed
vehicle
- It is dangerous to use damaged or incorrectly functioning equipment
CYLINDER STORAGE
NOZZLE CHART
TIP SIZE ORIFICE WELDING RANGE
0# 0.7mm 0.5mm - 1mm
1# 0.8mm 1mm - 2mm
2# 0.9mm 2mm - 3mm
3# 1.0mm 3mm - 4mm
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