#flamefast

HAZARDS

Fumes produced during either forging or brazing operations.

Burns from material being heated, chips, tools in use etc.  (especially black hot metal).  Ceramic chips remain hot for some considerable time after the heat source has been removed.

Infra-red radiation from hot surfaces.

Foreign materials present in a forge can explode or be ejected e.g clinker.

Quenching of hot metals, particularly tubular components, present a risk of scalding.

Environmental: keep area around machinery clear of surplus materials, wood waste and other tripping or slipping hazards.

Inadvertent starting/stopping of the machine.

Unauthorised persons using the machine.

Personal Protective Equipment (PPE)

Goggles (BSEN-166-349B) – (Those observing must be wearing suitable goggles)

Operator must wear a suitable face shield

Operator must wear protective gloves 

Suitable leather apron

Suitable protective footwear Loose clothing must be secured and long hair tied back 

Emergency Stop Systems

Room Emergency Stop System – various sites around the room

Gas isolator – sited on the wall close to the forge.  

Fume Extraction

The Flamefast Chip Forge / Brazing Hearth as installed comes fitted with a fully COSHH compliant fume extraction system.  The fume extraction systemmust be switched on each and every time the forge and / or brazing hearth is used and must remain in operation for at least 30 minutes after the forge has been switched off.  All the forges in Glasgow schools have been fitted with aDifferential Pressure Switch (DPS) to ensure that the forge cannot be operated without the extraction sytem as regulation IGE/UP/11 section 8.1.2.4.

SAFETY CHECKS BEFORE USE

Clear Working Area around the Chip Forge / Brazing Hearth

The area around the Chip Forge / Brazing Hearth should be regularly checked to ensure that it is clear of any slipping or tripping hazard, since anyone carrying a hot object will not be concentrating on the floor.

Chip Forge: Pre checks

Always check the condition of the ceramic chips, remove any clinkers, slag and foreign objects and “riddle” the chips to remove any debris if required.  Check the condition of the burner tile, the holes should be clear and the tile undamaged.  There should be a sufficient amount of ceramic chips to cover the burner tile (approximately 12.5 Kg).  The chips, as supplied, are made from a ceramic “heat retentive” material and are designed to absorb and retain the heat in order to exchange the heat to the material placed in the forge.  Only the ceramic chips provided with the forge or Flamefast approved chips should be used with the forge.

Brazing Hearth: Pre checks

The brazing hearth is lined with heat resistant refactory and provided with specially tested “heat reflective” blocks and is designed to reflect and concentrate the heat on the material being worked on.  Only the heat reflective blocks provided with the brazing hearth or Flamefast approved blocks should be used.  Before use check the condition of the brazing surface and the blocks and remove any debris or foreign objects.

RF80 Torches

The RF80 Torches as supplied with the Flamefast Chip Forge / Brazing Hearth are regulated by a single control valve and are used in brazing and for lighting the forge.  When not in use they should be hung by the hook at the side of the brazing hearth.  Avoid hanging the torch by the control valve as this may cause damage.

POWERING THE CHIP FORGE / BRAZING HEARTH

Energise the Chip Forge / Brazing Hearth

Switch on the power supply to the work room, this may be controlled by a keyswitch

Switch on the mains gas supply to the work room (This maybe supplied from an external “proving” system)

Switch on the forge extraction system – the Flamefast Chip Forge / Brazing Hearth will not operate without the extraction system switched on 

Ensure that the forge “gas” and “air” valves are switched “OFF” (the handles should be in a horizontal positon).  The gas supply for the brazing torch does not come through these valves so ensure that the brazing torch is switched “OFF” (turn the control valve fully clockwise) 

Switch the machine isolator to the “on” position  

Switch on the gas supply to the forge: the gas valve should be situated on the wall towards the rear of the forge

Insert the key into the keyswitch and release the RED stop button(remove the key for safe keeping)

Press the green start button, this will initiate the “Proving Cycle”, the amber gas proving neon will illuminate

The “Proving Cycle” or “Gas Soundness Test”  is to check that there are no leaks in the system or that the torches or valves have been left open after previous use.  A small flow of gas is released into the system and the pressure in the system is measured, if the pressure is maintained then the system is sound and has no leaks or open valves.The “Proving Cycle” can take up to 30 seconds, but if there is a small amount of gas still in the system after the previous use, the forge can “Prove” very quickly and go straight to “Gas On”.

When proving is complete the green neon will illuminate indicating that the “Gas Proving” is complete and the gas is now “ON”

Igniting the RF80 Torch / Forge

To light the brazing torch, hold the nozzle at the cage containing theingnition electrode

Press the ingnition button at the front of the forge, sparks should appear at the electrode

Turn on the torch, ¼ turn anti-clockwise, at the control valve

Hold the nozzle of the torch near the ignitor while pressing the ignition button, when the torch lights release the ignition button