Broco BR-22 Operating Instructions

Underwater cutting and welding equipment is potentially dangerous and can result in serious injury or death. This equipment
must be used in strict accordance with the instructions provided. Users must read and understand these operating instructions thoroughly
and follow all procedures when using the BROCO Underwater Ultrathermic cutting system.
Underwater cutting and welding should be performed by trained commercial divers only and according to industry accepted safe
diving practices. Always adhere to ANSI Z49.1:2005 "Safety in Welding and Cutting" standards or similar locally prevailing standards
when using this equipment and follow industry accepted safe diving practices as found in the Association of Diving Contractors Interna-
tional "Consensus Standards for Commercial Diving."
All personnel and supervisors engaged in underwater cutting operations must be familiar with these instructions, the correct use of
underwater cutting equipment, and accepted safe commercial diving practices. Employers must provide operator training before allowing
their personnel to begin using the BROCO Underwater Ultrathermic cutting system. Supervisors must ensure that all personnel become
thoroughly familiar with all safety precautions prior to cutting.
If you have any questions regarding the safe operation of BROCO Underwater Ultrathermic cutting systems, STOP! DO NOT ATTEMPT
TO CUT UNDERWATER. Contact BROCO, Inc., Tel: 800-845-7259 / 909-483-3222, fax 909-483-3233, for technical information.
See: American National Standard Z49.1:2005 "Safety in Welding and Cutting" published by the American Welding. Society, 550 N.W. LeJeune Rd., Miami, FL 33126, Tel. 305.443.9353
"Consensus Standards for Commercial Diving", published by the Association of Diving Contractors International, Inc., 5606 FM, 1960 West, Suite 202, Houston, TX 77069, Tel. 281.893.8388.
OSHA Safety and Health Standards "29 CFR 1910" available from the U.S. Department of Labor, Washington, D.C. 20210, Tel. 202.693.1999.

CUTTING EQUIPMENT

To avoid serious injury or death, follow the safety in-
formation in this section a a n n d d i i n n a a l l l l o o t t h h e e r r w w a a r r n n i i n n g g s s e e c c t t i i o o n n s s . .
Modification of this equipment can cause oxygen leaks that
can lead to an explosion. DO NOT modify this equipment or use it
in any way not specified in these instructions.
To prevent burns to your hands and body 1) Use only BROCO
replacement parts; 2) Always release the oxygen lever to extin-
guish the torch while there is at least 2" of rod remaining; 3) DO
NOT use a damaged Ultrathermic cutting rod; 4) Always insert the
correct end (recessed, untaped) of the rod into the torch; 5) Always
wear insulated suit and gloves.
Using compressed air, oil, solvents or other material to clean
the oxygen system can contaminate the oxygen system, cause in-
ternal burning in the torch or hose or cause an explosion. Always
keep oil and grease away from oxygen cylinders, valves, regula-
tors, hoses and fittings. A qualified and knowledgeable technician
must perform all service on oxygen delivery parts.
Using a torch without a flash arrester and screen can cause
flashback in the torch and an explosion. DO NOT operate the torch
without the flash arrestor and screen in place.
Using a torch or cutting rods designed for surface use for under-
water cutting can shock the diver. Always use a BROCO Underwa-
ter cutting torch and BROCO Underwater cutting rods.
To prevent electrical shock to the diver and electrical damage
to the diver's life support equipment, always ensure that the
safety knife switch is open before changing cutting rods.
DO NOT use a "burning bar" for underwater cutting operations.
It can cause excessive gas buildup and an oxygen explosion. A
burning bar is considered to be any underwater cutting rod oper-
ating with oxygen as a fuel source whose diameter is greater than
3/8" or length is longer than 36".
The use of underwater cutting rods from other manufacturers
can cause flashbacks or internal burning and injury to the diver. Al-
ways use BROCO Underwater ultrathermic cutting rods with the
BROCO Underwater BR-22 cutting torch.
BROCO UNDERWATER
Underwater Cutting Products Operating Instructions
Equipment Required
1. Broco BR-22 cutting torch, preferred because it is designed for diver comfort,
maximum oxygen flow, and ease of operation and maintenance.
2. Broco Underwater Ultrathermic cutting rods.
3. Broco HVR-4401 high volume two-stage oxygen regulator.
4. Single pole single throw or double pole single throw safety knife switch.
(Rated 400 amps DC, unfused.)
5. C-type grounding clamp. (Appropriate for underwater use.)
6. 150-200 amp 100% duty cycle DC welding power source or 12v or 24v battery.
7. Size 1/0 (minimum) welding cables for torch power and ground leads.
8. Oxygen supply. (Gas only, 99.5% purity minimum.)
9. 3/8" inside diameter oxygen supply hose. (Regulator to torch. Taped to torch
power cable at 2' intervals.)

TOPSIDE (AT SURFACE)

To avoid serious injury or death, follow the safety
information in this section regarding topside safety and i i n a a ll o o t t her
warning s s ections.
The use of damaged or worn components can cause equipment
failure and result in injury. Before entering water, check equip-
ment for leaks and replace damaged or worn components.
To reduce the risk of injury in the unlikely event of regulator fail-
ure, DO NOT stand directly in front of or directly behind the oxygen
regulator while opening the oxygen cylinder valve.
Using the vessel's primary battery as a power source for rod ig-
nition can damage or cause wear to the battery and could render
the vessel inoperable. Always use a separate battery for cutting.
Using alternating current (AC) for underwater cutting can elec-
trocute the diver. DO NOT use AC power for underwater cutting op-
erations. Use only direct current (DC) from a known power source.
To avoid electrocution, DO NOT touch live electrical parts.
1. Before beginning, inspect components to ensure that:
A. Hose and cables are in good condition with no visible cuts, cracking
or splitting. Cable lug connectors should be securely attached and
without visible excessive corrosion.
B. All electrical connections are made watertight by carefully taping
with UL approved electrical insulating tape. Tape should extend at
least 4" up the cable on both sides of the connection.
C. Cutting torch is in good condition with no visible gaps in the seam
between the handle halves. Torch should be inspected to make
sure flash arrestor, neoprene compression washer, collet washer
and appropriate size collet are in good condition and in place.
. . .continued