Broco PRIME-CUT Operating Instructions And Technical Manual
  1. Manuals
  2. Brands
  3. Broco Manuals
  4. Cutter
  5. Prime-Cut
  6. Operating instructions and technical manual

Broco PRIME-CUT Operating Instructions And Technical Manual

Ultrathermic cutting system
Hide thumbs Also See for PRIME-CUT:
Table of Contents

Advertisement

Quick Links

OPERATING INSTRUCTIONS
AND
TECHNICAL MANUAL
FOR
PRIME-CUT
ULTRATHERMIC CUTTING SYSTEM

Advertisement

Table of Contents
loading

Related Manuals for Broco PRIME-CUT

Summary of Contents for Broco PRIME-CUT

  • Page 1 OPERATING INSTRUCTIONS TECHNICAL MANUAL PRIME-CUT ULTRATHERMIC CUTTING SYSTEM...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Chapter 1 GENERAL INFORMATION AND SAFETY PRECAUTIONS Section I. INTRODUCTION 1-1. THERMAL TORCH CUTTING 1-2. PRIME-CUT RESCUE & RECOVERY TORCH KIT 1-3. WARNINGS 1-4. SAFETY PRECAUTIONS Section II. EQUIPMENT DESCRIPTION 1-5. PC/A-5V2HR CUTTING TORCH SYSTEM Chapter 2 PREPARATION Section I.
  • Page 4 3-3-3. Ignition using the RapidFire cutting rod igniter- Underwater 3-4. OPERATING TECHNIQUES 3-4-1. Piercing 3-4-2. Cutting 3-4-3. Gouging 3-5. RESTART PROCEDURES 3-6. SHUTDOWN PROCEDURES 3-7. BATTERY CHARGING INSTRUCTIONS 3-7-1. Charging the Lightweight Battery. 3-7-2. Charging the 12-Volt/24-Volt Vehicle Battery 3-8. TRANSFILLING OXYGEN CYLINDERS 3-9.

  • Page 5: Chapter 1 General Information And Safety Precautions

    1-2. PRIME-CUT RESCUE and RECOVERY TORCH KIT. Broco is the leading manufacturer of self contained lightweight exothermic systems for emergency rescue and salvage operations.

  • Page 6: Warnings

    SYMBOL LEVEL OR DEGREE OF HAZARD Calls attention to a critical step or procedure which, if improperly performed, may adversely affect the function of the product or overall quality. Indicates a potentially hazardous situation, which, if not avoided, may result in moderate injury. Used to warn against unsafe practices.
  • Page 7 Always use the Leather Shield to protect yourself from sparks and splatter. Always remove all personal metal items (i.e., rings, watches, etc.) when working with the torch as they can trap sparks and slag causing a severe burn and damage to the item. Always keep your head away from the fume plume.
  • Page 8 See: American National Standard Z49.1-88 Safety in Welding and Cutting published by the American Welding Society, 550 N.W. LeJeune Road; Miami, FL 33126. OSHA Safety and Health Standards 29 CFR 1910 available from the U.S. Department of Labor; Washington, D.C. 20210.

  • Page 9: Section Ii. Equipment Description

    Cutting Rod. The kit is designed to use either 1/4” or 3/8” cutting rods. Standard rod length is 18 inches. 36” rod length is also available. (1/2” x 48” cutting rods are also available from Broco but are only appropriate when working from a large cylinder of oxygen.) 3818PC-SPS 3/8”...
  • Page 10 Oxygen Supply System. The oxygen (02) supply system consists of the following component parts: Oxygen Regulator. The oxygen regulator has a hand-tighten cylinder connection (CGA 540) and a quick connect coupler outlet fitting. The PC/TAC- R-B single stage industrial regulator is preset to 65 psig outlet pressure to balance performance with oxygen consumption for most applications.
  • Page 11 Battery Ignition Components. The battery ignition components are used to ignite the cutting rod by means of an electric arc. Lightweight Battery. The lightweight battery (PC/BISLW) contains a rechargeable 12-volt, sealed, lead acid (gel-type) battery. The battery provides DC power (through AWG #6 welding cables) to both the torch and the striker plate assembly.
  • Page 12 16 inches and is used to enable the operator to gain reach or standoff, employ the torch in otherwise inaccessible places and or make best use of available cover. A 36” long extender is available from Broco as an optional accessory. PC/TACXT16 CUTTING ROD EXTENDER Safety Equipment.
  • Page 13 Transfill Hose Assembly. The Transfill hose assembly with bleed valve (PC/TFHBL) is used to transfer oxygen from a larger cylinder to the oxygen cylinder included in the torch kit. PC/TFHBL TRANSFILL HOSE ASSEMBLY Medical Oxygen Adapter. The medical oxygen adapter (M87-1) is used with oxygen cylinders having post type medical valves to provide a CGA 540 industrial oxygen outlet thread.

  • Page 14: Chapter 2 Preparation

    CHAPTER 2 PREPARATION Section I. SETUP PROCEDURES 2-1. PREPARING THE WORK AREA. Never operate the torch in explosive or flammable environments. Never cut into unknown material. Never operate the torch with other personnel or bystanders in front of the torch or in the immediate work area.

  • Page 15: Section Ii. Pc/Tacmod1 Assembly Procedures

    Export kits. The US standard oxygen outlet fitting (CGA 540) is used in many parts of the world. For those countries where it is not accepted, Broco offers export versions of the cutting sets that utilize the British standard for oxygen cylinder valve and regulator inlet fittings. Oxygen cylinders and oxygen cylinder valves are certified to EN standards and marked accordingly.
  • Page 16 Thread the BR-541 onto the US CGA 540 standard oxygen cylinder valve outlet connection. Tighten with a wrench. Attach the fill hose (or British standard regulator) to the other side of the BR-541 adapter. BR-540 adapter can also be used with a US standard transfill hose assembly to transfer oxygen between a US standard cylinder and a British standard cylinder.
  • Page 17 Do not use a wrench to tighten the regulator inlet nipple as damage to the nipple may occur. Connect the oxygen regulator to the oxygen cylinder ensuring that the regulator quick connect fitting for the oxygen hose is pointed straight down and is parallel to the oxygen cylinder. Note that the regulator inlet is fitted with a hand-tight nut and Teflon tipped or o-ringed inlet nipple.

  • Page 18: Ignition System

    CHARGE A NEW BATTERY BEFORE USING. CHARGE IMMEDIATELY AFTER EACH SUBSEQUENT USE. THE BROCO BATTERY MODEL PC/BISLW MAY TAKE UP TO 16 HOURS TO FULLY CHARGE IF COMMENCING FROM A FULLY DISCHARGED STATE. DO NOT STORE A RECHARGEABLE BATTERY IN A FULLY OR PARTIALLY DISCHARGED STATE.

  • Page 19: Battery Adapter Clamps

    d. Connect the other end of the 5 foot power cable to the battery. Firmly seat the black plug into the black receptacle then twist 1/4 turn to lock in place. e. Separate the striker plate cable into two segments. Connect the striker plate cable to the battery by firmly seating the red plug into the red receptacle then twisting 1/4 turn to lock it in place.
  • Page 20 Never use a battery for ignition that is connected to a battery charger. Always unplug the battery charger before attaching the ignition power cables to the battery. Never let the striker plate accidentally contact the torch, rods, or work area. Electrical shock and sparks may result.

  • Page 21: Leather Shield

    The leather shield is intended to reduce the sparks and spatter coming back at the operator’s hand. Always use the leather shield when piercing. Always use the leather shield designed for the Prime-Cut torch (in conjunction with protective outer wear and gloves) to protect yourself from spark and splatter burns.
  • Page 22 The rod igniters utilized with the Prime-Cut torch contain oxygen reactive material, a pyrophoric / self-heating solid / combustible in air. Combustion is achieved through rapid oxidation. Exposure to high concentrations of oxygen will cause material to super heat into a molten state.
  • Page 23 They must be transported by truck or vessel. Small quantities (5 boxes or less) of cutting rod igniters may be shipped as Class 9 materials via UPS. Igniters can not be shipped via post, Federal Express, or DHL. Contact Broco for specific information about shipping RapidFire cutting rod igniters.

  • Page 24: Chapter 3 Operating Instructions

    Never use a damaged cutting rod. Always use Prime-Cut ultrathermic cutting rods with Prime-Cut torch kits. Prime-Cut rods are specially designed to fit with the collets used in Prime-Cut torches. Never use any other rods as hazardous backflashes or internal burning may result.

  • Page 25: Rod Insertion

    CHAPTER 3- OPERATING INSTRUCTIONS (cont.) Refer to the table to determine the correct cutting rod size for the target material and type of work being performed. 3-2. ROD INSERTION. Check to see that the collet in the torch assembly is the appropriate size to properly fit the rod being used.
  • Page 26 If none of the preceding remedy the leak, remove the torch from service and contact Broco customer service or another qualified person for inspection and repair. Fully close the plug valve until ready to use the torch. Table 3.1. Cutting rod size selection chart.

  • Page 27: Igniting The Rod

    3-3. IGNITING THE CUTTING ROD. 3-3-1. Ignition using the striker plate. Always hold the striker plate by the plastic handle to avoid electric shock. Never touch the copper plate. Avoid prolonged contact between the cutting rod and the striker plate. Damage to the battery may result.
  • Page 28 3-3-2. Ignition using RapidFire cutting rod igniter - Land Environment. Do not attempt to break the cutting rod igniter internal seal while the cutting rod is in the torch. Damage to the collet washer may result which could contribute to an oxygen leak and subsequent injury to the operator or damage to the equipment.

  • Page 29: Ignition Using The Rapidfire Cutting Rod Igniter- Underwater

    3-3-3. Ignition using RapidFire cutting rod igniter - Underwater. General. The Broco Prime-Cut PC/A-5V2HR torch can be used to conduct underwater cutting at depths to 30 fsw (with the industrial oxygen regulator). As the lightweight battery cannot be submersed, and cutting frequently must be performed where surface support (oxygen source and a power supply) is not practical, RapidFire cutting rod ignition cartridges are used to ignite cutting rods underwater.

  • Page 30: Operating Techniques

    Hold the rod tip in the molten puddle which forms (approximately 4- 5 seconds). Sparkling indicates rod ignition. Keeping the oxygen control lever depressed, fully open the plug valve. Raise the cutting rod to the work piece/target material and commence cutting. 3-4.

  • Page 31: Cutting

    Remove the rod from the pierced hole before releasing the oxygen control lever. Oxygen must not be shut off while cutting rod is inside a pierced hole or else the rod may seal itself shut or weld itself to the target material. When piercing is completed, first, remove the rod from the pierced hole.
  • Page 32 PULL TO CUT. MAINTAIN CONTACT BETWEEN ROD AND TARGET (DRAG). SLAG SPRAY ANGLE DURING CUTTING.
  • Page 33 3-4-3. Gouging/Push Cutting. Gouging is conducted by holding the rod at a very slight angle to the target material and pushing into the direction of the desired gouge. It is the recommended cutting method when the target material is the same as the cutting rod diameter or thinner or if the target material is backed by concrete or another hard substance.

  • Page 34: Restart Procedures

    3-5. RESTART PROCEDURES. If at any time the cutting rod goes out while in use, move the torch away from the cutting surface. Check the oxygen flow and pressure and then re-ignite the rod as previously explained. If re- ignition fails or the rod continues to go out, insert a new rod and ignite the rod as previously explained.

  • Page 35: Battery Charging Instructions

    CHARGE A NEW BATTERY BEFORE USING. CHARGE AFTER EACH SUBSEQUENT USE. THE BROCO BATTERY MODEL PC/BISLW MAY TAKE UP TO 16 HOURS TO FULLY CHARGE IF COMMENCING FROM A FULLY DISCHARGED STATE. DO NOT STORE A RECHARGEABLE BATTERY IN A FULLY OR PARTIALLY DISCHARGED STATE.

  • Page 36: Charging The 12-Volt/24-Volt Vehicle Battery

    Battery chargers supplied with Broco Prime-Cut cutting torch kits are 110 volt input. 220v to 110v low amperage converters are available from Broco. Ensure the proper charger setup is being used to suit local standards. Plug the black and red electrical connectors from the charger cord into the black and red electrical receptacles on the Lightweight Battery.
  • Page 37 Always keep oil and grease away from the torch, oxygen cylinders, valves, regulators, hoses, and fittings. Oxygen reacts explosively when mixed with oil or grease. Never clean any internal part of the oxygen system. Never use compressed air, oil, solvents, or any other material to clean the oxygen system.

  • Page 38: Oxygen Regulator Adjustment Procedure

    Ensure the transfill hose assembly bleed valve is closed by turning the knob clockwise until it stops. Slowly open the valve on the target cylinder by turning the valve handle counter-clockwise, allowing the transfill hose to pressurize. Listen for oxygen leaks. Pause for 10 seconds then continue slowly opening the valve all the way until it stops.
  • Page 39 Attach the regulator adjusting gauge assembly to the regulator outlet. Attach the 5’ long oxygen hose to the torch and to the regulator adjusting gauge assembly by pressing the quick connect plugs into the respective quick connect couplers. Insert a 3/8” diameter cutting rod into the end of the torch, tighten collet nut to hold in place. Slowly open the oxygen cylinder valve.

  • Page 40: Chapter 4 Scheduled Maintenance

    CHAPTER 4 SCHEDULED MAINTENANCE Section I. INTRODUCTION 4-1. PREVENTIVE MAINTENANCE. Preventive maintenance is the responsibility of the equipment operator. Preventive maintenance should be conducted in accordance with this Manual and consist of inspecting, servicing, and cleaning. Inspections will also reveal the need for repairs. Periodic Limited Technical Inspections (LTI) will be required to ensure the torch kit is safe and serviceable.
  • Page 41 Preventive maintenance for the striker plate will include the following: Disconnect the striker plate power cable from the battery prior to cleaning the striker plate surface. Failure to do so could result in electric shock. Repeated ignition will cause a build-up of slag deposits on the surface of the striker plate. This build-up is easily removed by scraping the striker plate across a rough surface or hard edge.

  • Page 42: Section Ii. Scheduled Maintenance

    CHAPTER 4- SCHEDULED MAINTENANCE (cont.) Section II. SCHEDULED MAINTENANCE 4-2. PREVENTIVE MAINTENANCE PROCEDURES. As soon as possible after each use, the torch kit should be cleaned and inspected as described in paragraph 4-1 of this Manual. In addition, preventive maintenance checks should be performed every 120 days (quarterly) to keep the kit ready for use.
  • Page 43 Collet (3/16”, 1/2”, Ensure proper functioning. Test with rod to ensure proper fit. Inspect for cracks, bends, other damage. Replace as necessary. 3/8" and 1/4") Collet Washer Inspect for cuts, excessive wear, or any other damage. Replace as required. Ensure correct size washer is being used to fit collet. Flash Arrestor Unscrew the flash arrestor from the torch body.
  • Page 44 Backpack Harness Ensure proper functioning of adjusters and snaps. Inspect for wear and/or other damage. Tank Strap / Keeper Inspect for cuts, excessive wear, or any other damage. Ensure the Strap serviceability of the buckle / tensioner. Rod Extender, 16" Ensure proper functioning.

  • Page 45: Chapter 5 Troubleshooting

    CHAPTER 5 TROUBLESHOOTING This guide is intended to assist in determining the probable causes of torch malfunctions and their associated repairs. For each potential problem identified a probable cause and recommended repair procedure is listed. Section I. OXYGEN SYSTEM MALFUNCTIONS 5-1.

  • Page 46: Uneven Oxygen Flow

    mating surface of the Remove the valve nut. Inspect and clean or replace valve nut is dirty, worn as needed. or damaged. 5-2. UNEVEN OXYGEN FLOW. Table 5-2. Troubleshooting Uneven Oxygen Flow TYPE OF PROBABLE RECOMMENDED REPAIR PROCEDURES PROBLEM / CAUSE MALFUNCTION UNEVEN...

  • Page 47: Section Ii. Valve Stem Malfunctions

    Section II. VALVE STEM MALFUNCTIONS 5-3. STICKING CONTROL VALVE. Table 5-3. Troubleshooting Valve Stem Malfunctions TYPE OF PROBABLE RECOMMENDED REPAIR PROCEDURES PROBLEM / CAUSE MALFUNCTION THE VALVE The valve stem is Follow the oxygen control valve disassembly / STEM WILL bent.

  • Page 48: Chapter 6 Corrective Maintenance Section I. Introduction

    Broco Prime-Cut Tactical torch kits. Section II. ADJUSTMENTS, ALIGNMENTS, AND REPAIRS If you have any questions about the maintenance or repair of Broco Prime Cut torch systems CONTACT BROCO, INC. AT (800) 845-7259, (909) 483 3222, BY FAX (909) 483 3233, OR BY EMAIL Sales@Brocoinc.com BEFORE PROCEEDING.
  • Page 49 Always remove, clean, and/or replace the flash arrestor and flash arrestor screen after the torch has been submerged in water. The flash arrestor and flash arrestor screen must be removed and inspected before and after each use to insure an unrestricted oxygen path. Disassembly.

This manual is also suitable for:

Pc/a-5v2hr

Table of Contents