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Broco PRIME-CUT PC/TAC Operating Instructions Manual

Tactical cutting torch kits
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TACTICAL CUTTING TORCH KITS
PC/TAC
&
PC/MINI-TAC
OPERATING INSTRUCTIONS
MANUAL
Broco, Inc.
8690 Red Oak St.
Rancho Cucamonga, CA 91730-4819
Tel: 909 483 3222 Fax: 909 483 3233
Toll Free: 800 845 7259
E-mail Broco@Worldnet.att.net
www.brocoinc.com
Aug.'99 ed.

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  • Page 1 TACTICAL CUTTING TORCH KITS PC/TAC & PC/MINI-TAC OPERATING INSTRUCTIONS MANUAL Broco, Inc. 8690 Red Oak St. Rancho Cucamonga, CA 91730-4819 Tel: 909 483 3222 Fax: 909 483 3233 Toll Free: 800 845 7259 E-mail Broco@Worldnet.att.net www.brocoinc.com Aug.’99 ed.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Chapter 1 GENERAL INFORMATION AND SAFETY PRECAUTIONS Section I. INTRODUCTION 1-1. THERMAL BREACHING 1-2. PRIME-CUT TACTICAL TORCH KITS 1-3. WARNINGS 1-4. SAFETY PRECAUTIONS Section II. EQUIPMENT DESCRIPTION 1-5. PC/TAC TACTICAL CUTTING TORCH SYSTEM 1-6. PC/MINI-TAC COMPACT CUTTING TORCH SYSTEM Chapter 2 PREPARATION Section I.
  • Page 3 Chapter 3 OPERATING INSTRUCTIONS Section I. INTRODUCTION 3-1. TORCH OPERATION Section lI. OPERATING PROCEDURES 3-2. ROD INSERTION 3-3. IGNITING THE ROD (PC/TAC) 3-3-1. Ignition using the striker plate 3-3-2. Ignition using the RapidFire cutting rod igniter- Land environment 3-3-3. Ignition using the RapidFire cutting rod igniter- Underwater 3-4.
  • Page 4 Chapter 5 TROUBLESHOOTING Section I. OXYGEN SYSTEM MALFUNCTIONS 5-1. OXYGEN LEAKS 5-2. UNEVEN OXYGEN FLOW Section II. CUTTING ROD MALFUNCTIONS 5-3. COLLET PROBLEMS Section III. VALVE STEM MALFUNCTIONS 5-4. BENT CONTROL VALVE/WORN PARTS Chapter 6 CORRECTIVE MAINTENANCE Section I. INTRODUCTION 6-1.

  • Page 5: Chapter 1 General Information And Safety Precautions

    1-2. PRIME-CUT TACTICAL TORCH KITS. Broco is the leading manufacturer of self contained lightweight exothermic systems for emergency rescue and salvage operations. These kits have the capability of quickly burning, melting, or vaporizing nearly any metallic, non-metallic, or composite material.

  • Page 6: Safety Precautions

    Never use the equipment unless you are familiar with acceptable industrial welding and cutting procedures and practices. Always use this equipment following generally accepted industrial safety procedures and practices. Always apply and adhere to ANSI/ASC Z49.1-88 Safety in Welding and Cutting standards, or similar locally prevailing standards when using this equipment.
  • Page 7 m. Always keep oil and grease away from the torch, oxygen cylinders, valves, regulators, hoses, and fittings. Never use compressed air, oil, solvents, or other material to clean any part of the oxygen system. Oxygen reacts explosively when mixed with oil or grease. Never clean any internal part of the oxygen system.

  • Page 8: Section Ii. Equipment Description

    Cutting Rod. The kit is designed to use either 1/4” or 3/8” cutting rods. (3/16” and 1/2” diameter cutting rods are also available from Broco but are not appropriate for this kit.) Standard rod length is 18 inches. The 3/8” rod is also available in a 36” length.
  • Page 9 Pressure Gauge. This submersible high pressure gauge is connected to the regulator by an 18 inch length of high pressure hose. It measures the pressure of the compressed oxygen in the cylinder from zero to 5000 psi and is designed for use with oxygen only. PC/TAC-G PRESSURE GAUGE WARNING Never use a standard SCUBA pressure gauge as they contain oil.
  • Page 10 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 11 A 36” long extender is available from Broco as an optional accessory. Quiver. The quiver is a nylon pouch designed to hold the cutting rods. It is adjustable to accommodate either 18 inch or 36 inch rods.

  • Page 12: Pc/Mini-Tac Compact Cutting Torch System

    Cutting Rod. The kit is designed to use either 3/16”, 1/4” or 3/8” cutting rods. (1/2” diameter cutting rods are also available from Broco but are not appropriate for this kit.) Standard rod length is 18 inches. The 3/8” rod is also available in a 36” length.
  • Page 13 They have a standard oxygen valve (CGA 540) for ease of filling and attachment to a regulator. MINI-TAC REGULATOR, HOSE AND CYLINDER Battery Ignition Components. The battery ignition components are used to ignite the cutting rod by means of an electric arc. Lightweight Battery.
  • Page 14 Fanny Pack. The Fanny Pack is a nylon pouch designed to hold an oxygen cylinder with regulator attached, packet of cutting rods (18” long), torch and hose. Mounting straps and Alice Clips allow the fanny pack to be carried horizontally or vertically, attached to belt, tactical vest, or load bearing harness.

  • Page 15: Chapter 2 Preparation

    CHAPTER 2 PREPARATION Section I. SETUP PROCEDURES 2-1. PREPARING THE WORK AREA. WARNING 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 16: Section Ii. Pc/Tac Assembly Procedures

    British standard for oxygen fittings is usually the local standard (e.g. most of Asia). Adapters to convert from US to British standard are available from Broco. BR-540 adapter allows the US standard regulators supplied in the tactical torch kits to be used with British standard oxygen cylinders.
  • Page 17 Thread the BR-540 onto the British standard oxygen cylinder valve outlet connection. Tighten with a wrench. Thread one end of the transfill hose assembly onto the other end of the BR-540. Attach the other end of the transfill hose assembly to the US standard oxygen cylinder valve outlet connection.
  • Page 18 PC/TAC SETUP- OXYGEN SYSTEM CAUTION 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 inlet nipple.

  • Page 19: Ignition System

    2-4. IGNITION SYSTEM. (PC/TAC) WARNING Always use a 12-volt DC ignition system. Lead-acid batteries generate explosive gases during normal battery operation. Never smoke or allow spark or flame in the near vicinity of the battery. Always make sure the battery is safely positioned away from the immediate work area and adequately ventilated.

  • Page 20: Battery Adapter Clamps

    PC/TAC SETUP- IGNITION SYSTEM NOTE There may be times when the backpack need not be used (e.g. training). At these times it may also be advantageous to use oxygen from a larger cylinder (more cutting duration). In these instances leave the torch power cable and striker plate cable at 15 feet. Also join the 10 foot long oxygen hose to the 5 foot hose for a total of 15 feet.
  • Page 21 WARNING 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 22: Section Iii. Pc/Mini-Tac Assembly Procedures

    CHAPTER 2- PREPARATION (cont.) Section lII. PC/MINI-TAC ASSEMBLY PROCEDURES 2-5. OXYGEN SYSTEM. (PC/Mini-Tac) WARNING To reduce the risk of injury in the event of regulator failure, never stand directly in front of or directly behind the oxygen regulator while opening the oxygen cylinder valve. Always keep oil and grease away from the torch, oxygen cylinders, valves, regulators, hoses, and fittings.
  • Page 23 Ensure that the oxygen is turned off. Hold the oxygen cylinder in an up-right position. CAUTION 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. To ensure a proper grip, position the regulator quick connect fitting so it points away from the operator while the oxygen cylinder valve points away from the operator’s palm (e.g.

  • Page 24: Conventional Mode

    Close the oxygen cylinder valve. 2-5-2. CONVENTIONAL MODE. (PC/Mini-Tac) The PC/Mini-Tac can be setup to emulate a conventional exothermic torch kit where the oxygen source and the torch are separated by a 4 foot long length of hose. Ensure the proper regulator spring is in the regulator.

  • Page 25: Ignition System

    PC/MTMOD1 MINI-TAC CONVENTIONAL MODE COMPONENTS WARNING Regulators may fail when pressurized. Never stand directly in front of the regulator while opening the oxygen cylinder valve. Always point the PC/Mini-Tac regulator away from the operator and other bystanders when opening the oxygen cylinder valve. Always open the oxygen cylinder valve slowly.
  • Page 26 Never use the battery while the battery charger is plugged into an AC outlet. 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 27: Leather Shield

    CHAPTER 2- PREPARATION (cont.) Section IV. ACCESSORY EQUIPMENT 2-7. 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. WARNING 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 28 Ensure the 3/8" collet is in the torch assembly. Loosen the collet nut one-half turn. Insert the end of the rod extender into the collet until it is firmly seated against the collet washer. Tighten the collet nut to lock the rod extender in place. Check for oxygen leaks at the collet nut.
  • Page 29 2-10. RAPIDFIRE CUTTING ROD IGNITERS. RapidFire cutting rod ignition cartridges are used to light the cutting rods without the need for a battery, striker plate, and related cables. RapidFire cutting rod ignition cartridges contain a material which when exposed to pure oxygen near instantaneously heats to incandescence, in turn causing the cutting rod tip to quickly ignite.

  • Page 30: Chapter 3 Operating Instructions

    CHAPTER 3 OPERATING INSTRUCTIONS Section I. INTRODUCTION WARNING Never operate the torch without protective safety gear nor without the leather shield in place. Always protect yourself from spark and splatter burns. Prime-Cut Tactical Torch Kits operate at a temperature of approximately 10,000 degrees Fahrenheit, enabling them to cut or melt almost any known material.

  • Page 31: Rod Insertion

    CHAPTER 3- OPERATING INSTRUCTIONS (cont.) NOTE 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 32 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 33: Igniting The Rod (Pc/Tac)

    3-3. IGNITING THE CUTTING ROD. (PC/TAC) WARNING 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 34 3-3-2. Ignition using RapidFire cutting rod igniter - Land Environment. WARNING Do not depress the oxygen control lever until the internal igniter seal has been penetrated by the rod (when on dry land). Do not apply too much oxygen or excessive sparks and/or spray may result. Do not remove the safety clip from the rod igniter until the igniter has been placed on the rod tip and the operator is ready to initiate cutting.

  • Page 35: Ignition Using The Rapidfire Cutting Rod Igniter- Underwater

    Depress the oxygen control lever to introduce the light flow of oxygen into the rod igniter. Hold the rod tip in the molten puddle which forms (approximately 4-5 seconds). Sparkling indicates rod ignition. Keeping the oxygen control lever depressed, raise the rod to the work piece/target material and fully open the plug valve to commence cutting.
  • Page 36 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.

  • Page 37: Igniting The Rod (Pc/Mini-Tac)

    3-4. IGNITING THE CUTTING ROD. (PC/Mini-Tac) 3-4-1. Ignition using the dual pole striker plate. WARNING Always hold the dual pole striker plate by the handle to avoid electric shock. Never touch the copper plates. Avoid prolonged contact between the cutting rod and the copper plates. Damage to the battery may result.

  • Page 38: Ignition Using The Rapidfire Cutting Rod Igniter- Conventional

    Do not depress the oxygen control lever until the internal igniter seal has been penetrated by the rod (when on dry land). Do not apply too much oxygen or excessive sparks and/or spray may result. Do not remove the safety clip from the rod igniter until the igniter has been placed on the rod tip and the operator is ready to initiate cutting.

  • Page 39: Ignition Using The Rapidfire Cutting Rod Igniter- Underwater

    WARNING Do not depress the oxygen control lever until the internal igniter seal has been penetrated by the rod (when on dry land). Do not apply too much oxygen or excessive sparks and/or spray may result. Do not remove the safety clip from the rod igniter until the igniter has been placed on the rod tip and the operator is ready to initiate cutting.
  • Page 40 Although a self-heating material, the ingredients within the rod igniter are not violently reactive with air. A strong oxidizer is required to achieve good combustion. Prolonged contact with water will cause the material within the igniter to become inert. Do not raise the rod from the ignition point until ignition has been achieved. Ignition is more efficient if a molten puddle is allowed to form around the tip of the rod.

  • Page 41: Operating Techniques

    3-5. OPERATING TECHNIQUES. WARNING Never let the cutting rod burn down into the torch. Always release the torch oxygen control lever to extinguish the torch while there is at least two inches of rod remaining. 3-5-1. Piercing. A pierce is accomplished by holding the torch with the rod at a 90 degree angle (perpendicular) to the pierce point.
  • Page 42 CAUTION 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 43 PULL TO CUT. MAINTAIN CONTACT BETWEEN ROD AND TARGET (DRAG). SLAG SPRAY ANGLE DURING CUTTING.

  • Page 44: Gouging

    3-5-3. Gouging. Gouging is conducted by holding the rod at a slight angle to the target material and pushing into the direction of the desired gouge. Comply with the following steps. WARNING Always wear adequate protective clothing and eye and face protection. Exercise extreme caution. PUSH TO GOUGE.

  • Page 45: Shutdown Procedures (Pc/Tac)

    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 46: Shutdown Procedures (Pc/Mini-Tac)

    NOTE Always replace any damaged or worn parts with factory replacement parts. Always inspect the cables and hoses for cuts, burns, or any other signs of damage or wear. m. Charge the lightweight battery. Store the cutting torch kit in a clean, dry place. 3-8.

  • Page 47: Battery Charging Instructions

    NOTE Battery chargers supplied with Broco Prime-Cut Tactical cutting torch kits may be either 110 volt or 220 volt input. Ensure the proper charger is being used to suit local standards. Pin adapters are available to configure the 220 volt battery charger to local requirements.

  • Page 48: Charging The 12-Volt/24-Volt Vehicle Battery

    CHARGING THE PC/BISLW. 3-9-2. Charging the 12-Volt/24-Volt Vehicle Battery. WARNING Always disconnect torch and striker plate power cables prior to charging the battery. Working in vicinity of a lead-acid battery is dangerous. Batteries generate explosive gases during normal battery operation and there is a risk of these gases exploding. Never smoke or allow a spark or flame in the immediate vicinity of the battery to reduce the risk of battery explosion.
  • Page 49 Always check the manufacturer’s working pressure of the cylinder to be filled, and the stamped safety device on the cylinder valve to ensure the cylinder will not be overfilled. NOTE When transfilling cylinders the resulting pressure in both cylinders can be determined by … Transfill procedures: Ensure that the transfill hose, adapters, cylinder valves, tools and any other items to be used are clean and free from oil, grease or other contaminants.

  • Page 50: 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 51 Any torch, rod or igniter which has become wet must be completely dry before being placed into long term storage. Flush the interior with oxygen, argon, or nitrogen gas to displace residual moisture. Preventive maintenance for the striker plate will include the following: WARNING Disconnect the striker plate power cable from the battery prior to cleaning the striker plate surface.

  • Page 52: 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 53 Collet Nut Check for dents or other damage. Inspect the serviceability of the threading. Collet (3/16”, 1/2”, 3/8" Ensure proper functioning. Test with rod to ensure proper fit. Inspect for and 1/4") cracks, bends, other damage. Replace as necessary. Collet Washer Inspect for cuts, excessive wear, or any other damage.

  • Page 54: Rod Extender

    Back Harness Assembly: Clean with oil-free cloth/rags and oil-free brushes. If extremely dirty, clean with warm soapy water, rinse with clean fresh water, and air dry. Confirm the serviceability of the straps, buckles, and fasteners. SCUBA Backpack Check for wear and other damage. Inspect serviceability. Backpack Pad Inspect the serviceability / check for damage.

  • Page 55: Chapter 5 Troubleshooting

    CHAPTER 5 TROUBLESHOOTING NOTE 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 56: Uneven Oxygen Flow

    The valve stem washer 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...

  • Page 57: Section Ii. Cutting Rod 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 58: Chapter 6 Corrective Maintenance

    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 Tactical torch systems CONTACT BROCO, INC. AT (800) 845-7259, (909) 483 3222 OR BY FAX (909) 483 3233 BEFORE PROCEEDING.
  • Page 59 CAUTION 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.

  • Page 60: Oxygen Control Valve

    6-3. OXYGEN CONTROL VALVE CAUTION The oxygen control valve is disassembled as part of a major overhaul of the torch kit system, when damaged, when obstructed, or when an oxygen leak is detected. During the normal course of operations it should not be necessary to disassemble the oxygen control valve. The repair procedure calls for securing brass/aluminum components in a vise.
  • Page 61 OXYGEN CONTROL VALVE COMPONENTS. Reassembly. If the valve stem o-ring is to be replaced, secure the valve stem with the rounded end exposed. Cut the old o-ring off the valve stem. Apply a light coating of silicone lubricant to the rounded end of the valve stem.

  • Page 62: Oxygen Control Valve Assembly Leak Testing Procedure

    6-4. OXYGEN CONTROL VALVE ASSEMBLY LEAK TESTING PROCEDURE. Connect one end of the oxygen to the torch assembly and connect the other end of the oxygen hose to a regulated oxygen source. Set the oxygen delivery pressure to 100 psi. Fill a tank or tub with enough fresh water to submerge the torch assembly.

  • Page 63: Striker Plate Assembly

    6-5. STRIKER PLATE ASSEMBLY. General. 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. After each use, wipe the striker plate assembly and cable with a clean, dry, oil-free cloth. WARNING Always disconnect the striker plate power cable from the battery prior to disassembly or cleaning the striker plate surface.
  • Page 64 Inspection. Ensure the striker plate power cable and the wire terminal lug is free of cuts and is not frayed. Repair or replace as required. Ensure the two nylon screws, two brass nuts and two brass screws are present and properly tighten.

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