Broco PC/A-5V2HR, Operating Instructions And Technical Manual

Page 1: ...OPERATING INSTRUCTIONS AND TECHNICAL MANUAL FOR PRIME CUT ULTRATHERMIC CUTTING SYSTEM ...

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Page 3: ...THE WORK AREA 2 2 PRE ASSEMBLY INSPECTION Section II PC TACMOD1 ASSEMBLY PROCEDURES 2 3 OXYGEN SYSTEM 2 4 IGNITION SYSTEM 2 4 1 Lightweight Battery 2 4 2 Battery Adapter Clamps Section IV ACCESSORIES 2 7 LEATHER SHIELD 2 9 ROD EXTENDER 2 10 RAPIDFIRE CUTTING ROD IGNITORS Chapter 3 OPERATING INSTRUCTIONS Section I INTRODUCTION 3 1 TORCH OPERATION Section lI OPERATING PROCEDURES 3 2 ROD INSERTION 3 ...

Page 4: ...4 1 PREVENTIVE MAINTENANCE Section II SCHEDULED MAINTENANCE 4 2 PREVENTIVE MAINTENANCE PROCEDURES Chapter 5 TROUBLESHOOTING Section I OXYGEN SYSTEM MALFUNCTIONS 5 1 OXYGEN LEAKS 5 2 UNEVEN OXYGEN FLOW Section II VALVE STEM MALFUNCTIONS 5 3 STICKING CONTROL VALVE Section III CUTTING ROD MALFUNCTIONS 5 4 COLLET PROBLEMS Chapter 6 CORRECTIVE MAINTENANCE Section I INTRODUCTION 6 1 GENERAL Section II A...

Page 5: ...s and operating techniques to enable the user to make the best decisions concerning the deployment of thermal cutting equipment and its subsequent use 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 These kits have the capability of quickly burning melting or vaporizing nearly...

Page 6: ... 1 88 Safety in Welding and Cutting standards or similar locally prevailing standards when using this equipment e Never remove cover or alter the warning labels attached to this equipment f All users and their supervisory personnel must read and be thoroughly familiar with these operating instructions prior to using this equipment g Never modify this equipment in any manner or use it in any way no...

Page 7: ...n the oxygen system The oxygen system could become contaminated and cause internal burning in the torch or hose All service on oxygen delivery parts must be performed by a qualified and knowledgeable technician o Never use a high pressure gas cylinder that does not comply with current inspection and testing requirements Always ensure the cylinder is marked with a sticker showing a valid inspection...

Page 8: ...ard 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: ...collet washer and a collet nut The integral plug valve allows the oxygen cylinder to be opened without the oxygen flow entering the torch handle and facilitates the use of the RapidFire cutting rod igniters The torch comes with one 1 4 and one 3 8 collet PCRP 305B 3 8 COLLET KIT PCRP 305A 1 4 COLLET KIT PCRP 305C 1 2 COLLET KIT PC T 5 TORCH W CABLE HOSE PCRP 303 TORCH COLLET NUT b Cutting Rod The ...

Page 10: ...il contamination may result PC TAC R B INDUSTRIAL REGULATOR PRESET W OXYGEN QUICK CONNECT AND HAND TIGHTEN CGA 540 INLET FITTING 2 Oxygen Cylinder The all metal aluminum oxygen cylinder is a seamless aluminum compressed gas cylinder with a 45 cubic foot cu ft capacity at 2200 psi The cylinder is manufactured in compliance with U S Department of Transportation DOT specifications It has a standard o...

Page 11: ...nsists of a replaceable insulated copper grounding plate with battery cable The 5 long cable is fitted with a male Cam Lok electrical quick connect Spare parts are available PC LSH AND LEATHER STRIKER HOLDER PC SP 5 STRIKER PLATE 3 Battery Clamps The battery clamps PC BAK attach to the end of the striker plate cable and torch power cable by means of quick connect fittings allowing the use of stand...

Page 12: ...modate either 18 inch or 36 inch rods Molle straps make for easy attachment to the backpack assembly or other vests or load bearing gear h Extender The cutting rod extender PC TACXT16 included in the torch set extends the reach of the rod 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 ...

Page 13: ...ndustrial oxygen outlet thread M87 1 MEDICAL OXYGEN ADAPTER j Component Case The plastic Pelican case PC C 1650 is foam lined with internal nylon straps to secure the hardware and absorb shock There is a manual pressure relief valve on the front under the handle PC C 1650 PELICAN CASE W STRAPS FOAM Available Separately k Rod Igniter PC RFC 10 The RapidFire cutting rod ignition cartridges are an al...

Page 14: ... such as nitrogen or argon prior to cutting f Ensure that falling material molten metal sparks or severed pieces of target material will not cause injury to operator or bystanders or cause damage to property 2 2 PRE ASSEMBLY INSPECTION Never use any equipment which is unsafe or appears to be unsafe Always replace damaged or worn components to reduce the risk of injury Never operate the torch witho...

Page 15: ...equirements Cylinders must undergo internal visual inspection annually and pass hydrostatic testing every three years composite or five years all metal Always ensure the cylinder to be used is stamped or marked with a sticker showing a valid inspection certification b 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 ac...

Page 16: ...e BR 540 c Attach the other end of the transfill hose assembly to the US standard oxygen cylinder valve outlet connection d Follow transfill instructions detailed elsewhere in this manual d Inspect and wipe clean with a clean dry cloth all fittings hoses and cables Ensure there is no grease oil or other contaminant on these items e Ensuring that the oxygen is turned off place the oxygen cylinder i...

Page 17: ...to the oxygen quick connect coupler on the regulator Route the oxygen hose down along the oxygen cylinder bag Use a keeper clip to h Attach the torch assembly to the oxygen hose by pushing the plug end oxygen quick connect on the torch into the oxygen quick connect coupler on the hose Turn the plug valve to the open position Regulators may fail when pressurized Never stand directly in front of the...

Page 18: ...e 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 Do not submerge the battery in water The battery can discharge if the striker plate continuously contacts the work area Exercis...

Page 19: ...ay 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 and a larger capacity battery 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 2 4 2 Battery Adapter Clamps The battery adap...

Page 20: ...ignition since only a direct short is required to ignite the rod a Connect the 15 foot power cable to the torch by firmly seating the black plug in the hole in the back of the torch assembly then twisting 1 4 turn to lock in place b Connect the other end of the 15 foot power cable to the black battery adapter clamp Firmly seat the black plug into the receptacle then twist 1 4 turn to lock in place...

Page 21: ...c Re insert the collet and screw the collet nut back onto the torch assembly INSTALLING THE LEATHER SHIELD 2 6 ROD EXTENDER The rod extender is used to enable the operator to reach otherwise inaccessible places make better use of existing cover or create a stand off between the torch and the burning rod to avoid excessive splatter when cutting aluminum or piercing a Ensure the collet washer and 3 ...

Page 22: ...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 The rod igniters utilized with the Prime Cut torch contain oxygen reactive material a pyrophoric ...

Page 23: ...gniters 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 d Storage Cutting rod igniters should be stored in the metal pails they are shipped in until they are needed for use Do not store the cutting rod igniters next to flammable liquid e Disposal The reactive...

Page 24: ...lloy rod for fuel When the tip of the burning rod is held on or in close proximity to the target material and the appropriate technique is applied a cut or pierce will result Section II OPERATING PROCEDURES Never operate the Prime Cut torch without proper eye protection Either a helmet with 5 face shield or 5 safety glasses shall be worn when using the tactical torch kits Ultraviolet rays can caus...

Page 25: ...ed with either white washer or black washer b Ensure the plug valve is closed Loosen the collet nut one half turn Do not remove the collet nut c Insert the end of the cutting rod that has the recessed internal wires into the collet until it is firmly seated against the collet washer d While maintaining slight pressure tighten the collet nut to lock the rod in place CUTTING ROD INSERTION e Open the...

Page 26: ... bar in concrete re bar All steel plate mild and high strength to 1 2 thick All steel plate mild and high strength over 1 2 thick to 2 thick All steel plate mild and high strength over 2 thick Aluminum titanium magnesium alloys and other volatile alloys PIERCING Broken bolts to 3 4 diameter Pins and broken bolts 3 4 diameter to 1 1 4 diameter Steel plate less than 6 thick Steel plate greater than ...

Page 27: ...en control lever on the torch assembly d Bring the striker plate 2 into contact with the end of the rod 3 e While holding the rod at a 45 to 90 degree angle to the striker plate slowly and lightly pull the rod across the striker plate surface using a slight back and forth motion The resulting arc will ignite the tip of the rod f Rod sparkling indicates ignition Approximately 2 4 seconds of contact...

Page 28: ...er are not violently reactive with air A strong oxidizer is required to achieve good combustion Water will render the material inert Place the igniter on the rod and break the seal before putting the cutting rod into the torch This makes it easier to impact the igniter against a hard surface to break the internal seal without bending the rod or damaging the collet washer Do not raise the rod from ...

Page 29: ... 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 When using a RapidFire cutting rod ignition cartridge to ignite a cutting rod underwater the oxygen must be flowing...

Page 30: ...wear adequate protective clothing and full face shield Always use the leather shield during piercing operations Blowback is greater when piercing Exercise extreme caution Never touch a used rod the target material or the work surface with a bare hand until it has cooled Always wear welding gloves a With the oxygen control lever slightly depressed light flow of oxygen press the burning tip of the r...

Page 31: ...thinner materials same as diameter of cutting rod being used Following the ignition of a cutting rod it is brought to the work surface that is to be cut The rod is dragged or pulled along the surface in the direction of the desired cut The operator should strive for a proper balance between the speed of the cut and rod consumption When the operator cannot see through the kerf groove or notch made ...

Page 32: ...PULL TO CUT MAINTAIN CONTACT BETWEEN ROD AND TARGET DRAG SLAG SPRAY ANGLE DURING CUTTING ...

Page 33: ...erial will puddle in approximately 1 to 2 seconds Keep the rod at a very slight angle to the work piece and the tip of the rod in the puddle d With the oxygen control lever fully depressed push the rod in the direction of the desired gouge Ensure the tip of the rod does not hang up and burrow into the target material as blowback of sparks splatter will occur e When the gouge is complete lift the r...

Page 34: ...ained 3 6 SHUTDOWN PROCEDURES a Release the oxygen control lever to stop the rod from burning b Loosen the collet nut and remove the rod from the torch assembly then close the oxygen cylinder valve c Depress the oxygen control lever to relieve any pressure from the oxygen hose and the pressure gauge hose Always place a protective cap or piece of tape over the open end of the oxygen hose to prevent...

Page 35: ...STATE NOTE BATTERIES MAY LOSE UP TO 3 OF THEIR CHARGE PER MONTH DURING STORAGE Always disconnect power cables prior to charging the Lightweight 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 t...

Page 36: ... the wall receptacle Unplug the battery charger s black and red electrical connectors from the battery s receptacles e Replace the Lightweight Battery in the cutting kit CHARGING THE PC BISLW 3 7 2 Charging the 12 Volt 24 Volt Vehicle Battery Always disconnect torch and striker plate power cables prior to charging the battery Working in vicinity of a lead acid battery is dangerous Batteries genera...

Page 37: ...mped safety device on the cylinder valve to ensure the cylinder will not be overfilled PC TFHBL TRANSFILL HOSE ASSEMBLY WITH BLEED VALVE AND GAUGE b Transfill procedures 1 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 2 Lay both cylinders on the ground so they can t fall and position them so as ...

Page 38: ...embly bleed valve by turning the knob counter clockwise to relieve pressure from the hose 18 Loosen the connection between the transfill hose and the target cylinder Remove the transfill hose from the target cylinder 19 Remove the transfill hose from the source cylinder 20 Check the pressure in each cylinder using the gauge attached to the regulator Mark cylinder E empty 1 4 1 2 or 3 4 with chalk ...

Page 39: ...ssure read from the regulator adjusting gauge to 60 65 psig iii Release the oxygen lever to stop the flow of oxygen b Industrial type regulator i Use a 9 16 combination wrench to loosen the acorn nut at the back of the regulator body ii Use hex head wrench to turn the socket head adjusting screw at the back of the regulator body Turn it clockwise to increase pressure and counter clockwise to reduc...

Page 40: ...oil contamination may result Always use oxygen Always replace any worn or damaged parts with authorized replacement parts Always use Viton o rings only a After each use wipe the torch assembly striker plate assembly battery oxygen cylinder and regulator with a clean dry oil free cloth b Remove the collet nut collet collet washer flash arrestor and flash arrestor screen Inspect for damage and wear ...

Page 41: ... necessary i Recharge the battery as needed j Oxygen cylinder maintenance 1 Inspect and clean the oxygen cylinder Look for damage to cylinder windings Damaged windings can weaken the cylinder Should damage be visible take the cylinder to a certified technician for testing 2 Attach the regulator and check the cylinder pressure If pressure is below minimum required for anticipated use have the oxyge...

Page 42: ...r Wipe all surfaces with oil free cloth Brush can be used on metal surfaces Regulator Body Fittings Check for nicks dents or other damage Soft Tip Nipple O Ring Check for nicks gouges excessive wear or other damage that may cause leaks Valve Nut Ensure proper functioning Hand tight only Inspect for cracks damaged threads etc Female Quick Disconnect Check for dents or other damage Inspect for obstr...

Page 43: ...he oxygen hose assemblies Cable Power w Connector Wipe all surfaces with an oil flee cloth An oil free brush can be used on metal surfaces CAMLOK Black Check for broken insulator nicks dents bends excessive wear or other damage Ensure proper seating and locking with the receptacles on the torch battery and battery adapter clamp Striker Plate Assembly Wipe all surfaces with an oil free cloth An oil...

Page 44: ...damage Make sure all securing hasps hardware functions properly Rod Quivers Ensure functionality of all snaps buckles fasteners and clips Inspect the stitching as well as for holes and other damage Leather Striker Holder Check for wear and damage Ensure the item is serviceable Leather Shield Check for burns holes damage and or wear Ensure the shield functions properly on torch Replace as required ...

Page 45: ...he valve stem washer is dirty or worn d The valve stem is worn e The valve stem washer Loosen the collet nut 1 2 turn CCW Firmly seat the rod and tighten the collet nut If the leak persists remove the collet nut collet and collet washer Clean or replace the collet washer If the collet washer is worn and a new one is not available and only as a temporary expedient remedy turn the washer over and re...

Page 46: ...orn c The torch is dirty a Follow the flash arrestor inspection replacement procedures to remove the flash arrestor Clean or replace as needed b Remove the flash arrestor screen as described in the repair procedure Clean or replace with a new screen as needed c Remove the flash arrestor and flash arrestor screen as described in the inspection replacement procedure With the torch connected to an ox...

Page 47: ...gen control valve disassembly reassembly procedures to remove and replace the valve stem o ring Section lII CUTTING ROD MALFUNCTIONS 5 4 COLLET PROBLEMS Table 5 4 Troubleshooting Collet Cutting Rod Malfunctions TYPE OF PROBLEM MALFUNCTION PROBABLE CAUSE RECOMMENDED REPAIR PROCEDURES 1 THE CUTTING ROD WILL NOT FIT INTO THE COLLET IN THE TORCH a The wrong size collet is in the torch b The collet in ...

Page 48: ...shall only be conducted by qualified personnel trained and authorized to perform work on high pressure oxygen cylinders and oxygen cylinder valves The oxygen cylinders included with these kits must be inspected regularly and hydrostatic tested every five years Always use a clean dry oil free cloth to wipe any part of the torch kit Mild soap and water may be used to wash components Never use compre...

Page 49: ...pection 1 Inspect the collet nut collet torch assembly and collet washer for damage and or wear Repair or replace as required 2 Inspect the flash arrestor for damage wear and clogging of the ports Clean or replace as required 3 Inspect the flash arrestor screen for damage wear corrosion and or clogging If dirty clean the screen with warm soapy water rinse with fresh water and dry If damaged or cor...