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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 [email protected]

www.brocoinc.com

Aug.’99 ed.

Содержание PRIME-CUT PC/MINI-TAC

Страница 1: ...ITS 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...

Страница 2: ...ING TORCH SYSTEM Chapter 2 PREPARATION Section I SETUP PROCEDURES 2 1 PREPARING THE WORK AREA 2 2 PRE ASSEMBLY INSPECTION Section II PC TAC ASSEMBLY PROCEDURES 2 3 OXYGEN SYSTEM 2 4 IGNITION SYSTEM 2...

Страница 3: ...g rod igniter Handheld configuration 3 4 3 Ignition using the RapidFire cutting rod igniter Conventional configuration 3 4 4 Ignition using the RapidFire cutting rod igniter Underwater 3 5 OPERATING T...

Страница 4: ...3 COLLET PROBLEMS Section III VALVE STEM MALFUNCTIONS 5 4 BENT CONTROL VALVE WORN PARTS Chapter 6 CORRECTIVE MAINTENANCE Section I INTRODUCTION 6 1 GENERAL Section II ADJUSTMENTS ALIGNMENTS AND REPAIR...

Страница 5: ...e the user to make the best decisions concerning the deployment of thermal breaching equipment and its subsequent use 1 2 PRIME CUT TACTICAL TORCH KITS Broco is the leading manufacturer of self contai...

Страница 6: ...nders c The operator and all bystanders must always wear adequate protective flame and or spark resistant clothing footwear and gloves when using this system d Never operate this equipment without pro...

Страница 7: ...lways ensure the correct over pressure safety relief device is installed in the high pressure cylinder valve Never use a safety relief device whose burst pressure is higher than that recommended by th...

Страница 8: ...4 and one 3 8 collet b 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 Stan...

Страница 9: ...n foot hose Both are fitted with brass quick connect ends The five foot hose enables the operator to freely use the torch system in the backpack configuration The additional hose may be combined if th...

Страница 10: ...ong cable is fitted with a set of electrical quick connects allowing it to be shortened to 5 long for use in a back packed mode 3 Torch Power Cable The Torch Power cable has electrical quick connects...

Страница 11: ...included with each kit consists of welder s gloves and two pairs of safety glasses with number 5 lenses WELDER S GLOVES SAFETY GLASSES PC LWB LIGHTWEIGHT BACKPACK Never operate this equipment without...

Страница 12: ...er 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 c Oxygen Supply System The Oxygen 02 Su...

Страница 13: ...triker plate assembly A dead short spark is all that is necessary for igniting the cutting rod 2 Dual Pole Striker Plate Assembly The Dual Pole Striker Plate Assembly consists of a handle two copper g...

Страница 14: ...of safety glasses with number 5 lenses WELDER S GLOVES TINTED SAFETY GLASSES Never operate this equipment without proper face and eye protection Always use a number 5 or 6 shade filter lens h Componen...

Страница 15: ...know the material previously contained therein Always thoroughly purge pipelines and containers with an inert gas such as nitrogen or argon prior to cutting f Ensure that falling material molten meta...

Страница 16: ...must undergo internal visual inspection annually and pass hydrostatic testing every three years Always ensure the cylinder to be used is marked with a sticker showing a valid inspection certification...

Страница 17: ...grease oil or other contaminant on these items d Ensuring that the oxygen is turned off place the oxygen cylinder into the back harness assembly 1 The oxygen cylinder will be in an up right position...

Страница 18: ...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 whe...

Страница 19: ...ontinuously contacts the work area Exercise caution to prevent complete discharge of the battery The battery should never be left in a total discharged state for an extended period of time Damage coul...

Страница 20: ...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...

Страница 21: ...ce 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 tur...

Страница 22: ...quired to comply with current inspection and testing requirements Cylinders must undergo internal visual inspection annually and pass hydrostatic testing every three years Always ensure the cylinder t...

Страница 23: ...trol lever is positioned correctly i e short side contacting valve stem long side parallel to cylinder To change remove the quick release pin turn the lever around replace the pin Regulators may fail...

Страница 24: ...gulator spring 4 Install the replacement regulator spring Place cap back into position and thread clockwise until hand tight Snug with a tool Be careful not to over tighten b Ensure that the oxygen is...

Страница 25: ...n control lever on the torch assembly to verify proper functioning i e not sticking no obstructions etc j Close the oxygen cylinder valve 2 6 IGNITION SYSTEM PC Mini Tac Always use a 12 volt DC igniti...

Страница 26: ...a Lightweight Battery The Lightweight Battery PC BISLW contains a rechargeable 12 volt sealed lead acid gel type battery It can be stored in any position b Dual Pole Striker Plate The battery provides...

Страница 27: ...8 FANNY PACK PC Mini Tac The Fanny pack is used for carrying the PC Mini Tac in either handheld or conventional mode It is sized to accommodate the oxygen cylinder with the regulator attached A packet...

Страница 28: ...he appropriate size to properly fit the rod being used To replace the collet remove the collet nut and collet from the rod extender Make sure the appropriate size collet washer is in place Insert the...

Страница 29: ...erial be exposed to air the strips can be inerted by the application of water carbon dioxide CO2 or foam Material will self inert in air over a time of approximately 30 45 minutes b Packaging RapidFir...

Страница 30: ...en 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...

Страница 31: ...ith 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 int...

Страница 32: ...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...

Страница 33: ...rol 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 r...

Страница 34: ...en flowing when the igniter seal is first broken Too rapid a reaction will result Do not raise the rod from the ignition point until complete ignition has been achieved Ignition is more efficient if a...

Страница 35: ...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...

Страница 36: ...ten puddle which forms approximately 4 5 seconds Sparkling indicates rod ignition h Keeping the oxygen control lever depressed fully open the plug valve Raise the cutting rod to the work piece target...

Страница 37: ...n contact with the side of the rod and the lower plate in contact with the tip of the cutting rod d Hold the rod at a 60 to 90 degree angle to the bottom plate and slowly rotate the rod against the pl...

Страница 38: ...gnition has been achieved Ignition is more efficient if a molten puddle is allowed to form around the tip of the rod a Place the cutting rod igniter on the cutting rod and press gently until the rod i...

Страница 39: ...cutting rod and press gently until the rod is seated within both igniter alignment bushings and is against the safety clip c Remove the safety clip by pulling on the attached cord d With the operator...

Страница 40: ...the cutting rod and press gently until the rod is seated within both igniter alignment bushings and is against the safety clip b Remove the safety clip by pulling on the attached cord c Pace the botto...

Страница 41: ...ercing 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...

Страница 42: ...he 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 pro...

Страница 43: ...PULL TO CUT MAINTAIN CONTACT BETWEEN ROD AND TARGET DRAG SLAG SPRAY ANGLE DURING CUTTING...

Страница 44: ...od 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 bl...

Страница 45: ...lose 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...

Страница 46: ...de Disconnect and remove the oxygen hose from the torch assembly at the quick disconnect fitting Disconnect and remove the oxygen hose from the regulator at the quick disconnect fitting e Handheld mod...

Страница 47: ...use recharge at least every three months Do not leave the Lightweight Battery on charge for more than 72 hours Damage to the battery may result Battery chargers supplied with Broco Prime Cut Tactical...

Страница 48: ...p 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 Ne...

Страница 49: ...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 Turn the valve handle 1 4 tur...

Страница 50: ...ed to wash components Never use compressed air to purge any part of the oxygen system as oil contamination may result Always use oxygen Always replace any worn or damaged parts with authorized replace...

Страница 51: ...the striker plate cable assembly with a clean dry oil free cloth Inspect for damaged parts and replace or repair as necessary i Recharge the battery as needed j Oxygen cylinder maintenance 1 Inspect a...

Страница 52: ...Regulator Body Adapters Check for nicks dents or other damage Soft Tip Nipple Check for nicks gouges excessive wear or other damage that may cause leaks Valve Nut Ensure proper functioning Hand tight...

Страница 53: ...ge Replace o rings or plug insert as necessary Male Quick Connect Inspect for dents bends or other damage Check for correct seating and locking with the oxygen hose assemblies Cable Power 15 feet w Co...

Страница 54: ...sure proper functioning Inspect for bends wear and or other damage Check the serviceability of the collet collet nut and threading Case Inspect for dents cracks holes or other damage Make sure all sec...

Страница 55: ...worn c The valve stem washer is dirty or worn d The valve stem is worn 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 coll...

Страница 56: ...dirty or worn 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 describe...

Страница 57: ...en 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 Mal...

Страница 58: ...perform work on high pressure oxygen cylinders and oxygen cylinder valves The composite cylinders included with these kits must be inspected and hydrostatic tested every three years The maximum servi...

Страница 59: ...on 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...

Страница 60: ...alve nut facing up The valve spring is under tension and may cause an uncontrolled separation of the control valve nut from the torch body Use caution to avoid damaging the valve nut gasket 3 Using a...

Страница 61: ...alve stem 3 Press the valve stem assembly into the rear of the control valve nut with a rotating motion 4 Attach the valve stem spring to the rear of the valve stem 5 If the valve nut gasket is to be...

Страница 62: ...valve d Depress and release the oxygen control lever three or four times Ensure the torch appears to be working correctly e Completely submerge the torch assembly in the water Inspect around the valv...

Страница 63: ...1 Ensure the striker plate power cable is not connected to the battery 2 Using a flat tip screwdriver remove the two nylon screws from the striker plate handle 3 Grasp the copper striker plate and sl...

Страница 64: ...the groove in the wooden insulator 2 Insert the copper striker plate into the groove in the wooden insulator taking care to overlap the wire terminal lug with the copper striker plate Align these par...

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