Broco BR-22 User manual

BROCO UNDERWATER
Underwater Cutting Products 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: [phone], fax [phone], 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. [phone]
"Consensus Standards for Commercial Diving", published by the Association of Diving Contractors International, Inc., 5606 FM, 1960 West, Suite 202, Houston, TX 77069, Tel. [phone].
OSHA Safety and Health Standards "29 CFR 1910" available from the U.S. Department of Labor, Washington, D.C. 20210, Tel. [phone].
To avoid serious injury or death, follow the safety in-
formation in this section a
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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.
CUTTING EQUIPMENT
To avoid serious injury or death, follow the safety
information in this section regarding topside safety
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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.
TOPSIDE (AT SURFACE)
. . .continued
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.)
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.

To replace the collet:
• Remove the collet nut and collet from the torch.
• Make sure the neoprene collet washer is in place.
• Insert the desired collet and replace the collet nut.
D. Welding power source is DC output.
E. Diver is equipped with proper diving dress and life support equip-
ment in good condition. Rubber "linesman" gloves must be worn
in addition to other gloves the diver may have.
F. Appropriate eye protection is attached to the diver's faceplate. Use
an approved welding lens. A minimum #4 shade is usually sug-
gested for muddy water, #6 shade for average conditions and #8
shade or above for clear water, however the diver must use his best
judgment as experience and conditions dictate.
Note: Set the welding power source to 150 amps delivered to the torch; and the
oxygen regulator delivery pressure to 90 psig over ambient pressure at depth.
2. Make sure the supply valve, regulator, hose and torch are clean and
free of any grease, oil or particles. Purge the oxygen cylinder valve by
opening it and then closing it. Attach the oxygen regulator to the oxy-
gen supply and purge the oxygen cylinder valve by opening and closing
it. Attach the oxygen supply hose to the regulator outlet. Make sure the
supply valve, regulator, hose and torch are clean and free of any
grease, oil or particles. Purge the regulator and hose with oxygen to
clear any obstructions.
3. Attach the torch to the oxygen supply hose.
4. Set the regulator delivery pressure to 90 psig over the ambient bottom
pressure or other pressure which may be required due to depth or nature
of operation. Regulator delivery pressure must be increased with increased
working depth. (See Table 1 - "Setting Oxygen Delivery Pressure for Depth.")
5. Purge the torch. Check fittings, connections and the torch for leaks
using soap suds.
6. Attach the safety knife switch to the torch power lead. Attach the other
end of the torch power lead to the torch cable. Attach a cable from the
welding power source negative terminal to the safety knife switch. En-
sure the safety knife switch is positioned within reach of the tender.
The safety knife switch is activated only upon command from the diver.
7. Wrap all cable-to-cable connections with rubber strips and electrical tape.
8. Attach the ground cable to the welding power source positive terminal.
Attach the other end of the ground cable to the ground clamp.
9. With the safety knife switch in the open position, start the welding
power source and set output for 150 amps maximum at the rod tip.
(See Table 2 "Setting Amperage for Cable Length and Size.")
10. Check polarity by immersing the rod tip and ground clamp in a bucket of
salt water approximately 2" apart. Energize the rod by closing the safety
knife switch. A stream of bubbles should rise from the rod tip. If not, re-
verse the polarity and retest.
11. Check amperage using a clamp-on or in-line gauge. Do not rely on
dial indicators on the welding power source.
UNDERWATER GAS/EXPLOSION DANGERS
To avoid serious injury or death, follow the safety in-
formation in this section regarding gas/explosion dangers
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sections.
Underwater cutting can lead to a buildup of potentially explosive
gas mixtures that may be ignited by a spark from a cutting rod. Al-
ways flood area with an inert gas (such as argon or nitrogen) before
cutting and/or vent the area by drilling holes behind and above the
cut to allow the escape of gases generated during cutting.
To avoid explosions caused by cutting into chambers or other
areas filled with gas, check what is behind the material being cut.
If there is a possibility that there is gas, flood area with an inert gas
or vent the area by drilling holes to provide for the escape of gases.
When melting concrete ensure entry hole is large enough to
allow venting of all gases in and above work area.
Cutting where there is a pressure differential – either blowing
out or sucking in – can cause an explosion and injuries to extrem-
ities. Drill a hole and wait for pressure to equalize.
Oxygen and hydrogen trapped in mud can cause an explosion.
Before cutting below the mudline, jet and airlift or pump the mud
from behind the cut.
To avoid serious injury or death, follow the safety in-
formation in this section regarding diver safety in underwater op-
erations
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sections.
For the diver’s safety, never conduct underwater cutting or weld-
ing operations without a topside tender to monitor the diving op-
eration and a standby diver for emergency response.
To avoid burns, diver’s hands should not be closer than 4-
inches from the electrode tip.
Using SCUBA breathing apparatus while performing underwa-
ter cutting or welding can result in electric shock and does not
allow for communications with the topside tender. Always use
surface supplied breathing air and hard-wire communications.
DO NOT use life support equipment that has been modified from
the manufacturer's original specifications.
Failure to wear protective clothing while cutting can result in
electrical shock. Divers must wear full wet or dry suits and rubber
electrical insulating gloves (in good condition) to insulate their
bodies and hands.
A diver is at risk of severe electrical shock when cutting while
only partially immersed in water. This splash zone is the most haz-
ardous location where divers work. Always wear full wet or dry suit,
rubber insulating gloves, appropriate eye protection, and dive hel-
met when working in the spash zone.
To prevent damage to the diver’s life support equipment, seri-
ous injury or death, DO NOT touch the cutting rod to any metal on
the diver's helmet, dress or equipment including any part of the
diver’s body, hoses, cables and compressed gas cylinders.
Wearing improper eyewear during underwater cutting can result
in vision damage. DO NOT use cutting equipment without using
an approved welding lens with a shade appropriate for the condi-
tions of the water.
Material may fall and injure the diver. Always be aware of the
environment around you and position yourself and your life sup-
port equipment away from falling debris.
If a diver's body comes between the cutting rod and the ground,
the diver may become part of the electrical circuit and risk electro-
cution. Always face your ground and DO NOT turn your back to the
ground connection.
Oxygen pops can disintegrate the flash arrester and screen and
cause serious injury to torch user. If diver feels an oxygen pop strong
enough to move his hands or arms back, stop work immediately and
bring torch topside to have flash arrester and screen checked.
Failure to securely tighten collet nut may cause arcing and pos-
sible flashback and result in serious injury or death. Tighten the
collet nut securely. If there is a loose connection between the rod
and collet nut, oxygen bubbles may escape from the collet nut
when operating torch. If bubbles escape, remove and reinsert the
rod against the collet washer. If bubbles continue to escape, stop
using the torch immediately and have it repaired.
UNDERWATER OPERATIONS
Explosive gases can accumulate within an energized
underwater cutting rod. DO NOT energize a cutting rod until ready to
initiate underwater cutting. Purge the cutting rod with oxygen by
squeezing and holding the oxygen lever for at least four seconds with
the rod in cutting position prior to energizing the cutting rod and ini-
tiating the arc.
UNDERWATER GAS/EXPLOSION DANGERS CONT. TOPSIDE (AT SURFACE) CONT.
. . .continued
. . .continued

UNDERWATER OPERATIONS CONT.
Note: Broco Underwater Ultrathermic cutting rods will continue to burn as long
as the oxygen flow is maintained, even with the power off. The oxygen lever
must be released to extinguish the cutting rod.
1. Ensure the safety knife switch is in the open position and the welding ma-
chine is turned off prior to securing the ground clamp to the workpiece as
close to the area to be cut as possible. Ensure the ground clamp is away
from the diver as he proceeds to cut.
2. Check that the oxygen delivery pressure is correctly set by squeezing the
torch lever to release a stream of oxygen. A 6” jet of oxygen should issue
from the cutting rod tip.
3. Loosen the torch collet nut 1/2 turn.
4. Insert the end of the Broco Underwater Ultrathermic cutting rod that has the
recessed internal wires into the collet opening until it bottoms on the collet
washer.
5. Tighten the collet nut to lock the rod in place.
6. Check for oxygen leaks at the collet nut and around the collet by squeezing
the oxygen lever. If a leak exists: make sure the rod is firmly seated on the
collet washer; inspect the rod for damage; inspect the collet washer for
damage and replace if necessary.
7. Place the tip of the rod against the work at the point where the cut is to be
initiated and squeeze the oxygen lever for four seconds to purge the rod
and torch.
8. With the oxygen still flowing call for the current to be switched on. The ten-
der will close the safety knife switch.
9. Draw the tip of the cutting rod across the work to strike the arc.
10. Once the arc is struck and the rod ignited, pull (drag) the cutting rod along
the line to be cut. The angle of the rod to the work should be between 30
and 90 degrees, depending on the metal thickness.
11. Maintain pressure to keep the rod against the work. Keep the tip of the rod
in the puddle at all times. Move slowly at first, making sure full penetration
is achieved. As cutting speed is increased, back spray and increased cut-
ting noise will indicate insufficient penetration.
Note: Do not try to hold an "arc". Keep the tip of the burning rod in direct con-
tact with the target material at all times. Hold the rod "like a pool cue" with
your free hand approximately 4" from the rod tip for a more stable cut. Keep
moving the hand back as the rod consumes.
12. When the rod has burned to within approximately 3" of the torch collet nut
call for the current to be switched off.
13. Lift the rod from the work and release the oxygen lever to extinguish the
cutting rod.
14. After the tender has confirmed the current is off, loosen the collet nut 1/2
turn and remove rod stub from the torch.
15. Insert a new cutting rod and repeat the process until the cut is complete.
Note: When cutting or melting non-conductive materials such as concrete,
rock, coral, mastic, rope or marine growth, a striker plate (consisting of a steel
or copper plate connected to the ground cable) is necessary to initiate the
arc and light the rod. Once the rod is ignited, maintain the oxygen flow and
bring the rod into contact with the target material.
Table #1
Setting Oxygen Delivery Pressure for Depth
Depth Pressure Gauge Setting
ft m psig kpa
33 10 108 7.4
40 12 112 7.6
60 18 123 8.4
80 24 134 9.1
100 30 145 9.9
120 37 155 10.5
140 43 166 11.3
160 49 177 12.0
180 55 188 12.8
200 61 199 13.5
220 67 210 14.3
240 73 221 15.0
260 79 232 15.8
280 85 243 16.5
Calculate regulator gauge pressure setting as follows:
For every 10' of hose required, add 1 psig to the 90 psig necessary at the
tip. This compensates for frictional line losses. Additionally, add 0.445 psig
for every foot of working depth.
Table #2
Setting Amperage for Cable Length and Size*
Length of Power Cable Amperage setting
(supply to work distance) for Cable Size
ft m # 1/0 #2/0 #3/0
150 46 155 152 150
200 61 157 154 152
250 76 159 156 154
300 91 161 158 156
350 107 163 160 158
400 122 165 162 160
450 137 167 164 162
500 152 169 166 164
*The increases in amperage compensate for resistance losses. For greater
lead lengths, add 2 amperes per fifty feet to settings.
TROUBLESHOOTING
Broco Underwater Ultrathermic cutting rods are different from steel tubu-
lar cutting rods in that Broco Underwater Ultrathermic cutting rods require
higher oxygen flow and lower amperage. Additionally Broco Underwater
Ultrathermic cutting rods require direct contact with the work, not main-
tenance of an arc. Most operational problems stem from operators using
steel tubular cutting rods' setup and cutting techniques.
Oxygen supply problems:
1. Efficient cutting with Broco Underwater Ultrathermic cutting rods relies
on high volume unobstructed oxygen flow. With inadequate oxygen
flow, the rod can burn without significantly affecting the work.
Symptoms include: the rod burning longer than 60 seconds of contin-
uous use; cuts of less than 12" in 1/2" thick steel plate; and an oxygen
jet of less than 6" length underwater.
Solutions:
A. Ensure that a high volume two-stage oxygen regulator and 3/8" oxy-
gen hose are being used.
B. Ensure that the hose is not kinked, pinched or obstructed.
C. Ensure that the oxygen cylinder valve (valves if using a manifold sys-
tem) are fully opened.
. . .continued

SURFACEPRACTICEFORNEWUSERS
If you are a new cutting torch user, to avoid serious
injury or death, follow the safety information in this section regard-
ing surface practice for new users
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sections.
Fumes from burning tape can cause respiratory injury. Always re-
move the tape insulation from underwater cutting rods before burn-
ing at the surface and keep your head away from the fume plume.
Cutting torches can cause burn injuries. Always wear adequate
protective clothing, welder's gloves, and face and eye protection
specifically designed for burning (use a #6 welding lens if using a
battery and a #10 with a welding machine).
1. Cutting with Broco Underwater Ultrathermic cutting rods requires prac-
tice. A diver with surface arc welding or cutting qualifications will get ex-
cellent results underwater in a short time.
2. Burning at least three or four rods on the surface before attempting to
cut underwater is essential to gaining maximum proficiency with the
Broco Underwater Ultrathermic cutting system.
3. Do not try to "maintain an arc." Instead practice metal to metal contact,
keeping the rod tip in the molten puddle, and adjusting travel speed to
ensure complete penetration.
TECHNIQUES
Note: Continuous power is recommended for cutting with the 1/4" diam-
eter Broco Underwater Ultrathermic cutting rod, otherwise it is difficult to
maintain ignition.
Cutting Steel
The 1/4" diameter Broco Underwater Ultrathermic cutting rod may be used
for cutting steel up to 1/2" in thickness for maximum cutting economy. The
1/4" rod leaves a narrow kerf and is preferable for fine cutting.
In bad visibility or for thicker steels, the 3/8" diameter cutting rod will give
better production. For materials 1/2" thick or thicker, the 3/8" rod is prefer-
able. For metal several inches thick, employ saw and wedge cutting (anal-
ogous to chopping wood) to achieve full penetration.
Broco, Inc.
10868 Bell Court
Rancho Cucamonga, CA 91730 USA
Ph: [phone] [phone] Fax: [phone]
e-mail [email protected]
www.Brocoinc.com
www.strongweldingproducts.com
© Copyright 2007 by Broco, Inc., all rights reserved. Any reproduction
in whole or in part without the express written permission of Broco,
Inc. is expressly prohibited.
2. The Broco Underwater Ultrathermic cutting rod requires oxygen of at
least 99.5% purity to sustain ignition without power. Cutting with con-
tinuous power, a reduction in the purity of the oxygen by 1% can de-
crease cutting efficiency by 25%.
If the rods continuously extinguish underwater, or burn erratically, the
problem is probably poor quality oxygen.
Solution:
A. Obtain a source of oxygen from a different, unrelated supplier.
Note: Since a gas supplier will usually have all his oxygen coming from
one manufacturer, changing cylinders for one filled at the same place or
time will not solve oxygen purity problems, Using oxygen of other manufac-
ture will either solve or rule out an oxygen purity problem.
Power source problems:
1. If the rods consume too quickly, it is likely the welding power source is
delivering greater than 150 amps.
Solution:
A.Use an in-line or clamp type ammeter to verify current output. Adjust
as necessary.
Note: The U.S. Navy Underwater Cutting and Welding Manual, NAVSEA
0929-LP-000-8010, gives estimates for the 3/8" Broco Ultrathermic cut-
ting rod at the high end of these ranges.
Cutting Cast Iron, Stainless Steel and Non-Ferrous Metals
The Broco Underwater Ultrathermic cutting rod will melt all of these ma-
terials. Make sure that the tip is firmly buried in the work. Saw and wedge
cutting may be necessary. Maximum cutting efficiency may be achieved
by burning a series of holes through the piece prior to cutting across it.
Cutting Thick Non-Ferrous Metals
Note: Increase oxygen delivery pressure to 110 psig over ambient pres-
sure for metal over 3" in thickness.
Create a puddle and dip the rod tip slightly below the surface of the
molten metal. From time to time push the cutting rod deeper into the
metal to wash it out and blow the slag away.
Cutting (Melting) Concrete and Rock
Note: Always use the 3/8" diameter Broco Underwater Ultrathermic cut-
ting rod when cutting concrete or rock.
Light the rod by striking the tip against a copper or steel plate attached
to the ground cable. Keep the oxygen lever depressed and raise the rod
from the plate to the workpiece. Call for the current to be switched off.
Press the rod tip into the material to create a molten pool. While melting
through the material, periodically move the rod in and out and around to
enlarge the hole to vent gases and to blow the molten material away.
Cutting Rope and Wood
Light the rod by striking the tip against a copper or steel plate attached
to the ground cable. Keep the oxygen lever depressed and raise the rod
from the plate to the workpiece. Call for the current to be switched off.
Apply firm pressure to the tip to keep the maximum heat in direct contact
with the material to be cut. In ship work, the rod may be angled or bent
up to 90 degrees to prevent damage to the hull, shaft or stern tube. On
wire rope the 1/4" diameter rod may be used for finer cut control. When
using the 1/4” rod, continuous metal to metal contact is necessary to
maintain rod ignition.
Using 3/8" Broco Underwater
Ultrathermic Cutting Rods With a Battery
Note: Use of a battery power source is not recommended for cutting at
depths below 60 fsw.
A vehicle or boat battery (12v or 24v DC) may replace a welding machine
as the ignition power source. The use of a safety knife switch is recom-
mended, although jumper cables may be used as the make/break con-
nection. To preserve battery life, the tender must disconnect the battery
immediately on the diver's command once the rod is ignited.
ROD DIA. PLATE THICKNESS
RANGE OF CUT
PER ROD
1/4”1/4”20”–25”
1/4”1/2”10” – 15”
3/8”1/2”12” – 20”
3/8”1” 9” – 14”
3/8” 11/2” 8” – 12”
"Rule of Thumb" estimates: