'. .

UNDERWATER BURNING
PROCEDURES

&

SPECIFICATIONS
 TABLE OF CONTENTS

Page

Safety on Deck 1

Safety Underwater 2

Underwater Checklist 3

Cutting Techniques 5

Procedure for Cutting Conductor Strings 6

Broco Literature

Arcair Literature

Tescom Literature
 SAFETY ON D ECK

POTENTIAL PROBLEMS

Electricity

Electric shock can occur anywhere along the cables from the welder to the work including the
hot lead to the knife switch, the burning lead, and the ground lead.

1. Inspect the entire length of all three leads for broken insulation. Repair broken insulation
with electricians tape, rubber tape, or better.

2. Clean and dry knife switch so that current cannot leak across contacts to the diver or up
the handle to the tender.

3. When setting up or moving leads or knife switch, shut down the welder so that the leads
are cold.

Flash

l. When testing the torch on deck, shield eyes from the flash.

Communications

1. Insure good communications with everyone involved before the diver enters the water.

Oxygen

Oxygen bottles are potentially hazardous. They are high pressure vessels and oxygen is
combustible.

1. When handling a bottle, have a cap screwed on tight to prevent the valve from being
broken off or damaged.

2. Oxygen bottles must be secured in a rack to prevent accidental falling or rolling.

3. Determine the pressure by guage the bottle. Do try to calculate pressure by cracking the
valve.

4. Ensure that valve outlet, regulator, and all fittings are grease, dirt, and other forgein
matter.
 SAFETY lJNDER WATER

Gas Explosion

If necessary, drill or bum a vent hole 3 inches above cutting area so that a pocket of gas cannot
build up an ignite.

Mechanical Impact

l. When burning something that may be under stress, secure with Chain or come-a-longs or
wires if possible. Keep clear of possible movement.

Crush

l. Make sure yo u are not in position where cut piece will fall on you.

2. Make sure that torch lead, ground lead, diver's hose and all rigging are free and away
from work.

3. Keep all hoses and leads above work.

Bums

1. Keep hands, feet and body from directly under cut so that molten slag won't fall on you.

Flash

l. Ultraviolet rays are absorbed in 1 1 inches of sea water, but if you are in crystal clear
water and have to put your face close to the arc, a face shield may be needed.

Electricity

I. Wear at least a wet suit jacket and booties.

2. \Vear rubber gloves with no holes in them.

3. \Vear cloth gloves over the rubber gloves to protect them from tearing.

4. Ground your work. Establish an excellent ground electrical connection all the way from
the welder positi ve terminal to a shiney spot on the work that is free of rust and dirt.

S. Make sure all leads are insulated.

2
6. Never get between a "hot" electrode and the work or ground. Yo u could beco me part of
the circuit.

UNDERWATER BURNING CHECK LIST

I. Welding Machine
A. Check oil, water, foe]
B. Machine setting -- large electrode -- straight polarity
C. Check terminals -- ensure that they are clean, tight, and not grounded to
frame or deck.

2. Ground Cable
A. Check for a g'.)od mechanical connection on each end of the ground cable.
B. Check for proper insulation of ground cable. There should be no breaks in the
insulation on the ground cable. If a taped section of the cable is to go in the water.
it should carefolly inspected to ensure that the insulation is adequate.
C. When connecting the ground lead to the work, make sure that the connection is
clean and tight.

3. Load to Knife Switch

A. Check for a good mechanical connection on each end of the lead.
B. Check for proper insulation of the lead.

4. Knife Switch
A. Inspect the knife switch to make sure it is clean and in good operating condition.

5. Torch Lead
A. Check for proper insulation of the torch lead.
B. All cable within ten feet of electrode holder shall be continuous. (i.e. free of
splices)
C. Check for leaks in the oxygen hose.
D. The oxygen hose will be taped to the burning lead at intervals not to exceed 18
inches.
E. Check for a strain relief.

6. Torch Head
A. Remove and inspect collet, lock nut, washer, and flash arrestor.
B. Check function of oxygen valve.
C. Torch may be tested for electrical continuity on the surface providing that no
oxygen is used.
D. Check for adequate oxygen flow.

7. Oxygen

3
 A. Check that oxygen bo tt le is full and the spare oxygen bott les or recidy in case
needed.
B. Adjust regulator on oxygen bottle to the proper pressure setting.

8. Electrodes
A. Ensure that oxygen will pass unrestricted through the electrode.
B. If the ends of the electrodes are dirty or fouled, they should be cleaned.
C. If the insulation on the electrode is damaged, the electrode should be taped with
electrical tape.

ON DECK PREPARATION

1. Diver
A. Make sure above check list is completed.
B. Have burning rods in a secure pouch.
C. Talk to tenders a bo ut how they will send additional rod to yo u.
D. Have a spare washer and collet.
E. Have spare gloves.
F. Have a scraper
G. Have a welding lens. (#4 for murky water, #6 for clear water)

2. Tender
A. Make sure above check list is completed
B. Make sure additional rods, collet, gloves, washer, too ls, etc. are ready to send to
the d iver if needed.
C. Talk to diver a bo ut how he wants ad ditional thing sent down.
D. Check for good communications.
E. If communication with the diver is lost for any length of time during the dive,
make it cold and leave it cold until communications are reestablished.

UNDERWATER PREPARATION

1. Define what is to be burned.

2. Know what you are burning into. ( A pipeline, for example, may have explosive gases in
it.)

3. Check to see if vent ho les are needed.

4. Check polarity at tip of rod.

4
5. [s surface to be burned clean and free of barnacles and heavy rust.

6. Do you need a cutti ng guide, a rope around a pi pe. or a straight edge.

REMEMBER:: OCEANEERING 'S POLICY : SAFETY FIRST

CUTTING TECHNIQUES

I. Tubular Steel Electrode (Sea Cut, Tuff Coat, etc.)

A. 1/4" steel plate (thin plate) 300 amps - 70 degree angle.

B. Yi'' steel plate and thicker (thick plate) 400 amps - 90 degree angle.
C. Pipe 3 00 amps 90 angle.
D. Cast iron and non ferrous metals -- essentially a melting process. 500 amps and
just eno ugh oxygen ro roll the molten metal away from the cut.

2. Ultra therrnic Rod (Broco Rod)

A. 150 amps, 150 PSI oxygen over ambient, 3/8" hose.

B. Drag the rod at a 45 degree angle. This technique appl ies to both thin and thick
metal.

3. Cutting Nonconductive Materials with the Ultra Therrnic Rod

\Vhen preparing to cut or melt a nonconductive material such as concrete, rock, or

coral, a conductive striker plate is required to create an arc.

This plate is a piece of metal connected to the ground cable and placed next to the
work.

\Vhen you "make it hot" and open the oxygen, strike an arc on the striker plate.

When the arc is struck and the oxygen is flowing, the electrode ignites at the tip
and will continue to bum as long as the oxygen feed is maintained.

5
 P ROCED URE FOR CUTTING CONDUCTOR STRINGS

l. EXCAVATION:

Dri ve pi pe should be exposed to minimum depth of I O' below natural bottom or 2 feet
below the proposed lower cut line, whichever is deeper.

The jetted hole should be of sufficient width to reduce the risk of a wall caving in and
allow 3 feet of working room on all sides of the conductor at the bottom.

An airlift should remain positioned in the hole to remove sediment and hel p maintain
visibility at the worksite.

Handjetting equipment should remain at the worksite secured above the hole but readily
accessi ble in case it is needed.

2. DRIVE PIPE:

The upper and lower limits of drive pipe to be removed should be determined by the
depth of damage and/or angle of each conductor below the mudline. Every effort should
be made to remove sufficient drive pipe to expose 8 feet of good casing below any behind
any bend, break, or buckle.

Slings fro n: the main block of the rig crane will be choked around the conductor above
the section to be removed and the load held before any cut are made.

Two or three circumferential cuts, depending on condition of the condition of the

conductor, should be made using ultra-thermic rods. Vent holes will first be drilled at
several locations above each proposed cut. This will Jet the diver know if there is a void
and/or an accumulation of gas between the drive pipe and grout.

Three longitudinal cuts will then be made to split and remove the drive pipe. Burning
will be done in a downhill direction only. Additional vent holes should be cut as the
diver deems necessary to avoid the risk of explosion.

All grout will be removed to completely expose the first casing, and the worksite cleared
of scrap and debris.

3. CASING:

Each casing string will be checked for pressure either at the wellhead or by hot-tapping at
the worksi te prior to cutti ng.

6
Oxy-arc type cutti ng rods will be used exclusively for all required burni ng on the casing
strings. Divers are to use a shallow rod angle and extreme caution to avo id damaging
other casing or tu bing. Speed is NOT of the essence.

The first cut on each casing will be made as close to the top of the exposed wi ndow as
possible using a Port-a-Lathe cutter. This should eliminate any chance of damage at the
cut location as well as at the bottom of the window in the event that any movement
occurs.

A second Port-a-Lathe cut will be made at the very bottom of the window to free a sleeve
of the casing. lf divers are unable to move the sleeve, a third mechanical cut may be
required to facilitate removal of a narrow ring of casing.

The resulting casing sleeve will then be forced to one side and wedged in position to
ensure maximum separation from the internal casing or tubing. Separation will be
measured at both ends of the sleeve and the proposed cut line clearly marked with a paint
stick.

The need for a vent hole at the top of the casing will be determined by the angle and
condition of the cond uctor. lf a vent is deemed advisable, separation from the inner
casing must first be measured by drilling and probing the annulus.

The longitudinal cuts will be made using oxy-arc burning rods. The diver will probe his
cut after each rod to ensure no movement has taken place and adequate separation exists.

When the first cut is complete, the sleeve will be rotated 1 80 degrees and a second cut
made using the same procedure.

After the sleeve has been removed, addit ional casing can be trimmed off above and below
the mechanical cuts as required. Before trimming, the next casing string must be checked
for pressure and the question of adeq uate vents re-evaluated relative to condition of the
casing.

During the course of any burning operation, if the diver is not completely comfortable
with the separation between casing strings, he is to stop work and advise topside. If
adequate separation cannot be attained, rubber gasket material will be used to protect the
internal casing or tubing.

7
 2824 No rth Locust Aven ue, R ia l to, Ca l i fo rn ia 92376
Cutting With BR OCO
Virtually atl metals and other ma1erials can be cut. burned,
pierced or melted w!fh !he Broce sys1em.
Broce cuts all. inc.1.Jding the cosis of cu'ning.
The Broce System:
Made by divers for divers. the Brcco sysiem ma:omizes
diver"s performance. salery and ease al use. The system
consis \s of a series of com9onen1s. from the oxygen bor tle to
the workpiece.
The 9roco Rod
18 inches (45.72 crn) long, lengthens the time between rad
changes. gives G9'¥o more useable rod.
Aod stays lit as Jeng as :he oxygen is !lowing.
G Reds are factor ·wrapped for better insulation.
• Seven interior .·ods provide an alloy burning at approxi-
mately I0,000°F (5538°C) at :he tip.
Copper coated for belier conductivity and corrosion
resistance.
The 8rcco Torch
desu ned for maximum ox ygen flow to support Sroco rods
at any deo1h.
offset handle cesogn decreases forearm fatigue.
acme·!hread inside collet nut requires fewer turns to se·
cure and re!ease !he aroco rod. The nur is also less
vuJneraote to fouling from gnt or sand.
reduced electrolysis derived from utilization of like metals.
rwo-piece plas<ic =:cay .cermi1s raprd disassemoly and field
service.
internac1ona! .Jrange casing prov1des maximum
recognr!ion.
•1alve handle electncally uncouoJeo.
The Broce .9 egulator
hign oxygen flow: a.t.QO ct.0t1 hr.. over 70 c.Lrn.
saie!y stage reduces cylinder pressure by 90J o .
large second stage diaohragm affords c!ose adjusiment
accurate and cans(anr delivery at unrform pressure.
ven!ed and equioped with pressure relief valve between
stages.
• 1nlet Ulter to keep ou! lorei< n matter.
UnderNrite·s Laooratory aoproved.
Applications
Cutting an old H·Beam? Forget about pre-c\eaning \he cut.
Broce cuts right through the fouling. Strike an arc on a sinker
pla1e and go.
Notching a rock lor a lift cable? Brcco·s high tip temperature
will melt granite under....acer.
Removing wire rope or Jine /ram a wneel? The 8roco Sys!em
w1!fcu! 11 whether ifs steel. nylon. hemp or sisal. Jusl be
careful no! to contact the shalt
Trimming a propeller blade? Drilling or sawing is painfully
stow. 1Vfeff through phosohor·bronze or other similar alloys on
the biggest wheel w1!h your Broco ·system.
(909) 350-470 I , FAX (909) 356-1 42:
(800) 845-7259
Removing a composite piling? You don·t need t'No differer
loots to cue two diHerenl matena!s.
Trimming a cemenl-coveredsubmarine pipeline? Your Broe::
System will cut or melt through the concrete, wire mes."1
wrap, mastic and pipe.
Srcco' s Ultra·Thermic rod does ii all.
Operating Instructions
Equipment required:
1. Tne Braco torch, preferred since it is designed far dive
comfan. maximum flow, ease al ooeration anc
maintenance. ' ·
2. High-volume 01 regulator, capable of handling over 70
c./.m. The Broco High-Volume regulator meets these
specifications. 1'vfany other good regulators do not.
3. Single-pole single throw or double-ihrow single pole
salery switch (400 ampere DC, unfused}.
4. C-Type grounding clamp {appropriate lor undeMater
use).
5. 1 50 to 200 Ampere DC Welding machine, 1 OOo/o duty
cycle er 12 voH car battery.
6. 110 welding cables for tore!"! and ground c:amp.
7. Oxygen cylinder(s).
8. 318 inside diameter 01 suoply hose. from regulator to
torch.
9. 2·way diver-topside communication system.
Rigging For Cutting Operations
1. Assemble ·at supply or manifold. utilizing c\ean high·
volume regulator. and clean 3'8 inside diameter supply
hose. Make sure regulator. hose and torch are free from
any grease. oil. or particles.
2. Set o? pressure to 90 o.s.i qyer bo!!Om or whichever
is recurred due to dep!h or ooeration. Pressure must
be increased wl!h increased wOrking depth. See Table
#1
- ..Setting 01 Deliver}' Pressure vs. Oep!h''.
3. Purge regulator, hose and torch. Check for leaks with
soapsuds.
4. Tape 01 hose to power cable at 2' intervals.
5. Connect safety switch along the negative lead to !he
torch and within easy reac,'l of the tender. The switch is
activated only upon command from !he diver.
\. . Sec welding machine to straight_ polarity. Verity correct
polarity: negative to torch, positive lo ground or ··c"
clamp. If !here is any question about the efficiency of the
) cutting, cneck to see that the leads are properly connect-
( ed and !ha! the welding machine is delivering !he indicat-
ed ampe(age and correct polanty.
7. To check polarity, immerse rod and grounding clamp in
bucket al salt water. approximately 2 aoart. A s!ream of
bubbles w11f rise from the lip of the cutting rod when the
current is !urned on. It they don't. reverse me polanty.
Note: AC weld"1ng current is undesirable for underwater
culling because 1! has no constanl pofanry. Accordi ngly,
it increases electrical _hazard to the diver and shortens
!he lile of underwater equipment due to eleccrolysis.
 9. Esiab!ish that C3bles and connections are :n perfec: laole # 2
concition.
Sernng Amcerage for Cable Length and Size 1

i0. All connec:icns must be installed ar:d made 'Naternc;h! b'f

Length of Amperage Sewng
careful tao1ng.
Power Cao!e for Ca.b1e Size
1 1 . Furnish diver with prcoer diving dress. (succly to . ...or
12. Slart welder. and sec dial to 1 50 amperes ma'(1mum (at distance)
the rod tip). Consult Taole # 2 -"Semng Amoerage ror Ft. M # 1/0 #2/0 #3'0
Cable Length and Size". Establish that salery sw1!cn rs 1 50 46 1 55 i 52 1 50
open {oft).
200 61 1 57 . 1 54 152
13. Attach eyeshield to diver's faceplate; 250 76 159 1 56 1 54
#4 lens far muddy 'Nater 300 91 161 158 156
• #6 lens for average conditions 350 107 163 1 60 1 53
400 1 22 1 65 1 62 160
Once diver is in the water: 450 137 167 1 64
1 62
500 1 52 1 69
166 164
1. Secure ground clamp to work. If any part of work is aaove ""The increases in amperage compensate for resistance
water, ground clamp ma'( be secured there. In any case, losses.
!he diver mus! face the work as he performs. Serious For greater lead lengths, add 2 amperes per rifty feet ta
shock hazard to the diver and electrolytic damage to the settings.
diver's helmet and equipment can result if his body
Calculating Pressure and Amoerage Settings
comes ber.veen the red and the ground.
Example: A working dfve lo 500 .'t.
2. Call tor "current an·· or "make it hot" and commence
cutting apera11ons. .equired: 1 50 amperes at the rod ti p plus 90 p.s.i. over
bottom.
3. NEVER "TURN YOUR BACK" ON THE GROUND
CONNECTION. Given: 650' of hose, ana 4:210 cable.

Pressure calculations:
550 ft.x o.«5 = 249.2 p.s.i.
Table #1 plus
Setting Oz Delivery Pressure for Depth 650 ft. of hose x 1 o.s.i.
o·
tor each 1 of hose 65.0 p.s.i.
Depth Pressure Gauge Setting plus
M psi atm base requiremenr = 90.0 o.s.i.
33 tO 1 08 7.J. Total: '104.2 p.s.L
40 12 1 12 7.6 Sec gauge at '1Q4_2 p.s.i. to deliver 90 p.s.i. at the rod tio at
50 15 117 8.0 560' depth with 650' hose.
60 18 1 23 8.4 Amperage calculailans:
70 21 1 28 8.7 for 650' ol #2'0 cable. start with 166 amperes for 500',
80 24 1 34 9.1 and add 6 amperes for 3 additional 50' sec:ions = 1 72.0
90 27 139 9.5 amps.
1 00 30 1 45 9.9
1 10 34 150 !0.2
1 20 37 155 10.5
130 44 i1.0
Safety Procedures
1 61
1 40 43 166 1 1.3 Underwater cutting involves lethal electrical currenis. cam·
150 46 1 72 1 1.7 bustion promoting oxygen, and a cutting rod tip temoera!ure
1 50 49 1 77 12.0 in excess al 1O.OdO"F. Nevertheless. this procedure can be
1 70 52 1 83 performed in salery providing good judgment is used. and the
1 2.5
180 55 procedures in !his manual are observed.
188 12.8
1 90 5a 194 i 3.2 Following, same general precaulions.
200 61 199 1 3.5 1. Na work al any kind may be permitted on the surface
210 64 _. 204 13.9 over ihe area in •.vhich the diver may be working. A radius
220 67 210 1 4.3 equal to the deo<h at which the diver will be working must
230 70 215 14.6 be kept c!ear.
240 73 221 15.0 2. The diver's dress and communications equipment .1 1ust
250 76 226 15.4 be in perfect working order.
260 79 232 1 5.8 3. The cable connections should be fuily insulated and
270 82 237 16. 1 watertight
280 85 243 16.5
4. The diving station and the immediate area around it must
290 88 248 1 6.9 be free al combustible or explosive materials.
300 91 254 1 7.J
310 94 5. The diver and supervisor should take eveiy precaution ta
259 1 7.6
320 98 264 18.0 assure that the structures being cut are gas·lree and 011·
330 101 270 18...i. free. And the diver should make certain that oxygen and
340 104 18.7 combustion. by-products are noc captured in a pcckeC
275
350 107 281 19.1 overhead where they can ignite and explode.
6. Tend the diver closely. Keep air lines. torch 01and power
When depths exceed 350 leec. calculate your gauge pressure supply out of work area.
as follows:
7. Since Broco 3/8" cuuing rods will sustain ignition wd/1·
For every 1o· al hose required, add 1 p.s.i. to the 90 p.s.i. out eleclrical supply while oxygen is flowing, diver may
necessary at the tip. This compensates for frictional line tell topside to ··make it cold" or turn ''current oii'' once the
losses. Additionally, add 0.445 for every foot cl working depth rod is Iii. Broce 1/4" rads require electrical supply dunng
to compensate for increased hydro static pressure. the cut. In any case. current must be ott while changing
rods, and except when actually cutting. (Rad should be
 removec lrom :arch before tcrc.'11s lowered :nto or raised
from tile 'Nater).
8. crc.'1 ma1n!enance: rinse torc.1in fresn wa1er and ar1 r t
at:er each day·s opera!1on. Check flasn arres:or and
monel screen atter eac11Clay"s ocera!icn !er elec:ro1ys1s
or cicggrng. The screen must be reolaceo 1 / c:cgged w1ch
dirt or slag, or 1f burned out. (Frecuen1 c:ogg1ng or sceen
burn-oui indicates either 1nadequare Oi suooiy pressure.
or burning me red past the minimum J'. remainder.)
Note: It is not safe to ooerate (he torc,'1 without the !lash
arrester.
S tarting To Cut.
1. Loosen the Broce Collet nut Slide (he SROCO Ultra-
Thermic Rod inco the collet ooening untJ! it boctoms out
on the washer. Lac!< the rod in place on lhe »vasher by
tightening the collet nut. The heavy, coarse acrne
threads of the colle! nut permit la s t and positive rod
emplacement
A variety of coflels are availaole for (he Srcco ;arch. A
3/8'° Collet is standard, but 5i 1 6u. 1/'1". 3116'' , 5/32"
and 1/8" are available to adaoc the torc.1to oti",er cutting
or welding rods.
IMFORTANI NOTE: Use the aoorocriate '.vasi1er with
the proper callee An ovefstze washer •.vii! cause me red
to bottom on the flash arrestor. crea1ing elecrroiysis and
possibly arcing. An unders1ze washer will res1ric1 rhe ilow
of oxygen !O the larger bare reds, causing (hem to work
inefficiently.
2. Before starting !he cut, test for 01 llcw by'squeezing the
lever. A six·inch stream of oxygen should issue from the
red. Release the lever.
3. Call for "current on." The :ender wiil c:ose the salety
switch.
4. Draw !he tip of the cutting rod across the "';crK :o stnke
the arc.
5. Once arc is established, squeeze 0 1lever :'ull en, and at
the same time, drag the cutting red along the line to be
cut The angle of the rod to the work should be oe1ween
30 and 90 degrees depenaing on the metal :nicxness.
6. ,'vfaintain pressure 10 keep the red against :he work while
holding !he rod with your lree hand !ike a .::col cue.
approximately .:i" from tip for a more stable cuL Keep !he
tip of the rod in the puddle at all times. ,\.Jove slowly at
first, maintaining lull penetration oi cue As you increase
cutting speed. bac!< spray ana increased cumng noise
will indicate lack. of penetra11on. (Do NOT tr; to haid or
maintain an ar,:;. Just keep the rad against the work while
cutting at all times.)
7. 1Nhen the rod has burned to within 3 inches of the torch
collet nut. cat! lor ·:_current aft". 'Nhen tender has con-
lirmed "current off", loosen collet nut a half·tur.1ar.d blow
cutting rod stub from torch by squeezing O, lever. Insert
--... a new cutting rod in the callet and reoeat the starting
procedure.
Nate: There is no economy in using !he fas! 3 inches of
rod. You can damage t/'1e interior ot the torch.
8. Broce Ul!ra-Thermic Rods will continue to burn with
power off , as long as the 01 is still flowing through the
rod.
9. When using Broce Rods with other torches. make sure
that both the Broco calle! and its washer are emoloyed.
The smaller washers in other torches restrict 01 l!ow, and
wilt reduce the effectiveness of the Broce reds.
10. When cutting or melting nonconductive materials sucn
as concrete, reek, coral, mastic, rope or mannegro\Vlh, a
striker plate is necessary to strike an arc. This metal plate
is connected to the ground cable and placed next to the
material to be cut. 1Nhen the rod is lit, maintain the O
flow and bring the rod to tile target material. If tile rod
ignition is lose. relight the rad /rem tile stnker plate by
repeating the ignition procedure, Each subsequent rod
must be Iii from the striker plate in tne same manner.
Techniques
CUTilNG STE=:L
The Broco !/.!" :co may Oe useo !er steei uo :a 112" !n
thickness 'er .'T!ax1rnum cut:mg economy. The 1/.1." :cc
ieaves a nnrrcw ken' anc is _creleraoie :or fine c:.itt1ng.
However. :n oac •11s1cliity er for heavier S(ee1s. :Ile 318'' rec
wiil give nigr.er prcduc:1on. For materials 1/Z" th1c!< and over.
!he Srcco 318" rod is preierab!e. FGr macenals several
•nches th1cx, saw and wecge cutting (analogous :o choop1ng
a tree with an axe) may be necessary ta make en!ry space tor
the cutting ;Jrocess.
"Rule al \humo" es11mates.
Rea ?!are Range of c:..i!
a1a. hic!<ness per rod.
!/4'. 114·· 20·25"
1/2" 10-15··
3/8' 0
1/2" 12-W'
r· 9-1 4"
1/2" 3·1 2"
,\/ate: The U.S. ,\javy Under.'later Cutting and 1Ne!Cing Man-
ual. NAVSCA 0929-LP-000·8010. gives estimates fer :J/8
3rcco rca ac :he high enc oi <hese ranges.
CUTTING CAST IRON. STAINLESS STE::'... ANO ,\/QN.
FE,R ROUS METALS.
The Brcco ,=led w1il melt all of :hese materials ·,v1th its
1 0,000..;... 'F .:fp heat. ,\.fake sure !hat the tia is firmly buried in
the work. Saw and wedge c:.itting (see above) may be neces·
sary. Alternat1ve1y, n1ax1mum c:..itting efficiency may be
achieved by burning a series of holes througn t.'"le piece prior
to cutting across it.
CUTllNG THICX NON-FE:RROUS METALS.
Create a cuddle and dip the rod tip sligntly be!cw the surface
al :he molten meraL From time ro time, .::ush the cutting rod
deeper into the metal to •.vash it out and blow the GCCI
through. he soeed of the cue will deper.d on the type and
grade al metal and he technique developed by ihe burner.
Increase O, pressure to ; 10 p.s.i. at (he !10 ior metal over 3" in
thickness.
CUTllNG CONCRETE ANO ROCK 1NITH 3/8' HOO.
0
Light :he roe [!0 on a s;nker olate and press (i'le rod tip into
(he matenal to create a molten cool.As you melt througn (/le
macenal. oer1oa1cally move me roa 1n and out a a1Jov1the O
to OIO\v tile mo1ten ma[enal away.
CUTIJNG ROP£ ANO 'NOOO
Apply lir m pressure to the tio ta keeo :he heat in direct contact
with the matena! to be cul. In ship work, you may choose ro
angle the cut and/or Cena the rod uo to 90 to preven!
damage !O a null. snait or stern tube. On '.<1ire rooe you may
encase to use i/4" rod far liner cu! concrol. However. it is
aiHicu!t to ma1nca1n 1gnit1on with the 1/<l." rod w1tnouc connnu·
ous rod·lo -metal contact
USING 3/8° BROCO ROD WITHOUT A WE!..DING
0
MACHlJE.
A '1ehicle or boat battery may replace a welding machine as
ignition source. 1Nhi!e we recommend use of a knife switch
wherever pos::s1ble. jumper cables can be used In a pinch as
the makeJbreak connection. in this mode, ihe tender should
disconnect !he batter/ on the diver's command as scan as
the rod is lit. This ·.vii! guarantee maximum battery life. Obvi-
ously, the baHerr used to ignile he Brace red should nae be
relied on later to re-start the boat engine. Chee!< alternator
circuitry' before attempting to light a Broco rod /ram a running
and charging rrio!ar.
USING Y B BROCO ROD l1VJ TI-10UT ELECTRICAL
JGNITION.
To free a shac.':!e or Ourn aH a nut in very shallow water. the
rod may be lit on the surface and taken below ta do the work.
Accordingly, if an oxygen suoply is ava1!aOle. the rod can
easily be lit w1!ll a gas torch or. with same care. with a
cigarette and wooden plank. For the second method, place
the cigarette on a plank and use a very !ow i!ow ol Oi lrom tile
 rod to ilame the wc:cd. Press the !lo of the rod 1n!o me cnarrea
•,yood to crea!e 3 hot Gacke!. stcwiy increasing the Oi :low and
heating the rad tip to 1nc.ancescence. The roo '.viii hen ignite.
The lal!er technique takes a delicate taucn on :he Oi suoply
to keep the oxygen lrcm cooling the !1p and blowing the !lame
away from it.
SURFACE PRACTICE
Cutting with Broce red requires mrnima! skill ana exoenence.
In a recent test at the Professional Diving Sd1ca! of New
York, diver-trainees using Srcco rod outcut lhe1r insiructcrs
when the latter used the leading big-bore tubular sieel rad. A
diver •,y1(h suriace arc welding or cu!!ing qua ficaoons will get
exceHent results unC!er.vater in a very snort time. HC\'-'.ever,
bur.ning !hree or four rods on !he surlace belore going under·
\vater is the qurc.l.:.es! route to maximum prolic1enc·1wuh tne
rod.vOo not try to ""ma1nca1n an arc""· instead ma1nta1n metal-
to·meta! contact by keeprng the rad in the pudale.
Surlace cutting requirements:
Far surface cutting, use a welder"s helmet and the proper
lens. Good body protection (either '.velding feathers or other
heavy c!othing) is essential.
Maintenance
.'v1aintaining the torcn.
1 . .After each use, remove colle! nut and wasner, .:Jarts
#104 and #105, remo•1e collet and washer, pans :#106
and #123, and with medium screwdriver, unscrew ana
remove flash arrester ar.d manel screen, parts # 107 and
#108. Inspect all par ts far corrosion damage er :ore1gn
matter. Clean or replace as necessary.
2. Dip head of torch in fresh water ta dean exterior and
ilush interior ( the hose need not be disconnected for this
procedure).
•'v1aintalning the regulator.
1. Seiore each use. prior to connecting the 3'8" oxygen
hose. flush with oxygen from hign pressure suopiy to
blew out any tare1gn ma{ter.
Maintaining the reds.
1. If rods are taken into salt water, rinse with fresh water
before storing.
Troubleshooting
The Broca rod is different from the conventional tubuiar stee!
rod. A single rad will cut t\110 to three times as far :is conven·
tianal rods and do so at a higher rate oi soeed. Alternatively,
cutting a fixed distance normally takes under ha!I the time
and half the rods of conventional sysiems.
However, conventional oxygen and amperage requirements
do NOT apply to the most eHect1ve use al Brace reds. aroco
rads require higher axyg n Jlo'.Vc.=i."nd lower amperages than
conven!ianat rads. and most operational problems stem /ram
operators accustomed to convent1ona! techniques.
01 Supply Problems
Brace cutting relies on good and unobstructed oxygen flaw
for maxirnum effectiveness. With in;i.dequate oxygen llaw.
!he red can burn without affecting the work. Since the cutting
effect is largely derived from the 'lolume al oxygen reaching
the work at !he high tip temperatures provided by the rod ,
anything restricting oxygen /low decreases eHiciency.
Symptoms: R0<.1 burns down in more than 60 seconds of
continuous use, cuts less than 1 z·
al 1/2" thick steel place.
co
When 01 jet from end at rad is less than 6 undef\vater. look
for oxygen delivery- refated problems.
2824 North Locust Avenue, R ial to, Cal i fornia 92376
Prooacle causes:
' . 11Vrong Oren. lfalume at 0 :o rod :10 tao !cw. Cutting
:arcn Cles1r.;ned for 5.i 1 6"' roas. (Cid ArcA1 r, Craltswe!O.;
2. M:egu1a1cr :ncaoacfe al ;:e11venng aver 10 c.!.;n
3. Din er cosrrr.;cttcn in (i1e :crcn. sucn as aarnagea ::2sh
arrester. c:ogged or Jt.:rnt r.ione! sc;een. camagea O
now valve.
J.. Use of 1/4" or 511 6". O .'1ose, c:cgging er obsrruc:ian al
3/8 hose.
Note: in all of these cases. he pressure at tt1e re-;ulator ·Ntil
aaoear normal.
Finding and solving :he prcolem:
a. Shut off power :o (orc.1.
b: Remove rod from !he torc.'1 and blow througn cuwng rod to
check passage.
'"'· Ciieck suppiy pressure al regulator !or deole(iOn ct Oi
supply. CiiecX delivery pressure, nominally 90 o.s.i. at the
tip while Oi is flawing.
d. Remove Oi iine from lorcn handle and flow C 1 :hrough the
hose. If the tlow race is weak, the prcolem may be either :n
the hose or regulator. ChecX eacn 1ndeoenden!ly, anc
clean and/er replace. ii the flow ra[e is strong at the end
cl the hose. then:
e. Check torch callet washer to estaalish that 1t is in place.
tr.at 1 t is tne proper one far the red used, and thac it is noc
oostructing the caller. (Note: washers for non-8rcco
5/16.. or smaller diameter cutting reds w1il obsrruct l!cw
significantly.)
I. Remove l!asn arrestor and screen from tcrcn and inspec:.
Replace as necessary. Stow O? through the torch and
valve to ensure dear passage.
This should compiete the cnecXaut of O supply. ,gechec.i..:
symptoms to establish that problem ;ias been solved .
Excessive Current Suppiy Problems
8rcco rods reau1re no mere than 150 arnoeres at the tip
at any time. 2.-.:cessive ampetage w11! cause tne 3roco red
lo burn too quicXly.
Old hands. exoenenced in convenc1ana1 underNa!er culling,
will frequently endeavor to "'help" the diver by increasing
amperage to !eveis normal tar tucular sieel rads -JOO to 400
amperes. particularly lor thicker rnetals. This can create
severe operatlonal problems ".'11th the 3roco system. One
hunared filty amps· at the tip is the aosalute maximum.
Symotoms: Poor cutting eHiciency, insulation bursting off rod.
rapid e!ec:rolytic damage to unaer.vater equipment.
Possible causes: 1Nefding machine set at too high an amper-
age, welding machine delivering too high an amoerage even
though se!ting appears correc: (this is not uncomrnonl), po-
lanry wrong (caoles can oe crossed or weiding machine can
be incorrectly wired or marked.)
Finding and solving the problem: Use the polarity test in
Section C, #6 and #7. Check indicated amperage. If appar·
ently O.K .. reduce by 2So/o and c.1ecX results.
Inadequate Current Supply Proolems
This problem provides a ramiliar sec al symptoms ta the
experienced operator.
Symptoms: Slow culling, difficulty in sinking arc. cuwng rad
sticks or welds itself to !he ....ark.
Possible causes: bad cable connections (they must be insu-
lated and \vatertight), ground damp making poor contact with
work, welding maCnine delivering too low a current.
Solving the problem. Check indicated amperage on '.11elding
machine. Then check ground clamp and clean ground ii
possible. If problem persists.
amperage redo at
settings all welding
cable ccnnec!lons.
macnine.
Finally, increase
(909) 350-470 I , FAX (909) 356- 1 426
1800) 845-7259
 B R - 2 2 To r ch P a r ts L ists

1 02 t--1 28
e

1 26
1-1 27

'
tl
·t--1 25

i09

:•
J I .. · :•
,: ..
1 01 ' ) Gt"ip, Handle (left side) 1 15
1 02' )' Gri p, Handle (right side) 1 16 / 0-Ring, Valve Siem .§
IOJ ! Head, Torch 1 17 '
! '1Yosher, Neoprene Valve Stem
1 04 ! Nut, Collet 1 18 !casket, Copper
1 05 i Wcshec,..- Neoprene 1 1 9t ) Scre•N, Brass Valve Lever .§
'I 106 !collet INut, Brass Valve lever leek I .§
120t
'
I - 107 / Flash Arrestor .§ 1 21 -r l I screw, Nylon Handle i .§

I 108 j Screen, 1'-Acnel ·§ 1 221' 4 r Nut, Nylon Handle .· I .§

I 109' ) lever, Control Valve 1 2J
'
I j Washer, Neoprene Collet
1 10 iVoive Stem, Delrin ·§ I2J I IAda pier, Oxygen Hose
I 1 11 'I Coupler Assembly .§ 1 25 I j Connector, Hose, Delrin ( 1 /8'' NPD i
I 1 12 / Coble Assembly 1 26 I 2 / Ferrules, K.:<. ]
'
1 13 Cantre! Valve
IS . ,
1 27 I / Hose, Oxygen

I pnng, Vaive Siem 1· / Connector, Brass ( 1 / J.'' NPT)

11J 1 28 I
·t f must be purchased ,'ogether Component of Complete Spares Kil UW·CSP § Component of Aiini Spores Kif U\V·1\.i S P

©1 985, 1 989, 1 994 Amron lnlernotiono/ Diving Supply, Inc.

,-7
619-746-3834 l.MX J 619-746- 1 508 2'
 I MPO RTANT SAFETY I NSTR UCTIO NS
Underwater Welding & Cutting Oper ations

A WAR NING A
READ THESE PR OTECT YOUR SELF
WARNINGS AND OTHERS

SERIOUS INJURY OR DEATH may result ii this underwater welding and cutting equipment is not
properly installed, used and maintained.
Only trained proiessionals shall be allowed to perform underwater cutting and welding operations .
.C\11 diving should be done in accordance with all governing professional aiving organizations in the
area oi the diving ::ioeraticns.
All safeiy precauticns shall b§J observed topside, as well as.underNater, during any diving operation.
It is essential that the operator, supervisor and others in the work area are aware of the dangers ol
underwater welding and cutting processes. Training and proper supervision are important for a safe
dive operation. Keep these instructions for future use. Additional recommended safeiy and operating
information is referenced in each section.
No work of _any kind.-should be permitted on the surface over ;he area in which the diver wiil be work·
ing. This area should be a circle with a radius at least equal to the working depth of the dive .

. .

=
Inspect torch and other equipment to be sure all insulations and other protective cov-
ers are in place and in good condition at all times.

?
S!..ECTRIC SHOCKand
Only use torches CAN CAUSEholder
electrode INJURY OR DEATH
s designed far underwater applications.
-----!
Do not touch the electrode or any live electrical part and workpiece at the same time.
The diver/welder /cutter must never allow himself to become part of the electrical cir-
cuit. A)LeJectrical connections must be wrench tight and properly insulated. The use
of AG·power supplies for welding or cutting current is not recommended.
There must be a positive operating disconnect switch (also referred to as a knife
switch) in the welding lead side oi the current path. This switch shall not be operated
unless speciiically directed by the diver. When the diver calls far a change the tender
must confirm that change to the diver.
Never assume that because contact one time is not harmful similar contact at other
times will also be harmless. Changes can occur which would change the effects oi tr«
contact. A procedure shall be developed ta check the integriiy of the electrical circuit
before starting each operation. ··

SEE SAFETY AND OPERATING REFERENCES i , 2, AND 3.

' ..

/ 1
. l r: oTn Rn:: o tti Ne :i c '.h 1A ih : ti a :
maole ana/or explosive ingredients apply to underwater work. Prior to cuttino or we!c
ing in a dosed compartment, a means must be provided to permit escape of all
emrapped gases.
'------=----'
Having the diver work from the highest point down could reduce the. possibiliiy oi trao-
ping gas mixtures that could lead. to explosions. ·

Beiore each dive, torches using spark arrestors must be checked to ensure the
arrestor is clean and in place. Removal of the spark arrestor or any torch parts creates
a saieiy hazard which could cause internal burning of the torch.
Most underwater cutting operations use oxygen, thereiore all safeiy precautions con-
cerning the use of oxygen must be obsenved. Oxygen itself is not flammable, however
the presence of pure oxygen will drastically increase the speed and force with which
burning takes place. Always refer to oxygen by its full name 'oxygen,' and not by the
word 'air.' Never allow oil, grease or other petroleum-based substances to come in
contact with cylinder valves, regulators, hoses or any other part of the oxygen supply
system. Do not let an arc, cutting rod or flame touch any part oi the oxygen suoply
system.
Chain or secure cylinders to an object such as a cylinder cart, wall, workbench, post,
etc. When moving cylinders, always be certain that valve protection caps are securely
in place. Never stand in front or behind a regulator when opening the cylinder valve.
Always stand so the cylinder is between you and the regulator. Never use compressec
air instead oi oxygen. Keep oxygen cylinders away irom electrical connections.

SEE SAFETY AND OPERATI NG REFERENCES 1, 2, 3, 4, AND 5.

SAFETY AND OPERATI NG REFERENCES

1. CODE OF FEDER AL REGULATIONS, (OSHA), SECTION 29 P. RT 1910.101, 251, 252, 253, 254, 401, .110. 420, 427, 4.2D.
"4(), AN 0 "-"1.
U.S. GOVERNMENT PRINTING OFFICE. WASHINGTON, DC 2()4()2
2. ANSI Z49. 1 SAFETY IN WELDING ANO CUTTING. ·
3. AWS F4.1 RECOMMENDED SAFE PRACTICES FOR WELDING ANO CUTTING CONTAINERS.
THE AMERICMI WELDING SOCIETY; 550 NW LEJEUNE RD.. P.0.SOX 351()4(), MIAMI FL :3.3135
4. ADC CONSENSUS STANDARDS FOR COMMERICAL DIVING OPERATIONS
ASSOCIATION OF DIVING CONTRACTORS, INC. P.O. BOX 1483 HARVEY, LA. 7COS9
5. NFPA 51 B FIRE PREVENTION IN CUTTING AND WELDING PROCESSES.
NATIONAL FIRE PROTECTION ASSOCIATION, BATTERY PARK, QUINCY MA 02259
6. CSA STANDARD W117.2.
CANADIAN STANDA.RDS ASSOCIATION, 178 REXDALE BLVD., REXNALE ONTARIO, CANADA MSW 1R3

THERMADYN
Arcair Campa

Customer Ser't'fce Executive Ottfces International Canada Europe

P.O. Sox 12250 101 S. Hanley Road P.O. Sox 1 2250 2220 1Nyecrort Road Europa Building
Wichita. KS 67277 SI. Louis. MO 63105 1
Nichita. KS 67?.n Oakvi!!e. Ontario. Canada L6LSV6 Cllocley Nortll lndusrria! Park
316-942-1421 314-721-5573 316·942·6501 905-327-1111 C,'lorley, Llncasnire PRS ?BX. Englar
FAX 800-633-9513 FAX 314-i2H822 FAX 316-946-8130 FAX 905-327-3648 . 44-2572-61755
F. +4-2572-61 756

Printed in U
Form No. 89---250-939 (5/23/90) © Tweco Producrs, Inc., 1990
B R - 2 2 To r c h p a rts L i sts

I
I Grio H 'l"':'.' .X
---= .
1 --; --j ---'----i Hecd, T:o:rc:h : ::::'_
1 17

i. 102· ' ,, .one e (left side )

'

I, -1 03;--t----'--1!G:J:'ri;?:':,_ Hloon d1J'l e. ( ri;gih;;t- sic'e:);- :_ ·§

r1 --i11 0045:;----i1-_! J)elut,Co lle t ------t---- 1 18 : as et, Copper .
IWasher-:- N -;-;:: j
106 ) ) ccllet ' __:_ l_.:
-1 I9::t;:---f-------'-JIl Sco'r-ew,-,BB:ra;ss':.:l;/;a;:liv:e:=-e;v-e-r----_J- ·§
ec_>pr_en_e
I!I 110081 )I I Flash Arrestor l 1 2ot
1 211' i ,J. !I1 Nut, Brass Vaive lever Loe:'<
Screw N 1
.§
I 4 I , y on Handle .§
) ) Scre n -------+
, I09 i -·"_ I
I .§
- , Mone
"_ I !
! -1 227 jI--_.'.'. j Nluul, Nylon Hondfe
llever C 1 ------+) __±
0
o
jWosher ' Neoprene Collet II
I 1 10 ) ' antral Valve •o
I I 1 23 I
I
111 I !Valve Stem, Del;r;i;n:-- _J_ .§ I f-
1
I '----J· ;IlAdopter
+-----'
1 24
,.:;;O' xygenHHose
Connedor
1

1 I j Coupler Assembly I ·§ I -; --1-]

1 25
·Jr<Jl·e ·'
ose, Delrin (1 /S" i'lPD
!

'
Ferru l e s,K_K_
1 12 l I
I
Coble Ammbl y
I
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126
I
I 2
IHose, Oxygen
1
I
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I Control Volv 1 27 .
1 13 I I ' e
1 14 I I . iSpri ng , V a lve Siem • C I I 1 28 I IConnect 8 )
' omponent of C or, rms {I/ d" NPT)
 . t r must be purc fi ased together. 1 § Comp
..,. 6 1 97
---;.;' ; ;::;:;;:; -'""'""'"'"'m om'.plele Spores
A mro n 1 t
""'"''"'""pom
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g;1 UW -MSP
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:; uiving
w-CSP "'Inc.
Supply,
- - 46-3834 n ema/1onal o· .
AJ- \ ,.,=;r,-'.;.,..,N 61 9-746- 1 508
 SAFETY R EQ UIR EMENTS vise and 1Nith a scre'Ndriver, remo ve val v e
cap (item 45) . R emove sea t (item 46).
1. The regula tor must never be opera ted 5. Replace seat (i tem 46) and reassemble
above the maximum pressure rating not ed main valve assembly (items 45, 46 & 47) .
on the data pla te, drawing and/or the
speci fication sheet for the speci fic model. 6. Inspec t seals (items 41 & 42) on cap (item
43). Replace ii worn o r excessively dirty.
2. All upstream fittings mus t be rated for 0-ring (item 41) and back-up (item 51) are
the maximum supply pressure. accessible by removing snap ring (item 40)
3. All downstream fittings mus t be rated for and retainer (item 50) .
the maximum supply pressure or the 7. Reassemble by reversing the appropriate
downstream pressure mus t be limited by a disassembl y s teps.
relief valve.
4. The regulator mus t be kep t free of oil SENS O R AND OR IFICE SEALS
con tamination if it is to be used for oxygen
service. 8. Remove plug (item 23) with screwdriver.
9. Using ex ternal snap-ring pliers, remove
MAINTENANCE retaining ring (item 25) and hand knob
(item 26).
The regulator may be ser 11iced for a-ring, sea t
and seal replacement without remove! from the 1O. With 1-5/8" open end wrench remove
line. The following steps outline the basic. bonnet (item 27) by turning counter-
disassembly and reassembly operations clockwise. (Note: Sprint item 34 and rod
necessary to reoair the majority o f all item 15 are free and may fall if care is no t
malfunc tions. taken.)
1 1. Remove sensor assembly (items 1 thru 11
R EPAIR KITS venting models and 16 thru 19 non-
ven ting).
STANDARD R EPA.IR KITS
12. Inspec t seals (items 6 & 8 venting models
S td. Model "4-13XX-2081 --P/N 389-1 875 or 16 & 18 non-venting). Replace if
44-13XX-2122--P/N 389-1876 damaged or worn.
44-13XX-2081 -002--P/N 389-2343
13. R emove sea t re tainer (item 1 ) and vent
44-1 3XX-21 22-002--P/N 389-1 993 valve seat (item 2) by snapping valve (item
44-13X2-2122 --PIN 389-2727 3) agains t seat. Remove nut (item 5).
SOFT SPARE K:TS Inspec t sea t (item 2) and o-ring (item 10).
S td. Model 44-13XX-2081 --P/N 389-1873 Replace if worn or damaged.
Std. Model 4d-13XX-2122--P/N 389-1 874 14. With a 3/4" deep well sock et remove
Model 44-13 XX-2081-002--P/N 389-1459 orifice (item 21).
Model 44-13XX-2122-002--P/N 389-1896 15. Inspec t gask et (item 22) . Replace if
44-13X2-2122 --PIN 389-2726 damaged.
Panel Mounting Bracket Assembly P/N 1129
RECOMMENDED TOOLS B ONNET, ADJUSTING SCR EW,
B EAR ING AND SPR ING CAP
Scr ewdriver, 3/16" or 1/4" bit
Wrench, 1-5/8" open-end 16. Remove limit screw (item 28) with screw-
Socket, 3/4" deep well driver.
Socket, 1/2" deep well
Socket, 3/4" std. 17. Slide the adjusting screw assembly out
Pliers, Ext. retaining ring of bonnet (item 27) .
18. Spring cap (item 33), bearing (item 30) and
SEAT REPLA CEMENT thrust washers (item 29) may be removed
for service or replacement as required.
1. Remove valve cap (item 43)
The reassembly is the reverse of the
2. Remove washer (item 49), valve spring disassembly with the following notes and
(item 48) and main valve assemble (items precau tions:
45, 46 & 47)
a. Clean all part to insure f reedom from dirt.
3. Inspect seat (item 46). I f dirty, chipped Con tac t the fac tory with ques tions
or cracked - replace. pertaining to the proper cleaning agent
4. Place flats of valve s tem (item 47) in ·and/or procedure.

3
 b. Install ven t valve sea t (item 2 venting
models only) with cham fered side toward
valve (item 3) .
c. Lubrica te (with DuPont Krytox 240A C
lubrican t o r equivalent) threaded portions
of items 27, 38, 28, 1 1, 45, 21, 32, & 43; o-
rings items 6, 8 , 16, 18, 41 & 42; bearing
(item 30) and washers (item 29) .
d. Apply the following torque values:
I tem 45, P/N 1081 . . . . . . .. 15-20 in.-!bs.
P/N 1713 . . . . . . . . 25-30 in.-lbs.
I tem 38 . . . . . .. . . . . . . .. . . . 20-30 in.-lbs.
Item 5 ( vent models onl y) . . . 75-90 in.-lbs.
Item 28 · . . . . . . . . . . . . . . . . . . 20-25 in.-lbs.
Item 1 . . . . . . ... . . . . . . .. . . . 60-75 in.-lbs.
Item 21 . . . . . . . . . . . . . . . . . . . . . 30 ft.-lbs.
Item 27 . . . . . . . . . .. . . .. . . . 40-50 ft.-lbs.
Subsequent to reassembl y, the regulator
should be connected to a pressure source
equal t o its opera tional pressure and check for
internal and ex ternal leakage with a leak
detec ting f luid and operating charac teristics
consis tent witn the specific application
requirements.
TR OUB LESHO O TING
Problem:
Continuous leak age through bonnet with
outlet pressure on the regulator.
Possible Cau!:es:
1. V ent valve needs adjustmen t, proceed as
follo,,vs:
u s
Pressure Con trols Div ision
Fann z747 {Revised 5186)
a. Adjus t outlet pressure o f regula tor to
50-75 psi.
b. Remove plug (item 23) and using a
scre•..v driver turn 1en t valve adjustinc
1
screw (item 13) coun terclock wise unt
ven ting stops, then add approxima t ely
1/8 turn.
c. Adjus t regula tor in both direc tions
checking to insure the proper ventina
ac tion and the ability of the regulator
to vent to zero psi.
Problem:
V e n t ing c o n t in u e s s u b s e q ue n t t o
performing step 1.
Possible Causes:
1. Vent valve seat (item 2) and/or sensor
seals (items 6, 3, 16 & 1 8) require replacing
- fo!lo\v disassembly procedure steps 8
through 13.
2. 1vfain valve seat (item 46) and/or seal
(item 22) needs replac ing - follow steps 1
through 5.
Problem:
Regulated pressure drops sharply when
flow is increased - pressure regulation
becomes erratic.
Possible Causes:
1. S enso r seals (items 6, 8, 16 & 1 8) need
lubrication or replacemen t - follow steps
8 through 13.
2. Din and con tamina tion are causing main
1
1aJve (item 47) to "s tick " - foll o w s teps 1
through 7.
1 2616 Industrial Boulevard
Elk River, Minnesota 55330
(612)
441-6330 Telex: 290488
6 Printed in l'
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niedium :a high cap aci tv ga s ser vic e
Single s t a ge c ons truc t ion a f fords troub!e
free per formc:i nc e in iJ Y'tidc 112 rie ty o f in
dus trial, co m111ercial, a nd technic al/labor 2
tory applic o t ions. A very rugged an.
duro ble r egula tor. 1Vl ode!s available fc
cylinder and m Jni fold us e.

D irnens i o ns :

S P E C l f"= l C J-\T l0 l\J S

DES i G l'-1/ C.: O t'J STR UCTI Oi\l I P E f; f O R :Vi1.\ N C E l
o Forged Oody & Ca p o Max imu m I nle t J OCO psig Sr<iSS
0
2 Vz" G a u ges 0 ,\'\;::xi mum Ou t!r.: t 2 50 Sta inl ess Stce:
• St ':!rn-!yµe Seil t :-.iec hunisii1 s c oo 5cf h . " Ho usillq Ca p
"' 31,1 " Oia phraq m 9 Inlet Filter
01'.' l riil Ca p Bush ioq
0 Sel l-Resea ting Sa f e t'/
Rc!i::?·: e l/alvcr
'Slntcred I nl e t Fihc r ·
I G AS
I
SPE CIF'( CGA
!
,\1100EL SPECI!= '( DELIVER Y

---·1
..
P l::R l-O i /l/\ f\!C f: C A P f.\ B I L!T Y C UR VE
I SE f.l.1/ICS N V r/1 f.\ Ei1 I I N LST CO:'J N EC:T!O I
!0.CCO .- -
.- -
-, -
-,-- -
--, 5'0 580
I
.-\ir. O xy,.
Inert G;:i s I SR •\00
I
_J H•:rlrogen ·

C01 & N10

I
I
sn

SR ilOJ
,. 02 A.8.D.S

I
JSO
320

300
Acctylcna sn ,1 1 0
I A 51 0
510
s L.P. G.;s··· SH 4 l 1 0.0

I
<:
t DE LI V E R Y R AN G E K E Y O U T L ET CONNE CT
F ?.':iOO

1
H S!l 410A (l l '.l f'$1G
A 0- 1 s p:=ia 0 ... 0- \ 2S psig
C·rlindc r Type -
9/1 6""- 1 8 (,\.\)
Ma nifold Type -
0 0-'? psiq E ... .. . a.- 2 so osig 1··.1 \ - 1/2 NPS ( f
0
7•100 1 800 1200 WO 0 N OT E: PJnol mO<J n< cLI models aYJda tJl'l on rcquosr.
240 IGO 110 GO
CYUNOOt f'R(<;Su11f 1rs1c1 • ' Sao Section II. 1).:1\l C 68. . • " ' PropJno. 0u(Jrl0, ,\.\APP- . i\ PhCH I" , H.P.G.""
NOTE S: To order r c:gulutors lor mJ.nilo!d service. J/fix " ,"I\'.' to roaulutor model number. Ex;:i rnplo: SR 400ME. Models SR .\

.
402 . .'.Ind 403 /or nianilold survicc <iv.:iilJbla in "O"' ",Jnd ..E.. dclivory r nn9c s on!y. Other 1nodels as shovn ubovo. iv\ J ni
c onnec ting r egu!,1tors use largo cunuc11y in!c! und OlJ (f \ finings. I..- l 1 · 1 /2 N PS LH a net RH.
.1 O R DE R ING EX A1\'1PLE S : Cyl. conncc:inu S fl 400 E- 5 40 (Oxy). SR 4 \ 0 A - 5 ! 0 {Acot.). 1"1\undold connec ting: SR 400fv1E. (C
·1 511 11- IOMA. (Ace!.).
' F r oo A ir lfi? 70 ° F. - No flow 1ostrict1onj
M;ui1m1 rn fin...., wi ch r.O, - !25 SC Fl l ,11 \ GO PS!G 0u1lo« ri1c .uro.
= -· '."·f:""?"."':""·-.·-:-:
:
- . ·:-..-:::.-.!. i'" :'""":'"".'-:'":"_2 .:::•', ".' ?'< • O_v"'' '. • .,.,,-l,••-'.:''77'.·!'ii.• ·1.' -:::.:::::.:: :·.}.:_ '"'0';.·
 :'i \· i c-·.\ :.! j ..: \- j
' .. " -
r

>._;,,_.:,.-::.::::-:_._'.:_ .'..:_.:::;'._::.: :'.'_ ::-:. .::-.-!,;_;;,--;- ·' •;' I ,,--:'\ :''J /\

•' _',
.,
°']/ \ / :Y :;·.\ .,' ;i

D l '--_<-':> ,"' '.1.'

\: : =; ?\_ i,; 7'"-' .,........ :O"" ;.
- :;-... •.,. ?. :' ·1 - · -"' T"' r.=>

.., :u ") ./ - . , L) '"' :tJ l.': · :J

j,-.--. ) "'°' I
J .:'.:.. .;- ;;o ' '...:i ...--,, J J ,J;.- ,; " " '
iE ) '. " \ '. \ 7 lv::} q

A c cU>3t e Heat Cont rol - Eoch weldor has his own Diesel Engine Adva nt a.ges lis t ed be!ow provicJ e e
pre ference for mJchine s et tings t o do his best work. 11Vi th ce!len t operJt ing economy .:i nd machine life under rugg·.:
c on tinuous c on trol o f bo \h current and •:o!tJge, the op- conditions.
ero tor ciizils t he hea t and ar c chorac t eristic s - f rom a sof t o Lo•N fuel consump tion per hour o f apen:i tlon .
..buttering" arc t o a snJppy "digging" ;:i re - he needs to
., LO"'' cosr fut:I and minln1un1 fuel pil fera ge.
suit his individuci! techniques for fast. lligh qt1Jli ty •.,veid-
ing in all posi tions. • Fuel sa ier ta hnndle - import an t f ar o ff·si1ore drii!i-
rigs nncl other places ;vhere fire c.Jn Ce disJstr01_

-.-.;.'<""""..........". '""......,_.. ··"'=""'- - -'--"=---.--...--..,.. . ._._----.,,,.._,-

-....... -.. .,_.._ =-=-_,,.=<.=· ·.....,..,· '<'"-'..,.,....-
_,Y
/

O pe ra t i ng P..dva ntages . ,.......- ,'.":

..-

(:
,.

/\ux f liary Po1;•1er a va i!Jble f rom -

- --- ---
grounding :y pe r e c ep ta c t e 5 pro· t
vides electricity for 1 ;ghts and tools, r
Choose:
l . StancL:- rd 1000;•1a t ts, i15 11alts
CC.
2. Optional 3000 'N<J ttS, 1 1 5/230
'tOlt3 .<\C.
3. Optional 30CO 'Nat t s, 1 :i
A .:. volts
DC.
Sh ow wili1ou l
1lon d::ird doon
( s e !:lock )

Engine Features

Prcs:;u;-c Lubric a tion S·1stern wi th

replaceable fil t er s assures e fficient
lubrication even on 30 ° slopes.
Rugged Bo x Fr3me maintains <:i!ignment during roe
Manual Egif'e Idler lets opera tor
field hJndfing. Canopy, door s and radia tor shield prot
reduce engine s pe ed •,v h en no t
welding. internal parts.

Engine Cooled by a la rge pressure type radia tor and Slo\v Engine S peeds and R eserve Hor sepower prodL
centrifugal water pump. low engine ·Ne<J r 'Hith maximum per formance throe
years of service.
Large Fuel Capa c ity for all-day welding. Lead pla t ed t ank
resist s co_rrosion. A sediment bow! and filters in the fuel
lines help keep the fuel clean. User Benefit s
·. Cons tan t Spee d Governor maintains speed withi n 4 % The combinal ion o f dependable genera tors, dual cc
"f;- for st eady we!ding out put. t inuous output control, reliable diesel engines <:ind rugf
--· cons truc tion has earned Shield·Arc welders an unm<J tch
- Oil Bath Aii' Cleaner removes dirt from intk e air.
rcputa tio"n among pipeliner s and ot her field welders
Pushbu t ton S tarting is powered by two 6- voll ba tteries. outS tanding welding ch<J rac teristic s and long, troublc- f:
Buil t -in s t arting aids provide easy cold weather st arting. welder lile.
/ • E EPL.t\C S:

Weldin') ;\1lclt::"r K its arc (--:::....

opl1onJI uquipinent \- ·:-. -1, ·
-·----
.:-=-··
--- '
i\ D VAiHil.G ES i
\,)
1vLJximum \·:e!dability 1,vilh 17linin1um fue! cos ts.
Reduced risk al lire and fuel the f t. i
!
;\. ux iliar y power.
Long lite sCrvice. .'
'I
Positive cold 111eather sl2rling ch.::irac terls tics. ·;·
·( . ·- - ':.:... '
'

;, P P L!C,..'\Tl 'J f'

The drooping volt-a;npere c:uc •::el d er m.J.y be used for-

S t ick E!cc trodc (Shielded \, 2!21 Arc } VVe!ding
,,·;·'
Tungsten Arc VVelding ,!. _
Carbon-Arc and;\ir Carbon-Arc Cu tt ing and Gouging •
S tud 11Ve( ding \ 11ith O fle Gun, etc.
;\. !! processes n1us t be applied '<vithin the ra ting o f the
mac hines.

ESS:::r· T f /:':..!... D /'.\ T11.

A odsl Nun1ber-v-1ith St andard Batter y 2nd Self-S tar ter .................................... 0- 400
Rating
-Amoe res . . . . . . . . . . . . . 400 •
-Val is . ...... . . . . . . . . . 40 "
-Duty Cyc le . .. .. .. . . . .60 •
Current R 2r.ge nt Norn1 ! V./2!ding \/o!tuge-;\mps .... 25-525
!'-lumber ot Srushes-0.1Jln Generator ................................................................................. 12
-Exciter . . . . . . , , . , ..................................................... 4
r\uxiliar y Pov1 (-1 f s Vol t s, OC-Kilo"11alts ....................................................................... 1
St o..ndi.lrd lr.dustri2! Engine . . . . . G i\l -2056
Number o f Cy linders . , . . . . . . . , . , , . ,............................................................................. 2
Pis ton Oi::;plo.ccment . ...... ........ . . . . . . . 142 c i. (2329 cc)
Dyn. Br ake Horsepov er al (ndicated Speed ................................................................. 53
Operoling Speed-R.P.M. . . . . . . . . . . . .. . . . .. . . . . . ..1 800
Cooling Sysiam Capacity· . . . . . . . . . 20 qt s. (19 liters)
FUe! Tank Capacit y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 gal. (94.G liters)
Dimensions-Overall..:.Length . . , .. . , .. . , . . , . . . . . . , 72" (1829 mm)
-Wid th , . ... , . , , , , . . , . . , , . . .. . . , . , . , , . . . .31" ( 737 mm)
-Haight . . . . . . . . . . . . . . . . .· .. . . . . . .. . . . .45 1/2 " (1156 mm)
Net Weight-Approximat e . , . . . . . . , . . . . . , . , , , . . .. , . . . . .2,145 lbs. (1109 kgs)
·Exceeds NE.'.IA :spccifica. /ions

OPTIO NAL EQ UIPMENT

Portable Mounting (4 wheel spring mounted t ype) . . . . . . , . . . . , , , . , , . . . 353752·6
Welding Voll and Amp Meter Kit ._ . . . . . . , . .. . . , . . . . . , . , . . . , , . . . . , . . , .355078
Engine Hour f1let er K i t . . , . . . . , , , , , . . , . , , , , , , , , , , , . . . , . . . . , , . , , , . . . .357212
Remote (Hond Type) _Control , . , , . , . . , , . , . , , , , :·. , . . . . , . . . , , . , .. . , . , , , , .14 27
Thinwcld (Porloble A t tachment) , , , , , , , . . , . .. , , , ,., , , . . . , . . , , . , ................ 1192
Sa fety Fuel Cap . , . ... . . . . ·. . . . , . , , . , , . . , . , , , . . , . . , . . , . . . . . , , . . . 6FW-5072
with Adapt.er , , , , , . . . .. ,_ ..?... , ,, . . . . , , . . . , , . , . . . . . . , , . . , . . . . , , . .3579 1 7
3 KW DC Au xiliar y Power (Fac ldry Inst alled Only) ·
220 Volt- DC 1\uxiliary Power (Fac lory Installed Only)
 : '. :..·_ _'< ".. ::i U _I
- 0
fu:rt b e r :,
O h s pe r Size o r
1 ()OO :"' t .

,01 634 3-4/0 1 220 1 9 151 7YJ I 6!0 '

.0 2060 3-3/0 970 I 7 25 1 ;.8 5
I
, 0 21_,5 1 2-4/0 3 i5 1
6 10 1
485 1
!0 () 5 I
., 0 2593 3- 2/0 575 1
320 1
, 03090 2-3/0 645 1
48 5 1
3 2C· 1
.03897 2- 2,IO 5 10 1 330 1
• 01,.90 1 4/0 L0 5 1 30 5 ' 240 I 200 I
.06 1 80 3/0 _320 I 2Lf0 1
1 90 1
1 60 1
r.7 9 .,
V / ( ) 2/0 255 1
I ')0 I 1 50 1 1 25 1

Bas e d on :
i. 605,_; dut y- c:1i: l e , that s 6 rnin . us e i 1 1 0 :-c.:t_11,.
2 >1-:J.:-:i;:1u::! 6 1.r() J. t.s d.2..oi; in c -::i. bl e

··