Instruction Manual For SLICE Exothermic Cutting Equipment 1
lance), and the third the heat of combustion (some external source of heat). However, when the lance pierces a slag puddle, the puddle becomes the source of heat until the lance is withdrawn, at which time burning stops. FUNDAMENTALS OF THE PROCESS Process Description The SLICE Exothermic Cutting process uses an exothermic chemical reaction that burns, melts, or vaporizes most materials. The reaction begins with an electrical arc or alternate energy source that causes a steel cutting rod to burn.
PRINCIPLES OF OPERATION rod is in direct contact with the workpiece, ensuring the best cutting speeds. General FIGURE 1 How the Torch Works SLICE Exothermic Cutting uses heat from a chemical reaction between a consumable steel rod and oxygen flowing through the rod. Test data show that little or no oxygen remains. The oxygen not used in the reaction blows the molten material out of the cut area. This action creates the kerf that allows cut progression.
Constant-voltage power supplies should not be used with exothermic cutting equipment. When the exothermic cutting rod contacts the workpiece, the power supply is being dead shorted, causing maximum amperage output of the power supply. This surge can exceed the rated output of the machine and the recommended amperage for powered exothermic cutting. Cutting Rods SLICE Cutting Rods are made of carbon steel. They are made by rolling a steel strip into a rod. There are coated and uncoated cutting rods.
power, wear at least a #5 shade lens for eye protection. OPERATING TECHNIQUES FIGURE 2 Cutting Without Power Cutting Without Power This is the most commonly used method of cutting with this type of equipment. To cut without power connect the torch to either terminal of a 12-volt battery or constant-current welding power source. Connect the striker or a strike plate to the other terminal. If using a welding power source, set output level for 100 amps.
direction of cut. When cutting with power, the operator must use a protective lens shade #10 or higher to protect from arc flash. torch, an optional 6" collet extension and extension shield are available for the SLICE cutting torch. Piercing in the flat position is more difficult than piercing horizontally. Progression while piercing flat will also be slower. (Example: Piercing a hole in a floor is more difficult and slower than piercing a hole in a wall.) FIGURE 3 Cutting With Power TORCH 1.
power cable and oxygen hose. The power cable is of sufficient size to carry 200 amps in a power cutting operation. The oxygen hose comes with a standard size oxygen fitting and is ready to be connected to the user's oxygen regulator. This standard torch comes with a flexible hand shield that is easily replaceable if damaged. The SLICE Torch is molded from a glass reinforced thermoset plastic, which is rugged and will withstand the punishment of frequent everyday use.
When using the battery supplied with this unit, the three-position switch on the face of the battery box must be in the "CUT" position when igniting the rod. To check the charge on the battery, push the mode switch to the "TEST" position. The meter will register the charge level. The mode switch must be put in the "CHARGE" position when the battery is recharged. The battery should be recharged when the indicator is close to or in the red zone of the meter.
around 200 amps. Exceeding this amperage could cause equipment damage. When cutting without power, current from the battery ignites the rod. To ignite the rod a surge of at least 100 amps is needed. If the battery has not been properly charged it will not have enough amperage to ignite the cutting rod. procedures and other safety precautions apply when using this equipment. This section highlights these procedures. Refer to ANSI/ASC "Safety in Welding and Cutting" safety standards (Z49.
and local codes. Do not service or repair equipment with power on. Do not operate equipment with protective insulators or covers removed. Service or repair to equipment must only be done by qualified, trained personnel. Do not contact electrically live parts. Do not touch electrode with bare skin and electrical ground at the same time. Always wear dry welding gloves in good condition. Aluminized protective clothing can become part of the electrical path.
When in a confined area, prevent the reflected arc rays from entering around the helmet. Make sure others are protected from arc rays and sparks. Approved shielding curtains and appropriate goggles should be used to provide protection to others in the surrounding area and operators of nearby equipment. Skin should also be protected from arc rays, heat, sparks and molten metal. Always wear protective gloves and clothing, which will not allow skin to become exposed.
American National Standards Institute 1430 Broadway New York, NY 10018. 5. AWS F4.1 "Recommended Safe Practices for Welding And Cutting Containers." The American Welding Society 550 NW Lejeune RD. P.O.Box 351040 Miami FL. 33135 6. NFPA 51B "Fire Prevention in Cutting and Welding Processes." National Fire Protection Association Battery Park Quincy MA 02269 7. CSA Standard W117.2. "Safety in Welding, Cutting and Allied Processes" Canadian Standards Association 178 Rexdale Blvd.
Metal Fabrication Problem: Molten material not being blown out of cut area. Solution: (1) Insufficient oxygen pressure being used. (2) Rubber washer behind collet chuck worn and needs to be replaced. (3) Travel speed too fast. Pierce starter holes in thick plates. Rough-cut pieces of material from large plates. Field construction. Demolition Cut through rebar. Pierce concrete. Remove rivets and frozen bolts. Cut steel imbedded in concrete. Equipment maintenance/repair. Cut corroded material.
Application Data The following chart will help determine the best settings for a specific use. The chart is a result of extensive laboratory testing of the SLICE Equipment to determine the best cutting rates. Actual cutting results obtained in the field will vary due to conditions and to the experience of the user. The way you use SLICE Equipment will also cause your results to vary. For any use, you will need to adjust the settings. The following chart is presented only as a guide.
Cutting rates in this chart were obtained using 80 PSI oxygen pressure and 1/4" x 22" cutting rods. These rates are averaged values based on multiple cutting tests. Actual cutting rates may vary due to parameters used and operator expertise. Cutting Electrode Types Coated Optimum Oxygen Package or Flow Oxygen Quantity Uncoated Pressure Rate Part Number Rod Diameter Rod Length 42-049-002 1/4" 22" Coated 25 80 7.5 CFM 42-049-003 1/4" 22" Coated 100 80 7.
Item 1 2 3 3 4 4 5 6 7 8 9 10 10 11 12 NS NS NS Description Torch Torch Handle Kit (with screws) Shield ¼” Collet Nut 3/8” Collet Nut ¼” Collet Chuck 3/8” Collet Chuck Seat Washer Spark Arrestor Head Assembly Lever Assembly Oxygen Hose Torch Cable - #1 Torch Cable - #10 6” Extension Extension Shield Striker Striker Handle Kit Striker Bar Striker Cable Part Number 94-370-182 94-777-109 94-168-022 94-168-024 94-158-048 94-158-048 94-940-109 94-305-009 94-378-338 94-476-082 94-396-193 96-130-279 96-130-319
Slice Packs Parts Listings Utility Pack Industrial Cart Battery Pack Cordless Striker Pack Complete Pack Part Number 63-991-026 63-991-021 63-991-003 63-991-032 63-991-002 Tool Box, Case or Cart 94-134-049 N/A 94-134-047 94-134-047 94-134-034 Torch 03-003-001 03-003-001 03-003-006 N/A 03-003-006 Striker 72-012-002 72-012-002 72-012-002 72-012-002 72-012-002 Battery or Igniter NONE NONE 96-076-021 72-012-007 96-076-021 Torch Extension 94-168-023 94-168-023 94-168-023 94
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