instruction manual slice exothermic cutting equipment

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Instruction ManualFor

SLICE Exothermic CuttingEquipment

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FUNDAMENTALS OF THEPROCESS

Process DescriptionThe SLICE Exothermic Cuttingprocess uses an exothermic chemicalreaction that burns, melts, orvaporizes most materials. Thereaction begins with an electrical arcor alternate energy source thatcauses a steel cutting rod to burn.Oxygen flows through the center ofthe rod.

Because of the rod's design, theburning makes excess heat ("exo -thermic"). This heat cuts theworkpiece. Once started, the burn willcontinue as long as oxygen flowsthrough the rod. The heat createdmelts the material being cut. Thevelocity of oxygen through the rodblows the molten material away,creating the kerf or cut line.

This arc ignition process led toinvention of the "oxy-arc" torch anddesign of equipment for underwaterconstruction and salvage.

The electrical arc that starts the burncan be from a welding power sourcethat delivers at least 100 amps, a 12-volt lead acid or similar lowimpedance battery. The cuttingprocess can run without power, usingthe heat of the reaction only, or withpower, cutting with an electrical arcfrom a welding power sourceproviding more heat.

HistoryThe exothermic cutting rod is a small"oxygen lance." It is a prime exampleof the combustion triangle, one sidebeing fuel (the steel lance), thesecond the oxygen source (pureoxygen being forced through the

lance), and the third the heat ofcombustion (some external source ofheat). However, when the lancepierces a slag puddle, the puddlebecomes the source of heat until thelance is withdrawn, at which timeburning stops.

In 1888, a published paper describedpassing oxygen through a steel tubeand heating the tube to a bright red.Heat resulted. In 1901, Ernst Hennerfiled a German patent on an earlyoxygen lance made of two concentrictubes. In 1902, documentationshows that the oxygen lance replacedoil and gas torches for openingfurnace taps in steel blast furnaces.The oxygen lance has since beenused to cut rocks and concretestructures. An example of this use iscutting up reinforced concretestructures such as bunkeremplacements and tank traps built inEurope during World War II.

An ideal way to start the lance,workers found, was to use a weldingpower source on conductive materialto strike an arc and start the burn. Inconstruction this process worked well,even in mud and water.

Around 1940, the burning bar orexothermic lance was first marketedas a cutting tool. A flexible versionmade of an insulated cable wasintroduced around 1960. Not until theearly 1980's were smaller burningbars designed for hand-torch use,above and below water. A one-pieceunit now allows for adequate rodsurface exposure to an oxygensupply for exothermic cutting. ArcairCompany, a world leader in metalremoval and cutting, sells thisexothermic cutting equipment underthe trade name SLICE.

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PRINCIPLES OFOPERATION

GeneralSLICE Exothermic Cutting uses heatfrom a chemical reaction between aconsumable steel rod and oxygenflowing through the rod. Test datashow that little or no oxygen remains.The oxygen not used in the reactionblows the molten material out of thecut area. This action creates the kerfthat allows cut progression.

Exothermic cutting can be used withor without power. Without power, theheat from the reaction alone willmake the cut. With power, anelectrical arc from a welding powersource increases the heat from thereaction. These differences will bediscussed in detail later.

Both methods use the sameconsumable rod. This rod is insertedinto the torch and locked into place.The oxygen lever on the torch isdepressed and the arc, to start theburn, is established. Once the rodburn has begun, the rod tip should beplaced at the cut area with slightcontact between the tip of the rod andthe work piece.

The burning rod tip must be kept inslight contact with the work piece toachieve the most efficient cut. Rodsused in exothermic cutting can beconsumed without any cutting takingplace. Tip contact tells the operatorthat the most intense heat from the

rod is in direct contact with theworkpiece, ensuring the best cuttingspeeds.

FIGURE 1 How the Torch Works

Cutting Without PowerCutting without power is cutting withthe heat from the reaction betweenthe rod and the oxygen. This type ofcutting is done by igniting the rod offa spark supplied by a 12-volt batteryor by a welding power source capableof delivering a 100-amp surge.

Once this spark has ignited the rod,the electrical path is broken and theheat of the reaction melts the materialand cuts it.

Cutting without power can be done inremote areas. Bulky power sourcesand support equipment is not needed.

Cutting With PowerCutting with power requires anelectrical arc from a welding powersupply and increases the heatcreated exothermically. Almost allconstant-current welding powersupplies can be used in poweredexothermic cutting. Cutting withpower is faster than cutting withoutpower.

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SLICE RODCOLLET CHUCKHEAD ASSEMBLYCOLLET NUTCUTTING OXYGENOXYGEN LEVERSHIELDSPARK ARRESTOR

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Constant-voltage power suppliesshould not be used with exothermiccutting equipment. When theexothermic cutting rod contacts theworkpiece, the power supply is beingdead shorted, causing maximumamperage output of the power supply.This surge can exceed the ratedoutput of the machine and therecommended amperage for poweredexothermic cutting.

Oxygen SupplyThis cutting process uses standardindustrial-grade oxygen to support theexothermic reaction and to removemolten metal. All SLICE equipmentuses standard oxygen fittings. SLICEtorches are equipped with 10 feet of1/4" I.D. oxygen hose. The usualoperating pressure is 80 psi.Applications such as cutting materialsections 3" and thicker might requirehigher operating pressures.Pressures as low as 40 psi havebeen used to do jobs such aswashing off rivet heads and scarfingout small cracks for repair.

The oxygen consumption rate forSLICE cutting rods at 80 psi is 7 to7.5 cfm for the 1/4" diameter cuttingrods and 12 to 13 cfm for the 3/8"diameter cutting rods. This rate willvary if a different operating pressureis used.

Compressed air should not be usedfor exothermic cutting. Compressedair does not contain enough oxygento support the burn. Impurities incompressed air can damage ordestroy the torch and components.Compressed air could cause seriousinjury to the operator. The torchcould burn from the inside or evenexplode from the buildup of dirt fromthe compressed air in the oxygen-supply tube.

Cutting RodsSLICE Cutting Rods are made ofcarbon steel. They are made byrolling a steel strip into a rod.

There are coated and uncoatedcutting rods. The coating is made ofarc stabilizers and a binder. Thereare several advantages to using thecoated rods with power. Advantagesare (1) more efficient cutting rates(more cut per inch of rod burnt andmore cut per minute of burn time); (2)easier rod operation; and (3)protection from burning out on theside of the rod especially whenpiercing.

These SLICE cutting rods areavailable:

1/4" x 22" (6.4 mm X 558.8 mm)Standard size cutting rods used in avariety of jobs. This rod isrecommended for all straight-linecutting and most general-cuttingapplications. It is available coated oruncoated.

1/4" x 44" (6.4 mm X 1117.6 mm)This rod is used when greater lengthis needed to reach the cutting area orwhen piercing holes in materialsthicker than 18". 1/4" x 44" rods areavailable uncoated.

3/8" x 18" (9.5 mm X 457.2 mm)These rods are used for heavypiercing with a large bore. The 3/8" x18" cutting rod comes coated oruncoated.

3/8" x 36" (9.5 mm X 914.4 mm) Thisrod is used when added length isneeded to complete cutting. 3/8" x36" cutting rods come uncoated only.

All SLICE cutting torches come readyto use the 1/4" diameter rods. Use ofthe 3/8" diameter rods requires the3/8" adapter kit.

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OPERATINGTECHNIQUES

Cutting Without PowerThis is the most commonly usedmethod of cutting with this type ofequipment. To cut without powerconnect the torch to either terminal ofa 12-volt battery or constant-currentwelding power source. Connect thestriker or a strike plate to the otherterminal. If using a welding powersource, set output level for 100 amps.Turn on the oxygen supply and adjustthe regulator to the proper workingpressure. Insert the cutting rod intothe collet and tighten the collet ring.

Tap the cutting rod on a hard,ungrounded surface to seat the rod inthe torch. Depress the torch oxygen-valve lever and check for oxygenleaks around the collet ring. Ifoxygen is leaking, repeat theprocedure until no oxygen is leaking.

Put the torch in one hand and strikerin the other. Depress the oxygenlever and touch the cutting rod to thestriker. As soon as the rod is ignited,remove the striker. Move the burningrod to the workpiece and begincutting. The cutting rod should beheld at a 45° to 80° drag angle fromthe workpiece surface. This angledepends on the thickness and type ofmaterial being cut. (See Section"Important Process Variables",Paragraph "Electrode-to-WorkAngle")

As the cut progresses, slight contactshould be made between the burningrod tip and the workpiece. Thisplacement requires two motions: first,inward towards the workpiece as therod is consumed, and second, in thedirection of the cut. Since there is noelectrical arc when cutting without

power, wear at least a #5 shade lensfor eye protection.

FIGURE 2 Cutting Without Power

Cutting With PowerCutting with power or an electric arcis done by connecting the torch toone terminal and connecting awelding ground clamp to the otherterminal of a CC welding powersource. The ground clamp is thenattached to the workpiece. Unlikeother processes, this process can usea welding power source set for DCEP(reverse polarity) or DCEN (straightpolarity). AC (alternating current)power supplies can also be usedwithout affecting cutting performance.Don't cut with power using aconstant-potential power source.

Insert the cutting rod into the colletand tighten. Start the oxygen flow,touch the rod tip to the workpiece,and begin cutting. Again, as incutting without power, the cutting rodshould be held at a 45° to 80° dragangle from the workpiece surface.(See Section "Important ProcessVariables", Paragraph "Electrode-to-Work Angle") As the cut proceeds,make slight contact between theburning rod and the workpiece. Thisplacement requires two motions: first,inward towards the workpiece as therod is consumed and, second, in the

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�� 12 VOLT BATTERY(IGNITION SOURCE)

TORCH

STRIKER

CUTTING ROD

OXYGEN SUPPLY

1. CONNECT TORCH TO NEGATIVE LUG ON BATTERY.2. CONNECT STRIKER TO POSITIVE LUG ON BATTERY.3. SET OXYGEN PRESSURE TO 80 PSI.4. TIGHTEN CUTTING ROD IN TORCH COLLET.5. DEPRESS OXYGEN TRIGGER ON TORCH.6. TOUCH CUTTING ROD TO STRIKER TO IGNITE ROD.

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direction of cut. When cutting withpower, the operator must use aprotective lens shade #10 or higher toprotect from arc flash.

FIGURE 3 Cutting With Power

Hole PiercingMost piercing operations should bedone without power. To pierce ahole, ignite the cutting rod asexplained in the cutting-without-Power section. Move the burning rodto the pierce point and with the rodangled away from the operator, beginpiercing the hole. Once the hole isunder way, bring the cutting rodperpendicular to the surface of theworkpiece. Keep the cutting rod deepenough in the hole to feel slightresistance from the non-moltenmaterial at the base of the hole.While the hole is being pierced, use aslight circular motion to keep the rodfree of molten material coming out ofthe hole. During the piercingoperation, the rod should be moved inand out of the hole occasionally tomaintain an open path for the moltenmaterial.

During a piercing operation themolten material will be coming backup the rod. Wear proper clothing forprotection from the molten spray.The torch should be held at arm'slength to keep the operator as faraway from the molten material aspossible. To protect the operator and

torch, an optional 6" collet extensionand extension shield are available forthe SLICE cutting torch.

Piercing in the flat position is moredifficult than piercing horizontally.Progression while piercing flat willalso be slower. (Example: Piercing ahole in a floor is more difficult andslower than piercing a hole in a wall.)

Cutting Copper and CopperAlloysBecause of the very rapid heatabsorption of copper and its alloys, allcutting on these materials should bedone with power. The maximumamperage to use with copper is 300amperes. Copper quickly absorbsthe heat created from the exothermicreaction, reducing the effectivenessof the cutting process. The heat isstronger when cutting with power,making it possible to cut some copperpieces. The larger the size of the partthe more difficult it is to cut. A sawingmotion into the cut kerf will speedcutting.

Piercing Copper and CopperAlloysWhen piercing copper and its alloys,use power. Using power to piercecopper will cause extremely fast rodconsumption. The higher the coppercontent of the part the harder thematerial is to cut. Brass, bronze andother alloys are slightly easier to cut,but these alloys should be cut usingpower, if possible.

EQUIPMENT SELECTION

SLICE Torch and StrikerThe SLICE Torch is a gun shapedtool that provides a means of grippingthe rod and supplying the oxygen andpower to the cutting rod. The basictorch comes complete with 10 feet of

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CUTTING ROD

WORKPIECE

OXYGENSUPPLY

WELDING POWER SOURCE

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1. CAN USE EITHER DCEP(REVERSE) ORDCEN(STRAIGHT) POLARITY

2. NEVER USE CONSTANT VOLTAGE(CV) POWERSUPPLY.3. USE MAXIMUM OF 200 AMPS

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power cable and oxygen hose. Thepower cable is of sufficient size tocarry 200 amps in a power cuttingoperation. The oxygen hose comeswith a standard size oxygen fittingand is ready to be connected to theuser's oxygen regulator. Thisstandard torch comes with a flexiblehand shield that is easily replaceableif damaged. The SLICE Torch ismolded from a glass reinforcedthermoset plastic, which is ruggedand will withstand the punishment offrequent everyday use.To help reduce torch wear or damagewhen piercing, an optional 6" colletextension and 6" diameter extensionshield is available. Also available is a3/8" adapter kit consisting of a colletchuck, collet nut, washer, andflashback arrestor needed to adaptthe torch for using the 3/8" diametercutting rods.To compliment the basic SLICE torchwhen cutting without power a SLICEStriker is also available. The striker isan insulated piece of copper platewith a serrated surface to provide aconvenient means of igniting thecutting rod. By scratching the rodagainst the copper plate an arc isinitiated and the cutting processbegins. The SLICE striker alsocomes standard with a 10-foot cable.

FIGURE 4 SLICE Torch and Striker

Other EquipmentSLICE Cutting Equipment is alsoavailable in ready to go packages.Each pack is design to fit a specificneed. The packs give the user all theexothermic cutting equipment heneeds to compliment his shop orservice vehicle.These packs start with the very basicunit that includes; torch, striker andother support items in a handytoolbox. This type pack is just rightfor a service truck or for the weldingjobber who has oxygen and anignition source available.A complete package is also available.The SLICE Pack Complete wasdesigned for use in emergencies. Allyou need for cutting is available andready for immediate use. This packcontains a 12-volt rechargeablebattery for rod ignition. The carryingcase has a compartment for a 40-cubic-foot oxygen bottle (supplied bythe user).The amount of burning this unit cando depends on the size of the oxygensupply. With a 40-cubic-foot oxygenbottle 8 to 10 rods can be burned,representing 5 to 7 minutes of cuttingtime.Other packages are also available forboth field use and inside a largefactory. Each of these units isdesigned to fit a specific need.The Arcair Company has alsodeveloped specialty exothermiccutting units. They have developed aunit being called "PECU” or PortableExothermic Cutting Unit that is beingsupplied to the U.S. Navy for use indamage control.

SLICE Pack Battery BoxAssemblySome packs include a 12-voltrechargeable battery. The batteryand charging circuitry are enclosed ina protective case. Supplied with thebattery box is a cord for rechargingfrom a 120-volt AC outlet.

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SLICE TORCH

SLICE STRIKER

RED MALE CONNECTOR

TORCH CABLE

BLACK MALE CONNECTOR

STRIKER CABLE

OXYGEN HOSE CONNECTION

COLLECT RING

OXYGEN VALVE LEVER

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SLICE TORCH ANDSTRIKER ASSEMBLIES

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When using the battery supplied withthis unit, the three-position switch onthe face of the battery box must be inthe "CUT" position when igniting therod.To check the charge on the battery,push the mode switch to the "TEST"position. The meter will register thecharge level. The mode switch mustbe put in the "CHARGE" positionwhen the battery is recharged.The battery should be rechargedwhen the indicator is close to or in thered zone of the meter. Rechargetime depends on the level of battery'sdischarge level. A fully dischargedbattery will take 12 hours to recharge.

FIGURE 5 SLICE Battery BoxAssembly

IMPORTANT PROCESSVARIABLES AND THEIREFFECTS

Process VariablesExothermic cutting is easier thanmost cutting processes to do. It canbe done improperly though.Variables can reduce the efficiency ofthis process, resulting in poor cutting.Major variables requiring attention arelisted and discussed below.

Oxygen PressureThe oxygen in this process maintainsthe exothermic burn and removes themolten material from the cut. 80 psiyields the most efficient cutting rates(amount of cut per inch of rodburned), on materials up to 3" thick.Using pressures less than 80 psi onsuch materials reduces cutting ratesbecause there is not enough pressureto remove the molten material.Using pressures under 80 psi isadvantageous for scarfing. Lowerpressures offer a more controllablescarfing action. With material thickerthan 3", pressures over 80 psi can beused to give the oxygen enoughvelocity to blow away molten materialat the bottom of the cut. Using higherpressures on thicker materials causesa more forceful oxygen jet and fasterrod consumption. A sawing motionwith 80 psi or a larger-diameter rodmay help cut these materials moreefficiently.80 psi is the best pressure to usewhen piercing. To pierce, anoperator should reduce the pressureslightly to control the distance themolten material travels. Once there isa hole, full pressure should be used.The operator can vary pressure byusing the torch's oxygen lever. Theonly time pressures above 80 psi areused in piercing is when the thicknessof the material - usually more than12" - needs added pressure to blowthe molten material out of the piercehole.

AmperageIn exothermic cutting electricalcurrent increases the heat from thereaction, allowing faster cutting. 200amps yields the most efficient cuttingrates with power. When cutting withpower and using less than 200 amps,the amount of cut per minute will belower. Amperage above 200 ampsconsumes the rod faster, reducing thecut per inch of rod burned.Exothermic cutting equipment uses

CUT

CHARGE TEST

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GOODRECHARGE

STRIKER

TORCH

CUT

CHARGE TEST

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SWITCH IN TEST POSITION

SWITCH IN CHARGE POSITION

ARCAIR SLICE BATTERY ASSEMBLY

SWITCH IN CUT POSITION

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around 200 amps. Exceeding thisamperage could cause equipmentdamage.When cutting without power, currentfrom the battery ignites the rod. Toignite the rod a surge of at least 100amps is needed. If the battery hasnot been properly charged it will nothave enough amperage to ignite thecutting rod.

Travel SpeedThis cutting rod will burn without anelectrical arc, regardless of whetherthe user is cutting. Therefore, cut asfast as possible without losing the cutkerf. If the travel speed is too fast,the material will not be cut completelythrough and molten slag will be blownback from the workpiece.

Electrode-to-Work AngleThe electrode-to-work angle is themost forgiving process variable.However, use of an improper anglecan cause reduced cutting efficiency.For most cutting jobs this angle isbetween 45° and 80°. The thicker thematerial the closer to the 80° anglethe rod should be held. In almost allcutting the electrode-to-work angle isa drag angle. A drag angle is one inwhich the rod is held so the tip of theburning rod is away from the directionof travel. One exception is cuttingsheet metal. Such cutting is usuallyfaster and better controlled when theuser keeps a 45° angle or slightly lessand pushes the rod in the direction ofcut. Aluminum, regardless of itsthickness, requires a 70° to 80° dragangle.

SAFETY AND HEALTH

IntroductionSLICE Cutting Equipment usesindustrial grade oxygen to produce itsvery effective cuts. Industrialstandards associated with oxygenuse, electrical equipment, cutting

procedures and other safetyprecautions apply when using thisequipment. This section highlightsthese procedures. Refer to ANSI/ASC"Safety in Welding and Cutting"safety standards (Z49.1-1983) orother prevailing standards for furtherdetails. SERIOUS INJURY ORDEATHmay result if exothermic cuttingequipment is not properly installed,used and maintained. Misuse of thisequipment and other unsafe practicescan be hazardous. The operator,supervisor and helper must read andunderstand the following safetywarnings and instructions beforeinstalling or using any cutting torch orequipment.The exothermic cutting process isused in many potentially dangerousenvironments such as elevatedheights, areas of limited ventilation,close quarters, in hostileenvironments, etc., and it is importantthat the operators are aware of thedangers associated in working inthese types of conditions. Be certainthat the operator(s) are trained in safepractices for the environments inwhich they are expected to work andare under competent supervision.It is essential that the operator,supervisor and others in the workarea are aware of the dangers of theexothermic cutting process. Trainingand proper supervision are importantfor a safe work place. Keep theseinstructions for future use. Additionalrecommended safety and operatinginformation is referenced in eachsection.

ELECTRIC SHOCKCAN CAUSE INJURYOR DEATH

Install and maintainequipment in accordance with theNational Electrical Code NFPA 70

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and local codes. Do not service orrepair equipment with power on. Donot operate equipment with protectiveinsulators or covers removed.Service or repair to equipment mustonly be done by qualified, trainedpersonnel. Do not contact electricallylive parts. Do not touch electrodewith bare skin and electrical ground atthe same time. Always wear drywelding gloves in good condition.Aluminized protective clothing canbecome part of the electrical path.Keep oxygen cylinders, chains, wireropes, cranes, hoists, and elevatorsaway from any part of the electricalcircuit. All ground connections mustbe checked periodically to determinethat they are mechanically strong andelectrically adequate for the requiredcurrent.Using alternating current is notrecommended for exothermic cuttingunder wet conditions or warmsurroundings where perspiration is afactor. Constant potential type powersupplies shall not be used to supplycurrent for exothermic cutting. It isnot recommended to use anamperage output greater than 200amps.When cutting is to be suspended forany substantial period of time, suchas during lunch or overnight, all rodsshould be removed from the torchand the torch carefully located so thataccidental contact cannot occur. Thetorch must be disconnected from thepower source when not in use. Neverimmerse exothermic cutting torchesin water when cutting with an arc froma welding power supply. Wheneverpossible do not use electrical powerto do exothermic cutting.SEE SAFETY AND OPERATINGREFERENCES 1 AND 2

SMOKE, FUMES ANDGASES CAN BEDANGEROUS TO YOURHEALTH

Keep smoke, fumes and gases fromthe breathing area. Fumes from thecutting process are of various typesand strengths, depending on the kindof base metal being worked on. Toensure your safety, do not breathethese fumes. Ventilation must beadequate to remove smoke, fumesand gases to protect exothermiccutting operators and others in thearea. Vapors of chlorinated solventscan form the toxic gas "Phosgene"when exposed to ultraviolet radiationfrom an electric arc. All solvents,degreasers and potential sources ofthese vapors must be removed fromthe work areaFumes produced by cuttingparticularly in confined places cancause discomfort and physical harm ifinhaled over an extended period oftime. Provide adequate ventilation inthe cutting area. Use air-suppliedrespirators if ventilation is notadequate to remove all fumes andgases. Never ventilate withoxygen, because oxygen supportsand vigorously accelerates fire.SEE SAFETY AND OPERATINGREFERENCES 1, 2, 3, AND 4

ARC RAYS, HOT SLAGAND SPARKS CANINJURE EYES AND BURNSKIN

This cutting process producesextreme localized heat, and canproduce strong ultraviolet rays.Never attempt to cut without eye andface protection that complies withfederal guidelines. A number 10 to12 shade lens provides the bestprotection against arc radiation whenusing an electrical arc. A number 5-shade lens should be used whencutting without an electrical arc.

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When in a confined area, prevent thereflected arc rays from enteringaround the helmet. Make sure othersare protected from arc rays andsparks. Approved shielding curtainsand appropriate goggles should beused to provide protection to others inthe surrounding area and operators ofnearby equipment.Skin should also be protected fromarc rays, heat, sparks and moltenmetal. Always wear protective glovesand clothing, which will not allow skinto become exposed. All pocketsshould be closed and cuffs sewnshut. Leather aprons, sleeves,leggings, etc. should be worn for out-of-position cutting. High top workshoes provide adequate protectionfrom foot burns. For added protectionuse leather spats. Flammable hairpreparations should not be usedwhen cutting. Wear earplugs toprotect ears from sparks.SAFETY AND OPERATINGREFERENCES 1, 2, AND 3.

WELDING SPARKSAND COMPRESSEDGASES CAN CAUSEFIRES ANDEXPLOSIONS

Causes of fire and explosion are;combustibles reached by the arc,flame, flying sparks, hot slag orheated materials. Removecombustibles from the work areaand/or provide a fire watch. Avoidoily or greasy clothing as a spark mayignite them. Have a fire extinguishernearby, and know how to use it. Bealert to the danger of conduction orradiation, for example if cutting is tobe done on a metal wall, partition,ceiling or roof, precautions must betaken to prevent ignition ofcombustibles on the other side. Donot cut containers that have heldcombustibles. All hollow spaces,cavities and containers should bevented prior to cutting to permit the

escape of air or gases. Purging withinert gas is recommended.Exothermic cutting operations useoxygen, therefore all safetyprecautions concerning the use ofoxygen must be observed. Oxygenitself is not flammable, however, thepresence of pure oxygen willdrastically increase the speed andforce with which burning takes place.Always refer to oxygen by its fullname "oxygen," and not by the word"air." Never allow oil, grease or otherpetroleum-based substances to comein contact with cylinder valves,regulators, hoses or any other part ofthe oxygen supply system. Do not letan arc, cutting rod or flame touch anypart of the oxygen supply system.Chain or secure cylinders to an objectsuch as a cylinder cart, wall,workbench, post, etc. When movingcylinders, always be certain that valveprotection caps are securely in place.Never stand in front or behind aregulator when opening the cylindervalve. Always stand so the cylinder isbetween you and the regulator.Never use compressed air instead ofoxygen. Keep oxygen cylinders awayfrom electrical connectionsSEE SAFETY AND OPERATINGREFERENCES 1, 2, 5, AND 6.

SAFETY AND OPERATINGREFERENCES

1. Code of Federal Regulations,(OSHA)

Section 29 Part 1910.95, 101, 132, 133, 134, 139, 251, 252, 253, 254, AND 1000. U.S. Government Printing Office Washington, DC 204022. ANSI Z49.1 "Safety In Welding And Cutting."3. ANSI Z87.1 "Practice for

Occupational and EducationalEye and Face Protection

4. ANSI Z88.2 "Standard Practicefor Respiratory Protection."

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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. 331356. NFPA 51B "Fire Prevention in

Cutting and Welding Processes." National Fire Protection Association Battery Park Quincy MA 022697. CSA Standard W117.2. "Safety

in Welding, Cutting and AlliedProcesses"

Canadian Standards Association 178 Rexdale Blvd. Rexdale, 0ntario, Canada M9W 1R3

AREAS OF APPLICATION

Here is a partial list of uses for SLICEequipment.

ConstructionBridge repair. Cutting structural steel.Pierce and remove rivets and boltswithout damaging surroundingmaterial. Punch holes in concrete,crack rocks. Highway maintenance.Repair of highway guardrails. Cutreinforcing rods. Cut plaster orconcrete insulated pipes. Repairs onheavy equipment. Removing oldstructural steel. Scrap clean up.Salvage work.

Plant MaintenanceEquipment/machinery repair.Remove headless bolts or frozenpins. Remove seized bearings. Plantrenovation. Removing old pipingsystems. Punch lag holes to secure

machinery. Repair machine bases.Remove old machinery. Cut up orrepair storage tanks.

Heavy Equipment MaintenanceGeneral maintenance (field or shoprepairs). Repair buckets. Removeseized or worn pins. Cut worn orfrayed control cables. Cut badlycorroded material.

FoundryRemove core sand trapped in holesof castings. Remove areas ofimbedded sand. Cut gates, risers, finsfrom castings. Cut small multiplecastings from runners. Cut throughslag in furnace cleanup. Punch reliefholes in molds. Cut up spilledmaterials for remelting. Cut up scrapcastings. General plant maintenance.

Fire Service RescueDepartmentsRapid entry into buildings. Cutthrough steel doors, dead bolts,barred windows, overhead doors. Cutthrough debris (metal, concrete,plaster, rock) from building collapse.Rescue operations.

Police/SwatRapid entry into buildings. Cutthrough steel doors, dead bolts,barred windows, overhead doors.Rescue operations.

RailroadRail car repair and maintenance.Track maintenance/cut damagedsections of track. Repairs in remoteyard locations. Remove old railloading docks.

MiningEquipment maintenance (field andshop repairs). Cut steel cables.Repair coal tipples. Belt repairs.Remove abandoned piping andrailways. Piercing holes in rock to setblasting charges.

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Metal FabricationPierce starter holes in thick plates.Rough-cut pieces of material fromlarge plates. Field construction.

DemolitionCut through rebar. Pierce concrete.Remove rivets and frozen bolts. Cutsteel imbedded in concrete.Equipment maintenance/repair. Cutcorroded material.

Power PlantsGeneral maintenance. Removal ofpiping. Cut out scrap feeder pans.Remove old grating covered withrefractory. Remove old boilers.Remove or repair storage tanks.

FarmingGeneral maintenance.Equipment/machinery repair. Repairstainless steel fertilizer tanks. Cutmetal encrusted with rust and/or mud.

Scrap/Salvage YardsCut all types of scrap metal, includingcast iron, stainless steel, andaluminum. Cut up scrap cars inremote areas of yard. Equipmentmaintenance. Cut badly corroded orcrusted material.

TROUBLE SHOOTINGThe SLICE Exothermic Cuttingprocess is not complicated to use ormaintain, but sometimes problems doarise. Some common problems andtheir solutions are listed below:Problem: Rod burns but with no cutprogression.Solution: (1) To much gap between theburning rod tip and the workpiece.Must maintain slight pressure againstworkpiece.(2) Travel speed too slow.(3) Oxygen pressure too low.

Problem: Molten material not being blown outof cut area.Solution:(1) Insufficient oxygen pressure beingused.(2) Rubber washer behind colletchuck worn and needs to bereplaced.(3) Travel speed too fast.Problem:Battery will only start a few rodsbefore charge is depleted.Solution:(1) Battery was not given sufficienttime to recharge.(2) Three-position switch on batterybox not put in the "CHARGE"position.(3) Battery needs to be replaced.(4) Battery left exposed tosubfreezing temperatures.Problem:Torch shield is being burnt off aroundcollet nut.Solution:(1) Rod is not properly seated intorch. Refer to section on operatingtechniques to properly seat rod.(2) Collet extension not used whenpiercing holes.Problem:When piercing anything but copperand its alloys, the rod consumesextremely fast.Solution:(1) Operator is piercing with power.All piercing operations except oneson copper and its alloys should bedone without power.Problem:Arced collet chuck and/or rod isburned off just outside of collet chuck.Solution:(1) Using a CP type welding powersource.

Application DataThe following chart will help determine the best settings for a specific use. The chartis a result of extensive laboratory testing of the SLICE Equipment to determine thebest cutting rates. Actual cutting results obtained in the field will vary due toconditions and to the experience of the user. The way you use SLICE Equipment willalso cause your results to vary. For any use, you will need to adjust the settings. Thefollowing chart is presented only as a guide.How To Use ChartThe data chart is simple to use. First, best cutting was achieved by using an oxygenpressure of 80 psi. Some uses may require higher or lower oxygen pressures.Minimum oxygen pressure to use with the SLICE Torch is 40 psi.; maximumpressure is 100 psi. Amperage over 200 amps does not improve cutting speed.The chart is divided first by metal type and thickness.A) Find the right metal and thickness. For composites or unlisted metals, locate thelisted type that most resembles the material to be cut.NOTE: All these cutting values are based on 1/4" diameter flux-coated rods. Cuttingrates with 1/4" bare rods will be slightly less than the values listed in the chart.

Cutting Rates

MaterialThickness

Length of CutPer Inch

Rod UsedCutting SpeedMaterial

TypeInches mm Inches cm In/Min cm/Min

1/8 3.2 2.25 5.7 72 183¼ 6.4 1.50 3.8 52 132

3/8 9.5 1.38 3.5 42 106½ 12.7 1.25 3.2 35 89

CarbonSteel

¾ 19.1 0.75 1.9 22 56

1/8 3.2 2.00 5.1 65 165Stainless ¼ 6.4 1.13 2.9 36 91

¼ 6.4 1.75 4.4 58 1473/8 9.5 1.25 3.2 38 97Aluminum3/4 19.1 0.75 1.9 23 58

Sample SelectionsCutting 3/8" (9.5 mm) aluminum with 1/4" fluxed rod: APPROX. cut/inch rod = 1.25in. (3.2 cm) Amount of cut per rod = 19 usable inches (48.3 cm) of rod multiplied by1.25 in. (3.2 cm) of cut/inch rod = 23.8 in. (60.5 cm) cut per rod used. APPROX.cut/min. arc time = 38 inches (97 cm).

Cutting 1/4" (6.4 mm) carbon steel with 1/4" fluxed rod: APPROX. cut/inch rod = 1.5in. (3.8 cm) Amount of cut per rod = 19 usable inches (48.3 cm) of rod multiplied by1.5 in. (3.8 cm) of cut/inch rod = 28.5 in. (72.4 cm) cut per rod used. APPROX.cut/min. arc time = 52 in. (132 cm).

Cutting rates in this chart were obtained using 80 PSI oxygen pressure and 1/4" x22" 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 TypesPart

NumberRod

DiameterRod

LengthCoated

orUncoated

PackageQuantity

OptimumOxygen

Pressure

OxygenFlowRate

RodBurnTime

42-049-002 1/4" 22" Coated 25 80 7.5 CFM 40 – 45Seconds

42-049-003 1/4" 22" Coated 100 80 7.5 CFM 40 – 45Seconds

43-049-002 1/4" 22" Uncoated 25 80 7.5 CFM 40 – 45Seconds



42-049-005 3/8" 18" Coated 50 80 12 CFM 30 – 35Seconds

43-049-007 3/8" 18" Uncoated 50 80 12 CFM 30 – 35Seconds

43-049-009 3/8” 36" Uncoated 25 80 12 CFM 60 – 70Seconds

SLICE Cutting Torches

CableSize

PowerCableLength

OxygenHose

Length

CuttingWith

Power

CuttingWithoutPower

03-003-000 #1 10' 10' Recommended Can Be Used

03-003-001 #6 10’ 10’ Limited Use Only Recommended

03-003-006 #10 10' 10' Not Recommended Recommended

Item Description Part NumberTorch

1 Torch Handle Kit (with screws) 94-370-1822 Shield 94-777-1093 ¼” Collet Nut 94-168-0223 3/8” Collet Nut 94-168-0244 ¼” Collet Chuck 94-158-0484 3/8” Collet Chuck 94-158-0485 Seat Washer 94-940-1096 Spark Arrestor 94-305-0097 Head Assembly 94-378-3388 Lever Assembly 94-476-0829 Oxygen Hose 94-396-193

10 Torch Cable - #1 96-130-27910 Torch Cable - #10 96-130-31911 6” Extension 94-168-02312 Extension Shield 94-777-111

StrikerNS Striker Handle Kit 94-370-181NS Striker Bar 96-070-031NS Striker Cable 96-130-320

SLICE AccessoriesDescription Part

Number Description PartNumber

3/8” Rod Conversion Kit 94-463-032 55 Cu Ft. Oxygen Cylinder 94-208-0023/8” Collet Chuck 94-158-045 Oxygen Cylinder Carry Case 94-134-046SLICE Gloves 94-351-002 Torch Extension & Shield 94-287-013Harness Assembly 94-463-042 Replacement 12-volt Battery 96-076-01810’ (3 m) Cable & Hose Extension 96-130-294 Battery Box Assembly 96-076-021Preset Oxygen Regulator 94-698-084

Slice Packs Parts ListingsUtilityPack

IndustrialCart

BatteryPack

CordlessStrikerPack

CompletePack

Part Number 63-991-026 63-991-021 63-991-003 63-991-032 63-991-002

Tool Box, Case orCart 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 94-168-023 94-168-023

Extension Shield 94-777-111 94-777-111 94-777-111 94-777-111 94-777-111

Red BatteryClamp 96-168-035 96-168-035 NONE NONE NONE

Black BatteryClamp 96-168-036 96-168-036 NONE NONE NONE

Instruction Manual 89-250-845 89-250-845 89-250-845 89-250-845 89-250-845

!/4” Cutting Rods NONE 43-049-002 25UNCOATED

25UNCOATED

25UNCOATED

Battery Charger orCable NONE N/A 96-130-297 96-076-034 96-130-297

Oxygen Regulator NONE 94-698-084 NONE NONE 94-698-084

Oxygen Cylinder NONE NONE NONE NONE 94-208-002

Ref. No. Description Part Number1 Front Half Battery Case 94-134-0432 Back Half Battery Case 94-134-0323 Circuit Board Assembly 96-162-7524 Battery Assembly 96-076-0185 6-Pin Male Connector 96-169-3826 Red Female Panel Receptacle 96-169-3747 Black Female Panel Receptacle 96-169-3758 Meter 96-508-0419 Toggle Switch 96-834-34710 Toggle Switch Seal 94-766-05211 Circuit Breaker 96-110-01212 Circuit Breaker Seal 94-766-05313 Connector Cover 94-171-285

WORLD HEADQUARTERS: Suite 300, 16052 Swingley Ridge Road, St. Louis, MO 63017 636-728-3000 THERMADYNE®U.S. CUSTOMER Service: P.O. BOX12250 • Wichita, KS 67277 800-231-9353 • FAX 800-633-9513

Form No. 89-250-845 (07/2003) © Tweco Products Inc., 2003 Printed in U.S.A.

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