Page 1 HEAVY-DUTY HAND CUTTING TORCHES AND ACCESSORIES
Page 2 Heavy-Duty Hand Cutting Torch HCT 663: With lever-operated valve for cutting oxygen, for cutting duties involving high thermal loads on slabs, ingots, billets, steel castings and forgings comprising non-alloy and low-alloy steels, and also for cutting up steel scrap. Cutting range with propane, methane (natural gas), town gas up to 600 mm with NZ16BMCD nozzle. Hose connections as per EN 560: Oxygen G1/2 Fuel gas G3/8 -LH HCT 663 with angled torch head HCT 663 with straight torch head Hand Cutting Torch HCT 663 Overall length Version with angled torch head 1.500 mm 9MH10015 2.000 mm 9MH10020 2.500 mm 9MH10025 3.000 mm 9MH10030 Version with straight torch head 1.500 mm 9MH20015 2.000 mm 9MH20020 2.500 mm 9MH20025 3.000 mm 9MH20030 Torch Cutting Nozzles Cutting range Block mixing nozzle type: Cutting nozzle NZ13BMCD 50-300 mm NZ13BMCD Cutting nozzle NZ16BMCD 50-600 mm NZ16BMCD Post mixing nozzle type: Cutting nozzle NZ13PMCD 50-300 mm NZ13PMCD Cutting nozzle NZ14PMCD 50-400 mm NZ14PMCD Cutting nozzle NZ16PMCD 50-600 mm NZ16PMCD
Page 3 Torch head with skid attachment HCT 663 Torch head with torch carriage HCT 663 Accessories Torch Carriage HCT 663 Skid Attachment HCT 663 Attachment Screw HCT 663 9MA00001 9MA00002 9MA00003 Hand cutting torch for iron powder cutting: Iron powder feeding system HCT 663, for cutting of stainless steel, high alloyed steel grades and casted iron. Powder valve Accessories Powder pipe complete, length 725 mm Powder valve Cutting nozzle attachment screw Powder nozzle for straight cut 9MA00004 9MA00005 9MA00006 9MA00007
Page 4 Gas control station: Description Gas control station 9MRH0001 Medium: Consumption max. [m³n/h] Operating pressure max. [bar] Propan 4* 5 Natural gas 20* 5 Oxygen 130* 16 *) Calculated for Block cutting nozzle NZ16BMCD, cutting range up to 600 mm (Consumption data acc. DIN 1945) Separate hose lines: Description Hose Oxygen G1/2 x 20000 x G1/2 DN12,5 Hose Fuel Gas G3/8 -LH x 20000 x G3/8 -LH DN10 5H331200 5H322200
Page 5 Take-up reel with double hose set: Description Take-up reel 20 m hose line; Fuel Gas G3/8 -LH & Oxygen G1/2 Hose Oxygen G1/2 x 2000 x G1/2 DN12,5 (connection to gas station) Hose Fuel Gas G3/8 -LH x 2000 x G3/8 -LH DN10 (connection to gas station) 9CT00200 5H331020 5H322020 Iron powder container IPC75H1W (incl. wheels for transport): Description Iron powder container IPC75H1W Hose Iron Powder G1/4 x 15000 x G1/4 10 x 1,86 Hose Compressed Air G3/8 x 5000 x G3/8 DN10 Iron powder GRISINIT (20 kg bag) PE21HW00 5H415150 5H324050 9MA00008
Page 6 ACCIDENT PREVENTION - SAFETY REGULATIONS The use is required to observe strictly the regulations that exist both in his country and within his company with regard to the operation of machinery and the use of oxygen, fuel gas, compressed air, water and electricity. The following remarks represent a summary of the safety regulations. It is stressed that the user is obliged to comply with all relevant regulations in their entirety. Oxygen Oxygen is an odourless, tasteless, colourless gas that is heavier than air; it lowers the ignition temperature and promotes combustion. All components that come into contact with oxygen must be kept free from oil and grease. (Examples: pipes, hoses, fittings, hand cutting torches, cutting nozzles, tools, rags, clothing, hands). Fuel gases Fuel gases are poisonous and flammable. Mixtures with air or oxygen are explosive. Personnel Persons who operate or maintain cutting equipment must be fully trained and experienced in handling oxygen and fuel gases. Instruction Employees are to be instructed of the hazards and safety regulations. Instructions must be repeated periodically. Eye protection Suitable types of eye protection with protective lenses that comply with safety standard specifications, e.g. goggles or face shields, must be worn to protect against sparks, heat, visible and invisible radiation. Maintenance and repairs All responsible persons and departments must be informed before carrying out maintenance and repair work.
Page 7 Unauthorized persons Unauthorized persons are not permitted in the vicinity of the cutting area, the torch cutting machine, its controls or the operator s cabin. Idle times During periods when the hand cutting torch is not in operation or work is interrupted temporarily the main fuel gas and oxygen valves must be closed. Noise protection Due to the economic performance heavy duty hand cutting torches have a noise level of more than 90 db(a) up to 110 db(a), according to use. At the operator s position the necessary measures must be taken, and protection must be provided by the user. These are so-called secondary measures.
Page 8 CUTTABILITY OF STEEL GRADES The alloy components of steel influence the cuttability and cutting speed as follows: Carbon (C) All carbon steels up to approx. 1,6 % can be cut in the conventional flame cutting process, i.e. without additional fuel gas or iron powder. Steel grades must be preheated in order to prevent cracking where the carbon content exceeds approx. 0,3 % (see also section *Carbon Equivalent*). Other alloy components Conventional flame cutting, i.e. without the use of iron powder, is possible on steel grades which contain the following alloy components: Alloy component Maximum content [%] Remarks C 1,6 if C 0,3 % preheat to prevent cracking Si 2,5 with max. 0,2 % C Mn 13,0 and 1,3 % C 1,3 with pure manganese steels Cr 1,5 without Ni-contents W 10,0 with max. 0,5 % Cr 0,2% Ni, 0,8 % C Ni 7,0 35,0 if C 0,3 % Cu 0,7
Page 9 C-Equivalent: The so-called carbon equivalent C Equivalent = C + Mn Ni Cr Mo V 6 15 5 4 4 gives a guide as to the behaviour of the alloy components by converting them into an approximately equivalent carbon content. Where there is any doubt, it is always advisable to perform test cuts. Where the alloy components account for a high proportion - particularly with Cr and Ni - only the iron powder flame cutting method can be used. START - UP Before start-up of the hand cutting torch the complete plant must be checked under presumption of the relevant accident prevention regulations. Start-up of the torch is only allowed under strict observation of these regulations. Special regard must be given to leak-proofness of all armatures and connections. CAUTION: EXPLOSION HAZARD! During switch-on of the pilot flame an explosive mixture of fuel gas and air is streaming out from the nozzle. Pilot torch must be ignited immediately! Basically the hand cutting torch must be switched on respectively switched off in following sequences: Switch on: 1. Heating oxygen Switch off: 1. Cutting oxygen 2. Fuel gas 2. Fuel gas 3. Cutting oxygen 3. Heating oxygen For safe operation of the torch it is absolutely necessary to install flashback arrestors for fuel gas, heating oxygen an ignition fuel gas at the flexible hose line outlets.
Page 10 MAINTENANCE Regular, thorough maintenance (e.g. at the beginning of a shift) - related to the frequency of plant using - is necessary in order to ensure long service life and high cutting performance. Damaged cutting nozzles are useless; cutting performance will be lost and cutting quality worsens considerably. Cleaning of the block cutting nozzle a) Mechanical cleaning Cleaning of nozzle faces: Minor contaminations at nozzle faces and in direct vicinity of heating bores and of the cutting oxygen channel can be removed by a soft brass brush Cleaning the bore holes: Free the bore holes form dirt by pushing the corresponding cleaning drill gently inside. If the bore holes are burred in any way, remove the burring with a fine emery cloth. Do not chamfer the edges under any circumstances! Spray cutting nozzles with silicone spray in order to prevent adhesion of slag. b) Mechanical machining If the cutting nozzle face is damaged, it is advisable to machine the surface on a lathe. The nozzle can be shortened several times up to a maximum length of 3 mm. Check the three-face cone sealing of the cutting nozzle and the torch head. If damages have been caused, replace cutting nozzle and/or machine cutting torch. Spray cutting nozzles with silicone spray in order to prevent adhesion of slag. Further mechanical machining may not be carried out by the user. c) Important hint for the use of cutting nozzles with cone seals When exchanging the cutting nozzle, in particular on use of new nozzles, firmly tighten the set screw before start-up of the torch, in order to make sure that the sealing faces of the cutting nozzle adapt to the sealing faces of the torch head.
Page 11 In case of extreme heat at the cutting nozzle and the torch head and subsequent cooling down it may cause the cutting nozzle loosen in the torch head and becomes leaky. Therefore, firmly re-tighten the set screw after first heat loading. For this use also a spanner at the torch head as counter measure. Inspecting the cutting nozzle Flame shape: The heating flame of the post mixing cutting nozzle must burn in the form of a well defined, concentrated jet. It must not stray to any side. The single flames of the block mixing cutting nozzle must take the form of a well defined, uniform, elongated cone and must not flatter or emerge at an angle from the bore holes. The cutting jet must appear as a distinct, well defined jet within the flame shape. Checking the torch connections for leak-proofness Check the torch connections for leaks at regular intervals (approx. every 4 weeks), using a leak detection agent. Note: We request your understanding that we reserve the right to make technical changes at any time to the hand cutting torches, block cutting nozzles and accessories, compared with the data and illustrations.