slice® exothermic cutting equipment

slice® exothermic cutting equipment
SLICE® TORCH
SLICE® PACKAGE
SLICE® STRIKER
SLICE® EXOTHERMIC
CUTTING EQUIPMENT
SAFETY AND
OPERATING INSTRUCTIONS
English
Art# A-13112
Revision: AC Issue Date: Jan. 15, 2015
Manual No.: 89250845
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Arcair® product. We are proud to have you as our customer and
will strive to provide you with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network. To locate your nearest
distributor or service agency call 800-426-1888, or visit us on the web at www.esab.com/
arcair.
This Manual has been designed to instruct you on the correct installation and use of your Arcair
product. Your satisfaction with this product and its safe operation is our ultimate concern.
Therefore, please take the time to read the entire manual, especially the Safety Precautions.
They will help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Arcair is a Global Brand of cutting Products for ESAB. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive,
Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through market-leading, dependable products
that have stood the test of time. We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support, together with excellence
in sales and marketing expertise.
Above all, we are committed to develop technologically advanced products to achieve a safer
working environment within the welding industry.
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before
installing, operating, or servicing the equipment. While the information contained in
this Manual represents the Manufacturer’s judgment, the Manufacturer assumes no
liability for its use.
SLICE® Exothermic Cutting Equipment
Safety and Operating Instructions
Manual Number: 89250845
Published by:
ESAB Group Inc.
2800 Airport Rd.
Denton, TX. 76208
(940) 566-2000
www.esab.com/arcair
U.S. Customer Care: (800) 426-1888
International Customer Care: (940) 381-1212
Copyright © 2010, 2015 ESAB. All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident,
or any other cause.
For Printing Material Specification refer to document 47X1920
Publication Date: November 18, 2010
Revision Date: January 15, 2015
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #
i
Table of Contents
SECTION 1: INTRODUCTION..................................................................................... 1-1
1.01 How to Use this Manual......................................................... 1-1
1.02 Receipt of Equipment............................................................. 1-1
1.03 Description............................................................................ 1-1
SECTION 2: SAFETY PRECAUTIONS ........................................................................ 2-2
SECTION 3: PROCESS FUNDAMENTALS.................................................................. 3-5
SECTION 4: EQUIPMENT.......................................................................................... 4-6
4.01 SLICE Torch........................................................................... 4-6
4.02 SLICE Striker......................................................................... 4-6
4.03 SLICE Packs.......................................................................... 4-6
4.04 Cutting Rods.......................................................................... 4-7
SECTION 5: CUTTING DATA..................................................................................... 5-9
5.01 Material Cutting Rates........................................................... 5-9
5.02 Cutting Electrode Types....................................................... 5-10
5.03 SLICE Cutting Torches.......................................................... 5-10
SECTION 6: OPERATION......................................................................................... 6-11
6.01 Cutting without Power......................................................... 6-11
6.02 Cutting with Power.............................................................. 6-12
6.03 Hole Piercing....................................................................... 6-13
6.04 Copper and Copper Alloys.................................................... 6-14
SECTION 7: IMPORTANT PROCESS VARIABLES.................................................... 7-15
7.01 Oxygen Pressure................................................................. 7-15
7.02Amperage............................................................................ 7-16
7.03 Travel Speed........................................................................ 7-16
7.04 Electrode-To-Work Angle..................................................... 7-16
SECTION 8: APPLICATIONS................................................................................... 8-17
SECTION 9: TROUBLESHOOTING........................................................................... 9-18
SECTION 10: PARTS LISTING............................................................................... 10-19
SECTION 11: STATEMENT OF WARRANTY........................................................... 11-22
ii
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 1: INTRODUCTION
1.01 HOW TO USE THIS MANUAL
To ensure safe operation, read the entire manual, including the chapters on safety instructions and
warnings.
Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these headings. These special annotations are easily
recognized as follows:
NOTE
NOTE conveys installation, operation, or maintenance information which is important
but not hazard-related.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result
in injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
1.02 RECEIPT OF EQUIPMENT
When you receive the equipment, check it against the invoice to make sure it is complete and
inspect the equipment for possible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim. Furnish complete information concerning damage claims or
shipping errors to the location in your area, listed in the inside back cover of this manual. Include a
full description of the parts in error.
If you want additional or replacement copies of this manual, please contact Arcair at the address
and phone number in your area listed on the inside back cover of this manual. Include the Manual
number (Page i).
1.03 DESCRIPTION
Arcair® SLICE® systems can cut, burn or pierce almost any metallic, non-metallic or composite
material. The SLICE exothermic torch cuts right through hard-to-cut materials such as mild, stainless
and alloy steels, cast iron, aluminum, magnesium and other non-ferrous metals, slag and refractory
materials, and concrete or brick.
89250845
1
Introduction
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 2: SAFETY PRECAUTIONS
WARNING
SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not properly
installed, used, and maintained. Misuse of this equipment and other unsafe practices
can be hazardous. The operator, supervisor, and helper must read and understand the
following safety warnings and instructions before installing or using any welding or cutting
equipment, and be aware of the dangers of the welding or cutting process. Training
and proper supervision are important for a safe work place. Keep these instructions for
future use. Additional recommended safety and operating information is referenced in
each section.
WARNING
This product contains chemicals, including lead, or otherwise produces chemicals
known to the State of California to cause cancer, birth defects and other reproductive
harm. Wash hands after handling. (California Health & Safety Code § 25249.5 et
seq.)
ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH
Install and maintain equipment in accordance with the National Electrical Code (NFPA
70) 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 be done by qualified and/or trained personnel only.
Do not contact electrically live parts. Always wear dry welding gloves that are in good
condition. Aluminized, protective clothing can become part of the electrical path. Keep oxygen cylinders,
chains, wires, ropes, cranes, and hoists away from any part of the electrical path. All ground connections
must be checked periodically to determine if they are mechanically strong, and electrically adequate for
the required current. When engaged in AC welding/cutting under wet conditions or where perspiration
is a factor, the use of automatic controls for reducing the no load voltage is recommended to reduce
shock hazards. Accidental contact must be prevented when using open circuit voltage exceeding 80
volts AC, or 100 volts DC by adequate insulation or other means. When welding is to be suspended for
any length of time, such as during lunch or overnight, all electrode holders and electrodes should be
removed from the electrode holder and the power supply should be turned off to prevent accidental
contact. Keep MIG Guns, electrode holders, TIG torches, Plasma torches, and electrodes away from
moisture and water. See safety and operating references 1, 2, and 8.
SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH
Safety Precautions
2
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
Ventilation must be adequate to remove smoke, fumes, and gases during operation to
protect operators and others in the area. Vapors of chlorinated solvents can form the
toxic gas "Phosgene" when exposed to ultraviolet radiation from an electric arc. All
solvents, degreasers, and potential sources of these vapors must be removed from the
operating area. Use air-supplied respirators if ventilation is not adequate to remove all
fumes and gases. Oxygen supports, and vigorously accelerates fire and should never be used for
ventilation. See safety and operating references 1, 2, 3, and 4.
ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN
Welding and cutting processes produce extreme localized heat and strong ultraviolet
rays. Never attempt to weld/cut without a federally compliant welding helmet with the
proper lens. A number 12 to 14 shade filter lens provides the best protection against
arc radiation. When in a confined area, prevent the reflected arc rays from entering
around the helmet. Approved shielding curtains and appropriate goggles should be used
to provide protection to others in the surrounding area. Skin should be protected from arc rays, heat,
and molten metal. Always wear protective gloves and clothing. All pockets should be closed and cuffs
sewn shut. Leather aprons, sleeves, leggings, etc. should be worn for out-of-position welding and cutting,
or for heavy operations using large electrodes. Hightop work shoes provide adequate protection from
foot burns. For added protection, use leather spats. Flammable hair preparations should not be used
when welding/cutting. Wear ear plugs to protect ears from sparks. Where work permits, the operator
should be enclosed in an individual booth painted with a low reflective material such as zinc oxide. See
safety and operating references 1, 2, and 3.
WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS
Combustibles reached by the arc, flame, flying sparks, hot slag, and heated materials
can cause fire and explosions. Remove combustibles from the work area and/or provide
a fire watch. Avoid oily or greasy clothing as a spark may ignite them. Have a fire
extinguisher nearby, and know how to use it. If welding/cutting is to be done on a metal
wall, partition, ceiling, or roof, precautions must be taken to prevent ignition of nearby
combustibles on the other side. Do not weld/cut containers that have held combustibles.
All hollow spaces, cavities, and containers should be vented prior to welding/cutting to permit the escape
of air or gases. Purging with inert gas is recommended. Never use oxygen in a welding torch. Use only
inert gases or inert gas mixes as required by the process. Use of combustible compressed gases can
cause explosions resulting in personal injury or death. Arcing against any compressed gas cylinder can
cause cylinder damage or explosion. See safety and operating references 1, 2, 5, 7, and 8.
NOISE CAN DAMAGE HEARING
Noise from the air carbon-arc process can damage your hearing. Wear protective hearing
devices to ensure protection when noise levels exceed OHSA standards. Adequate hearing
protection devices must be worn by operators and surrounding personnel to ensure personal
protection against noise. See safety and operating references 1, 2, and 6.
89250845
3
Safety Precautions
SLICE EXOTHERMIC CUTTING EQUIPMENT
SAFETY AND OPERATING REFERENCES
1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139, 251, 252,
253, 254 and 1000. U.S. Government Printing Office, Washington, DC 20402.
2. ANSI Z49.1 "Safety in Welding and Cutting".
3. ANSI Z87.1 "Practice for Occupational and Educational Eye and Face Protection".
4. ANSI Z88.2. "Standard Practice for Respiratory Protection". American National Standards
Institute, 1430 Broadway, New York, NY 10018.
5. AWS F4.1. "Recommended Safe Practices for Welding and Cutting Containers."
6. AWS C5.3. "Recommended Practices for Air Carbon-Arc Gouging and Cutting". The American
Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL 33135.
7. NFPA 51B. "Fire Prevention in Cutting and Welding Processes".
8. NFPA-7. "National Electrical Code". National Fire Protection Association, Battery Park, Quincy,
MA 02269.
9. CSA W117.2. "Safety in Welding, Cutting and Allied Processes". Canadian Standards Association,
178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.
Safety Precautions
4
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 3: PROCESS FUNDAMENTALS
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. Oxygen flows through the center of the rod.
Because of the rod’s design, the burning makes excess heat ("exo - thermic") which cuts the
workpiece. Once started, the burn will continue as long as oxygen flows through the rod. The heat
created melts the material being cut. The velocity of oxygen through the rod blows the molten material
away, creating the kerf or cut line.
This arc ignition process led to invention of the oxy-arc torch and design of equipment for underwater
construction and salvage.
The electrical arc that starts the burn can be from a welding power source that delivers at least 100
amps, a 12-volt lead acid or similar low-impedance battery. The cutting process can run without
power, using the heat of the reaction only, or with power, cutting with an electrical arc from a welding
power source providing more heat.
HISTORY
The exothermic cutting rod is a small oxygen lance. A prime example of the combustion triangle is one
side being fuel (the steel lance); the oxygen source (pure oxygen being forced through the lance); 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.
In 1888, a published paper described passing oxygen through a steel tube and heating the tube to
a bright red. Heat resulted. In 1901, Ernst Henner filed a German patent on an early oxygen lance
made of two concentric tubes. In 1902, documentation shows that the oxygen lance replaced oil
and gas torches for opening furnace taps in steel blast furnaces. The oxygen lance has since been
used to cut rocks and concrete structures. An example is cutting up reinforced concrete structures
such as bunker emplacements and tank traps built in Europe during World War II.
An ideal way to start the lance, workers found, was to use a welding power source on conductive
material to strike an arc and start the burn. This process worked well in construction, even in mud
and water.
Around 1940, the burning bar or exothermic lance was first marketed as a cutting tool. A flexible
version made of an insulated cable was introduced around 1960. Not until the early 1980’s were
smaller burning bars designed for hand torch use, above and below water. A one-piece unit now
allows for adequate rod surface exposure to an oxygen supply for exothermic cutting. Arcair, an ESAB
brand, is a world leader in metal removal and cutting and sells this exothermic cutting equipment
under the trade name Arcair SLICE.
89250845
5
Process Fundamentals
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 4: EQUIPMENT
4.01 SLICE TORCH
The SLICE Torch, a gun-shaped tool, provides a means of gripping the rod and supplying the oxygen
and power to the cutting rod. The basic torch includes 10 ft. (3.05 m) of power cable and oxygen
hose. The power cable can carry 200 amps in a power cutting operation. The oxygen hose includes
a standard size oxygen fitting and is ready to be connected to the user’s oxygen regulator. This
standard torch has a flexible hand shield which is easily replaceable if damaged, plus the torch is
molded from a glass reinforced thermoset plastic.
An optional 6" (152 mm) collet extension and 6" (152 mm) diameter extension shield is available
to help reduce torch wear or damage when piercing. Also available is a 3/8" (9.5 mm) adapter kit
consisting of a collet chuck, Collet Nut, washer, and flashback arrestor needed to adapt the torch for
using the 3/8" (9.5 mm) diameter cutting rods.
4.02 SLICE STRIKER
A SLICE Striker is available for cutting without power. The striker is an insulated piece of copper
plate with a serrated surface By scratching the rod against the copper plate an arc is initiated and
the cutting process begins. The SLICE striker comes standard with a 10 ft. (3.05 m) cable.
4.03 SLICE PACKS
SLICE® Utility Pack
Includes a rugged tool box carrying case. Power connections (12 volt battery only), tong style battery
clamps makes power connection quick and easy. Industrial oxygen hose connected to the torch;
industry standard "green" hose supplies the torch with oxygen, and standard fittings used to connect
to oxygen regulators.
SLICE® Battery Pack
Includes a rugged tool box carrying case. Power connections twist-lock style connection; easy to
connect to battery box for both torch and striker and color coded connectors. Industrial oxygen hose
connected to the torch; industry standard "green" hose supplies the torch with oxygen, standard
fittings used to connect to oxygen regulators, and color coded connections.
SLICE® Industrial Pack
Versatility for industrial type applications. Industrial cart capable of carrying a 9" diameter oxygen
cylinder. Packed with the basic items needed to do a cutting job; SLICE Torch Assembly - 10 ft leads,
striker assembly, oxygen regulator, battery charger, and cutting rod holder. Industrial oxygen hose
connected to the torch; industry standard "green" hose supplies the torch with oxygen and standard
fittings used to connect to oxygen regulators.
Equipment
6
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
SLICE® Complete Pack
Rugged aluminum carrying case; packed with the basic items needed to do a cutting job. Selfcontained cutting system lends itself well to the emergency type cutting situations where seconds
count. Complete unit weights 75 lbs (34kg). Storage compartment with hinged door for parts storage
during transportation. Power connections twist-lock style connection; easy to connect to battery box
assembly for both torch and striker and color coded connectors. Industrial oxygen hose connected
to the torch; industry standard "green" hose supplies the torch with oxygen. Standard fittings used
to connect to oxygen regulators.
4.04 CUTTING RODS
SLICE Cutting Rods are made of carbon steel, by rolling a steel strip into a rod, and are coated or
uncoated. The coating is made of arc stabilizers and a binder. Several advantages to using the
coated rods with power include:
• More efficient cutting rates (more cut per inch of rod burnt and more cut per minute of burn
time)
• Easier rod operation
• Protection from burning out on the side of the rod, especially when piercing
Rod Size
Uses
1/4" x 22"
6,4 mm x 558,8 mm
Standard size cutting rods used in a variety of jobs. Recommended for
all straight-line cutting and most general-cutting applications. Coated
or uncoated.
1/4" x 44"
6,4 mm x 1117,6 mm
Used when greater length is needed to reach the cutting area or when
piercing holes in materials thicker than 18" (457,2 mm). Uncoated.
3/8" x 18"
9,5 mm x 457,2 mm
Used for heavy piercing with a large bore. Coated or uncoated.
3/8" x 36"
9,5 mm X 914,4 mm
Used when added length is needed to complete cutting. Uncoated.
NOTE
All SLICE cutting torches come ready to use the 1/4" (6.4 mm) diameter rods. Use of
the 3/8" (9.5 mm) diameter rods requires the 3/8" (9.5 mm) conversion kit, Part Number
94-463-032.
89250845
7
Equipment
SLICE EXOTHERMIC CUTTING EQUIPMENT
SLICE ROD
OXYGEN LEVER
COLLET NUT
SHIELD
HANDLE
Art# A-13109
Figure 1: SLICE Torch Components
SLICE Torch
Oxygen Valve Lever
Collet Ring
SLICE Striker
Art# A-13108
Torch Cable
Striker Cable
Oxygen Hose
Connection
Black Male
Connector
Red Male
Connector
Figure 2: SLICE Torch and Striker
RECHARGE
Art# A-13107
GOOD
CUT
STRIKER
RECHARGE
CUT
CHARGE
CHARGE
TEST
GOOD
2
SWITCH IN CHARGE POSITION
TORCH
TEST
RECHARGE
GOOD
CUT
SWITCH IN CUT POSITION
CHARGE
TEST
SWITCH IN TEST POSITION
Equipment
Figure 3: SLICE Battery Box Assembly
8
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 5: CUTTING DATA
The following chart helps determine the best settings for a specific use as a result of extensive laboratory
testing of the SLICE Equipment to determine the best cutting rates. Actual cutting results obtained in
the field vary due to conditions and experience of the user. Various usages of SLICE Equipment return
various results. Adjust the settings for any use. Use the following chart as a guide.
Oxygen pressure of 80 psi (551.6 kPa) achieves the best cutting. Some operations may require higher
or lower oxygen pressures - minimum 40 psi (275.8 kPa); maximum 100 psi (689.5 kPa). Amperage
over 200 amps does not improve cutting speed.
Find the right metal and thickness. For composites or unlisted metals, locate the listed type that most
resembles the material to be cut.
NOTE
All these cutting values are based on 1/4" (6.4 mm) diameter flux-coated rods. Cutting
rates with 1/4" (6.4 mm) bare rods are slightly less than the values listed in the chart.
5.01 MATERIAL CUTTING RATES
Material Type
Carbon Steel
Stainless
Aluminum
Material Thickness
Length of Cut per
Inch Rod Used
in(mm)
in(cm)
in/min
cm/min
1/8 (3,2)
2,25 (5,7)
72
183
1/4 (6,4)
1,5 (3,8)
52
132
3/8 (9,5)
1,38 (3,5)
42
106
1/2 (12,7)
1,25 (3,2)
35
89
3/4 (19,1)
,75 (1,9)
22
56
1/8 (3,2)
2,0 (5,1)
65
165
1/4 (6,4)
1,13 (2,9)
36
91
1/4 (6,4)
1,75 (4,4)
58
147
3/8 (9,5)
1,25 (3,2)
38
97
3/4 (19,1)
,75 (1,9)
23
58
Cutting Speed
SAMPLE SELECTIONS:
The approximate cut/inch rod x amount of cut per rod = cut per rod used
Data: Cutting 3/8" (9.5 mm) aluminum with 1/4" (6.4 mm) fluxed rod
1.25" (3.2 cm) x 19" (48.3 cm) = 23.8" (60.5 cm). Approximate cut/min arc time = 38" (97 cm)
Data: Cutting 1/4" (6.4 mm) carbon steel with 1/4" fluxed rod
1.5" (3.8 cm) x 19" (48.3 cm) = 28.5" (72.4 cm). Approximate cut/min arc time = 52" (132 cm)
89250845
9
Cutting Data
SLICE EXOTHERMIC CUTTING EQUIPMENT
5.02 CUTTING ELECTRODE TYPES
Cutting rates in this chart were obtained using 80 PSI (551.6 kPa) oxygen pressure and 1/4" x 22"
(6.4 mm x 559 mm) cutting rods. These rates are averaged values based on multiple cutting tests.
Actual cutting rates may vary due to parameters used and operator expertise.
Package
Quantity
Oxygen
Flow Rate
CFM(CMM)
Burn
Time
(sec)
Coated
25
7,5 (,21)
40-45
Coated
100
7,5 (,21)
40-45
22 (559)
Uncoated
25
7,5 (,21)
40-45
1/4 (6,4)
22 (559)
Uncoated
100
7,5 (,21)
40-45
43-049-005
1/4 (6,4)
44 (1117)
Uncoated
25
7,5 (,21)
80-90
42-049-005
3/8 (9,5)
18 (457)
Coated
50
12 (,34)
30-35
43-049-007
3/8 (9,5)
18 (457)
Uncoated
50
12 (,34)
30-35
43-049-009
3/8 (9,5)
36 (914)
Uncoated
25
12 (,34)
60-70
Part No.
Diameter
in(mm)
Length
in(mm)
Coated or
Uncoated
42-049-002
1/4 (6,4)
22 (559)
42-049-003
1/4 (6,4)
22 (559)
43-049-002
1/4 (6,4)
43-049-003
5.03 SLICE CUTTING TORCHES
Part No.
Cable
Size
03-003-000
#1
03-003-001
#6
03-003-006
#10
Cutting Data
Oxygen
Power Cable
Hose Length
Length ft(m)
ft(m)
10 (3,05)
10 (3,05)
10
Cutting with
Power
Cutting without
Power
Recommended
Can Be Used
Limited Use Only
Recommended
Not Recommended
Recommended
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 6: OPERATION
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.
6.01 CUTTING WITHOUT POWER
Cutting without power uses the heat reaction from the rod and the oxygen to cut. To initiate this type
of cutting, ignite the rod from a spark supplied by a 12-volt battery or by a welding power source
capable of delivering a 100-amp surge. Once this spark has ignited the rod, the electrical path is
broken and the heat of the reaction melts the material and cuts it.
SLICE Torch
Striker
Oxygen Supply
Art# A-13110
+
Battery
Figure 4: Cutting without Power
Cutting without power can be done in remote areas. Support equipment and bulky power sources
are not needed.
1. Connect the torch to either terminal of a 12-volt battery or constant-current welding power
source, then connect the striker or a strike plate to the other terminal. If using a welding
power source, set output level for 100 amps.
2. Turn on the oxygen supply and adjust the regulator to the proper working pressure. Insert
the cutting rod into the collet and tighten the Collet Nut.
3. Tap the cutting rod on a hard, ungrounded surface to seat the rod in the torch.
4. Depress the torch oxygen valve lever and check for oxygen leaks around the Collet Nut.
NOTE
If oxygen is leaking, repeat the procedure until no oxygen is leaking.
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11
Operation
SLICE EXOTHERMIC CUTTING EQUIPMENT
5. Put the torch in one hand and striker in the other. Depress the oxygen lever and touch the
cutting rod to the striker.
6. Once the rod is ignited, remove the striker, then move the burning rod to the workpiece and
begin cutting.
NOTE
Hold the cutting rod at a 45° to 80° drag angle from the workpiece surface. The angle
depends on the thickness and type of material being cut.
7. Make slight contact between the burning rod tip and the workpiece as the cut progresses.
This placement requires two motions:
a. Inward towards the workpiece as the rod is consumed
b. In the direction of the cut
Use a protective lens shade #5 since there is no electrical arc.
6.02 CUTTING WITH POWER
Cutting with power requires an electrical arc from a welding power supply and increases the heat
created exothermically. Almost all constant-current welding power supplies can be used in powered
exothermic cutting. Cutting with power is faster than cutting without power.
SLICE Torch
Ground Clamp
Work Piece
Oxygen Supply
Power
Supply
Art# A-13111
+
-
Figure 5: Cutting with Power
Operation
12
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
CAUTION
Constant-voltage power supplies should not be used with exothermic cutting equipment.
When the exothermic cutting rod contacts the workpiece, the power supply is 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.
1. Connect the torch to one terminal, then connect a welding ground clamp to the other terminal
of a CC welding power source.
2. Attach the ground clamp to the workpiece. Unlike other processes, this process uses either
a welding power source set for DCEP (reverse polarity) or DCEN (straight polarity). AC
(alternating current) power supplies can also be used without affecting cutting performance.
Do not cut with power using a constant-potential power source.
3. Insert the cutting rod into the collet and tighten. Start the oxygen flow, touch the rod tip to
the workpiece, and begin cutting. Hold the cutting rod at a 45° to 80° drag angle from the
workpiece surface.
4. Depress the torch oxygen valve lever and check for oxygen leaks around the Collet Nut.
5. As the cut proceeds, make slight contact between the burning rod and the workpiece. This
placement requires two motions:
a. Inward towards the workpiece as the rod is consumed
b. In the direction of cut
Use a protective lens shade #10 or higher to protect from arc flash.
6.03 HOLE PIERCING
Perform most piercing operations without power.
1. Remove the Collet Nut Assembly from the front of the torch and remove the brass collet,
washer and spark arrestor from the torch.
2. Attach the Collet Extension Assembly to the front end of the torch and once tighten re-install
the spark arrestor, washer and brass collet into the assembly.
3. Slide the Extension Shield over the Collet Extension Assembly until it bottoms out against
the metal ring on the assembly.
4. Reinstall the Collet Nut Assembly onto the Collet Extension Assembly.
5. Insert the SLICE cutting rod into the torch and tighten the Collet Nut Assembly. Tap the SLICE
rod against the work surface and tighten the Collet Nut again, this ensures the cutting rod
is seated against the rubber washer.
6. Ignite the cutting rod as explained in the "Cutting without Power" section.
89250845
13
Operation
SLICE EXOTHERMIC CUTTING EQUIPMENT
7. Move the burning rod to the pierce point and, with the rod angled away from the operator,
begin piercing the hole.
8. Once the hole is under way, bring the cutting rod perpendicular to the surface of the workpiece.
Keep the cutting rod deep enough in the hole to feel slight resistance from the non-molten
material at the base of the hole. Use a slight circular motion while piercing the hole to keep
the rod free of molten material coming out of the hole.
9. Move the rod in and out of the hole occasionally to maintain an open path for the molten
material.
CAUTION
The molten material travels back up the rod while piercing. Wear proper clothing for
protection from the molten spray. Hold the torch at arm’s length to keep the operator
as far away from the molten material as possible. An optional 6" (152.4 mm) collet
extension and extension shield are available for the SLICE cutting torch to protect the
operator and torch.
NOTE
Piercing in the flat position is more difficult than piercing horizontally. Piercing flat
progresses more slowly. For example, piercing a hole in a floor is more difficult and
slower than piercing a hole in a wall.
6.04 COPPER AND COPPER ALLOYS
CUTTING Because of the very rapid heat absorption of copper and its alloys, cut with power on these
materials. Use a maximum of 300 amps since copper quickly absorbs the heat created from the
exothermic reaction, reducing the effectiveness of the cutting process. Cutting with power releases
more heat so it is possible to cut some copper pieces. The larger the size of the part the more
difficult it is to cut. A sawing motion into the cut kerf speeds cutting. Brass, bronze and other alloys
are slightly easier to cut, but these alloys should be cut using power, if possible.
PIERCING Use power when piercing copper and its alloys. This results in extremely fast rod
consumption. The higher the copper content of the part, the harder the material is to cut.
Operation
14
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 7: IMPORTANT PROCESS VARIABLES
Exothermic cutting is easier than most cutting processes. Certain variables reduce the efficiency of this
process, resulting in poor cutting. The most important variables are listed and discussed below.
7.01 OXYGEN PRESSURE
Oxygen maintains the exothermic burn and removes the molten material from the cut. Eighty psi
(551.6 kPa) yields the most efficient cutting rates (amount of cut per inch of rod burned) on materials
up to 3" (76.2 mm) thick. Using pressures less than 80 psi (551.6 kPa) on such materials reduces
cutting rates due to inadequate pressure to remove the molten material.
However, scarfing is most efficient using pressures under 80 psi (551.6 kPa). Lower pressures offer
a more controllable scarfing action. With material thicker than 3" (76.2 mm), pressures over 80 psi
(551.6 kPa) can be used to give the oxygen enough velocity to blow away molten material at the
bottom of the cut. Using higher pressures on thicker materials causes a more forceful oxygen jet
and faster rod consumption. A sawing motion at 80 psi (551.6 kPa) or a larger diameter rod may help
cut these materials more efficiently.
When piercing, 80 psi (551.6 kPa) is the best pressure to use. To pierce, an operator should reduce
the pressure slightly to control the distance the molten material travels. Once there is a hole, full
pressure should be used.
The operator can vary pressure by using the torch’s oxygen lever. When the thickness of the material
- usually more than 12" (304.8 mm) - needs added pressure to blow the molten material out of a
pierced hole, pressures above 80 psi (551.6 kPa) are used. This is the only exception.
The SLICE cutting process uses standard industrial-grade oxygen to support the exothermic reaction
and to remove molten metal. All SLICE equipment uses standard oxygen fittings. SLICE torches are
equipped with 10 ft. (3.05 m) of 1/4" (6.4 mm) I.D. oxygen hose. The usual operating pressure is
80 psi (551.6 kPa). Applications such as cutting material sections 3" (76.2 mm) and thicker might
require higher operating pressures. Pressures as low as 40 psi (275.8 kPa) have been used to do
jobs such as washing off rivet heads and scarfing out small cracks for repair.
The oxygen consumption rate for SLICE cutting rods at 80 psi (551.6 kPa) is 7 to 7.5 cfm (0.21 cmm)
for the 1/4" (6.4 mm) diameter cutting rods and 12 to 13 cfm (0.34 to 0.37 cmm) for the 3/8" (95 mm)
diameter cutting rods. This rate varies if a different operating pressure is used.
WARNING
DO NOT use compressed air for exothermic cutting. Compressed air does not contain
enough oxygen to support the burn; therefore, impurities can damage or destroy the
torch and components. The torch could burn from the inside or even explode from the
buildup of dirt from the compressed air in the oxygen-supply tube and cause serious
injury to the operator.
7.02AMPERAGE
Electrical current increases the heat from the reaction in exothermic cutting, allowing faster cutting.
200 amps yields the most efficient cutting rates with power. When cutting with power and using less
89250845
15
Important Process Variables
SLICE EXOTHERMIC CUTTING EQUIPMENT
than 200 amps, the amount of cut per minute will be lower. Amperage above 200 amps consumes
the rod faster, reducing the cut per inch of rod burned. Exothermic cutting equipment uses 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.
7.03 TRAVEL SPEED
The cutting rod burns constantly without an electrical arc. Therefore, cut as fast as possible without
losing the cut kerf. If the travel speed is too fast, the material will not cut completely through and
molten slag will be blown back from the workpiece.
7.04 ELECTRODE-TO-WORK ANGLE
The electrode-to-work angle is the most flexible process variable. However, use of an improper angle
can cause reduced cutting efficiency. For most cutting jobs the ideal angle is between 45° and 80°.
For thicker material, hold the rod closer to an 80° angle. The electrode-to-work angle is typically a
drag angle - the rod is held so the tip of the burning rod is away from the direction of travel. Cutting
sheet metal is one exception since it is usually faster and better controlled when the user keeps a
45° angle or slightly less, and pushes the rod in the direction of cut. Aluminum, regardless of its
thickness, requires a 70° to 80° drag angle.
Important Process Variables
16
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 8: APPLICATIONS
Industry
Applications
Construction
Bridge repair. Cutting structural steel. Pierce and remove rivets and bolts without
damaging surrounding material. Punch holes in concrete, crack rocks. Highway
maintenance. Repair of highway guardrails. Cut reinforcing rods. Cut plaster or
concrete insulated pipes. Repairs on heavy equipment. Removing old structural
steel. Scrap clean up. Salvage work.
Plant Maintenance
Equipment/machinery repair. Remove headless bolts or frozen pins. Remove
seized bearings. Plant renovation. Removing old piping systems. Punch lag holes
to secure machinery. Repair machine bases. Remove old machinery. Cut up or
repair storage tanks.
Heavy Equipment
Maintenance
General maintenance (field or shop repairs). Repair buckets. Remove seized or
worn pins. Cut worn or frayed control cables. Cut badly corroded material.
Foundry
Remove core sand trapped in holes of castings. Remove areas of imbedded sand.
Cut gates, risers, fins from castings. Cut small multiple castings from runners.
Cut through slag in furnace cleanup. Punch relief holes in molds. Cut up spilled
materials for remelting. Cut up scrap castings. General plant maintenance.
Fire Service Rescue
Departments
Rapid entry into buildings. Cut through steel doors, dead bolts, barred windows,
overhead doors. Cut through debris (metal, concrete, plaster, rock) from building
collapse. Rescue operations.
Police/Swat
Rapid entry into buildings. Cut through steel doors, dead bolts, barred windows,
overhead doors. Rescue operations.
Railroad
Rail car repair and maintenance. Track maintenance/cut damaged sections of
track. Repairs in remote yard locations. Remove old rail loading docks.
Mining
Equipment maintenance (field and shop repairs). Cut steel cables. Repair coal
tipples. Belt repairs. Remove abandoned piping and railways. Piercing holes in
rock to set blasting charges.
Metal Fabrication
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.
Power Plants
General maintenance. Removal of piping. Cut out scrap feeder pans. Remove old
grating covered with refractory. Remove old boilers. Remove or repair storage
tanks.
Farming
General maintenance. Equipment/machinery repair. Repair stainless steel fertilizer
tanks. Cut metal encrusted with rust and/or mud.
Scrap/Salvage Yards
Cut all types of scrap metal, including cast iron, stainless steel, and aluminum.
Cut up scrap cars in remote areas of yard. Equipment maintenance. Cut badly
corroded or crusted material.
89250845
17
Applications
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 9: TROUBLESHOOTING
Problem
Solution
Rod burns but with no cut
progression.
1. Too much gap between the burning rod tip and the workpiece.
Must maintain slight pressure against workpiece.
2. Travel speed too slow.
3. Oxygen pressure too low.
Molten material not being
blown out of cut area.
1. Insufficient oxygen pressure being used.
2. Rubber washer behind collet chuck worn and needs to be
replaced.
3. Travel speed too fast.
1. Battery was not given sufficient time to recharge.
2. Three-position switch on battery box not put in the CHARGE
Battery will only start a few
position.
rods before charge is depleted.
3. Battery needs to be replaced.
4. Battery left exposed to subfreezing temperatures.
Torch shield is being burnt off
around Collet Nut.
1. Rod is not properly seated in torch. Refer to Section 6 on
operating techniques to properly seat rod.
2. Collet extension not used when piercing holes.
When piercing anything but
copper and its alloys, the rod
consumes extremely fast.
1. Operator is piercing with power. All piercing operations
except ones on copper and its alloys should be done without
power.
Arced collet chuck and/or rod
is burned off just outside of
collet chuck.
1. Using a CC type welding power source.
Troubleshooting
18
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
SECTION 10: PARTS LISTING
SLICE STRIKER REPLACEMENT PARTS
2
8
7
6
4
5
3
1
89250845
Item No.
Part No.
Description
1
94-370-168
Handle - Right Half
2
94-370-169
Handle - Left Half
3
96-070-031
Striker Bar
4
96-130-320
Cable Assembly
5
#10-32 x 3/8" Pan Head Screw
6
#10-32 Hex Nut
7
#6-32 x 1-1/14" Pan Head Screw
8
#6-32 x 3/4" Pan Head Screw
19
Parts Listing
SLICE EXOTHERMIC CUTTING EQUIPMENT
SLICE TORCH REPLACEMENT PARTS
1
13
14
12
16
8
11
9
4
5
6
2
7
17
3
10
15
Parts Listing
20
89250845
SLICE EXOTHERMIC CUTTING EQUIPMENT
Item No.
Part No.
1
94-370-166
Handle - Right Half
2
94-370-167
Handle - Left Half
3
94-777-109
Shield
94-168-022
1/4" Collet Nut Assembly
94-168-024
3/8" Collet Nut Assembly
94-158-048
1/4" Collet Chuck
94-158-045
3/8" Collet Chuck
6
94-940-109
Washer
7
94-305-009
Flashback Arrestor
8
94-378-338
Head/Body Assembly
9
94-476-082
Lever Assembly
10
94-396-193
Oxygen Hose - 10ft. (3m)
96-130-279
Cable Assembly for SLICE Torch Part No. 03-003-000
96-130-276
Cable Assembly (Utility & Industrial Pack)
96-130-319
Cable Assembly (Battery & Complete Pack)
96-130-324
Cable Assembly (Cordless Pack)
12
94-168-023
Extension - 6" (15.24cm)
13
94-940-108
Washer
14
94-777-111
Extension Shield
15
94-463-032
3/8" Conversion Kit
4
5
11
Description
16
10-32 Pan Head Screw
17
6-32 x 9/16" Pan Head Screw
89250845
21
Parts Listing
SLICE EXOTHERMIC CUTTING EQUIPMENT
BATTERY BOX
2
8
9
7
1
10
5
6
11
4
3
Item No.
Part No.
Description
1
94-134-032
Back Half Battery Case
2
96-162-752
Circuit Board Assembly
3
96-076-018
Battery Assembly
4
96-169-382
6-Pin Male Connector
5
96-169-374
Red Female Panel Receptacle
6
96-169-375
Black Female Panel Receptacle
7
96-508-041
Meter
8
96-834-347
Toggle Switch
9
94-766-052
Toggle Switch Seal
10
94-766-053
Circuit Breaker Seal
11
94-171-285
Connector Cover
22
89250845
SECTION 11: STATEMENT OF WARRANTY
LIMITED WARRANTY: Arcair, an ESAB brand, warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time
period applicable to the Arcair products as stated below, Arcair shall, upon notification thereof and
substantiation that the product has been stored, installed, operated, and maintained in accordance
with Arcair’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable
repair or replacement, at Arcair’s sole option, of any components or parts of the product determined
by Arcair to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
LIMITATION OF LIABILITY: Arcair, an ESAB brand, shall not under any circumstances be liable
for special or consequential damages, such as, but not limited to, damage or loss of purchased or
replacement goods, or claims of customers of distributor (hereinafter the "Purchaser") for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Arcair
with respect to any contract, or anything done in connection therewith such as the performance or
breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or
furnished by Arcair whether arising out of contract, negligence, strict tort, or under any warranty, or
otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which
such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED
WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY ARCAIR PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the
authorized distributor delivers the products to the Purchaser.
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized
Arcair repair facility within thirty (30) days of the repair. No transportation costs of any kind will be
paid under this warranty. Transportation charges to send products to an authorized warranty repair
facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk
and expense. This warranty supersedes all previous Arcair warranties.
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 70 233 075
Fax: +32 15 257 944
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
USA
ESAB Welding & Cutting
Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
www.esab.eu
©2015 ESAB Welding and Cutting Products
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.eu
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