Thermal Dynamics SL60 User manual

January 8, 2009 1 Manual 0-2880 Rev AB

General Information

The 1TorchTM SL60 and SL100 Torches work with most

plasma cutting power supplies. The Torches are equipped

with either O2B connectors or the Thermal Dynamics ATC

connector and are connected using various Adapter Kits

sold separately.

A label on the torch handle indicates the torch model

number. SL60 Torches provide cutting capabilities of up

to 60 amperes. SL100 Torches provide cutting capabili-

ties of up to 100 amperes. The torches use compressed

air as both the plasma and secondary gas.

The torches are suitable for drag cutting (with the torch

tip in contact with the workpiece, at up to 40 Amps out-

put); 40-100 Amp shielded drag cutting (with shielded

torch parts (cap, etc.) in contact with the workpiece);

standoff cutting; or gouging.

Refer to the Complete Assembly Replacement page for

configurations and catalog numbers.

These instructions are important for the proper installa-

tion of the Torches. Read the instructions thoroughly be-

fore attempting the installation. Keep these instructions

for reference.

Supplied Parts

The Replacement Torches include:

• Torch With Leads - 1 each

• Installation Instructions - 1 each

• Consumables (Installed on the Torch): Electrode,

Starter Cartridge, Tip, Shield Cup Body and Drag

Shield Cap)

• Standard Shield Cup

NOTE

The consumable parts installed in the Torch may

not necessarily be optimized for your Power Sup-

ply or cutting application. For best results, refer

to the selection charts in this manual to choose the

proper consumables for your application.

Manual 0-2880

SL60 and SL100

Replacement Plasma

Cutting Hand Torches

Installation and Operation Instructions

Options

The following options are available. Refer to the complete

assembly replacement list for catalog numbers.

• ATC Adapter Kit (for Torches withATC Connectors)

• Leads extensions (for Torches with ATC Connectors)

• Cutting Guide Kits

• Leather Leads Covers

• Standoff Cutting Guide

Torch Specifications

A. Torch Configurations and Dimensions

The torch head is at either 75° or 90° to the torch handle.

The torch includes a torch handle and torch trigger as-

sembly.

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

Art # A-03322_AB

B. Torch Leads Lengths

20 foot / 6.1 m, or 50 foot / 15.2 m

For torches withATC Connectors, leads extensions are

available to extend the leads to a maximum of 50 feet / 15.2

m. Total leads lengths must not exceed the power supply

manufacturer's recommendations.

January 8, 2009 2 Manual 0-2880 Rev AB

C. Current Rating (Refer to Note)

SL60 & SL100 Current Ratings

SL60 Torch & Leads

SL100 Torch & Leads

Up to 60 Amps, DC,

Straight Polarity

Up to 100 Amps, DC,

Straight Polarity

NOTE

Power Supply characteristics will determine mate-

rial thickness range.

D. Torch Ratings

Ambient

Tem

erature

104° F

40° C

Duty Cycle 100% @ 60 Amps @ 400 scfh

Maximum Current 60 Amps

Voltage (Vpeak)500V

Arc Striking Voltage 7kV

SL60 Torch Ratin

Ambient

Tem

erature

104° F

40° C

Duty Cycle 100% @ 100 Amps @ 400 scfh

Maximum Current 100 Amps

Voltage (Vpeak)500V

Arc Striking Voltage 7kV

SL100 Torch Ratin

E. Type of Cooling

Combination of ambient air and gas stream through

torch.

F. Gas Requirements

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE 60 - 75 psi

4.1 - 5.2 bar

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and Gouging) 300 - 500 scfh

(142 - 235 lpm)

SL60 and SL100 Torch Gas Specifications

WARNING

This torch is not to be used with oxygen (O2).

NOTE

Operating pressure varies with torch model, oper-

ating amperage, and torch leads length. Refer to

gas pressure settings chart for each model.

G. Direct Contact Hazard

For exposed tip the recommended standoff is 1/8" - 1/4"

(3 - 6.4 mm).

H. Parts-In-Place (PIP) Circuit - 12 vdc

The torch and leads include circuitry called Parts-In-

Place (PIP). This circuit includes a switch located at

the torch head. The shield cup closes this switch when

properly installed. The torch will not operate if this

switch is open.

Connecting Torch

There are two types of connection for the Torch Leads. One

type uses the Thermal Dynamics ATC connector. The other

uses O2B connections for gas and circuitry. Both types require

an adapter kit sold separately.

ATC Connectors

Follow the instructions provided with the adapter kit to con-

nect the adapter to the power supply.

Inspect the halves of theATC Connector. Align the male con-

nector with the female receptacle and push them together by

hand until they seat fully. Turn the Locking Ring until it pulls

the halves of the connector together fully. Do not use tools to

tighten the connector. If there is any resistance to the ring

turning, pull the halves of the connector apart, realign the inner

components, ensure that the threaded components are aligned,

and push the halves of the connector together again.

O2B Connectors

Leads with O2B connectors are connected to the power supply

using adapter kits sold separately. Follow the instructions

provided with the adapter kit to connect the gas and electrical

lines to the power supply.

January 8, 2009 3 Manual 0-2880 Rev AB

Spare Parts Label

The parts kit provided with the torch includes an adhe-

sive label. Select the small perforated section showing the

appropriate pressure setting for the amperage output and

leads length to be used with this torch. Refer to the charts.

Apply this section in the 'Gas Supply' area of the label

under the 'Recommended Operating Pressure' text. Dis-

card any pressure setting sections of the label that will not

be used. Apply the large label to the power supply, where

the operator can see it for easy reference.

Torch Parts Selection

Refer to the Consumables Selection Chart for the various torch

parts for the application and operation.

WARNINGS

Disconnect primary power to the system before dis-

assembling the torch or torch leads.

DO NOT touch any internal torch parts while the

AC indicator light of the Power Supply is ON.

The shield cup (or shield cup body and shield cap or deflector)

holds the tip and starter cartridge in place. Position the torch

with the shield cup facing upward to keep these parts from

falling out when the cup is removed.

Change the torch parts as follows:

1. Unscrew and remove the shield cup from the torch

head.

Art # A-03417

Electrode

Start Cartridge

Tip

Shield Cup

Assembly

Torch Head

2. Tilt the torch head to remove the tip and starter car-

tridge.

3. Fit the desired starter cartridge and tip onto the electrode.

NOTE

Refer to the consumables selection chart for the proper

combination of torch parts, including shield cups

and caps.

4. Hand tighten the shield cup until it is seated on the torch

head. Do not use tools to tighten the cup. If resistance is

felt when installing the cup, check the threads before pro-

ceeding.

NOTE

When operating the torch in a normal condition,

a small amount of gas vents through the gap be-

tween the shield cup and the torch handle. Do not

attempt to overtighten the shield cup as irrepa-

rable damage to internal components may result.

Gouging Parts Selection

Select gouging tips according to the desired gouge profile.

Gouging parameters shown are based on a 35° approach angle.

Output Range Depth Width

Tip A 40 Amps Max. Shallow Narrow

Tip B 40-100 Amps Deep Narrow

Tip C 40-100 Amps Moderate Moderate

Tip D 40-100 Amps Shallow Wide

Gouging Profiles

Operating Gas Pressure

Set gas pressure at the power supply regulator according to the

following charts. These charts are a guide only; adjust as nec-

essary for best performance.

Tip 20' / 6.1 m 50' / 15.2 m

30A, 40A,

50/55A, 60A 65 psi / 4.5 bar 75 psi / 5.2 bar

Leads Length

SL60 GasPressure Settings

Tip Up to 25' / 7.6 m 50' / 15.2 m

30A, 40A,

50/55A, 60A,

70A, 80A 60 psi / 4.1 bar 65 psi / 4.5 bar

90/100A 65 psi / 4.5 bar 70 psi / 5.2 bar

SL100 Gas Pressure Settings

Leads Length

January 8, 2009 4 Manual 0-2880 Rev AB

Cutting or Gouging

The torch can be held comfortably in one hand or steadied

with two hands. Choose the holding technique that feels

most comfortable and allows good control and movement.

Sequence of Operation

1. Turn on power and adjust gas pressure on the Power Sup-

ply pressure gauge. Refer to the charts for optimum pres-

sure settings for the combination of torch tip and total

leads lengths (including extensions) in use.

2. Adjust current output on the Power Supply to match the

selected tip and attach the work clamp firmly to the

work.

WARNING

Maximum current for is 60 Amps for SL60 Torches,

or 100 Amps for SL100 Torches. Operation of this

torch at higher outputs may damage the torch, the

leads, or the Power Supply. DO NOT operate the

SL60 Torch at more than 60 Amps, or the SL100

at more than 100 Amps.

CAUTION

Do not operate the torch with the torch tip in contact

with the work at outputs greater than 40 amps. Drag

cutting at higher output currents can cause irrepa-

rable damage to the torch parts. Use only shielded

parts at output currents higher than 40 amps.

3. Hold the torch away from your body.

4. Slide the trigger release toward the back of the torch

while simultaneously squeezing the trigger. The pi-

lot arc will start.

A-02986

Trigger

Trigger Release

5. Bring the torch within transfer distance to the work. The main

arc will transfer to the work, and the pilot arc will shut off.

NOTE

The gas preflow and postflow are a characteristic of

the power supply and not a function of the torch.

Art # A-03383

Trigger

Trigger Release

6. Cut as usual. Simply release the trigger assembly to

stop cutting.

7. Follow normal recommended cutting practices as pro-

vided in the power supply operator's manual.

NOTE

When the shield cup is properly installed, there is

a slight gap between the shield cup and the torch

handle. Gas vents through this gap as part of nor-

mal operation. Do not attempt to force the shield

cup to close this gap. Forcing the shield cup against

the torch head can damage components.

8. The optional Standoff Guide allows the user to easily ad-

just and maintain a consistent standoff height for most ap-

plications.

Art # A-04063

Shield Cup

Standoff Guide

Torch Tip

Workpiece

January 8, 2009 5 Manual 0-2880 Rev AB

Common Operating Faults

The following are the more common cutting faults and the

possible causes:

1. Insufficient Penetration

a. Cutting speed too fast

b. Torch tilted too much

c. Metal too thick

d. Worn torch parts

e. Cutting current too low

f. Non-Genuine Thermal Dynamics Parts

2. Main Arc Extinguishes

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Cutting current too high

d. Work cable disconnected

e. Worn torch parts

f. Non-Genuine Thermal Dynamics Parts

3. Excessive Dross Formation

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Worn torch parts

d. Improper cutting current

e. Non-Genuine Thermal Dynamics Parts

4. Short Torch Parts Life

a. Oil or moisture in air source

b. Exceeding system capability (material too thick)

c. Excessive pilot arc time

d. Gas pressure too low

e. Improperly assembled torch

f. Non-Genuine Thermal Dynamics Parts

5. Difficult Starting

a. Worn torch consumables

b. Non - Genuine Thermal Dynamics Parts

6. Torch will not pilot when torch switch is activated

a. Upper O-ring on torch head is in wrong position

Lower O-Ring

Upper O-Ring

in Correct Groove

Upper Groove

with Vent Holes

Must Remain Open

Threads

Art # A-03640

January 8, 2009 6 Manual 0-2880 Rev AB

Inspection and Replacement of

Consumable Torch Parts

A. General Information

WARNINGS

Disconnect primary power to the system before dis-

assembling the torch or torch leads.

DO NOT touch any internal torch parts while the

AC indicator light of the Power Supply is ON.

Unthread the shield cup assembly to remove the consumable

torch parts.

1. Inspect the cup for damage. Wipe it clean or replace if

damaged. Slag built up on the shield cup that cannot be

removed may affect the performance of the system.

Art # A-03417

Electrode

Start Cartridge

Tip

Shield Cup

Assembly

Torch Head

2. Check the tip for excessive wear (indicated by an elongated

or oversized orifice). Clean or replace the tip if necessary.

Good Tip Worn Tip

A-03406

3. On torches with a shield cup body and a shield cap or

deflector, ensure that the cap or deflector is threaded

snugly against the shield cup body. In shielded drag

cutting operations (only), there may be an O-ring be-

tween the shield cup body and drag shield cap. Do not

lubricate the O-ring.

Drag Shield Cap

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

4. Check the starter cartridge for excessive wear, plugged gas

holes, discoloration, and for free movement of the lower

end plate. Replace if necessary.

Lower End Fitting

Start Cartridge

Art # A-03621

5. Check the end of the electrode for excessive wear.

Worn Electrode

New Electrode

Art # A-03284

January 8, 2009 7 Manual 0-2880 Rev AB

6. Reinstall the Electrode by pushing it straight into

the torch head until it clicks.

WARNINGS

Refer to the consumables selection charts for the

proper combination of torch parts, including

shield cups and shield caps.

The use of any consumable parts other than

those specified by the Manufacturer may cause

irreparable damage to the torch head.

7. Reinstall the desired starter cartridge and tip into the

torch head.

8. Hand tighten the shield cup until it is seated on the torch

head. If resistance is felt when installing the cup, check

the threads before proceeding.

NOTE

When operating the torch in a normal condi-

tion, a small amount of gas vents through the

gap between the shield cup and the torch

handle. Do not attempt to overtighten the shield

cup as irreparable damage to internal compo-

nents may result.

B. O-Ring Lubrication

This section applies only to torches withATC connec-

tors.

An o-ring on the Torch ATC Male Connector requires

lubrication on a regular basis, depending on how fre-

quently the torch is disconnected and re-connected. This

willallow the o-ringto remainpliable and providea proper

seal. The o-ring will dry out, becoming hard and cracked,

if the o-ring lubricant is not used on a regular basis.

This can lead to potential performance problems.

It is recommended to apply a very light film of o-ring

lubricant (Catalog # 8-4025) to the o-ring on a weekly

basis.

NOTE

DO NOT use other lubricants or grease, they

may not be designed to operate within high tem-

peratures or may contain “unknown elements”

that may react with the atmosphere. This reac-

tion can leave contaminants inside the torch.

Either of these conditions can lead to inconsis-

tent performance or poor parts life.

ATC Male Connector

Art #A-03791

Gas Fitting

O-Ring

January 8, 2009 8 Manual 0-2880 Rev AB

Torch Consumables

The illustrations show all consumable parts for the SL60

and SL100 torches.

Various front - end torch parts are available for different

applications.

Drag Tip Cutting: Use the single - piece shield cup for

general purpose cutting operations with the torch tip in

contact with the work (up to 40 amps). This is the pre-

ferred method of cutting sheet metal up to 3/16" or 4.8 mm

thick.

Standoff Cutting: Also use the single - piece Shield Cup

for 'standoff' cutting (with the torch tip 1/8" to 1/4" from

the workpiece). This is the preferred method for cutting

metal thicker than 3/16" / 4.8 mm and at current levels

above 40 amps. This provides maximum visibility and

accessibility.

Use the Shield Cup Body with the Deflector Shield Cap for

extended parts life and improved resistance to reflected

heat. This combination provides cutting results similar to

the single-piece Shield Cup, as well as easy change-over

to gouging or drag shield cutting.

Drag Shield Cutting: Use the Shield Cup Body with the

Drag Shield Cap for a consistent standoff distance with

the drag shield in contact with the workpiece. This is a

simple and operator-friendly method of cutting between

50 and 100 amps.

Gouging: Use the Shield Cup Body with the Gouging

Shield Cap for excellent gouging performance and en-

hanced torch parts life.

The Standoff Guide fits all shield cup designs for the SL60

and SL100 RPT hand torches. The Guide allows the user

to easily adjust and maintain a consistent standoff height

for most applications. The Standoff Guide also fits Ther-

mal Dynamics PCH-62 and PCH-102 hand torches.

The electrode and starter cartridge are the same for all

applications.

Use only Genuine Thermal Dynamics consumables with

this torch. The use of any other consumables may irrepa-

rably damage the torch and/or void the warranty.

Drag Tip

Cutting

Drag Shield

Cutting

Gouging,

40 - 100 A

1/8" / 3.2 mm

@ 40A

3/16" / 4.8 mm

35 - 45

ABCD

40A 50 - 100A

1/8-1/4" / 3.2-6.4mm

@60 A

Standoff

Cutting

3/16" / 4.8 mm

1/8 - 1/4"

(3.2 - 6.4 mm)

40 A

50 - 100 A

Art # A-07039

Art # A-04063

Shield Cup

Standoff Guide

Torch Tip

Workpiece

January 8, 2009 9 Manual 0-2880 Rev AB

Output Range Depth Width

Tip A 40 Amps Max. Shallow Narrow

Tip B 40-100 Amps Deep Narrow

Tip C 40-100 Amps Moderate Moderate

Tip D 40-100 Amps Shallow Wide

Gouging Profiles

Consumables Selection

Starter

Cartridge

9-8213

Electrode

9-8215

Tips:

20A 9-8205

30A 9-8206

40A 9-8207

Tip A 9-8225 (40 Amps Max.)

Tip B 9-8226 (40 - 100 Amps)

Tip C 9-8227 (40 - 100 Amps)

Tip D 9-8228 (40 - 100 Amps)

Shield Cap, Gouging

9-8241

Shield Cap, Drag

40A 9-8244

40A 9-8208

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Drag

70-100A 9-8236

Shield

Cup Body,

9-8237

70-100A

50-60A

40A

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Tip:

Tips:

DRAG TIP

CUTTING

40-100A

GOUGING

CUTTING

Art # A-04037

DRAG SHIELD

CUTTING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

STANDOFF CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

for All Applications

9-8422

Shield Cap, Deflector

9-8243

O-Ring No. 8-3488

Shield Cap, Deflector

9-8243

O-Ring No. 8-3488

January 8, 2009 10 Manual 0-2880 Rev AB

Replacement Hand Torch Parts

Item # Qty Description Catalog #

11 75° Torch Handle Replacement Kit (include items no. 2 & 3) 9-7030

11 90° Torch Handle Replacement Kit (include items no. 2 & 3) 9-7037

2 1 Trigger Assembly Replacement Kit 9-7034

3 1 Handle Screw Kit (5 each, #6-32 x 1/2" cap screw, and wrench) 9-8062

41 75° Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219

41 90° Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8260

5 1 Large O-Ring 8-3487

6 1 Small O-Ring 8-3486

7Leads Assemblies with O2B Connectors (includes switch assemblies)

1 SL60 / 60 Amp, 20 - foot Leads Assembly with O2B connectors 4-7830

1 SL60 / 60 Amp, 50 - foot Leads Assembly with O2B connectors 4-7831

1 SL100 / 100 Amp, 20 - foot Leads Assembly with O2B connectors 4-7832

1 SL100 / 100 Amp, 50 - foot Leads Assembly with O2B connectors 4-7833

8Leads Assemblies with ATC Connectors (includes switch assemblies)

1 SL60 / 60 Amp, 20 - foot Leads Assembly with ATC connectors 4-7834

1 SL60 / 60 Amp, 50 - foot Leads Assembly with ATC connectors 4-7835

1 SL100 / 100 Amp, 20 - foot Leads Assembly with ATC connectors 4-7836

1 SL100 / 100 Amp, 50 - foot Leads Assembly with ATC connectors 4-7837

9 1 Switch Kit 9-7031

Not Shown:

1 Starter Cartridge Restrictor Pin Kit (for use with certain 8-3440

power supplies with high - volt start circuitry)

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