SL60
SL100
PLASMA CUTTING TORCH
Model SL60, SL100 Hand
Torch
Model SL100 Machine Torch
Instruction Manual
Rev. AA.01 Date: October 20, 2006 Manual # 0-2962
Operating Features:
60
100
100%
Duty
Cycle
H/F
LV
Start
Max
Flow
400 scfh
Op Pres
60-75
PSI
Max
Input
125PSI
PIP
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics 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 1-800-426-1888, or
visit us on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics 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.
Thermal Dynamics is a Global Brand of manual and automation Plasma
Cutting Products for Thermadyne Industries Inc.
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 developing 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 best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Torch
Model SL60 and SL100 Hand Torch
Model SL100 Machine Torch
Instruction Manual Number 0-2962
Protected under U.S. Patent Number 6,163,008. Other patents may apply.
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2003, 2004, 2005, 2006 by
Thermal Dynamics Corporation
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.
Printed in the United States of America
Publication Date: September 29, 2005
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Power Supply Serial #: ___________________________________
Torch Serial #: ___________________________________
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing aids,
or other electronic health equipment. Persons who
work near plasma arc cutting applications should
consult their medical health professional and the
manufacturer of the health equipment to determine
whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-2985711 or your local distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting, produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
Manual 0-2962 1-1 GENERAL INFORMATION
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have held
combustibles.
• Provide a fire watch when working in an area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut alu-
minum alloys underwater or on a water table unless the hydrogen gas can be eliminated or
dissipated. Trapped hydrogen gas that is ignited
will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your eyes
and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters may
be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable from
the Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-2 Manual 0-2962
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
Manual 0-2962 1-3 GENERAL INFORMATION
1.04 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
GENERAL INFORMATION 1-4 Manual 0-2962
1.05 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) 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 Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’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 Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal 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 “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal 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 Thermal 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 THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Year 1 Year
SureLok Torches 1 Year 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® 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 customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective August 6, 2001
Manual 0-2962 1-5 GENERAL INFORMATION
GENERAL INFORMATION 1-6 Manual 0-2962
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing aids,
or other electronic health equipment. Persons who
work near plasma arc cutting applications should
consult their medical health professional and the
manufacturer of the health equipment to determine
whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-2985711 or your local distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting, produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
Manual 0-2962 1-1 GENERAL INFORMATION
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have held
combustibles.
• Provide a fire watch when working in an area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut alu-
minum alloys underwater or on a water table unless the hydrogen gas can be eliminated or
dissipated. Trapped hydrogen gas that is ignited
will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your eyes
and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters may
be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable from
the Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-2 Manual 0-2962
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
Manual 0-2962 1-3 GENERAL INFORMATION
1.04 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
GENERAL INFORMATION 1-4 Manual 0-2962
1.05 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) 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 Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’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 Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal 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 “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal 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 Thermal 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 THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Year 1 Year
SureLok Torches 1 Year 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® 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 customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective August 6, 2001
Manual 0-2962 1-5 GENERAL INFORMATION
GENERAL INFORMATION 1-6 Manual 0-2962
SECTION 2:
2.03 Specifications
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and maintenance procedures for the 1Torch Models SL60
and SL100 Plasma Cutting Torches. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting
repairs or adjustments not covered in this manual, at the
risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding
of the characteristics and capabilities of this equipment
will assure the dependable operation for which it was
designed.
2.02 General Description
Plasma torches are similar in design to the automotive
spark plug. They consist of negative and positive sections
separated by a center insulator. Inside the torch, the pilot
arc starts in the gap between the negatively charged electrode and the positively charged tip. Once the pilot arc
has ionized the plasma gas, the superheated column of
gas flows through the small orifice in the torch tip, which
is focused on the metal to be cut.
A single torch lead provides gas from a single source to be
used as both the plasma and secondary gas. The air flow
is divided inside the torch head. Single - gas operation
provides a smaller sized torch and inexpensive operation.
NOTE
Refer to Section 2.05, Introduction To Plasma, for a
more detailed description of plasma torch operation.
Refer to the Appendix Pages for additional specifications as related to the Power Supply used.
A. Torch Configurations
1. Hand Torch, Models SL60 and SL100
The hand torch head is at 75° to the torch handle.
The hand torches include a torch handle and torch
trigger assembly.
9.5" (241 mm)
3.75"
(95 mm)
1.17" (29 mm)
2. Machine Torch, Model SL100
The standard machine torch has a positioning tube
with rack & pinch block assembly.
15.875" / 403 mm
9.285" / 236 mm
1.375" / 35 mm
1.75" /
44.5 mm
0.625" /
4.95" / 126 mm
16 mm
1.175" / 30 mm
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20 ft / 6.1 m, with O2B or ATC connectors
• 50 ft / 15.2 m, with O2B or ATC connectors
Machine Torches are available as follows:
• 5 foot / 1.5 m, with ATC connectors
• 10 foot / 3.05 m, with ATC connectors
• 25 foot / 7.6 m, with O2B or ATC connectors
• 50 foot / 15.2 m, with O2B or ATC connectors
C. Torch Parts
Art # A-03322
Art # A-02998
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch Head has built - in switch
12 vdc circuit rating
Manual 0-2962 2-1 INTRODUCTION
E. Type Cooling
p
g
p
g
s
!
s
!
H. Gas Requirements
Combination of ambient air and gas stream through
torch.
F. Torch Ratings
SL60 Torch Ratin
Ambient
Tem
erature
Duty Cycle
Maximum Current
Vol tage (V
Arc Striking Voltage
Ambient
Tem
erature
Duty Cycle
Maximum Current
Vol tage (V
Arc Striking Voltage
)
pea k
SL100 Torch Ratin
)
pea k
100% @ 60 Amps @ 400 scfh
100% @ 100 Amps @ 400 scfh
s
104° F
40° C
60 Amps
500V
7kV
s
104° F
40° C
100 Amps
500V
7kV
G. Current Ratings
Current Ra ting
SL60 Torch & Leads
SL100 Torch & Leads
Maximum current 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, the components, or the Power Supply. DO
NOT operate the SL60 torch at more than 60 Amps,
or the SL100 at more than 100 Amps.
Up to 60 Amps, DC,
Straight Polarity
Up to 100 Am ps, DC,
Straight Polarity
W ARNING
SL60 and SL 100 To rch Gas Specification
Gas (Plasma and Secondary) Compressed Air
Operating Pres sure
Ref e r to NOTE
Maxi m um Input P res s ure
Gas F l ow (Cu t ting and G ou gi ng)
W ARNING
This torch is not to be used with oxygen (O2).
NOTE
Operating pressure varies with torch model, operating amperage, and torch leads length. Refer to
gas pressure settings charts for each model.
60 - 75 psi
4.1 - 5.2 bar
125 psi / 8. 6
bar
300 - 500 scfh
142 - 235 lpm
I. Direct Contact Hazard
For exposed tip the recommended standoff is 3/16
inches / 4.7 mm.
J. Plasma Power Supply Used With
• CutMaster 50
• CutMaster 51
• CutMaster 75
• CutMaster 81
• CutMaster 100
• CutMaster 101
• CutMaster 151
• PakMaster 50XL Plus
• PakMaster 75XL Plus
• PakMaster 100XL Plus
NOTE
NOTE
Power Supply characteristics will determine material thickness range.
INTRODUCTION 2-2 Manual 0-2962
Refer to the Appendix Pages for additional specifications as related to the Power Supply used.
2.04 Options And Accessories
A-00002
Workpiece
Power
Supply
+
_
C
B
A
2.05 Introduction to Plasma
These items can adapt a standard system to a particular
application or further enhance performance (refer to Section 6 for ordering information).
• Spare Parts Kits - Various kits containing replacement consumable torch parts.
• Deluxe Cutting Guide Kit - Easy add - on attachments for precise straight line, circle cutting, and
beveling. Includes carrying case.
• Trigger Guard Kits (for hand torches) - These offer
additional protection from accidental activation of
the torch switch.
• 1 - 3/8" Mounting Tube (for machine torches)
• Pinion Assembly (for machine torches)
• Computer Control (CNC) Cable 25 Ft / 7.6 m or
50 Ft / 15.2 m (for machine torches)
• Remote Pendant Control Assembly - for machine
torch applications. Hand Pendant Control has
20 ft. (6.1 m) cable which provides ON & OFF signals to the Power Supply.
• Extension Cable for Hand Pendant Control - 25 ft /
7.6 m cable which can be added to the Hand Pendant Control cable to provide a total control cable
length of 50 ft / 15.2 m.
• Leads Extensions for torches with ATC connectors
• Leather Leads Covers
A. Plasma Gas Flow
Plasma is a gas which has been heated to an extremely
high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical
arc to the workpiece. The metal to be cut or removed is
melted by the heat of the arc and then blown away.
While the goal of plasma arc cutting is separation of
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.
In a Plasma Cutting Torch a cool gas enters Zone B,
where a pilot arc between the electrode and the torch
tip heats and ionizes the gas. The main cutting arc
then transfers to the workpiece through the column of
plasma gas in Zone C.
Typical Torch Head Detail
By forcing the plasma gas and electric arc through a
small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
arc is shown in Zone C. Direct current (DC) straight
polarity is used for plasma cutting, as shown in the
illustration.
Manual 0-2962 2-3 INTRODUCTION
Zone A channels a secondary gas that cools the torch.
This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast, slag
- free cut.
B. Gas Distribution
The single gas used is internally split into plasma and secondary gases.
The plasma gas flows into the torch through the negative
lead, through the starter cartridge, around the electrode,
and out through the tip orifice.
The secondary gas flows down around the outside of the
torch starter cartridge, and out between the tip and shield
cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates
a path for the main arc to transfer to the work.
D. Capacitive Discharge
Because direct current (DC) alone is not sufficient to strike
and maintain the pilot arc, capacitive discharge is also used.
The high voltage jumps between the tip and electrode with
the DC following.
NOTE
Not all power supplies have this feature.
E. Main Cutting Arc
DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
through the torch lead. The positive output is connected to the workpiece via the work cable and to the
torch through a pilot wire.
F. Parts - In - Place (PIP)
The torch includes a 'Parts - In - Place' (PIP) circuit.
When the shield cup is properly installed, it closes a
switch. The torch will not operate if this switch is
open.
To Control
Torch Switch
Cable Wiring
PIP Switch
A-02997
Torch Trigger
Shield Cup
Parts - In - Place Circuit Diagram for Hand Torch
To Control
Cable Wiring
PIP Switch
Shield Cup
A-03504
Parts - In - Place Circuit Diagram for Machine
Torch
INTRODUCTION 2-4 Manual 0-2962
SECTION 3:
INSTALLATION
3.01 Introduction
This section describes installation of the Torch. These
instructions apply to the Torch and Leads Assemblies
only; installation procedures for the Power Supply, Options and Accessories are given in Manuals specifically
provided for those parts.
The complete installation consists of:
• Site Selection
• Unpacking
• Setting Up Torch
• Connecting Torch
• Gas Connection
3.02 Site Location
Select a clean, dry location with good ventilation and adequate working space around all components.
3.05 Setting Up Machine Torch
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
The machine torch includes a positioning tube with rack
and pinch block assembly.
1. Mount the torch assembly on the cutting table.
2. To obtain a clean vertical cut, use a square to align
the torch perpendicular to the surface of the workpiece.
Pinch Block
Assembly
Review the safety precautions in the front of this manual
to be sure that the location meets all safety requirements.
3.03 Unpacking
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
1. Unpack each item and remove all packing material.
2. Locate the packing list and use the list to identify and
account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and / or
shipping company before proceeding with system
installation.
3.04 Setting Up Hand Torch
The hand torch requires no special set up. The proper
torch parts (shield cup, tip, starter cartridge, and electrode) must be installed for the type of operation. Refer
to Section 4.04, Torch Parts Selection for details.
Square
Workpiece
A-02585
Machine Torch Set - Up
3. The proper torch parts (shield cup, tip, starter
cartridge, and electrode) must be installed for the
type of operation. Refer to Section 4.04, Torch
Parts Selection for details.
Manual 0-2962 3-1 INSTALLATION
3.06 Connecting Torch
A. Hand Systems
The Torch Leads must be properly connected to the Power
Supply for proper operation. If the torch leads or ATC
Adapter were not factory - installed, make all torch connections as required.
The instructions for connecting the Torch Leads to the
Power Supply vary depending on the type of leads connections. This sub - section covers connecting the Torch
for the following applications:
A. Hand Systems
B. Mechanized Machine Torch Systems with ATC
Connectors
C. Mechanized Machine Torch Systems with O2B
Connectors
D. Remote Pendant Control (Optional)
E. Automated Machine Torch Systems with ATC
Connectors
F. Automated Machine Torch Systems with O2B
Connectors
Torches with ATC connectors connect either to an ATC
Adapter which connects to the power supply bulkhead,
or to an ATC Receptacle which mounts to the power supply front panel.
Torches with O2B fittings connect directly to the power
supply bulkhead. The connections to the bulkhead are
the same in both applications.
Follow Steps 1-8 to install either an ATC Adapter or a
torch with O2B fittings. Follow Step 9 to connect a torch
with an ATC connector to the ATC Adapter or to the
panel-mounted ATC receptacle.
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
1. Remove the retaining nut from the Through - Hole
protector.
Torch Leads
Assembly or ATC Adapter
Thru-Hole Protector
Negative /
Plasma Lead
Thru-Hole Protector
Pilot Lead
Nut
Art # A-03875
Through - Hole Protector Nut Removal
2. Fit the torch leads or ATC Adapter end and the
Through - Hole protector into the hole in the unit.
INSTALLATION 3-2 Manual 0-2962
3. Secure the Through - Hole protector with the retaining nut removed earlier.
4. Connect the torch leads or ATC Adapter Negative
/ Plasma Lead to the bulkhead connection inside
the Power Supply as shown.
Torch Leads
ATC Male
Connector
Note: Actual Bulkhead
configuration may
differ from that shown.
Adapter
Control Circuit
Connectors
Torch Leads
Assembly or
ATC Adapter
A-03527
Adapter
Connector
Plug
Negative/Plasma
Pilot Lead Stud
Negative/Plasma Lead
Connection
Pilot Lead
Lead
Bulkhead Connections - ATC Adapter or Hand
Torch Leads with O2B Fittings
5. The Leads or ATC Adapter Assembly includes two
wires joined with mating connectors and covered
with an insulating sleeve. These wires must remain joined and insulated. Connect the remaining torch leads connectors to the mating connectors on the Power Supply Adapter.
6. Remove the top nut and washer from the Pilot
Stud.
To
Power Supply
1
2
ATC Adapter
Female Receptacle
Torch Connection - Torch Leads with ATC Male
Connector, Power Supply with ATC Adapter
Control Cable
Connector (Machine
Torches Only)
ATC Female Receptacle
(Panel Mounted)
1
A-03627
2
ATC Male
Connector
7. Connect the pilot lead terminal to the stud and
secure with the nut and washer removed in the
above Step.
A-03602
8. Tighten the Through - Hole protector onto the
Torch Leads or ATC Adapter Leads Assembly.
9. For torches with the ATC Connector, align the
torch leads male connector with the ATC female
receptacle. Push the male connector into the female receptacle. The connectors should push together with a very small amount of pressure. Se-
Torch Connection - Torch Leads with ATC Male
Connector, Power Supply with Panel-Mounted ATC
Receptacle
cure the connection by turning the locking nut
clockwise until it stops. DO NOT use the locking
10. Check the torch for proper consumable parts.
nut to pull the connection together. Do not use
tools to secure the connection.
CAUTION
The torch parts must correspond with the type of
operation. Refer to Section 4.04, Torch Parts Selection.
Manual 0-2962 3-3 INSTALLATION
B. Mechanized Machine Torch Systems -
Torches with ATC Connectors
Torches with ATC connectors connect either to an ATC
Adapter which connects to the power supply bulkhead,
or to a panel-mounted ATC Receptacle. Mechanized
torch leads with ATC connectors include a control cable
connector to accept a remote pendant.
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
5. Connect the Control Circuit Connectors on the ATC
Adapter to the mating connectors on the Power
Supply Adapter.
Note: Actual Bulkhead
configuration may
differ from that shown.
Adapter
Control Circuit
Connectors
Plug
Adapter
Connector
Pilot Lead Stud
1. Remove the Through - Hole protector Nut from the
Through - Hole protector.
Torch Leads
Assembly or ATC Adapter
Negative /
Plasma Lead
Thru-Hole Protector
Thru-Hole Protector
Nut
Pilot Lead
Art # A-03875
Through - Hole Protector Nut Removal
2. The ATC Adapter Assembly includes two wires
joined with mating connectors and covered with
an insulating sleeve. These wires must remain
joined and insulated.
Torch Leads
Assembly or
ATC Adapter
A-03527
Negative/Plasma Lead
Connection
Pilot Lead
Negative/Plasma
Lead
6. Remove the top nut and washer from the Pilot Stud
on the power supply bulkhead.
7. Place the ATC Adapter Pilot lead terminal on onto
the stud and secure with the nut and washer removed in the above Step.
8. Tighten the Through - Hole protector onto the ATC
Adapter leads.
9. Connect the torch leads male connector to the ATC
female receptacle. The connectors should push
together with a very small amount of pressure.
Secure the connection by turning the locking nut
clockwise until it stops. DO NOT use the locking
nut to pull the connection together. Do not use
tools to secure the connections.
3. Connect the ATC Adapter as follows:
a. Feed the end of the adapter lead and the
Through - Hole protector into the hole in the
unit
b. Tighten the Through - Hole protector Nut to
secure the Through - Hole protector to the
Power Supply.
4. Connect the Adapter Negative / Plasma Lead to
the bulkhead connection inside the Power Supply.
INSTALLATION 3-4 Manual 0-2962
10. Connect the remote pendant adapter to the Remote
Control Cable Connector.
Control Cable
Connector (Machine
Torches Only)
ATC Male
Connector
To
Power Supply
1
Torch Leads
2
C. Mechanized Machine Torch Systems -
Torches with O2B Connectors
Torches with O2B connectors connect directly to the
power supply bulkhead. Mechanized torch leads with
O2B connectors require a remote pendant adapter to accept a remote pendant.
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
ATC Adapter
Female Receptacle
A-03582
Torch Connection - Torch Leads with ATC Male
Connector, Power Supply with ATC Adapter
Control Cable
Connector (Machine
Torches Only)
ATC Female Receptacle
(Panel Mounted)
1
2
ATC Male
Connector
A-03602
1. Remove the Through - Hole protector Nut from the
Through - Hole protector.
Torch Leads
Assembly or ATC Adapter
Remove Tie Wrap,
Remove Insulator,
Disconnect Wires
Art # A-03877
Through - Hole
Protector
Through - Hole
Protector Nut
Pilot Lead
Through - Hole Protector Nut Removal
2. The leads Assembly includes two wires joined with
mating connectors and covered with an insulating sleeve. Remove the tie wrap and insulating
sleeve. Disconnect the two joined wires.
3. Feed the end of the torch leads and the Through Hole protector into the hole in the unit.
4. Route the wire harness on the Remote Pendant
Torch Connection - Torch Leads with ATC Male
Connector, Power Supply with Panel-Mounted ATC
Receptacle
Adapter through the Through - Hole protector
and Through - Hole protector Nut. Tighten the
Through - Hole protector Nut to secure the
Through - Hole protector to the Power Supply.
11. Check the torch for proper consumable parts.
5. Connect the Negative / Plasma lead to the bulkhead connection inside the power supply.
CAUTION
The torch parts must correspond with the type of
operation. Refer to Section 4.04, Torch Parts Selection.
Manual 0-2962 3-5 INSTALLATION
6. Connect the control circuit connectors on the Torch
Leads to the mating connectors on the Remote
Pendant Adapter and Power Supply Adapter (see
Warning).
Control Circuit
Connectors
Power Supply
Adapter
WARNING
There are two additional connectors that are not
used and must be taped out of the way to prevent
contacting the Negative / Plasma or Pilot Leads.
7. Remove the top nut and washer from the Pilot
Stud on the power supply bulkhead.
8. Place the Torch Leads Pilot lead terminal on onto
the stud and secure with the nut and washer removed in the above Step.
Note: Actual Bulkhead
configuration may
differ from that shown.
Power Supply
Control Circuit
Connectors
Open
Adapter
Connector
Adapter
Pilot Lead Stud
Open
Negative/Plasma
Lead Connection
Open
Remote Pendant
Adapter Wire
Harness
Negative/Plasma
Lead
Torch Lead
Assembly
Open
Pilot Lead
A-03676
Bulkhead Connection Detail - Unshielded Machine
Torch with O2B Fittings and Remote Pendant
Adapter
10. Tighten the Through - Hole protector onto the
Torch Leads or ATC Adapter Leads Assembly.
11. Connect the remote pendant to the remote pendant adapter.
12. Check the torch for proper consumable parts.
Negative/Plasma
Remote Pendant
Adapter Wire Harness
Lead
Torch Lead
Assembly
Pilot Lead
A-03675
Bulkhead Connection - Unshielded Machine Torch
with O2B Fittings and Remote Pendant Adapter
9. Connect the Torch Leads connectors and the remote pendant adapter connector to the power
supply adapter as shown.
CAUTION
The torch parts must correspond with the type of
operation. Refer to Section 4.04, Torch Parts Selection.
D. Remote Pendant Control (Optional)
In mechanized applications an Adapter connects the
remote pendant control to the Power Supply.
Connect the remote pendant control cable to the torch
leads by aligning the control cable connector with the
adapter on the torch leads. Press the connector into
the adapter. Turn the locking ring to secure the connection.
INSTALLATION 3-6 Manual 0-2962
E. Automated Machine Torch Systems with
ATC Connectors
Torches with shielded leads and ATC connectors connect
to a shielded ATC Adapter which connects to the power
supply bulkhead.
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
7. Connect the ATC Adapter connectors to the power
supply adapter.
WARNING
The Shielded ATC Adapter includes two connectors that are not used and must be taped out of the
way to prevent contacting the Negative / Plasma
or Pilot Leads.
8. Tighten the Through - Hole protector onto the ATC
Adapter leads.
A-03677
Pilot Lead
Negative/Plasma
Lead
Shield
Connector
Torch Control
Connectors
Shielded ATC Adapter
Strain Relief
Strain Relief
Nut
Shield
Connector
Through - Hole protector Nut Removal
1. Remove the Through - Hole protector Nut from
the Through - Hole protector. Inside the Power
Supply Bulkhead area, route the connectors on
the free end of the Adapter through the Through
- Hole protector Nut.
2. Fit the ATC Adapter end and the Through - Hole
protector into the hole in the unit.
3. Secure the Through - Hole protector with the retaining nut removed earlier.
4. Connect the ATC Adapter Negative / Plasma
Lead to the bulkhead connection inside the Power
Supply.
5. Remove the top nut and washer from the Pilot
Stud.
9. Connect the torch leads male connector to the ATC
female receptacle. The connectors should push
together with a very small amount of pressure.
Secure the connection by turning the locking nut
clockwise until it stops. DO NOT use the locking
nut to pull the connection together. Do not use
tools to secure the connections.
Torch Leads
ATC Male
Connector
To
Power Supply
1
2
ATC Adapter
Female Receptacle
Torch Connection - Torch Leads with ATC Male
Connector, Power Supply with ATC Adapter
10. Check the torch for proper consumable parts.
CAUTION
The torch parts must correspond with the type of
operation. Refer to Section 4.04, Torch Parts Selection.
A-03627
6. Connect the pilot lead terminal to the stud and
secure with the nut and washer removed previously.
Manual 0-2962 3-7 INSTALLATION
F. Automated Machine Torch Systems with
O2B Connectors
8. Tighten the Through - Hole protector onto the ATC
Adapter leads.
Torches with shielded leads and O2B connectors connect
directly to the power supply bulkhead.
1. Remove the Through - Hole protector Nut from
the Through - Hole protector. Inside the Power
Supply Bulkhead area, route the connectors on
the free end of the torch leads through the Through
- Hole protector Nut.
2. Fit the leads ends and the Through - Hole protector into the hole in the unit.
3. Secure the Through - Hole protector with the retaining nut removed earlier.
4. Connect the Negative / Plasma Lead to the bulkhead connection inside the Power Supply.
5. Remove the top nut and washer from the Pilot
Stud.
6. Connect the pilot lead terminal to the stud and
secure with the nut and washer removed previously.
7. Connect the connectors to the power supply
adapter as shown.
9. Check the torch for proper consumable parts.
CAUTION
The torch parts must correspond with the type of
operation. Refer to Section 4.04, Torch Parts Selection.
3.07 Gas Connection
A. Connection
Connect the gas, compressed air only, to the Power
Supply as described in the Power Supply Manual.
CAUTION
Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture may
cause double - arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.
B. Checking Air Quality
Power Supply Bulkhead
May Differ from Type Shown
Shield
Connectors
Torch Control
Connectors
Strain Relief
Strain Relief
Nut
Shielded Torch Leads
with O2B Connector
Adapter
Connector
Pilot Lead
Pilot Lead Stud
Negative/Plasma
Lead
A-03678
To test the quality of air, place a welding filter lens in
front of the torch and turn on the gas. Any oil or
moisture in the air will be visible on the lens. Do not
initiate an arc!
C. Filtering
An in - line pneumatic dryer & evaporator type air
filter, capable of filtering to at least 5 microns, is required when using air from a compressor. This type
filter will insure that moisture, oil, dirt, chips, rust
particles, and other contaminants from the supply
hose do not enter the torch. For highly automated
applications, a refrigerated drier may be used.
Bulkhead Connections - Shielded Machine Torch
Leads with O2B Connectors
INSTALLATION 3-8 Manual 0-2962
SECTION 4:
!
OPERATION
4.01 Introduction
E. Power On
Place the ON - OFF Switch on the Power Supply to the ON
position. If the RUN - SET - LATCH , RUN - SET or RUN RAPID AUTO RESTART - SET Switch is in SET position,
gas will flow. If the switch is in RUN position there will be
no gas flow.
This section provides a description of the SL60 and SL100
Torch Assemblies followed by operating procedures.
4.02 Functional Overview
The Torch is designed to operate with various Power Supplies to provide a plasma cutting system which can cut
most metals. With gouging torch parts the torch can be
used for plasma arc gouging.
NOTE
Refer to Appendix Pages for additional information as related to the Power Supply used.
4.03 Getting Started
Follow this procedure at the beginning of each shift:
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
F. RUN - SET - LATCH , RUN - SET or RUN -
RAPID AUTO RESTART Switch
If the RUN - SET - LATCH , RUN - SET or RUN - RAPID
AUTO RESTART - SET switch is in SET position, gas will
flow. If the switch is in RUN position there will be no
gas flow.
G. Current Output Level
At the Power Supply, set the desired current output
level. For drag cutting set the control at 40 amps or
less only.
WARNING
Maximum current 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, the components, or the Power Supply. DO
NOT operate the SL60 torch at more than 60 Amps,
or the SL100 torch at more than 100 Amps.
H. Pressure Settings
A. Torch Parts
Check the torch for proper assembly. Install proper
torch parts for the desired application (refer to Section 4.04, Torch Parts Selection).
B. Input Power
Check the power source for proper input voltage.
Close main disconnect switch or plug unit in to supply primary power to the system.
C. Work Cable
Check for a solid cable connection to the workpiece.
D. Gas Supply
Select desired single gas supply. Make sure gas
sources meet requirements (see Note). Check connections and turn gas supply on.
NOTE
Refer to Appendix Pages for additional information as related to the Power Supply used.
Place the RUN - SET - LATCH , RUN - SET or RUN RAPID AUTO RESTART - SET switch to the SET position.
Adjust the gas pressure control on the Power Supply
for the proper gas pressure. Refer to Appendix Pages
for gas pressure and other specifics.
I. Ready for Operation
Return the RUN - SET - LATCH , RUN - SET or RUN RAPID AUTO RESTART - SET switch to RUN position.
NOTES
For general cutting, use the RUN position which
provides normal torch operation where the torch
switch must be held throughout the main arc transfer.
For specific applications, use the LATCH position
where the torch switch can be released after the main
arc transfer. The torch remains activated until the
main arc breaks from the workpiece.
Refer to Appendix 1 for a typical detailed block
diagram of Sequence of Operation.
The system is now ready for operation.
Manual 0-2962 4-1 OPERATION
4.04 Torch Parts Selection
Depending on the type of operation to be done determines the
torch parts to be used.
Type of operation:
Drag cutting, standoff cutting or gouging
Torch parts:
Shield Cup, Cutting Tip, Electrode and Starter Cartridge
3. Install the replacement Electrode by pushing it straight into
the torch head until it clicks.
4. Install the starter cartridge and desired tip for the op-
eration into the torch head.
5. Hand tighten the shield cup assembly until it is seated
on the torch head. If resistance is felt when installing
the cup, check the threads before proceeding.
4.05 Cut Quality
NOTE
Refer to Section 6 and the Appendix Pages for
additional information on torch parts.
Change the torch parts for a different operation as follows:
NOTE
The shield cup 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.
1. Unscrew and remove the shield cup assembly from
the torch head.
2. Remove the Electrode by pulling it straight out of the
Torch Head.
Torch Head
Electrode
NOTES
Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the
workpiece, cutting speed, gas pressures, and operator ability.
Refer to Appendix Pages for additional information as related to the Power Supply used.
Cut quality requirements differ depending on application. For instance, nitride build - up and bevel angle may
be major factors when the surface will be welded after
cutting. Dross - free cutting is important when finish cut
quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in the following figure:
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
Top Edge
Rounding
Start Cartridge
Tip
Dross
Build-Up
Cut Surface
Drag Lines
A-00007
Cut Quality Characteristics
Shield Cup
Assembly
Art # A-03417
A. Cut Surface
The desired or specified condition (smooth or rough)
of the face of the cut.
B. Nitride Build - Up
Torch Parts (Drag Shield Cap & Shield Cup Body
Shown)
OPERATION 4-2 Manual 0-2962
Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material
is to be welded after the cutting process.
C. Bevel Angle
A. Piloting
The angle between the surface of the cut edge and a plane
perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.
D. Top - Edge Rounding
Rounding on the top edge of a cut due to wearing from the
initial contact of the plasma arc on the workpiece.
E. Bottom Dross Buildup
Molten material which is not blown out of the cut area and
resolidifies on the plate. Excessive dross may require secondary cleanup operations after cutting.
F. Kerf Width
The width of the cut (or the width of material removed
during the cut).
G. Top Spatter (Dross)
Top spatter or dross on the top of the cut caused by slow
travel speed, excess cutting height, or cutting tip whose
orifice has become elongated.
4.06 General Cutting Information
WARNINGS
Disconnect primary power at the source before
disassembling the power supply, torch, or torch
leads.
Piloting is harder on parts life than actual cutting because
the pilot arc is directed from the electrode to the tip rather
than to a workpiece. Whenever possible, avoid excessive
pilot arc time to improve parts life.
B. Torch Standoff
Improper standoff (the distance between the torch tip and
workpiece) can adversely affect tip life as well as shield
cup life. Standoff may also significantly affect the bevel
angle. Reducing standoff will generally result in a more
square cut.
C. Edge Starting
For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touching) the edge
of the workpiece at the point where the cut is to start.
When starting at the edge of the plate, do not pause at the
edge and force the arc to "reach" for the edge of the metal.
Establish the cutting arc as quickly as possible.
D. Direction of Cut
In the torches, the plasma gas stream swirls as it leaves the
torch to maintain a smooth column of gas. This swirl effect
results in one side of a cut being more square than the
other. Viewed along the direction of travel, the right side of
the cut is more square than the left.
Left Side
Cut Angle
Right Side
Cut Angle
Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye
and ear protection. Make sure no part of the
operator’s body comes into contact with the workpiece while the torch is activated.
CAUTION
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
NOTE
Handle torch leads with care and protect them from
damage.
A-00512
Side Characteristics Of Cut
To make a square - edged cut along an inside diameter of a
circle, the torch should move counterclockwise around the
circle. To keep the square edge along an outside diameter
cut, the torch should travel in a clockwise direction.
Manual 0-2962 4-3 OPERATION
E. Dross
When dross is present on carbon steel, it is commonly
referred to as either “high speed, slow speed, or top
dross”. Dross present on top of the plate is normally
caused by too great a torch to plate distance. "Top
dross" is normally very easy to remove and can often
be wiped off with a welding glove. "Slow speed
dross" is normally present on the bottom edge of the
plate. It can vary from a light to heavy bead, but
does not adhere tightly to the cut edge, and can be
easily scraped off. "High speed dross" usually forms
a narrow bead along the bottom of the cut edge and
is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not
grinding.
4.07 Hand Torch Operation
A. Standoff Cutting With Hand Torch
NOTE
For best performance and parts life, always use the
correct parts for the type of operation.
2. Depending on the cutting operation, do one of the
following:
a. For edge starts, hold the torch perpendicular
to the workpiece with the front of the tip on
the edge of the workpiece at the point where
the cut is to start.
b. For standoff cutting, hold the torch 1/8 - 3/8
in (3-9 mm) from the workpiece as shown below.
Torch
Shield Cup
Standoff
Distance 1/8" - 3/8"
1. The torch can be comfortably held in one hand or
steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the holding technique that feels most comfortable
and allows good control and movement.
NOTE
The tip should never come in contact with the workpiece except during drag cutting operations.
A-00024
Standoff Distance
3. Hold the torch away from your body.
4. Slide the trigger release toward the back of the
torch handle while simultaneously squeezing the
trigger. The pilot arc will start.
Trigger
Trigger Release
A-02986
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.
OPERATION 4-4 Manual 0-2962
B. Shield Cup With Straight Edge
Trigger
1
2
Trigger Release
3
4
Art # A-03383
6. Cut as usual. Simply release the trigger assembly to stop cutting.
7. Follow normal recommended cutting practices as provided 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 normal operation. Do not attempt to force the shield
cup to close this gap. Forcing the shield cup
against the torch head or torch handle can damage components.
8. For a consistent standoff height from the workpiece,
install the standoff guide by sliding it onto the torch
shield cup. Install the guide with the legs at the sides
of the shield cup body to maintain good visibility of
the cutting arc. During operation, position the legs of
the standoff guide against the workpiece.
Shield Cup
Standoff Guide
Torch Tip
Workpiece
Art # A-04034
The drag shield cup can be used with a nonconductive
straight edge to make straight cuts by hand.
WARNING
The straight edge must be non - conductive.
Non-Conductive
Straight Edge
Cutting Guide
A-03539
Using Drag Shield Cup With Straight Edge
The crown shield cup functions best when cutting 3/16
inch (4.7 mm) solid metal with relatively smooth surface.
C. Drag Cutting With a Hand Torch
Drag cutting works best on metal 3/16" (4.7 mm) thick
or less.
NOTE
For best parts performance and life, always use the
correct parts for the type of operation.
1. Install the drag cutting tip and set the output current to 35 amps or less.
2. The torch can be comfortably held in one hand or
steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the holding technique that feels most comfortable
and allows good control and movement.
4. Keep the torch in contact with the workpiece during the cutting cycle.
5. Hold the torch away from your body.
6. Slide the trigger release toward the back of the torch
handle while simultaneously squeezing the trigger. The
pilot arc will start.
Manual 0-2962 4-5 OPERATION
Trigger Release
Trigger
A-02986
D. Piercing With Hand Torch
1. The torch can be comfortably held in one hand or
steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the technique that feels most comfortable and allows good control and movement.
NOTE
7. 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.
Trigger
1
2
Trigger Release
3
The tip should never come in contact with the workpiece except during drag cutting operations.
2. Angle the torch slightly to direct blowback particles
away from the torch tip (and operator) rather than
directly back into it until the pierce is complete.
3. In a portion of the unwanted metal start the pierce
off the cutting line and then continue the cut onto
the line. Hold the torch perpendicular to the workpiece after the pierce is complete.
4. Hold the torch away from your body.
5. Slide the trigger release toward the back of the
torch handle while simultaneously squeezing the
trigger. The pilot arc will start.
Trigger
4
Art # A-03383
Trigger Release
A-02986
6. Bring the torch within transfer distance to the
work. The main arc will transfer to the work, and
8. Cut as usual. Simply release the trigger assembly to stop cutting.
9. Follow normal recommended cutting practices as
provided 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 normal operation. Do not attempt to force the shield
cup to close this gap. Forcing the shield cup against
the torch head or torch handle can damage components.
the pilot arc will shut off.
NOTES
The gas preflow and postflow are a characteristic
of the power supply and not a function of the torch.
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 normal operation. Do
not attempt to force the shield cup to close this gap.
Forcing the shield cup against the torch head or torch
handle can damage components.
7. Clean spatter and scale from the shield cup and
the tip as soon as possible. Spraying the shield
cup in anti - spatter compound will minimize the
amount of scale which adheres to it.
OPERATION 4-6 Manual 0-2962
4.08 Machine Torch Operation
A. Cutting With Machine Torch
The machine torch can be activated by remote control pendant or by a remote interface device such as CNC.
1. Use a square to check that the torch is perpendicular to
the workpiece to obtain a clean, vertical cut
Pinch Block
Assembly
.
Direction of Torch Travel
Standoff Distance
Straight Arc
Square
Workpiece
A-02585
Checking Alignment
2. To start a cut at the plate edge, position the center of
the torch along the edge of the plate.
B. Travel Speed
Proper travel speed is indicated by the trail of the arc which
is seen below the plate. The arc can be one of the following:
1. Straight Arc
A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best
cut using air plasma on stainless or aluminum.
Trailing Arc
A-02586
Leading Arc
Machine Torch Operation
For optimum smooth surface quality, the travel speed
should be adjusted so that only the leading edge of
the arc column produces the cut. If the travel speed
is too slow, a rough cut will be produced as the arc
moves from side to side in search of metal for transfer.
Travel speed also affects the bevel angle of a cut.
When cutting in a circle or around a corner, slowing
down the travel speed will result in a squarer cut.
The power source output should be reduced also.
Refer to the appropriate Control Module Operating
Manual for any Corner Slowdown adjustments that
may be required.
2. Leading Arc
The leading arc is directed in the same direction as torch
travel. A five degree leading arc is generally recommended for air plasma on mild steel.
3. Trailing Arc
The trailing arc is directed in the opposite direction as
torch travel.
Manual 0-2962 4-7 OPERATION
C. Piercing With Machine Torch
To pierce with a machine torch, the arc should be started
with the torch positioned as high as possible above the
plate while allowing the arc to transfer and pierce. This
standoff helps avoid having molten metal blow back onto
the front end of the torch.
When operating with a cutting machine, a pierce or dwell
time is required. Torch travel should not be enabled until
the arc penetrates the bottom of the plate. As motion begins, torch standoff should be reduced to the recommended
1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cut
quality. Clean spatter and scale from the shield cup and
the tip as soon as possible. Spraying or dipping the shield
cup in anti - spatter compound will minimize the amount of
scale which adheres to it.
4.10 Gouging
WARNINGS
Be sure the operator is equipped with proper
gloves, clothing, eye and ear protection and that
all safety precautions at the front of this manual
have been followed. Make sure no part of the
operator’s body comes in contact with the workpiece when the torch is activated.
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
4.09 Recommended Cutting
Speeds
Cutting speed depends on material, thickness, and the operator ’s
ability to accurately follow the desired cut line. The following
factors may have an impact on system performance:
• Torch parts wear
• Air quality
• Line voltage fluctuations
• Torch standoff height
• Proper work cable connection
NOTES
This information represents realistic expectations
using recommended practices and well - maintained systems. Actual speeds may vary up to 50%
from those shown.
Refer to Appendix Pages for cutting speed chart
information as related to the Power Supply used.
CAUTIONS
Sparks from plasma gouging can cause damage to
coated, painted or other surfaces such as glass, plastic, and metal.
Check torch parts. The torch parts must correspond
with the type of operation. Refer to Section 4.04,
Torch Parts Selection.
A. Gouging Parameters
Gouging performance depends on parameters such
as torch travel speed, current level, lead angle (the
angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff).
B. Torch Travel Speed
NOTE
Refer to Appendix Pages for additional information as related to the Power Supply used.
Optimum torch travel speed is dependent on current
setting, lead angle, and mode of operation (hand or
machine torch).
C. Current Setting
Current settings depend on torch travel speed, mode
of operation (hand or machine torch), and the amount
of material to be removed.
OPERATION 4-8 Manual 0-2962
D. Lead Angle
The angle between the torch and workpiece depends on
the output current setting and torch travel speed. At 80
amps, the recommended lead angle is 35°. At a lead angle
greater than 45° the molten metal will not be blown out of
the gouge and may be blown back onto the torch. If the
lead angle is too small (less than 35°), less material may be
removed, requiring more passes. In some applications,
such as removing welds or working with light metal, this
may be desirable.
Torch Head
Standoff Height
1/8 - 1/4"
Workpiece
A-00941
35˚
Gouging Angle and Standoff Distance
E. Standoff Distance
The tip to work distance affects gouge quality and
depth. Standoff distance of 1/8 - 1/4 inch (3 - 6 mm)
allows for smooth, consistent metal removal. Smaller
standoff distances may result in a severance cut rather
than a gouge. Standoff distances greater than 1/4
inch (6 mm) may result in minimal metal removal or
loss of transferred main arc.
F. Slag Buildup
Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels,
can be removed easily in most cases. Slag does not
obstruct the gouging process if it accumulates to the
side of the gouge path. However, slag build - up can
cause inconsistencies and irregular metal removal if
large amounts of material build up in front of the arc.
The build - up is most often a result of improper travel
speed, lead angle, or standoff height.
Manual 0-2962 4-9 OPERATION
OPERATION 4-10 Manual 0-2962
SECTION 5:
5.02 General Torch Maintenance
SERVICE
5.01 Introduction
This section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted by other than properly
trained personnel.
WARNINGS
Disconnect primary power at the source before disassembling the torch or torch leads.
Frequently review the Important Safety Precautions at the front of this Manual. Be sure the operator is equipped with proper gloves, clothing, eye
and ear protection. Make sure no part of the
operator’s body comes into contact with the workpiece while the torch is activated.
A. Cleaning Torch
Even if precautions are taken to use only clean air
with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect
the pilot arc initiation and the overall cut quality of
the torch.
WARNINGS
Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.
The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet
rag. In severe cases, the torch can be removed from
the leads and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and blowing
it through with compressed air.
CAUTION
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
NOTE
Handle torch leads with care and protect them from
damage.
CAUTION
Dry the torch thoroughly before reinstalling.
Manual 0-2962 5-1 SERVICE
B. O-Ring Lubrication
5.03 Common Operating Faults
This section applies only to torches withATC connectors.
An o-ring on the Torch ATC Male Connector requires
lubrication on a regular basis, depending on how frequently the torch is disconnected and re-connected.
This will allow the o-ring to remain pliable and provide a 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 oring 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 temperatures or may contain “unknown elements” that
may react with the atmosphere. This reaction can
leave contaminants inside the torch. Either of these
conditions can lead to inconsistent performance or
poor parts life.
The following lists the more common cutting faults and
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
Gas Fitting
3. Excessive Dross Formation
a. Cutting speed too slow
ATC Male Connector
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. Air flow too low (incorrect pressure)
e. Improperly assembled torch
f. Non - Genuine Thermal Dynamics Parts
Art #A-03791
O-Ring
SERVICE 5-2 Manual 0-2962
5.04 Inspection and Replacement of
Consumable Torch Parts
WARNINGS
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 between the shield cup body and drag shield cap. Do
not lubricate the O-ring.
Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.
Remove the consumable torch parts as follows:
NOTE
The shield cup holds the tip and starter cartridge
shield cup in place. Position the torch with the
shield cup facing upward to prevent these parts
from falling out when the cup is removed.
1. Unscrew and remove the shield cup from the torch.
NOTE
Slag built up on the shield cup that cannot be removed may effect the performance of the system.
2. Inspect the cup for damage. Wipe it clean or replace
if damaged.
Drag Shield Cap
Shield
Cup Body
O-Ring No. 8-3488
Art # A-03878
4. Remove the tip. Check for excessive wear (indicated
by an elongated or oversized orifice). Clean or replace the tip if necessary.
Good Tip
Worn Tip
Torch Head
Electrode
Start Cartridge
Art # A-03417
Consumable Parts
Tip
Shield Cup
Assembly
A-03406
Tip Wear
5. Remove the starter cartridge. Check for excessive
wear, plugged gas holes, or discoloration. Check the
lower end fitting for free motion. Replace if necessary.
Start Cartridge
Lower End Fitting
Art # A-03621
Manual 0-2962 5-3 SERVICE
6. Pull the Electrode straight out of the Torch Head. Check
the face of the electrode for excessive wear. Refer to the
following figure.
Troubleshooting
A. Torch will not pilot when torch switch is activated
1. Power Supply RUN / SET switch in SET position
a. Place RUN / SET switch to RUN position.
New Electrode
Art # A-03284
Worn Electrode
Electrode Wear
7
. Reinstall the Electrode by pushing it straight into the
torch head until it clicks.
8. Reinstall the desired starter cartridge and tip into the
torch head.
9. 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.
5.05 Troubleshooting Guide
This subsection covers troubleshooting that requires dis-
assembly and electronic measurements. It is helpful for
solving many of the common problems that can arise with
this torch assembly.
How to Use This Guide
The following information is a guide to help the Customer
/ Operator determine the most likely causes for various
symptoms.
This guide is set up as follows:
X. Symptom (Bold Type)
Any Special Instructions (Text Type)
1. Cause (Italic Type)
a. Check / Remedy (Text Type)
Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
unit is fully operational after any repairs.
2. Parts - In - Place (PIP) not satisfied.
a. Check that shield cup is properly installed.
3. Upper O-ring on torch head is in wrong position.
a. Remove shield cup from torch; check position
of upper O-ring. Correct if necessary.
Art # A-03640
Upper Groove
with Vent Holes
Must Remain Open
Upper O-Ring
in Correct Groove
Threads
Lower O-Ring
4. Faulty Torch Switch or PIP Switch
a. Check PIP switch for continuity.
5. Faulty torch parts
a. Inspect torch parts and replace if necessary. Re-
fer to Section 5.04, Inspection and Replacement
Consumable Torch Parts
6. Gas pressure too low
a. Set proper operating gas pressure.
7. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if neces-
sary.
8. Faulty components in power supply
a. Return for repair or have qualified technician
repair per Service Manual.
SERVICE 5-4 Manual 0-2962
B. No cutting output
4. Excessive oil or moisture in torch
1. Torch not properly connected to power supply
a. Check that torch leads are properly attached to
power supply
2. Shield cup not properly installed on torch
a. Check that shield cup is fully seated against
torch head (do not overtighten)
3. Parts - In - Place (PIP) not satisfied.
a. Check that shield cup is properly installed.
b. Check switch - in hand torch handle or in ma-
chine torch head - for continuity.
4. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if neces-
sary.
5. Faulty components in power supply
a. Return for repair or have qualified technician
repair per Service Manual.
C. Limited output with no control
1. Poor input or output connections to power supply
a. Check all input and output connections.
a. Hold torch 1/8 inch (3.2 mm) from clean sur-
face while purging and observe oil or moisture
buildup (do not activate torch).
5. Torch tip dragged across workpiece
a. When the tip is dragged across the workpiece,
the amperage automatically cuts back to 35
amps (see Note).
NOTE
All power supplies may not have this feature.
E. No gas flow
1. Gas not connected or pressure too low
a. Check source for proper operating gas pressure
(refer to Appendix Page for Power Supply
used).
2. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if neces-
sary.
3. Faulty components in power supply
a. Return for repair or have qualified technician
repair per Service Manual.
2. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if neces-
sary.
3. Faulty components in power supply
a. Return for repair or have qualified technician
repair per Service Manual.
D. Erratic or improper cutting output
1. Poor input or output connections to power supply
a. Check all input and output connections.
2. Current set too low at power supply
a. Increase current setting.
3. Torch is being moved too fast across workpiece
a. Reduce cutting speed (refer to Appendix Page
for the Power Supply being used).
F. Torch cuts but not adequately
1. Current set too low at power supply
a. Increase current setting
2. Torch is being moved too fast across workpiece
a. Reduce cutting speed (refer to Appendix Page
for the Power Supply being used).
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3.2 mm) from clean sur-
face while purging and observe oil or moisture
buildup (do not activate torch).
Manual 0-2962 5-5 SERVICE
SERVICE 5-6 Manual 0-2962
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable
components. Torch Assemblies are field serviceable, so a
complete breakdown of parts is provided. The parts lists
are arranged as follows:
Section 6.03: Hand Torch Replacement Parts
Section 6.04: Machine Torch Replacement Parts
Section 6.05: Replacement Shielded Leads Assemblies
Section 6.06: Hand Torch Consumable Parts
Section 6.07: Hand Torch Spare Parts Kits
Section 6.08: Machine Torch Consumable Parts
Section 6.09: Machine Torch Spare Parts Kits
Section 6.10: Automated Torch Consumable Parts
Section 6.11: Automated Torch Spare Parts Kits
Section 6.12: Complete Assembly Replacements
Section 6.13: Options & Accessories
NOTE
Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your
authorized distributor. Materials returned without proper
authorization will not be accepted.
6.02 Ordering Information
Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial
number of the torch. Address all inquiries to your authorized distributor.
Manual 0-2962 6-1 PARTS LISTS
6.03 Replacement Parts for Hand Torch
Item # Qty Description Catalog #
1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
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
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O - Ring 8-3487
6 1 Small O - Ring 8-3486
7 Leads 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
8 Leads Assemblies with ATC connectors (includes switch assemblies)
1 SL60 / 60 Amp, 20 - foot Leads Assembly with ATC connector 4-7834
1 SL60 / 60 Amp, 50 - foot Leads Assembly with ATC connector 4-7835
1 SL100 / 100 Amp, 20 - foot Leads Assembly with ATC connector 4-7836
1 SL100 / 100 Amp, 50 - foot Leads Assembly with ATC connector 4-7837
9 1 Switch Kit 9-7031
10 1 Torch Control Cable Adapter (includes item # 11) 7-3447
11 1 Through - Hole Protector 9-8103
PARTS LISTS 6-2 Manual 0-2962
1
2
4
5
6
10
Requires Adapter Kit
For Proper Installation
OR
3
9
7
11
8
May Require ATC Adapter
A-03664
Kit For Proper Installation
Manual 0-2962 6-3 PARTS LISTS
6.04 Replacement Parts - for Machine Torches with Unshielded Leads
Item No. Qty Description Catalog No.
1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O - Ring 8-3487
3 1 Small O - Ring 8-3486
4 1 PIP Switch Kit 9-7036
5 Unshielded Mechanized Leads Assemblies with O2B connectors
1 25 - foot / 7.6 m Leads Assembly with O2B connectors 4-7838*
1 50 - foot / 15.2 m Leads Assembly with O2B connectors 4-7839*
6 Unshielded Automated Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853
7 Unshielded Mechanized Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845
8 1 11" / 279 mm Rack 9-7041
9 1 11" / 279 mm Mounting Tube 9-7043
10 1 End Cap Assembly 9-7044
11 2 Body, Mounting, Pinch Block 9-4513
12 1 Pin, Mounting, Pinch Block 9-4521
13 1 Torch Holder Sleeve 7-2896
14 1 PIP Plunger and Return Spring Kit 9-7045
15 1 Torch Control Cable Adapter for Unshielded Leads (includes item # 16) 7-3447
16 1 Through - Hole Protector 9-8103
1 Pinion Assembly (Not shown) 7-2827
1 5" / 126 mm Positioning Tube (Not shown) 9-7042
NOTE
* Does not include Control Cable Adapter or Through - Hole
Protector.
Refer to Section 6.05 for Replacement Shielded Leads Assemblies.
PARTS LISTS 6-4 Manual 0-2962
11
10
8
9
11
1
2
3
4
14
Requires Adapter Kit
For Proper Installation
15
May Require ATC Adapter Kit
For Proper Installation
12
13
5
16
OR
6
OR
7
May Require ATC Adapter Kit
For Proper Installation
A-03665
Manual 0-2962 6-5 PARTS LISTS
6.05 Replacement Shielded Machine Torch Leads Assemblies
Item No. Qty Description Catalog No.
1 Mechanized Shielded Leads Assemblies with ATC Connectors
1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846
1 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847
1 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848
1 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849
2 Shielded Leads Assemblies with O2B Connectors
1 25 - foot / 7.6 m Leads Assembly with O2B Connector 4-7840
1 50 - foot / 15.2 m Leads Assembly with O2B Connector 4-7841
3 Negative / Plasma Lead
1 25 - foot / 7.6 m Length 9-7969
1 50 - foot / 15.2 m Length 9-7974
4 Shield Lead
1 25 - foot / 7.6 m Length 9-7979
1 50 - foot / 15.2 m Length 9-7980
5 PIP Lead
1 25 - foot / 7.6 m Length 9-7977 *
1 50 - foot / 15.2 m Length 9-7978 *
6 Pilot Lead, 25 - foot / 7.6 m Length
1 25 - foot / 7.6 m Length 9-7975
1 50 - foot / 15.2 m Length 9-7976
7 1 Power Supply Adapter for Shielded Leads (not shown) 7-3479
NOTE
*Does not include Torch continuity (PIP) Switch.
PARTS LISTS 6-6 Manual 0-2962
1
2
3
Torch Connection Fitting
4
6
5
5
6
7
Torch Continuity
('PIP') Switch
Torch Continuity
('PIP') Switch
Adapter Wire
Art #A-03616
Manual 0-2962 6-7 PARTS LISTS
6.06 Hand Torch Consumables
The illustration shows all consumable parts for the
SL60 and SL100 hand torches. Refer to the Appendix
pages covering the power supply being used to ensure
proper selection for the application.
Various front - end torch parts are available for different
applications.
The Standoff Guide fits Shield Cup No. 9-8218 and enables the user to maintain a consistent standoff height for
most applications.
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 changeover to gouging or drag shield 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 preferred method of cutting
sheet metal up to 3/16" or 4.8 mm thick.
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 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.
Use the Shield Cup Body with the Gouging Shield Cap for
excellent gouging performance and enhanced torch parts life.
The electrode and starter cartridge are the same for all operations.
6.07 Hand Torch Spare Parts Kits
Hand Torch Spare Parts Kit Contents
Cat al o g No .
Item
Electrode 9-8215 3 3 3 3
40A Drag Tip 9-8207 5 2 2 2
40A Standoff Tip 9-8208 2
60A Standoff Tip 9-8210 5
80A Standoff Tip 9-8211 5
100A Standoff Tip 9-8212 5
Shiel d Cup Body 9-8237 1 1 1
Drag Shield Cap, 50-60A 9-8235 1
Drag Shield Cap, 70-100A 9-8236 1 1
Large O-Ri ng 8-3487 1 1 1 1
Sm all O-Ring 8-3486 1 1 1 1
St andoff Guide 9-8251 1
St andoff Guide 9-8281 1 1 1
40-Amp K i t ,
Cat No.
5-0050
60-Amp Kit,
Cat No.
5-0075
80-Amp K i t ,
Cat N o.
5-0110
100-Amp K i t ,
Cat No.
5-0170
PARTS LISTS 6-8 Manual 0-2962
Hand Torch Consumables Selection
Start
Cartridge
9-8213
DRAG TIP
CUTTING
40A
CUTTING
50-60A
CUTTING
Tips:
20A 9-8205
30A 9-8206
40A 9-8207
DRAG SHIELD
CUTTING
Tip:
40A 9-8208
STANDOFF
CUTTING
DRAG SHIELD
CUTTING
Tips:
50-55A 9-8209
60A 9-8210
STANDOFF
CUTTING
Shield
Cup Body,
9-8237
Shield Cup
9-8218
O-Ring No. 8-3488
Shield
Cup Body,
9-8237
Shield Cup
9-8218
O-Ring No. 8-3488
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield Cap, Deflector
9-8243
Shield Cap, Drag
40A 9-8244
Shield Cap, Deflector
9-8243
Standoff Guide
9-8251
Shield Cap, Drag
50-60A 9-8235
Shield Cap, Deflector
9-8243
Standoff Guide
9-8281
Electrode
9-8215
Art # A-03662
70-100A
CUTTING
40-100A
GOUGING
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)
Tip A 40 Am ps M ax. S hal l ow Narrow
Tip B 40-100 A m ps Deep Narrow
Tip C 40-100 Amps Moderate M oderat e
Tip D 40-100 Amps Shall ow Wide
DRAG SHIELD
CUTTING
Tips:
70A 9-8231
80A 9-8211
90/100A 9-8212
O-Ring No. 8-3488
Shield
Cup Body,
9-8237
Shield Cup
9-8218
STANDOFF CUTTING
Shield
Cup Body,
9-8237
Tips:
Gouging Profiles
Output Range Depth Wi dt h
Shield Cap, Drag
70-100A 9-8236
Shield Cap, Deflector
9-8243
Standoff Guide
9-8281
Shield Cap, Gouging
9-8241
Manual 0-2962 6-9 PARTS LISTS
6.08 Machine Torch Consumables
The illustration shows all consumable parts for the
SL100 machine torches. Refer to the Appendix pages
covering the power supply being used to ensure proper
selection for the application.
Various front - end torch parts are available for different
applications.
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 singlepiece Shield Cup, as well as easy change-over to gouging or
drag shield cutting.
Use the Shield Cup Body with the Gouging Shield Cap for excellent gouging performance and enhanced torch parts life.
The electrode and starter cartridge are the same for all operations.
6.09 Machine Torch Spare Parts Kits
Machine Torch Spare Parts Kit Contents
Cat al o g No .
Item
Electrode 9-8215 3 3 3 3
40A Standoff Tip 9-8208 5 5 5 5
60A Standoff Tip 9-8210 5
80A Standoff Tip 9-8211 5
100A Standoff Tip 9-8212 5
Shield Cup 9-82181111
Large O-Ri ng 8-3487 1 1 1 1
Sm all O-Ring 8-3486 1 1 1 1
Start Cart ridge 9 -8213 1 1 1 1
40-Amp K i t ,
Cat No.
5-0052
60-Amp Kit,
Cat No.
5-0077
80-Amp K i t ,
Cat N o.
5-0120
100-Amp K i t ,
Cat No.
5-0171
PARTS LISTS 6-10 Manual 0-2962
Machine Torch Consumables Selection
Ohmic Clip
9-8224
Electrode
9-8215
Starter
Cartridge
9-8213
20-40A
STANDOFF
CUTTING
50-60A
STANDOFF
CUTTING
70-100A
STANDOFF
CUTTING
Tip:
20A 9-8205
30A 9-8206
40A 9-8208
Tips:
50-55A 9-8209
60A 9-8210
Tips:
70A 9-8231
80A 9-8211
90/100A 9-8212
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield Cap, Machine
40A 9-8245
Shield Cap, Deflector
9-8243
Shield Cap, Machine
50-60A 9-8238
Shield Cap, Deflector
9-8243
Shield Cap, Machine
70-100A 9-8239
Shield Cap, Deflector
9-8243
Art # A-03663
Shield
Cup Body,
40-100A
GOUGING
Tips:
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)
9-8237
Gouging Profiles
Output Range Depth Wi dt h
Tip A 40 Amps Max. Shall ow Narrow
Tip B 40-100 A m ps Deep Narrow
Tip C 40-100 Amps Moderate M oderat e
Tip D 40-100 Amps Shallow Wi de
Shield Cup, Gouging
9-8241
Manual 0-2962 6-11 PARTS LISTS
6.10 Automated Torch Consumables
The illustration shows all consumable parts for the
SL100 automated torch. Refer to the Appendix pages
covering the power supply being used to ensure
proper selection for the application.
Various front - end torch parts are available for different ap-
Use the Shield Cup Body with the Gouging Shield Cap for
excellent gouging performance and enhanced torch parts
life.
The electrode and starter cartridge are the same for all operations.
plications.
The Shield Cup Body with the Deflector Shield Cap provides extended parts life and improved resistance to
reflected heat. This combination provides easy changeover to gouging or drag shield cutting.
6.11 Automated Torch Spare Parts Kits
Automation Torch Spare Parts Kit Contents
Cata l o g No .
Item
Electrode 9-8215 3 3 3 3
30A Standoff Tip 9-8206 5 5 5 5
40A Standoff Tip 9-8208 5 5 5 5
60A Standoff Tip 9-8210 5 5 5
80A Standoff Tip 9-8211 5 5
100A Standoff Tip 9-8212 5
Shiel d Cup Body 9-8237 1 1 1 1
Shiel d Cap, Deflector 9-8243 1 1 1 1
Shiel d Cap, M achine, 40A 9-8245 1 1 1 1
Shiel d Cap, M achine, 60A 9-8238 1 1 1
Shiel d Cap, M achine, 70-100A 9-8239 1 1
Large O-Ri ng 8-3487 1 1 1 1
Sm all O-Ring 8-3486 1 1 1 1
St art Cartridge 9-8213 1 1 1 1
Ohmic Clip Kit 9-8224 1 1 1 1
40-Amp K i t ,
Cat No.
5-0054
60-Amp Kit,
Cat No.
5-0079
80-Amp Kit,
Cat N o.
5-0122
Cat No.
100-Amp K i t ,
5-0174
PARTS LISTS 6-12 Manual 0-2962
Automated Torch Consumables Selection
Ohmic Clip
9-8224
Electrode
9-8215
Starter
Cartridge
9-8213
20-40A
STANDOFF
CUTTING
50-60A
STANDOFF
CUTTING
70-100A
STANDOFF
CUTTING
Tip:
20A 9-8205
30A 9-8206
40A 9-8208
Tips:
50-55A 9-8209
60A 9-8210
Tips:
70A 9-8231
80A 9-8211
90/100A 9-8212
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield Cap, Machine
40A 9-8245
Shield Cap, Deflector
9-8243
Shield Cap, Machine
50-60A 9-8238
Shield Cap, Deflector
9-8243
Shield Cap, Machine
70-100A 9-8239
Shield Cap, Deflector
9-8243
Shield
Cup Body,
9-8237
Shield Cup, Gouging
9-8241
Art # A-03663
40-100A
GOUGING
Tips:
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)
Gouging Profiles
Output Range Depth Wi dt h
Tip A 40 Am ps M ax. S hal l ow Narrow
Tip B 40-100 A m ps Deep Narrow
Tip C 40-100 Amps Moderate M oderat e
Tip D 40-100 Amps Shall ow Wide
Manual 0-2962 6-13 PARTS LISTS
6.12 Complete Assembly Replacement
NOTE
The Complete Torch & Leads Assembly Replacement does not include the Torch Control Cable Adapter.
Description Catalog #
60 - Amp Hand Torch and Leads Assemblies:
SL60 Hand Torch and 20 foot / 6.1 m Leads, with O2B Connector 7-5200
SL60 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5201
SL60 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector 7-5204
SL60 Hand Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5205
100 - Amp Hand Torch and Leads Assemblies:
SL100 Hand Torch and 20 foot / 6.1 m Leads, with O2B Connector 7-5202
SL100 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5203
SL100 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector 7-5206
SL100 Hand Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5208
100 - Amp Machine Torch and Leads Assemblies, Unshielded Leads:
SL100 Machine Torch and 25 foot / 7.6 m Leads, with O2B Connector 7-5209
SL100 Machine Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5210
SL100 Machine Torch and 5 foot / 1.5 m Leads, with ATC Connector 7-5213
SL100 Machine Torch and 10 foot / 3.05 m Leads, with ATC Connector 7-5214
SL100 Machine Torch and 25 foot / 7.6 m Leads, with ATC Connector 7-5215
SL100 Machine Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5216
100 - Amp Machine Torch and Leads Assemblies, Shielded Leads
SL100 Machine Torch and 25 foot / 7.6 m Leads, with O2B Connector 7-5211
SL100 Machine Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5212
SL100 Machine Torch and 5 foot / 1.5 m Leads, with ATC Connector 7-5219
SL100 Machine Torch and 10 foot / 3 m Leads, with ATC Connector 7-5220
SL100 Machine Torch and 25 foot / 7.6 m Leads, with ATC Connector 7-5221
SL100 Machine Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5222
PARTS LISTS 6-14 Manual 0-2962
6.13 Options & Accessories
Qty Description Catalog #
1 ATC Adapter Kit, Unshielded 7-5207
1 ATC Adapter Kit, Shielded 7-3472
1 Unshielded Leads extensions with ATC connectors, 15 - foot / 4.6 m length
7-7544
1 Unshielded Leads extensions with ATC connectors, 25 - foot / 7.6 m length
7-7545
1 Unshielded Leads extensions with ATC connectors, 50 - foot / 15.2 m length 7-7552
1 Shielded Leads extensions with ATC connectors, 25 - foot / 7.6 m length
4-7854
1 Shielded Leads extensions with ATC connectors, 50 - foot / 15.2 m length
4-7855
1 Deluxe Cutting Guide Kit 7-8910
1 Radius / Roller Cutting Guide Kit 7-7501
1 Circle Cutting Guide Kit 7-3291
1 Remote Hand Pendant Control with 20 ft. Cable 7-3460
1 Hand Pendant Extension - 25 ft 7-7744
1 Computer Control (CNC) Cable
25 Foot / 7.6 m length 8-5557
50 Foot / 15.2 m length 8-5558
1 Leather Leads Cover, 20 foot / 6.1 m 9-1260
1 Leather Leads Cover, 25 foot / 7.6 m 9-1270
1 Leather Leads Cover, 50 foot / 15.2 m 9-1280
1 Ohmic Clip Kit (for Automated Applications only) 9-8224
Manual 0-2962 6-15 PARTS LISTS
PATENT INFORMATION
The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512
Catalog Number Description
9-8235 Shield Cap, Drag 50-60A
9-8236 Sheild Cap, Drag 70-100A
9-8237 Shield Cup, Body
9-8238 Shield Cap, Machine 50-60A
9-8239 Shield Cap, Machine 70-100A
9-8244 Shield Cap, Drag 40A
9-8245 Shield Cap, Machine 40A
PARTS LISTS 6-16 Manual 0-2962
APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF
OPERATION BLOCK DIAGRAM
LATCH
ACTION
Close external
disconnect switch.
RESULT
Power to system.
ACTION
Protect eyes and
activate torch.
RESULT
Gas flows
(2 seconds)
After gas pre-flow:
DC indicator ON.
Pilot relay closes.
Pilot arc established.
ACTION
Torch deactivated (by torch switch
release or by remote device).
RESULT
(Power supply enable signal removed.)
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (3/8 in) of
Main Arc stops.
Gas flows briefly.
NOTE - If torch is activated during
workpiece, main arc will transfer.
After post-flow:
Gas solenoid closes, gas flow stops.
GAS indicator off.
ACTION
ON/OFF-Switch to ON.
RESULT
AC indicator blinks for 8
seconds, then steady on.
Fans on.
Power circuit ready.
Mode Switch* to SET.
Gas Solenoid open, gas
flows to set pressure.
PILOT ARC
ACTION
ON/OFF-Switch to OFF.
RESULT
All indicators OFF.
Power supply fan(s) off.
ACTION
RESULT
GAS indicator ON.
ACTION
Mode Switch* to RUN.
RESULT
Gas flow stops.
GAS indicator off.
ACTION
Torch moved away
from work (while still
activated)
RESULT
Main arc stops.
Pilot arc automatically
restarts.
ACTION
Torch moved within
transfer distance of workpiece.
RESULT
Main arc transfers.
Pilot arc off.
ACTION
Open external
disconnect switch.
RESULT
No power to system.
ACTION
Torch switch
can be released.
RESULT
Transfer will continue
until torch is removed
from workpiece.
Art # A-03779
* Mode switch settings in PakMaster Series are RUN / SET / LATCH.
* Mode switch settings in CutMaster 50, CutMaster 75 and CutMaster 100 are RUN / SET.
* Mode switch settings in CutMaster 51, CutMaster 81 and CutMaster 101 are RUN /
RAPID AUTO RESTART / SET.
Manual 0-2962 A-1 APPENDIX
This page intentionally blank
APPENDIX A-2 Manual 0-2962
APPENDIX 2: GENERAL APPLICATION NOTES
A. Hand Cutting Versus Machine (Mechanized) Cutting Speeds
A-02947
Hand Cutting Speeds
(Shaded Area)
Machine Cutting
Speeds
Speed
Material Thickness
Hand cutting speeds can be much less than those obtained from Machine (Mechanized) Type applications. Hand
cutting application speeds mostly depend on operator experience. The cut quality obtained at slower speeds for a
Hand application is just as good as those obtained from a Machine application. As the cut speeds increase or decrease from the Machine applications the following may occur:
• If cut speed is too fast the cut may exhibit one or more of the following: Insufficient Penetration, High Speed
Dross, Poor Consumable Life, Excessive Bevel Angle.
• If cut speed is too slow the cut may exhibit one or more of the following: Main Arc Extinguishes, Slow Speed
Dross, Wandering (Unstable) Arc, Poor Consumable Life.
Manual 0-2962 A-3 APPENDIX
APPENDIX 3A: CUTMASTER 50 & CUTMASTER 51
SYSTEM DATA (HAND TORCH)
Torch Specifica tions For
CutMaster 50 & CutMaste r 5 1 Pow er Supplies
Cutting Range
Materi al Mi ld Steel
Genuine Cut:
Up to 1/2 inch - 12.7 mm
Speed 12-14 ipm / 0. 3 - 0. 36 m pm
Pierce Rating
Materi al Mi ld Steel
Thickness:
Hand Cutting 1/2 inch - 12.7 mm
Mac hi ne Cutting 1/4 inc h - 6. 4 mm
Transfer Distance
Gouging
Wi dth 3/16 inch - 4.8 m m
Depth 1/8 inch - 3.2 mm
Number Passes Single
Speed 20 ipm / 0. 5 m pm
Bevel Cut Capability
Degrees 0° to 45°
Material Thickness 3/8 inch - 9.5 mm
Gas Requirement
Type Gas Air
Operating P res sure 75 psi / 5.2 bar
Max Input P ressure 125 psi / 8.6 bar
Total Flow Rate:
Cutt ing 350 s c fh / 165 lpm
Gouging 230 sc fh / 109 l pm
3/8 i nc h - 9. 5 m m
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various
materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Material Gas Characteristics
Gage
to
1/2 inch
( 12.7 mm )
Carbon Steel
Stai nless
Aluminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip
orifice diameter), little or no dross, smooth cut
surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip
orifice diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.
Gouging Profiles
Output
Range
Tip A 40 A m ps Max . Shallow Narrow
Tip B 40-100 Amps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Good - Excellent
Good
Good
Depth Width
SL60 - SL100 Hand Torch Consum abl es for 40- A m p Power Supply
Application Electrode
Drag Cutting 9-8215 9-8213 9-8207 (40A) None None 9-8218
9-8215 9-8213 9-8208 (40A) None None 9-8218
St andoff Cutting
9-8215 9-8213 9-8208 (40A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip A: 9-8225 (40A Max)
Tip B: 9-8226 (40-100A)
Tip C: 9-8227 (40-100A)
Tip D: 9-8228 (40-100A)
Tip
Shield
Cup Body
9-8237 9-8241 None
APPENDIX A-4 Manual 0-2962
Shield Cap
or Deflector
9-8244 or
9-8243
Shield Cup
None
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51
Type Torch: SL60 - Drag Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minut e) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.9 9-8207 80 40 300 7.62 N/A N/A 75 5.2 50 350 0 0.00 0.0
16 ga 1.5 9-8207 80 40 275 6.99 N/A N/A 75 5.2 50 350 0 0.19 4.8
10 ga 3.4 9-8207 80 40 75 1.91 N/A N/A 75 5.2 50 350 0 0.19 4.8
7 ga 4.6 9-8207 85 40 55 1.40 N/A N/A 75 5.2 50 350 0.5 0.19 4.8
1/4 6.4 9-8207 90 40 40 1.02 N/A N/A 75 5.2 50 350 0.5 0.19 4.8
3/8 9.5 9-8207 100 40 18 0.46 N/A N/A 75 5.2 50 350 1 0.25 6.4
1/2 12.7 9-8207 100 40 10 0.25 N/A N/A 75 5.2 50 350 1.5 0.25 6.4
(Cat. No .) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51
Type Torch: SL60 - Drag Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minut e) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.9 9-8207 80 40 300 7.62 N/A N/A 75 5.2 50 350 0 0.00 0.0
16 ga 1.5 9-8207 80 40 275 6.99 N/A N/A 75 5.2 50 350 0 0.19 4.8
10 ga 3.4 9-8207 80 40 105 2.67 N/A N/A 75 5.2 50 350 0 0.19 4.8
7 ga 4.6 9-8207 85 40 70 1.78 N/A N/A 75 5.2 50 350 0.5 0.19 4.8
1/4 6.4 9-8207 90 40 39 0.99 N/A N/A 75 5.2 50 350 0.5 0.19 4.8
3/8 9.5 9-8207 100 40 20 0.51 N/A N/A 75 5.2 50 350 1 0.25 6.4
1/2 12.7 9-8207 100 40 10 0.25 N/A N/A 75 5.2 50 350 1.5 0.25 6.4
(Cat. No .) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51
Type Torch: SL60 - Drag Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minut e) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.9 9-8207 80 40 300 7.62 N/A N/A 75 5.2 50 350 0 0.00 0.0
16 ga 1.5 9-8207 80 40 275 6.99 N/A N/A 75 5.2 50 350 0 0.19 4.8
10 ga 3.4 9-8207 80 40 75 1.91 N/A N/A 75 5.2 50 350 0 0.19 4.8
7 ga 4.6 9-8207 85 40 55 1.40 N/A N/A 75 5.2 50 350 0.5 0.19 4.8
1/4 6.4 9-8207 90 40 40 1.02 N/A N/A 75 5.2 50 350 0.5 0.19 4.8
3/8 9.5 9-8207 100 40 18 0.46 N/A N/A 75 5.2 50 350 1 0.25 6.4
1/2 12.7 9-8207 100 40 10 0.25 N/A N/A 75 5.2 50 350 1.5 0.25 6.4
(Cat. No .) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 85
psi / 5.9 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-5 APPENDIX
APPENDIX 3B: CUTMASTER 50 & CUTMASTER 51
SYSTEM DATA (MACHINE TORCH)
Torch Specifica tions For
CutMaster 50 & Cu tM aster 51 Power Supplies
Cutting Range
Mat erial Mil d Steel
Genui n e Cut:
Up to 1/2 inch - 12.7 mm
Speed 12-14 ipm / 0. 3 - 0. 36 mpm
Pierce Rating
Mat erial Mil d Steel
Thickness:
Hand Cutting 1/2 inch - 12. 7 m m
Mac hi ne Cutting 1/4 i nc h - 6. 4 m m
Transfer Distance
Gouging
Wi dth 3/16 inch - 4.8 mm
Depth 1/8 inch - 3.2 mm
Number Pas ses S i ngl e
Speed 20 ipm / 0.5 mpm
Bevel Cut Capability
Degrees 0° to 45°
Material Thickness 3/8 inch - 9.5 mm
Gas Requirement
Type Gas Air
Operating P res sure 65 psi / 4.5 bar
3/8 i nc h - 9. 5 m m
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Material Gas Characteristics
Gage
to
1/2 inch
( 12.7 mm )
Carbon Steel
Stai nless
Aluminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross,
smooth cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2
x tip orifice diameter), some dross (easily removed), medium - smooth cut surface, slight
top edge rounding.
Good - Excellent
Good
Good
Max Input P ressure 125 psi / 8.6 bar
Total Flow Rate:
Cutt ing 350 s cfh / 165 lpm
Gouging 230 sc fh / 109 l pm
SL100 Machine Torch Consumables f or 40- Amp Power Suppl y
Application Electrode
9-8215 9-8213 9-8208 (40A) None None 9-8218
St andoff Cutting
9-8215 9-8213 9-8208 (40A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip A: 9-8225 (40 A M ax)
Tip A 40 A m ps Max . Shallow Narrow
Tip B 40-100 Amps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Tip
Tip B: 9-8226 (40-100 A)
Tip C: 9-8227 (40-100 A)
Tip D: 9-8228 (40-100 A)
Gouging Profile s
Output
Range
Shield
Cup Body
9-8237 9-82 41 None
Depth Width
Shield Cap
or Deflector
9-8245 or
9-8243
Shield Cup
None
APPENDIX A-6 Manual 0-2962
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51
Type Torch: SL100 Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.8 9-8208 90 40 350 8.89 0.19 4.8 65 4.5 50 350 0 0.19 4.8
16 ga 1.3 9-8208 94 40 275 6.99 0.19 4.8 65 4.5 50 350 0 0.19 4.8
10 ga 2.6 9-8208 105 40 100 2.54 0.19 4.8 65 4.5 50 350 0 0.19 4.8
7 ga 3.7 9-8208 100 40 70 1.78 0.19 4.8 65 4.5 50 350 0 0.19 4.8
1/4 6.4 9-8208 107 40 40 1.02 0.19 4.8 65 4.5 50 350 0.5 0.19 4.8
3/8 9.5 9-8208 114 40 18 0.46 0.19 4.8 65 4.5 50 350 0.5 0.19 4.8
1/2 12.7 9-8208 121 40 10 0.25 0.19 4.8 65 4.5 50 350 1 0.19 4.8
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51
Type Torch: SL100 Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.9 9-8208 90 40 300 7.62 0.13 3.2 65 4.5 50 350 0 0.19 4.8
16 ga 1.5 9-8208 90 40 275 6.99 0.13 3.2 65 4.5 50 350 0 0.19 4.8
10 ga 3.4 9-8208 90 40 115 2.92 0.13 3.2 65 4.5 50 350 0 0.19 4.8
7 ga 4.6 9-8208 95 40 75 1.91 0.13 3.2 65 4.5 50 350 0.5 0.19 4.8
1/4 6.4 9-8208 110 40 45 1.14 0.19 4.8 65 4.5 50 350 0.5 0.19 4.8
3/8 9.5 9-8208 119 40 20 0.51 0.19 4.8 65 4.5 50 350 1 0.25 6.4
1/2 12.7 9-8208 121 40 14 0.36 0.19 4.8 65 4.5 50 350 1.5 0.25 6.4
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51
Type Torch: SL100 Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.9 9-8208 95 40 300 7.62 0.19 4.8 65 4.5 50 350 0 0.19 4.8
16 ga 1.5 9-8208 95 40 275 6.99 0.19 4.8 65 4.5 50 350 0 0.19 4.8
10 ga 3.5 9-8208 100 40 75 1.91 0.19 4.8 65 4.5 50 350 0 0.19 4.8
7 ga 4.6 9-8208 105 40 55 1.40 0.19 4.8 65 4.5 50 350 0 0.19 4.8
1/4 6.4 9-8208 105 40 40 1.02 0.19 4.8 65 4.5 50 350 0.5 0.19 4.8
3/8 9.5 9-8208 110 40 18 0.46 0.19 4.8 65 4.5 50 350 1 0.19 4.8
1/2 12.7 9-8208 119 40 10 0.25 0.19 4.8 65 4.5 50 350 1.5 0.19 4.8
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 70
psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-7 APPENDIX
APPENDIX 4A: CUTMASTER 75 & CUTMASTER 81
SYSTEM DATA (HAND TORCH)
Torch Specifica tions For
CutMaster 75 & Cu tM aster 81 P o wer Su p p lies
Cutting Range
Material Most Metals
Up to 3/4 inch - 19 mm
Speed 11 ipm / 0. 28 m pm
Pierce Rating
Materi al Carbon St eel
Thickness 3/8 inch - 9.5 mm
Transfer Distance
Gouging
Width 1/4 inch - 6.3 mm
Depth 1/8 inch - 3. 2 m m
Number Passes Single
Speed 20 ipm / 0.5 mpm
Bevel Cut Capability
Degrees 0° to 45°
Material Thickness 1/4 inch - 6.3 mm
Gas Requirement
Type Gas Air
Operating P res sure 70 psi / 4. 8 bar
Max Input P ressure 125 psi / 8.6 bar
Cutting & Gouging
Total Flow
3/8 inch - 9.5 mm
350 scfh / 165 lpm
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Mater ial Gas Characteristics
Gage
to
3/4 i nch
( 19 mm )
Carbon Steel
Stai nless
Al uminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross,
smooth cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x
tip orifice diameter), some dross (easily removed), medium - smooth cut surface, slight top
edge rounding.
Good - Excellent
Good
Good
Gouging Profile s
Output
Range
Tip A 40 A m ps Max . Shallow Narrow
Tip B 40-100 Amps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Depth Width
SL60 - SL100 Hand Torch Consum ables f or 60- A m p Power Suppl y
Application Electrode
Drag Cutting 9-8215 9-8213 9-8207 (40A) None None 9-8218
9-8215 9-8213 9-8210 (60A) None None 9-8218
St andoff Cutti ng
9-8215 9-8213 9-8210 (60A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip
Tip A: 9-8225 (40A M ax )
Tip B: 9-8226 (40-100A)
Tip C: 9-8227 (40-100A)
Tip D: 9-8228 (40-100A)
Shield
Cup Body
9-8237 9-8 241 None
Shield Cap
or Deflector
9-8235 or
9-8243
Shield Cup
None
APPENDIX A-8 Manual 0-2962
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81
Type Torch: SL60 Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Outpu t Volts Amperage Speed (Per Minute) Stando ff Plasma Gas Press F low (SCFH) Pierce Pierce Heigh t
Inches
0.06 1.6 9- 8210 95 60 350 8.89 0.19 4.8 70 4.8 80 400 0 0.19 4.8
0.125 3.2 9-8210 98 60 175 4.45 0.19 4.8 70 4.8 80 400 0 0.19 4.8
1/4 6.4 9- 8210 102 60 80 2.03 0.19 4.8 70 4.8 80 400 0 0.19 4.8
3/8 9.5 9- 8210 109 60 44 1.12 0.19 4.8 70 4.8 80 400 0 0.19 4.8
1/2 12.7 9-8210 115 60 23 0.58 0.19 4.8 70 4.8 80 400 0 0.19 4.8
3/4 19.1 9-8210 117 60 11 0.28 0.19 4.8 70 4.8 80 400 NR 0.19 4.8
Thickness Tip Outpu t Volts Amperage Speed (Per Minute) Stando ff Plasma Gas Press F low (SCFH) Pierce Pierce Height
Inches
0.06 1.6 9- 8210 95 60 350 8.89 0.19 4.8 70 4.8 80 400 0 0.19 4.8
1/8 3.2 9-8210 98 60 175 4.45 0.19 4.8 70 4.8 80 400 0 0.19 4.8
1/4 6.4 9-8210 102 60 80 2.03 0.19 4.8 70 4.8 80 400 0 0.19 4.8
3/8 9.5 9-8210 109 60 44 1.12 0.19 4.8 70 4.8 80 400 0 0.19 4.8
1/2 12.7 9-8210 115 60 23 0.58 0.19 4.8 70 4.8 80 400 0 0.19 4.8
3/4 19.1 9-8210 117 60 11 0.28 0.19 4.8 70 4.8 80 400 NR 0.19 4.8
(Cat. No.) (VDC) (Amps) In ches Meters Inches mm psi* bar Plasma Total** Delay ( Sec) Inch es mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81
Type Torch: SL60 Type Material: Mild Steel
Type Plasma Ga s: Air Type Secondary Gas: Single Gas Torch
(Cat. No.) (VDC) (Amps) In ches Meters Inches mm psi* b ar Plasma Total** Delay (Sec) In ches mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81
Type Torch: SL60 Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Outpu t Volts Amperage Speed (Per Minute) Stando ff Plasma Gas Press F low (SCFH) Pierce Pierce Heigh t
Inches
0.06 1.6 9- 8210 95 60 350 8.89 0.19 4.8 70 4.8 80 400 0 0.19 4.8
1/8 3.2 9-8210 98 60 150 3.81 0. 19 4.8 70 4.8 80 400 0 0.19 4.8
1/4 6.4 9- 8210 102 60 70 1.78 0.19 4.8 70 4.8 80 400 0 0.19 4.8
3/8 9.5 9- 8210 109 60 35 0.89 0.19 4.8 70 4.8 80 400 0 0.19 4.8
1/2 12.7 9-8210 115 60 20 0.51 0.19 4.8 70 4.8 80 400 0 0.19 4.8
3/4 19.1 9-8210 117 60 10 0.25 0.19 4.8 70 4.8 80 400 NR 0.19 4.8
(Cat. No.) (VDC) (Amps) In ches Meters Inches mm psi* bar Plasma Total** Delay ( Sec) Inch es mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 80
psi / 5.5 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-9 APPENDIX
APPENDIX 4B: CUTMASTER 75 & CUTMASTER 81
SYSTEM DATA (MACHINE TORCH)
Torch Specifica tions For
CutMaster 75 & Cu tM aster 81 P o wer Su p p lies
Cutting Range
Material Most Metals
Up to 3/4 inch - 19 mm
Speed 11 i pm / 0.28 mpm
Pierce Rating
Mat erial Carbon St eel
Thickness 3/8 inch - 9.5 mm
Transfer Distance
Gouging
Width 1/4 inch - 6.3 mm
Depth 1/8 inc h - 3. 2 m m
Number Pas s es Single
Speed 20 ipm / 0. 5 mpm
Bevel Cut Capability
Degrees 0° t o 45°
Material Thickness 1/4 inch - 6.3 mm
Gas Requirement
Type Gas A i r
Operating P res sure 65 psi / 4. 5 bar
Max Input P res sure 125 ps i / 8.6 bar
Cutt ing & Gouging
Tota l F low
3/8 inch - 9.5 mm
350 scfh / 165 lpm
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Mater ial Gas Characteristics
Gage
to
3/4 i nch
( 19 mm )
Carbon Steel
Stai nless
Al uminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross,
smooth cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x
tip orifice diameter), some dross (easily removed), medium - smooth cut surface, slight top
edge rounding.
Good - Excellent
Good
Good
SL100 Machine Torch Consumabl es for 60- A m p Power Suppl y
Application Electrode
9-8215 9-8213 9-8210 (60A) None None 9-8218
St andoff Cutti ng
9-8215 9-8213 9-8210 (60A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip A 40 Amps M ax. Shal l ow Narrow
Tip B 40-100 A m ps Deep Narrow
Tip C 4 0-100 A mps M od erate Mode rate
Tip D 40-100 Amps S hall ow Wide
Tip
Tip A: 9-8225 (40 A Max)
Tip B: 9-8226 (40-100 A)
Tip C: 9-8227 (40-100 A)
Tip D: 9-8228 (40-100 A)
Gouging Profiles
Output
Range
Shield
Cup Body
9-8237 9-8241 None
Depth Width
Shield Cap
or Deflector
9-8238 or
9-8243
Shield Cup
None
APPENDIX A-10 Manual 0-2962
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81
Type Torch: SL100 Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minut e) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
0.06 1.6 9- 8210 95 60 350 8.89 0.19 4.8 65 4.5 80 400 0 0.19 4.8
1/8 3.2 9-8210 98 60 175 4.45 0.19 4.8 65 4.5 80 400 0 0.19 4.8
1/4 6.4 9- 8210 102 60 80 2.03 0.19 4.8 65 4.5 80 400 0 0.19 4.8
3/8 9.5 9-8210 109 60 44 1.12 0.19 4.8 65 4.5 80 400 0 0.19 4.8
1/2 12.7 9-8210 115 60 23 0.58 0.19 4.8 65 4.5 80 400 0 0.19 4.8
3/4 19.1 9-8210 117 60 11 0.28 0.19 4.8 65 4.5 80 400 NR 0.19 4.8
(Cat. No .) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81
Type Torch: SL100 Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minut e) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
0.06 1.6 9- 8210 95 60 350 8.89 0.19 4.8 65 4.5 80 400 0 0.19 4.8
1/8 3.2 9-8210 98 60 175 4.45 0.19 65 65 4.5 80 400 0 0.19 4.8
1/4 6.4 9-8210 102 60 80 2.03 0.19 65 65 4.5 80 400 0 0.19 4.8
3/8 9.5 9-8210 109 60 44 1.12 0.19 65 65 4.5 80 400 0 0.19 4.8
1/2 12.7 9-8210 115 60 23 0.58 0.19 65 65 4.5 80 400 0 0.19 4.8
3/4 19.1 9-8210 117 60 11 0.28 0.19 65 65 4.5 80 400 NR 0.19 4.8
(Cat. No .) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81
Type Torch: SL100 Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minut e) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
0.06 1.6 9- 8210 95 60 350 8.89 0.19 4.8 65 4.5 80 400 0 0.19 4.8
0.125 3.2 9-8210 98 60 150 3.81 0.19 4.8 65 4.5 80 400 0 0.19 4.8
1/4 6.4 9-8210 102 60 70 1.78 0.19 4.8 65 4.5 80 400 0 0.19 4.8
3/8 9.5 9-8210 109 60 35 0.89 0.19 4.8 65 4.5 80 400 0 0.19 4.8
1/2 12.7 9-8210 115 60 20 0.51 0.19 4.8 65 4.5 80 400 0 0.19 4.8
3/4 19.1 9-8210 117 60 10 0.25 0.19 4.8 65 4.5 80 400 NR 0.19 4.8
(Cat. No .) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma To tal** Delay (Sec) Inches mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 70
psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-11 APPENDIX
APPENDIX 5: CUTMASTER 100 & 101 SYSTEM DATA
(HAND and MACHINE TORCH)
Cut Quality on Various Materials and
Torch Specifica tions For
CutMa ster 100 & CutMaster 101 Pow er Suppl ies
Cutting Range
Material Most Metals
Up to 1 inch / 25.4 mm
Speed 10 ipm / 0. 25 m pm
Pierce Rating
Materi al Carbon St eel
Thickness 3/8 inch / 9.5 mm
Transfer Distance
Gouging
Width 1/4 inch - 6.3 mm
Depth 3/16 inch - 4. 8 mm
Number Passes Single
Speed 20 i pm / 0.5 mpm
Bevel Cut Capability
Degrees 0° to 45°
Material Thickness 1/2 inch - 13 mm
Gas Requirement
Type Gas A ir
Operating P res sure 70 ps i / 4.8 bar
Max Input P ressure 125 psi / 8. 6 bar
Cutting & Gouging
Total Flow
3/8 inch / 9.5 m m
490 scfh / 231 lpm
Thicknesses
The following table defines the cut quality on various materials and thicknesses:
Cut Quality on Var ious Materials
Material Type of Type of Cut
Thickness Material Gas Char acteristics
Gage
to
1 inch
( 25.4 mm )
Carbon Steel
Stainl ess
Aluminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip
orifice diameter), little or no dross, smooth
cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x
tip orifice diameter), some dross (easily removed),
medium - smooth cut surface, slight top edge
rounding.
Good - Excellent
Good
Good
SL100 Machine Torch Consum ables f or 80-Amp Power Supply
Application Electrode
9-8215 9-8213 9-8211 (80A) None None 9-8218
St andoff Cutting
9-8215 9-8213 9-8211 (80A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip A 40 Amps M ax. Shal low Narrow
Tip B 40-100 A m ps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Tip
Tip A: 9-8225 (40A Max)
Tip B: 9-8226 (40-100A)
Tip C: 9-8227 (40-100A)
Tip D: 9-8228 (40-100A)
Gouging Profile s
Output
Range
Shield
Cup Body
9-8237 9-8241 None
Depth Width
Shield Cap
or Deflector
9-8239 or
9-8243
Shield Cup
None
APPENDIX A-12 Manual 0-2962
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For CutMaster 100 & CutMaster 101
Type Torch: SL100 Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
0.05 1.3 9-8211 100 80 350 8.89 0.19 4.8 70 4.8 90 490 0 0.19 4.8
0.125 3.2 9-8211 103 80 230 5.84 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1/4 6.4 9-8211 106 80 112 2.84 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/8 9.5 9-8211 111 80 55 1.40 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1/2 12.7 9-8211 112 80 38 0.97 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/4 19.1 9-8211 117 80 18 0.46 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
1 25.4 9-8211 120 80 10 0.25 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 100 & CutMaster 101
Type Torch: SL100 Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
0.05 1.3 9-8211 100 80 350 8.89 0.19 4.8 70 4.8 90 490 0 0.19 4.8
0.125 3.2 9-8211 103 80 230 5.84 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1/4 6.4 9-8211 106 80 112 2.84 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/8 9.5 9-8211 111 80 55 1.40 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1/2 12.7 9-8211 112 80 38 0.97 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/4 19.1 9-8211 117 80 18 0.46 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
1 25.4 9-8211 120 80 10 0.25 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For CutMaster 100 & CutMaster 101
Type Torch: SL100 Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
0.05 1.3 9-8211 100 80 350 8.89 0.19 4.8 70 4.8 90 490 0 0.19 4.8
0.125 3.2 9-8211 103 80 200 5.08 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1/4 6.4 9-8211 106 80 112 2.84 0.19 4.8 70 4.8 90 490 0.25 0.19 4.8
3/8 9.5 9-8211 111 80 55 1.40 0.19 4.8 70 4.8 90 490 0.25 0.19 4.8
1/2 12.7 9-8211 112 80 38 0.97 0.19 4.8 70 4.8 90 490 0.25 0.19 4.8
3/4 19.1 9-8211 117 80 18 0.46 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
1 25.4 9-8211 120 80 10 0.25 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 80 psi
/ 5.5 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-13 APPENDIX
APPENDIX 6: CUTMASTER 151 SYSTEM DATA
(HAND and MACHINE TORCH)
Torch Specifications For
CutMaster 151 Power Supply
Cutting Range
Material Most Metals
Up to 1-1/2 i nc h / 38 mm
Speed 11 ipm / 0. 28 m pm
Pierce Rating
Mat e ri al Carbon St ee l
Thickness 1/2 inch / 12.2 mm
Transfer Distance
Gouging
W idt h 1/ 4 i nc h - 6. 3 mm (m i n)
Depth 3/ 16 inch - 4.8 mm (mi n)
Number Passes Single
Speed 20 ipm / 0. 5 m pm
Bevel Cut Capability
Degrees 0° to 45°
Material Thickness 3/4 inch - 19 mm
Gas Require m ent
Type Gas Air
Operat ing Pressure 70 psi / 4.8 bar
Max Input P res s ure 125 psi / 8.6 bar
Cutting & Gouging
Tota l Flow
3/8 inch / 9.5 mm
490 sc fh / 231 lpm
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Material Gas Characteristics
Gage
to
1.5 inch
( 38 mm )
Carbon Steel
Stainless
Aluminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip
orifice diameter), little or no dross, smooth
cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip
orifice diameter), some dross (easily removed),
medium - smooth cut surface, slight top edge
rounding.
Good - Excellent
Good
Good
Gouging Profiles
Output
Range
Tip A 40 A m ps Max . Shallow Narrow
Tip B 40-100 A m ps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Depth Width
SL100 Machine Torch Consumables f or 100-A mp Power Supply
Application Electrode
9-8215 9-8213 9-8212 (100A) None None 9-8218
St andoff Cutting
9-8215 9-8213 9-8212 (100A) 9-8237
Gouging 9-8215 9-8213
Start
Cartridge
Tip
Tip A: 9-8225 (40A Max)
Tip B: 9-8226 (40-100A)
Tip C: 9-8227 (40-100A)
Tip D: 9-8228 (40-100A)
Shiel d
Cup Body
9-8237 9-8241 None
APPENDIX A-14 Manual 0-2962
Shield Cap
or De fl ector
9-8239 or
9-8243
Shield Cup
None
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For CutMaster 151
Type Torch: SL100 Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Ampe rage Speed (Per Minute) Plasma Gas Press Flow (SCFH) Pierce Pierce He ight
Inche s
1/4 6.4 9-8212 104 100 148 3.76 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/8 9.5 9-8212 110 100 118 3.00 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1/2 12.7 9-8212 113 100 79 2.01 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/4 19.1 9-8212 118 100 31 0.79 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1 25.4 9-8212 121 100 18 0.46 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
1-1/4 31.8 9-8212 128 100 14 0.36 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
1-1/2 38.1 9-8212 133 100 11 0.28 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
(Cat. No.) (VDC) (Am ps) Inches Meters Inches m m psi* bar Plasma Total** Delay (Sec) Inches m m
mm
Standoff
Air Plasma Cutting Speed Data Chart For CutMaster 151
Type Torch: SL100 Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage
Inches
1/4 6.4 9-8212 104 100 129 3.28 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/8 9.5 9-8212 110 100 65 1.65 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1/2 12.7 9-8212 113 100 49 1.24 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/4 19.1 9-8212 118 100 24 0.61 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1 25.4 9-8212 121 100 16 0.41 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
1-1/4 31.8 9-8212 128 100 10 0.25 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
1-1/5 38.1 9-8212 133 100 8 0.20 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
(Cat. No.) (VDC) (Amps) Inches Me ters Inches m m psi* bar Plasm a Total** Delay (Sec) Inches mm
mm
peed (Per M inute)Standoff Plasm a Gas PressFlow (SCFH) Pierce Pierce Height
Air Plasma Cutting Speed Data Chart For CutMaster 151
Type Torch: SL100 Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage
Inche s
1/4 6.4 9-8212 104 100 134 3.40 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/8 9.5 9-8212 110 100 67 1.70 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1/2 12.7 9-8212 113 100 40 1.02 0.19 4.8 70 4.8 90 490 0 0.19 4.8
3/4 19.1 9-8212 118 100 22 0.56 0.19 4.8 70 4.8 90 490 0 0.19 4.8
1 25.4 9-8212 123 100 12 0.30 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
1-1/4 31.8 9-8212 129 100 9 0.23 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
1-1/2 38.1 9-8212 135 100 6 0.15 0.19 4.8 70 4.8 90 490 NR 0.19 4.8
(Cat. No.) (VDC)
mm
(Amps)
peed (Per Minute)Standoff Plasma Gas PressFlow (SCFH) Pie rce Pie rce Height
Inches Me ters Inches m m psi* bar Plasma Total** Delay (Sec) Inches m m
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 75
psi / 5.2 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-15 APPENDIX
APPENDIX 7A: PAKMASTER 50XL PLUS SYSTEM DATA
(HAND TORCH)
Torch Specifica tions For
Pa kMa ster 50XL Pl us Powe r S upply
Cutting Range
Material Mild Steel
Produc t i on Cut :
Up to 1/4 inch - 6.3 mm
Speed 45 ipm / 1. 14 m pm
Genuine Cut:
Up to 1/2 inc h - 12. 7 m m
Speed 12-14 ipm / 0.3 - 0.36 mpm
Severance Cut :
Up to 3/4 i nc h - 19 mm
Speed 5-7 i pm 0. 13 - 0. 18 mpm
Pierce Rating
Material Mild Steel
Thickness:
Hand Cutting 1/2 inch - 12. 7 m m
Mac hi ne Cutting 1/ 4 i nch - 6.4 mm
Transfer Distance
Gouging
Wi dth 3/16 i nc h - 4. 8 m m
Depth 1/8 inc h - 3. 2 m m
Number Pas ses Si ngle
Speed 20 ipm / 0. 5 mpm
Bevel Cut Capability
Degrees 0° t o 45°
Material Thickness 3/8 inch - 9.5 mm
Gas Requirement
Type Gas A i r
Operating P res sure 65 psi / 4. 5 bar
Max Input P ressure 125 psi / 8.6 bar
Total Flow Rate:
Cutt ing 350 sc fh / 165 l pm
Gouging 230 s cfh / 108.5 lpm
3/8 inch - 9.5 mm
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Material Gas Characteristics
Gage
to
1/2 inch
( 12.7 mm )
Carbon Steel
Stai nless
Aluminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross,
smooth cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x
tip orifice diameter), some dross (easily removed), medium - smooth cut surface, slight top
edge rounding.
Gouging Profile s
Output
Range
Tip A 40 Amps M ax. Shal low Narrow
Tip B 40-100 A m ps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Depth Width
Good - Excellent
Good
Good
SL60 - SL100 Hand Torch Consum abl es for 40- A m p Power Supply
Application Electrode
Drag Cutting 9-8215 9-8213 9-8207 (40A) None None 9-8218
9-8215 9-8213 9-8208 (40A) None None 9-8218
St andoff Cutting
9-8215 9-8213 9-8208 (40A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip A: 9-8225 (40A Max)
Tip B: 9-8226 (40-100A)
Tip C: 9-8227 (40-100A)
Tip D: 9-8228 (40-100A)
Tip
Shield
Cup Body
9-8237 9-8241 None
APPENDIX A-16 Manual 0-2962
Shield Cap
or Deflector
9-8244 or
9-8243
Shield Cup
None
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus
Type Torch: SL60 - Drag Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.9 9-8207 80 40 300 7.62 N/A N/A 65 4.5 50 350 0 0.00 0.0
16 ga 1.5 9-8207 80 40 275 6.99 N/A N/A 65 4.5 50 350 0 0.19 4.8
10 ga 3.4 9- 8207 80 40 75 1.91 N/A N/A 65 4.5 50 350 0 0.19 4.8
7 ga 4.6 9- 8207 85 40 55 1.40 N/A N/A 65 4.5 50 350 0.5 0.19 4.8
1/4 6.4 9-8207 90 40 40 1.02 N/A N/A 65 4.5 50 350 0.5 0.19 4.8
3/8 9.5 9-8207 100 40 18 0.46 N/A N/A 65 4.5 50 350 1 0.25 6.4
1/2 12.7 9-8207 100 40 10 0.25 N/A N/A 65 4.5 50 350 1.5 0.25 6.4
(Cat . No.) (VDC) (Amps) In ches Meters In ches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus
Type Torch: SL60 - Drag Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.9 9-8207 80 40 300 7.6 N/A N/A 65 4.5 50 350 0 0.00 0.0
16 ga 1.5 9-8207 80 40 275 7.0 N/A N/A 65 4.5 50 350 0 0.19 4.8
10 ga 3.4 9-8207 80 40 105 2.7 N/A N/A 65 4.5 50 350 0 0.19 4.8
7 ga 4.6 9-8207 85 40 70 1.8 N/A N/A 65 4.5 50 350 0.5 0.19 4.8
1/4 6.4 9-8207 90 40 39 1.0 N/A N/A 65 4.5 50 350 0.5 0.19 4.8
3/8 9.5 9-8207 100 40 20 0.5 N/A N/A 65 4.5 50 350 1 0.25 6.4
1/2 12.7 9-8207 100 40 10 0.3 N/A N/A 65 4.5 50 350 1.5 0.25 6.4
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus
Type Torch: SL60 - Drag Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.9 9- 8207 80 40 300 7. 6 N/A N/A 65 4.5 50 350 0 0.00 0.0
16 ga 1.5 9- 8207 80 40 275 7. 0 N/A N/A 65 4.5 50 350 0 0.19 4.8
10 ga 3.4 9-8207 80 40 75 1.9 N/A N/A 65 4.5 50 350 0 0.19 4.8
7 ga 4.6 9- 8207 85 40 55 1. 4 N/A N/A 65 4.5 50 350 0.5 0.19 4.8
1/4 6.4 9-8207 90 40 40 1.0 N/A N/A 65 4.5 50 350 0.5 0.19 4.8
3/8 9.5 9-8207 100 40 18 0.5 N/A N/A 65 4.5 50 350 1 0.25 6.4
1/2 12.7 9-8207 100 40 10 0.3 N/A N/A 65 4.5 50 350 1.5 0.25 6.4
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 75
psi / 5.2 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-17 APPENDIX
APPENDIX 7B: PAKMASTER 50XL PLUS SYSTEM DATA
(MACHINE TORCH)
Torch Specifica tions For
Pa kMa ster 50XL Pl us Powe r Suppl y
Cutting Range
Material Mild Steel
Produc t i on Cut:
Up to 1/4 inch - 6. 3 m m
Speed 45 ipm / 1. 14 m pm
Genuine Cut:
Up to 1/2 inch - 12.7 mm
Speed 12-14 ipm / 0.3 - 0.36 mpm
Severance Cut :
Up to 3/4 inch - 19 mm
Speed 5-7 i pm 0.13 - 0.18 mpm
Pierce Rating
Material Mild Steel
Thickness:
Hand Cut ting 1/2 inch - 12. 7 m m
Mac hi ne Cutting 1/ 4 i nc h - 6. 4 m m
Transfer Distance
Gouging
Wi dth 3/16 inch - 4.8 mm
Depth 1/8 inch - 3.2 mm
Number Passes Single
Speed 20 ipm / 0. 5 m pm
Bevel Cut Capability
Degrees 0° t o 45°
Material Thickness 3/8 inch - 9.5 mm
Gas Requirement
Type Gas Ai r
Operating P res sure 60 psi / 4. 1 bar
Max Input P ressure 125 psi / 8. 6 bar
Total Flow Rate:
Cutt ing 350 sc fh / 165 l pm
Gouging 230 s cfh / 108.5 lpm
3/8 i nc h - 9. 5 m m
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Material Gas Characteristics
Gage
to
1/2 inch
( 12.7 mm )
Carbon Steel
Stai nless
Aluminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross, smooth
cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2 - 1/2 x
tip orifice diameter), some dross (easily removed),
medium - smooth cut surface, slight top edge
rounding.
Gouging Profiles
Output
Range
Tip A 40 Amps M ax. Shal l ow Narrow
Tip B 40-100 A m ps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Depth Width
Good - Excellent
Good
Good
SL100 Machine Torch Consumables f or 40- Amp Power Suppl y
Application Electrode
9-8215 9-8213 9-8208 (40A) None None 9-8218
St andoff Cutting
9-8215 9-8213 9-8208 (40A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip
Tip A: 9-8225 (40 A M ax)
Tip B: 9-8226 (40-100 A)
Tip C: 9-8227 (40-100 A)
Tip D: 9-8228 (40-100 A)
APPENDIX A-18 Manual 0-2962
Shield
Cup Body
9-8237 9-82 41 None
Shield Cap
or Deflector
9-8245 or
9-8243
Shield Cup
None
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus
Type Torch: SL100 Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.8 9-8208 90 40 350 8.89 0.19 4.8 60 4.1 50 350 0 0.19 4.8
16 ga 1.3 9-8208 94 40 275 6.99 0.19 4.8 60 4.1 50 350 0 0.19 4.8
10 ga 2.6 9- 8208 105 40 100 2.54 0.19 4.8 60 4.1 50 350 0 0.19 4.8
7 ga 3.7 9- 8208 100 40 70 1.78 0.19 4.8 60 4.1 50 350 0 0.19 4.8
1/4 6.4 9-8208 107 40 40 1.02 0.19 4.8 60 4.1 50 350 0.5 0.19 4.8
3/8 9.5 9-8208 114 40 18 0.46 0.19 4.8 60 4.1 50 350 0.5 0.19 4.8
1/2 12.7 9-8208 121 40 10 0.25 0.19 4.8 60 4.1 50 350 1 0.19 4.8
(Cat . No.) (VDC) (Amps) In ches Meters In ches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus
Type Torch: SL100 Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minut e) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
20 ga 0.9 9-8208 90 40 350 8.89 0.13 3.2 60 4.1 50 350 0 0.19 4.8
16 ga 1.5 9-8208 90 40 275 6.99 0.13 3.2 60 4.1 50 350 0 0.19 4.8
10 ga 3.4 9-8208 90 40 115 2.92 0.13 3.2 60 4.1 50 350 0 0.19 4.8
7 ga 4.6 9-8208 95 40 75 1.91 0.13 3.2 60 4.1 50 350 0.5 0.19 4.8
1/4 6.4 9-8208 110 40 45 1.14 0.19 4.8 60 4.1 50 350 0.5 0.19 4.8
3/8 9.5 9-8208 119 40 20 0.51 0.19 4.8 60 4.1 50 350 1 0.25 6.4
1/2 12.7 9-8208 121 40 14 0.36 0.19 4.8 60 4.1 50 350 1.5 0.25 6.4
(Cat. No .) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus
Type Torch: SL100 Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inch es
20 ga 0.9 9-8208 95 40 300 7.62 0.19 4.8 60 4.1 50 350 0 0.19 4.8
16 ga 1.5 9-8208 95 40 275 6.99 0.19 4.8 60 4.1 50 350 0 0.19 4.8
10 ga 3.5 9-8208 100 40 75 1.91 0.19 4.8 60 4.1 50 350 0 0.19 4.8
7 ga 4.6 9-8208 105 40 55 1.40 0.19 4.8 60 4.1 50 350 0 0.19 4.8
1/4 6.4 9- 8208 105 40 40 1.02 0.19 4.8 60 4.1 50 350 0.5 0.19 4.8
3/8 9.5 9- 8208 110 40 18 0.46 0.19 4.8 60 4.1 50 350 1 0.19 4.8
1/2 12.7 9-8208 119 40 10 0.25 0.19 4.8 60 4.1 50 350 1.5 0.19 4.8
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 65
psi / 4.5 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-19 APPENDIX
APPENDIX 8A: PAKMASTER 75XL PLUS SYSTEM DATA
(HAND TORCH)
Torch Specifica tions For
Pa k Ma ster 75XL Pl us Powe r Suppl y
Cutting Range
Material Most Metals
Up to 3/4 inch - 19 mm
Speed 11 i pm / 0. 28 m pm
Pierce Rating
Materi al Carbon Steel
Thickness 3/8 inch - 9.5 mm
Transfer Distance
Gouging
Width 1/4 inch - 6.3 mm
Depth 1/8 inch - 3.2 mm
Number Pas ses Si ngl e
Speed 20 ipm / 0.5 mpm
Bevel Cut Capability
Degrees 0° t o 45°
Material Thickness 1/4 inch - 6.3 mm
Gas Requirement
Type Gas Air
Operating P ressure 65 psi / 4. 5 bar
Max Input P ressure 125 psi / 8. 6 bar
Cutt ing & G ouging
Tota l F low
3/8 inch - 9.5 mm
350 scfh / 165 lpm
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various
materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Mater ial Gas Characteristics
Gage
to
3/4 i nch
( 19 mm )
Carbon Steel
Stai nless
Al uminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross,
smooth cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2 - 1/2
x tip orifice diameter), some dross (easily removed), medium - smooth cut surface, slight top
edge rounding.
Gouging Profiles
Output
Range
Tip A 40 A m ps Max . Shallow Narrow
Tip B 40-100 A m ps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Good - Excellent
Good
Good
Depth Width
SL60 - SL100 Hand Torch Consum ables f or 60- A m p Power Suppl y
Application Electrode
Drag Cutting 9-8215 9-8213 9-8207 (40A) None None 9-8218
9-8215 9-8213 9-8210 (60A) None None 9-8218
St andoff Cutti ng
9-8215 9-8213 9-8210 (60A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip
Tip A: 9-8225 (40A M ax )
Tip B: 9-8226 (40-100A)
Tip C: 9-8227 (40-100A)
Tip D: 9-8228 (40-100A)
APPENDIX A-20 Manual 0-2962
Shield
Cup Body
9-8237 9-8 241 None
Shield Cap
or Deflector
9-8235 or
9-8243
Shield Cup
None
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus
Type Torch: SL60 Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Outpu t Volts Amperage Speed (Per Minute) Stand off Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
1/16 1.6 9-8210 95 60 350 8.89 0.19 4.8 65 4.5 80 350 0.1 0.25 6.4
1/8 3.2 9-8210 95 60 175 4.45 0.19 4.8 65 4.5 80 350 0.25 0.25 6.4
1/4 6.4 9-8210 105 60 80 2.03 0.19 4.8 65 4.5 80 350 0.25 0.25 6.4
3/8 9.5 9-8210 105 60 45 1.14 0.19 4.8 65 4.5 80 350 0.25 0.25 6.4
1/2 12.7 9-8210 105 60 22 0.56 0.19 4.8 65 4.5 80 350 0.5 0.25 6.4
3/4 19.1 9-8210 115 60 12 0.30 0.19 4.8 65 4.5 80 350 NA NA NA
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus
Type Torch: SL60 Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
1/16 1.6 9-8210 90 60 350 8.89 0.19 4.8 65 4.5 80 350 0.1 0.25 6.4
1/8 3.2 9-8210 95 60 175 4.45 0.19 4.8 65 4.5 80 350 0.25 0.25 6.4
1/4 6.4 9-8210 105 60 80 2.03 0.19 4.8 65 4.5 80 350 0.25 0.25 6.4
3/8 9.5 9-8210 105 60 45 1.14 0.19 4.8 65 4.5 80 350 0.25 0.25 6.4
1/2 12.7 9- 8210 105 60 22 0.56 0.19 4.8 65 4.5 80 350 0.5 0.25 6.4
3/4 19.1 9- 8210 115 60 11 0.28 0.19 4.8 65 4.5 80 350 NA NA NA
1 25.4 9-8210 115 60 8 0.20 0.19 4.8 65 4.5 80 350 NA NA NA
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus
Type Torch: SL60 Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
1/16 1.6 9-8210 95 60 350 8.89 0.19 4.8 65 4.5 80 350 0.1 0.25 6.4
1/8 3.2 9-8210 95 60 150 3.81 0.19 4.8 65 4.5 80 350 0.25 0.25 6.4
1/4 6.4 9-8210 105 60 70 1.78 0.19 4.8 65 4.5 80 350 0.25 0.25 6.4
3/8 9.5 9-8210 105 60 35 0.89 0.19 4.8 65 4.5 80 350 0.25 0.25 6.4
1/2 12.7 9-8210 105 60 20 0.51 0.19 4.8 65 4.5 80 350 0.5 0.25 6.4
3/4 19.1 9-8210 115 60 10 0.25 0.19 4.8 65 4.5 80 350 NA NA NA
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 75 psi
/ 5.2 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-21 APPENDIX
APPENDIX 8B: PAKMASTER 75XL PLUS SYSTEM DATA
(MACHINE TORCH)
Torch Specifica tions For
Pa k Ma ster 75XL Pl us Powe r Suppl y
Cutting Range
Material Most Metals
Up to 3/4 inch - 19 mm
Speed 11 i pm / 0. 28 m pm
Pierce Rating
Materi al Carbon Steel
Thickness 3/8 inch - 9.5 mm
Transfer Distance
Gouging
Width 1/4 inch - 6.3 mm
Depth 1/8 inch - 3.2 mm
Number Pas ses Si ngl e
Speed 20 ipm / 0.5 mpm
Bevel Cut Capability
Degrees 0° t o 45°
Material Thickness 1/4 inch - 6.3 mm
Gas Requirement
Type Gas Air
Operating P ressure 60 psi / 4. 1 bar
Max Input P ressure 125 psi / 8. 6 bar
Cutt ing & G ouging
Tota l F low
3/8 inch - 9.5 mm
350 scfh / 165 lpm
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Mater ial Gas Characteristics
Gage
to
3/4 i nch
( 19 mm )
Carbon S teel
Stai nless
Al uminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross, smooth
cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2 - 1/2 x
tip orifice diameter), some dross (easily removed),
medium - smooth cut surface, slight top edge
rounding.
Good - Excellent
Good
Good
SL100 Machine Torch Consumabl es for 60- A m p Power Suppl y
Application Electrode
9-8215 9-8213 9-8210 (60A) None None 9-8218
St andoff Cutti ng
9-8215 9-8213 9-8210 (60A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip A 40 A m ps Max . Shallow Narrow
Tip B 40-100 Amps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Tip
Tip A: 9-8225 (40 A Max)
Tip B: 9-8226 (40-100 A)
Tip C: 9-8227 (40-100 A)
Tip D: 9-8228 (40-100 A)
Gouging Profile s
Output
Range
Shield
Cup Body
9-8237 9-8241 None
Depth Width
Shield Cap
or Deflector
9-8238 or
9-8243
Shield Cup
None
APPENDIX A-22 Manual 0-2962
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus
Type Torch: SL100 Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
1/16 1.6 9-8210 95 60 350 8.89 0.19 4.8 60 4.1 80 350 0.1 0.25 6.4
1/8 3.2 9-8210 95 60 175 4.45 0.19 4.8 60 4.1 80 350 0.25 0.25 6.4
1/4 6.4 9-8210 105 60 80 2.03 0.19 4.8 60 4.1 80 350 0.25 0.25 6.4
3/8 9.5 9-8210 105 60 45 1.14 0.19 4.8 60 4.1 80 350 0.25 0.25 6.4
1/2 12.7 9-8210 105 60 22 0.56 0.19 4.8 60 4.1 80 350 0.5 0.25 6.4
3/4 19.1 9-8210 115 60 12 0.30 0.19 4.8 60 4.1 80 350 NA NA NA
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus
Type Torch: SL100 Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
1/16 1.6 9-8210 90 60 350 8.89 0.19 4.8 60 4.1 80 350 0.1 0.25 6.4
1/8 3.2 9-8210 95 60 175 4.45 0.19 4.8 60 4.1 80 350 0.25 0.25 6.4
1/4 6.4 9-8210 105 60 80 2.03 0.19 4.8 60 4.1 80 350 0.25 0.25 6.4
3/8 9.5 9-8210 105 60 45 1.14 0.19 4.8 60 4.1 80 350 0.25 0.25 6.4
1/2 12.7 9-8210 105 60 22 0.56 0.19 4.8 60 4.1 80 350 0.5 0.25 6.4
3/4 19.1 9-8210 115 60 11 0.28 0.19 4.8 60 4.1 80 350 NA NA NA
1 25.4 9-8210 115 60 8 0.20 0.19 4.8 60 4.1 80 350 NA NA NA
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus
Type Torch: SL100 Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
1/16 1.6 9-8210 95 60 350 8.89 0.19 4.8 60 4.1 80 350 0.1 0.25 6.4
1/8 3.2 9-8210 95 60 150 3.81 0.19 4.8 60 4.1 80 350 0.25 0.25 6.4
1/4 6.4 9-8210 105 60 70 1.78 0.19 4.8 60 4.1 80 350 0.25 0.25 6.4
3/8 9.5 9-8210 105 60 35 0.89 0.19 4.8 60 4.1 80 350 0.25 0.25 6.4
1/2 12.7 9-8210 105 60 20 0.51 0.19 4.8 60 4.1 80 350 0.5 0.25 6.4
3/4 19.1 9-8210 115 60 10 0.25 0.19 4.8 60 4.1 80 350 NA NA NA
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm p si* bar Plasma Total** Delay (Sec) Inches mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 65 psi
/ 4.5 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-23 APPENDIX
APPENDIX 9: PAKMASTER 100XL PLUS SYSTEM DATA
(MACHINE TORCH)
Torch Specifica tions For
Pak Ma ster 100X L P l u s Power S upply
Cutting Range
Material Most Metals
Up to 1 inch / 25.4 mm
Speed 10 ipm / 0.25 mpm
Pierce Rating
Materi al Carbon St eel
Thickness 3/8 inch - 9.5 mm
Transfer Distance
Gouging
Width 1/4 inch - 6.3 mm
Depth 3/16 inch - 4. 8 mm
Number Passes Single
Speed 20 i pm - 0. 5 m pm
Bevel Cut Capability
Degrees 0° t o 45°
Material Thickness 1/2 inch - 13 mm
Gas Requirement
Type Gas Air
Operating P res sure 60 psi / 4.1 bar
Max Input P ressure 125 psi / 8. 6 bar
Cutting & Gouging
Total Fl ow
3/8 i nc h - 9. 5 m m
490 sc fh / 231 lpm
Cut Quality on Various Materials and
Thicknesses
The following table defines the cut quality on various materials and thicknesses:
Cut Quality on Various Materials
Material Type of Type of Cut
Thickness Material Gas Characteristics
Gage
to
1 inch
( 25.4 mm )
Carbon Steel
Stainl ess
Al uminum
Air
Air
Air
Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross,
smooth cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2 - 1/2
x tip orifice diameter), some dross (easily removed),
medium - smooth cut surface, slight top edge
rounding.
Good - Excellent
Good
Good
SL100 Machine Torch Consumabl es for 80-Amp Power Suppl y
Application Electrode
9-8215 9-8213 9-8211 (80A) None None 9-8218
St andoff Cutti ng
9-8215 9-8213 9-8211 (80A) 9-8237
Gouging 9-8215 9-8213
Starter
Cartridge
Tip A 40 A m ps Max . Shallow Narrow
Tip B 40-100 Amps Deep Narrow
Tip C 40-100 Amps Moderate Moderat e
Tip D 40-100 Amps S hall ow Wide
Tip
Tip A: 9-8225 (40A M ax)
Tip B: 9-8226 (40-100A)
Tip C: 9-8227 (40-100A)
Tip D: 9-8228 (40-100A)
Gouging Profile s
Output
Range
Shield
Cup Body
9-8237 9-82 41 None
Depth Width
Shield Cap
or Deflector
9-8239 or
9-8243
Shield Cup
None
APPENDIX A-24 Manual 0-2962
Cutting Speed Charts
Air Plasma Cutting Speed Data Chart For PakMaster 100XL Plus
Type Torch: SL100 Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Out put Volt s Amperage Speed (Per Minute) Stando ff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
0.05 1.3 9-8211 100 80 350 8.89 0.19 4.8 60 4.1 90 490 0 0.19 4.8
0.125 3.2 9-8211 103 80 225 5.72 0.19 4.8 60 4.1 90 490 0 0.19 4.8
1/4 6.4 9-8211 106 80 112 2.84 0.19 4.8 60 4.1 90 490 0 0.19 4.8
3/8 9.5 9-8211 111 80 55 1.40 0.19 4.8 60 4.1 90 490 0 0.19 4.8
1/2 12.7 9-8211 115 80 30 0.76 0.19 4.8 60 4.1 90 490 0 0.19 4.8
3/4 19.1 9-8211 117 80 10 0.25 0.19 4.8 60 4.1 90 490 NR 0.19 4.8
1 25.4 9-8211 120 80 8 0.20 0.19 4.8 60 4.1 90 490 NR 0.19 4.8
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 100XL Plus
Type Torch: SL100 Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Out put Volts Amperage Speed (Per Minute) Stando ff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
1/16 1.6 9- 8211 100 80 350 8.89 0.19 4.8 60 4.1 90 490 0 0.20 5.1
1/8 3.2 9-8211 103 80 230 5.84 0.19 4.8 60 4.1 90 490 0.1 0.20 5.1
1/4 6.4 9-8211 106 80 112 2.84 0.19 4.8 60 4.1 90 490 0.1 0.20 5.1
3/8 9.5 9-8211 111 80 55 1.40 0.19 4.8 60 4.1 90 490 0.1 0.20 5.1
1/2 12.7 9-8211 112 80 38 0.97 0.19 4.8 60 4.1 90 490 0.1 0.20 5.1
3/4 19.1 9-8211 117 80 18 0.46 0.19 4.8 60 4.1 90 490 NA NA NA
1 25.4 9-8211 120 80 10 0.25 0.19 4.8 60 4.1 90 490 NA NA NA
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay ( Sec) Inches mm
mm
Air Plasma Cutting Speed Data Chart For PakMaster 100XL Plus
Type Torch: SL100 Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Out put Volts Amperage Speed (Per Minute) Stando ff Plasma Gas Press Flow (SCFH) Pierce Pierce Height
Inches
0.05 1.3 9-8211 100 80 350 8.89 0.19 4.8 60 4.1 90 490 0 0.19 4.8
0.125 3.2 9-8211 103 80 200 5.08 0.19 4.8 60 4.1 90 490 0 0.19 4.8
1/4 6.4 9-8211 106 80 112 2.84 0.19 4.8 60 4.1 90 490 0.25 0.19 4.8
3/8 9.5 9-8211 111 80 55 1.40 0.19 4.8 60 4.1 90 490 0.25 0.19 4.8
1/2 12.7 9-8211 112 80 38 0.97 0.19 4.8 60 4.1 90 490 0.25 0.19 4.8
3/4 19.1 9-8211 117 80 18 0.46 0.19 4.8 60 4.1 90 490 NR 0.19 4.8
1 25.4 9-8211 120 80 10 0.25 0.19 4.8 60 4.1 90 490 NR 0.19 4.8
(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay ( Sec) Inches mm
mm
NOTES
* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 65 psi
/ 4.5 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-2962 A-25 APPENDIX
APPENDIX 10: HAND TORCH WIRING DIAGRAMS
SL60 - SL100 Hand Torch
Hand Torch and Leads with O2B Connector
Torch & Leads with O2B Connector
Torch Head
PIP
Switch
Torch
Switch
Pilot
Torch Leads
Negative / Plasma
Black
Orange
Green
White
Power Supply
Adapter
Pilot
Hand Torch and Leads with ATC Connector, Power Supply with ATC Adapter
Torch & Leads with
ATC Connector
Torch Head
PIP
Switch
Torch
Switch
ATC Male
Connector
Torch Leads
Black
Orange
Green
White
ATC Adapter Female
Receptacle
1
2
4
3
1
2
4
3
Black
Orange
Green
White
ATC Adapter
Assembly
Power Supply
Adapter
Power Supply
Bulkhead
Power Supply
Bulkhead
PIP
Switch
Torch
Switch
Art # A-03679
Pilot
Torch & Leads with
ATC Connector
Torch Head
Pilot
Negative / Plasma
Negative / Plasma
Hand Torch & Leads with ATC Connector,
Power Supply with Console - Mounted ATC Receptacle
ATC Male
Connector
Torch Leads
Black
Orange
Green
White
Negative / Plasma
ATC Female
Receptacle
1
2
4
3
1
2
4
3
Power Supply
Front Panel
(Console)
Negative / Plasma
Negative / Plasma
Pilot
Power Supply with
Console-Mounted
Pilot
ATC Receptacle
To Power Supply
Internal Connections
APPENDIX A-26 Manual 0-2962
APPENDIX 11: MECHANIZED TORCH WIRING DIAGRAMS
Unshielded SL100 Mechanized (Machine) Torch
Torch & Unshielded Leads
with O2B Leads Connector
Torch Head
PIP
Switch
Remote
Pendant
Adapter
Torch Leads
Orange
Black
Torch & Unshielded Leads
with O2B Connector
Power Supply
Bulkhead
Not Used
Negative / Plasma
Pilot
Mechanized Torch &
Unshielded Leads
with ATC Connector
Torch Head
PIP
Switch
Pilot
Torch Leads
Not Used
Not Used
Green
White
Remote
Pendant
Connector
Negative / Plasma
AT C
Male
Connector
Black
White
Green
1
2
5
4
3
8
7
Not Used
ATC Adapter
Female
Receptacle
Orange
1
Black
2
Green
4
3
White
Negative / Plasma
Pilot
ATC Adapter
Assembly
Power Supply
O2B Leads
Connector
Adapter
Torch & Unshielded Leads
with ATC Connector, Power Supply
with Unshielded ATC Adapter
Power Supply
Bulkhead
Power Supply
Adapter
Negative / Plasma
Pilot
Mechanized Torch &
Unshielded Leads
with ATC Connector
Torch Head
PIP
Switch
Pilot
Art # A-03680
Remote
Pendant
Connector
Torch Leads
Black
Orange
Not Used
Not Used
Negative / Plasma
ATC Male
Connector
Black
White
Green
1
2
5
4
3
8
7
ATC Female
Receptacle
1
2
4
3
with Console-Mounted ATC Receptacle
Power Supply
Front Panel
Negative / Plasma
Torch & Unshielded Leads
with ATC Connector, Power Supply
To Power Supply
Internal Connections
Pilot
Manual 0-2962 A-27 APPENDIX
APPENDIX 12: AUTOMATED TORCH WIRING DIAGRAMS
Shielded SL100 Automated (Machine) Torch
Torch and Shielded Leads
with O2B Connector
Torch Head
PIP
Switch
Pilot
Torch & Shielded Leads with ATC Connector
Torch Head
PIP
Switch
Torch Leads
Red
Black
Control Shield
Negative & Pilot Shield
Negative / Plasma
ATC Male Connector
Shielded
Torch Leads
Black
Red
1
2
Torch and Shielded Leads with O2B Connector
Female
Faston
Square
Socket
Negative / Plasma
Shielded ATC Adapter
ATC Adapter Female Receptacle
1
2
3
4
Black
Red
White
Green
Male
Faston
Square
Pin
Pilot
Power Supply
Bulkhead
O2B
Connector
Torch and Shielded Leads
with ATC Connector, Power Supply
with Shielded ATC Adapter
Power Supply
Adapter
Not Used
Power Supply
Bulkhead
Negative &
Pilot Shield
Negative / Plasma
Pilot
Torch & Shielded Leads with ATC Connector
Torch Head
PIP
Switch
Negative &
Pilot Shield
Negative / Plasma
Pilot
Control
Shield
ATC Male Connector
Shielded
Torch Leads
Black
Red
Control
Shield
8
6
1
2
8
6
8
6
ATC Female
Receptacle
1
2
Female
Faston
Square Socket
Negative / Plasma
Pilot
Torch and Shielded Leads with ATC Connector,
Power Supply with Console -Mounted
Power Supply
Front Panel
Negative / Plasma
Male
Faston
Square Pin
ATC Receptacle
To Power Supply
Internal Connections
Pilot
Art # A-03681
APPENDIX A-28 Manual 0-2962
APPENDIX 13: ATC ADAPTER PINOUT DIAGRAM
ATC Male Connector
Front View
4 - Green /
Switch
3 - White /
Switch
2- Orange /
PIP
1 - Black /
PIP
4- Open*
3 - Open*
2 - Orange /
PIP
1 - Black /
PIP
* Positions 3,4,8 used
for optional remote pendant
4
3
ATC Male Connector
Front View
4
3
2
1
HAND TORCH
Negative / Plasma
8 - Open
8
2
1
7
6
5
7 - Open
6 - Open
5 - Open
Pilot
Negative / Plasma
8 - Open
7 - Open
6 - Open
5 - Open
Pilot
ATC Adapter Female Receptacle
Front View
4 - Green - Switch-
8
7
6
5
2
1
3 - White - Switch -
4
3
to Large Socket
2 - Orange /PIP -
to Small Socket
1 - Black / PIP
to Large Pin
to Small Pin
UNSHIELDED MACHINE TORCH
ATC Female Adapter
Receptacle - Front View
Negative / Plasma
7 - Green /
8
7
6
5
Not Used
6 - Open
5 - White /
Not Used
8 - Open*
Pilot
Negative / Plasma
8* - Open
7 - Open
6 - Open
5 - Open
Pilot
4 - Green /
Not Used* -
to Small Pin
3 - White /
8
7
6
5
2
1
* Positions 3,4,8 used
for optional remote pendant
Not Used* -
4
to Large Socket
3
2 - Orange /PIP -
to Small Socket
1 - Black / PIP to Large Pin
Shielded ATC Male Connector
Front View
4- Open*
3 - Open*
2 - Red /
PIP
1 - Black /
PIP
* Positions 3 & 4 used
for remote pendant in
mechanized applications.
Pendant drain splices to
wire in position 8.
4
3
2
1
SHIELDED MACHINE TORCH
Negative / Plasma
8 - Shield Drain*
8
7
6
5
6 - Neg/Pilot
Shield Drain
7 - Open
5 - Open
Pilot
8 - Shield Drain* to Faston
7 - Open
6 - Neg/Pilot
Shield Drain to Square Socket
5 - Open
Pilot
Art # A-03666
Negative / Plasma
* Positions 3 & 4 used
for remote pendant in
mechanized applications.
Shielded ATC Adapter -
Female Receptacle Front View
8
7
6
5
4
3
2
1
4 - Green /
Not Used* to Small Pin
3 - White /
Not Used* -
to Large Socket
2 - Red / PIP
to Small Socket
1 - Black / PIP
to Large Pin
Manual 0-2962 A-29 APPENDIX
APPENDIX A-30 Manual 0-2962
Global Customer Service Contact Information
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermadyne.com
Thermadyne Victor Brasil
Avenida Brasil
13629-Cordovil
Rio de Janeiro, Brazil 21012-351
Telephone: 55-21-2485-8998
Fax: 55-21-2-485-8735
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne Chile
Piloto Lazo #90
Cerrillos
Santiago, Chile 7278-654
Telephone: 56-2-557-2465
Fax: 56-2-557-5349
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne South Africa
209 Risi Ave.
Linmeyer
Johannesberg, 2197
South Africa
Tel: (27) 11-917 3600
Fax: (27) 11-917 8580
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
Corporate Headquarters
16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017
Telephone: 636-728-3000
Email: TDCSales@Thermadyne.com
www.thermadyne.com
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