The 1TorchTM SL60 and SL100 Torches work with most
plasma cutting power supplies. The Torches are equipped
with either O2B connectors or the Thermal Dynamics ATC
connector and are connected using various Adapter Kits
sold separately.
A label on the torch handle indicates the torch model
number. SL60 Torches provide cutting capabilities of up
to 60 amperes. SL100 Torches provide cutting capabilities of up to 100 amperes. The torches use compressed
air as both the plasma and secondary gas.
The torches are suitable for drag cutting (with the torch
tip in contact with the workpiece, at up to 40 Amps output); 40-100 Amp shielded drag cutting (with shielded
torch parts (cap, etc.) in contact with the workpiece);
standoff cutting; or gouging.
SL60 and SL100
Replacement Plasma
Cutting Hand Torches
Installation and Operation Instructions
Options
The following options are available. Refer to the complete assembly replacement list for catalog numbers.
• ATC Adapter Kit (for Torches with ATC Connectors)
• Leads extensions (for Torches with ATC Connectors)
• Cutting Guide Kits
• Leather Leads Covers
• Standoff Cutting Guide
Torch Specifications
A. Torch Configurations and Dimensions
The torch head is at 75° to the torch handle. The torch includes
a torch handle and torch trigger assembly.
Refer to the Complete Assembly Replacement page for
configurations and catalog numbers.
These instructions are important for the proper installation of the Torches. Read the instructions thoroughly before attempting the installation. Keep these instructions
for reference.
Supplied Parts
The Replacement Torches include:
• Torch With Leads - 1 each
• Installation Instructions - 1 each
• Consumables (Installed on the Torch): Electrode,
Starter Cartridge, Tip, Shield Cup Body and Drag
Shield Cap)
• Standard Shield Cup
NOTE
The consumable parts installed in the Torch may
not necessarily be optimized for your Power Supply or cutting application. For best results, refer
to the selection charts in this manual to choose the
proper consumables for your application.
9.5" (241 mm)
3.75"
(95 mm)
1.17" (29 mm)
Art # A-03322
B. Torch Leads Lengths
20 foot / 6.1 m, or 50 foot / 15.2 m
For torches with ATC Connectors, leads extensions are
available to extend the leads to a maximum of 50 feet / 15.2
m. Total leads lengths must not exceed the power supply
manufacturer's recommendations.
Power Supply characteristics will determine material thickness range.
Up to 60 Amps, DC,
Straight Pol ari ty
Up to 100 Amps, DC,
Straight Pol ari ty
NOTE
WARNING
This torch is not to be used with oxygen (O
NOTE
Operating pressure varies with torch model, operating amperage, and torch leads length. Refer to
gas pressure settings chart for each model.
G. Direct Contact Hazard
).
2
D. Torch Ratings
SL60 Torch Ratin
Ambient
Tem
erature
Duty Cycle
Maximum Current
Vol tag e (V
Arc Striking Voltage
Ambient
Tem
erature
Duty Cycle
Maximum Current
Vol tag e (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
E. Type of Cooling
Combination of ambient air and gas stream through
torch.
F. Gas Requirements
For exposed tip the recommended standoff is 1/8" - 1/4"
(3 - 6.4 mm).
H. Parts-In-Place (PIP) Circuit - 12 vdc
The torch and leads include circuitry called Parts-InPlace (PIP). This circuit includes a switch located at
the torch head. The shield cup closes this switch when
properly installed. The torch will not operate if this
switch is open.
To Control
Torch Switch
Cable Wiring
PIP Switch
A-02997
Torch Trigger
Shield Cup
Connecting Torch
There are two types of connection for the Torch Leads. One
type uses the Thermal Dynamics ATC connector. The other
uses O2B connections for gas and circuitry. Both types require
an adapter kit sold separately.
ATC Connectors
Follow the instructions provided with the adapter kit to connect the adapter to the power supply.
SL60 and SL100 Torch Gas Specifications
Gas (P lasma and Sec ondary)Compress ed A ir
Inspect the halves of the ATC Connector. Align the male connector with the female receptacle and push them together by
hand until they seat fully. Turn the Locking Ring until it pulls
the halves of the connector together fully. Do not use tools to
Operat i ng P ressu re
Refer to NOTE
Max im um Input P res s ure125 psi / 8.6 bar
Gas Fl ow (Cutt i ng and Gouging)
60 - 75 psi
4.1 - 5.2 bar
300 - 500 scfh
(142 - 235 lpm)
tighten the connector. If there is any resistance to the ring
turning, pull the halves of the connector apart, realign the inner
components, ensure that the threaded components are aligned,
and push the halves of the connector together again.
O2B Connectors
Leads with O2B connectors are connected to the power supply
using adapter kits sold separately. Follow the instructions
provided with the adapter kit to connect the gas and electrical
lines to the power supply.
Revision AA.01 September 29, 20062Manual 0-2880
Spare Parts Label
The parts kit provided with the torch includes an adhesive label. Select the small perforated section showing the
appropriate pressure setting for the amperage output and
leads length to be used with this torch. Refer to the charts.
Apply this section in the 'Gas Supply' area of the label
under the 'Recommended Operating Pressure' text. Discard any pressure setting sections of the label that will not
be used. Apply the large label to the power supply, where
the operator can see it for easy reference.
Torch Parts Selection
Refer to the Consumables Selection Chart for the various torch
parts for the application and operation.
WARNINGS
2. Tilt the torch head to remove the tip and starter cartridge.
3. Fit the desired starter cartridge and tip onto the electrode.
NOTE
Refer to the consumables selection chart for the proper
combination of torch parts, including shield cups
and caps.
4. Hand tighten the shield cup until it is seated on the torch
head. Do not use tools to tighten the cup. If resistance is
felt when installing the cup, check the threads before proceeding.
NOTE
When operating the torch in a normal condition,
a small amount of gas vents through the gap between the shield cup and the torch handle. Do not
attempt to overtighten the shield cup as irreparable damage to internal components may result.
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 shield cup (or shield cup body and shield cap or deflector)
holds the tip and starter cartridge in place. Position the torch
with the shield cup facing upward to keep these parts from
falling out when the cup is removed.
Change the torch parts as follows:
1. Unscrew and remove the shield cup from the torch
head.
Torch Head
Electrode
Start Cartridge
Tip
Gouging Parts Selection
Select gouging tips according to the desired gouge profile.
Gouging parameters shown are based on a 35° approach angle.
Gouging Profiles
Outp ut RangeDepthW idth
Tip A40 Amps M ax.ShallowNarrow
Tip B40-100 A m psDeepNarrow
Tip C40-100 AmpsModerateModerate
Tip D40-100 AmpsShal lowW i de
Operating Gas Pressure
Set gas pressure at the power supply regulator according to the
following charts. These charts are a guide only; adjust as necessary for best performance.
SL60 Ga s Pressure Se ttings
Leads Lengt h
Tip
30A, 40A ,
50/55A , 60A
SL100 Gas Pressure Se ttings
Tip
20' / 6. 1 m50' / 15. 2 m
65 psi / 4.5 bar 75 psi / 5.2 bar
Leads Length
Up to 25' / 7.6 m50' / 15.2 m
Shield Cup
Assembly
Art # A-03417
30A, 40A ,
50/ 55A, 60A,
70A, 80A
90/100A65 ps i / 4. 5 bar70 psi / 5. 2 bar
60 psi / 4.1 bar65 psi / 4.5 bar
Revision AA.01 September 29, 20063Manual 0-2880
Cutting or Gouging
!
The torch can be held comfortably in one hand or steadied
with two hands. Choose the holding technique that feels
most comfortable and allows good control and movement.
Sequence of Operation
1. Turn on power and adjust gas pressure on the Power Supply pressure gauge. Refer to the charts for optimum pressure settings for the combination of torch tip and total
leads lengths (including extensions) in use.
2. Adjust current output on the Power Supply to match the
selected tip and attach the work clamp firmly to the work.
WARNING
Maximum current for is 60 Amps for SL60 Torches,
or 100 Amps for SL100 Torches. Operation of this
torch at higher outputs may damage the torch, the
leads, or the Power Supply. DO NOT operate the
SL60 Torch at more than 60 Amps, or the SL100
at more than 100 Amps.
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.
CAUTION
Do not operate the torch with the torch tip in contact with the work at outputs greater than 40 amps.
Drag cutting at higher output currents can cause
irreparable damage to the torch parts. Use only
shielded parts at output currents higher than 40
amps.
3. Hold the torch away from your body.
4. Slide the trigger release toward the back of the torch
while simultaneously squeezing the trigger. The pilot arc will start.
Trigger
Trigger Release
A-02986
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 can damage components.
8. The optional Standoff Guide allows the user to easily adjust and maintain a consistent standoff height for most applications.
Shield Cup
Standoff Guide
Torch Tip
Art # A-04063
Workpiece
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.
Revision AA.01 September 29, 20064Manual 0-2880
Common Operating Faults
The following are the more common cutting faults and the
possible causes:
6. Torch will not pilot when torch switch is activated
a. Upper O-ring on torch head is in wrong position
1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f.Non-Genuine Thermal Dynamics Parts
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts
f.Non-Genuine Thermal Dynamics Parts
3. Excessive Dross Formation
a. Cutting speed too slow
Art # A-03640
Upper Groove
with Vent Holes
Must Remain Open
Upper O-Ring
in Correct Groove
Threads
Lower O-Ring
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non-Genuine Thermal Dynamics Parts
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Gas pressure too low
e. Improperly assembled torch
f.Non-Genuine Thermal Dynamics Parts
5. Difficult Starting
a. Worn torch consumables
b. Non - Genuine Thermal Dynamics Parts
Revision AA.01 September 29, 20065Manual 0-2880
Inspection and Replacement of
Consumable Torch Parts
A. General Information
cutting operations (only), there may be an O-ring between the shield cup body and drag shield cap. Do not
lubricate the O-ring.
Drag Shield Cap
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.
Unthread the shield cup assembly to remove the consumable
torch parts.
1. Inspect the cup for damage. Wipe it clean or replace if
damaged. Slag built up on the shield cup that cannot be
removed may affect the performance of the system.
Torch Head
Electrode
Start Cartridge
Shield
Cup Body
O-Ring No. 8-3488
Art # A-03878
4. Check the starter cartridge for excessive wear, plugged gas
holes, discoloration, and for free movement of the lower
end plate. Replace if necessary.
Start Cartridge
Lower End Fitting
Tip
Shield Cup
Assembly
Art # A-03417
2. Check the tip for excessive wear (indicated by an elongated
or oversized orifice). Clean or replace the tip if necessary.
Good Tip
Worn Tip
A-03406
3. On torches with a shield cup body and a shield cap or
deflector, ensure that the cap or deflector is threaded
snugly against the shield cup body. In shielded drag
Art # A-03621
5. Check the end of the electrode for excessive wear.
New Electrode
Art # A-03284
Worn Electrode
Revision AA.01 September 29, 20066Manual 0-2880
6. Reinstall the Electrode by pushing it straight into the
torch head until it clicks.
WARNINGS
Refer to the consumables selection charts for
the proper combination of torch parts, including shield cups and shield caps.
The use of any consumable parts other than
those specified by the Manufacturer may cause
irreparable damage to the torch head.
7. Reinstall the desired starter cartridge and tip into the
torch head.
8. Hand tighten the shield cup until it is seated on the torch
head. If resistance is felt when installing the cup, check
the threads before proceeding.
NOTE
When operating the torch in a normal condition, a small amount of gas vents through the
gap between the shield cup and the torch
handle. Do not attempt to overtighten the shield
cup as irreparable damage to internal components may result.
Art #A-03791
ATC Male Connector
Gas Fitting
O-Ring
B. O-Ring Lubrication
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 o-ring
lubricant (Catalog # 8-4025) to the o-ring on a weekly
basis.
NOTE
DO NOT use other lubricants or grease, they
may not be designed to operate within high 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.
Revision AA.01 September 29, 20067Manual 0-2880
Torch Consumables
The illustrations show all consumable parts for the SL60
and SL100 torches.
Various front - end torch parts are available for different
applications.
Drag Tip Cutting: Use the single - piece shield cup for
general purpose cutting operations with the torch tip in
contact with the work (up to 40 amps). This is the preferred method of cutting sheet metal up to 3/16" or 4.8 mm
thick.
Standoff Cutting: Also use the single - piece Shield Cup
for 'standoff' cutting (with the torch tip 1/8" to 1/4" from
the workpiece). This is the preferred method for cutting
metal thicker than 3/16" / 4.8 mm and at current levels
above 40 amps. This provides maximum visibility and
accessibility.
Use the Shield Cup Body with the Deflector Shield Cap for
extended parts life and improved resistance to reflected
heat. This combination provides cutting results similar to
the single-piece Shield Cup, as well as easy change-over
to gouging or drag shield cutting.
Drag Shield Cutting: Use the Shield Cup Body with the
Drag Shield Cap for a consistent standoff distance with
the drag shield in contact with the workpiece. This is a
simple and operator-friendly method of cutting between
50 and 100 amps.
Gouging: Use the Shield Cup Body with the Gouging
Shield Cap for excellent gouging performance and enhanced torch parts life.
Drag Tip
Cutting
3/16" / 4.8 mm
v
v
Standoff
Cutting
v
3/16" / 4.8 mm
v
40 A
Drag Shield
Cutting
v
3/16" / 4.8 mm
50 - 100 A
35 - 45
Art # A-07039
40 A
1/8 - 1/4"
(3.2 - 6.4 mm)
Gouging,
40 - 100 A
The Standoff Guide fits all shield cup designs for the SL60
and SL100 RPT hand torches. The Guide allows the user
to easily adjust and maintain a consistent standoff height
for most applications. The Standoff Guide also fits Thermal Dynamics PCH-62 and PCH-102 hand torches.
The electrode and starter cartridge are the same for all
applications.
Use only Genuine Thermal Dynamics consumables with
this torch. The use of any other consumables may irreparably damage the torch and/or void the warranty.
A
40A
v
Workpiece
B
Standoff Guide
Torch Tip
C
50 - 100A
Shield Cup
D
Art # A-04063
January 3, 20068Manual 0-2880
Consumables Selection
Starter
Cartridge
9-8213
Electrode
9-8215
Tips:
20A 9-8205
30A 9-8206
40A 9-8207
Tip A 9-8225 (40 Amps Max.)
Tip B 9-8226 (40 - 100 Amps)
Tip C 9-8227 (40 - 100 Amps)
Tip D 9-8228 (40 - 100 Amps)
Shield Cap, Gouging
9-8241
Shield Cap, Drag
40A 9-8244
40A 9-8208
50-55A 9-8209
60A 9-8210
70A 9-8231
80A 9-8211
90/100A 9-8212
Shield Cap, Drag
50-60A 9-8235
Shield Cap, Drag
70-100A 9-8236
Shield
Cup Body,
9-8237
70-100A
50-60A
40A
Shield Cap, Deflector
9-8243
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Tip:
Tips:
Tips:
Tips:
DRAG TIP
CUTTING
40-100A
GOUGING
CUTTING
CUTTING
CUTTING
Art # A-04037
DRAG SHIELD
CUTTING
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield
Cup Body,
9-8237
Shield Cup
9-8218
STANDOFF
CUTTING
DRAG SHIELD
CUTTING
STANDOFF
CUTTING
DRAG SHIELD
CUTTING
STANDOFF CUTTING
Shield Cap, Deflector
9-8243
Shield
Cup Body,
9-8237
Shield Cup
9-8218
O-Ring No. 8-3488
Standoff Guide
for All Applications
9-8422
Shield Cap, Deflector
9-8243
O-Ring No. 8-3488
Shield Cap, Deflector
9-8243
O-Ring No. 8-3488
Gouging Profiles
Output RangeDepthWidt h
Tip A40 Amps M ax.Shall owNarrow
Tip B40-100 Am psDeepNarrow
Tip C40-100 AmpsM oderateModerat e
Tip D40-100 AmpsS hal l owWide
1Starter Cartridge Restrictor Pin Kit (for use with certain8-3440
power supplies with high - volt start circuitry)
January 3, 200610Manual 0-2880
1
2
4
5
6
Requires Adapter Kit
For Proper Installation
OR
3
9
7
8
May Require ATC Adapter
Kit For Proper Installation
A-03323
January 3, 200611Manual 0-2880
Complete Assembly Replacement
NOTE
All Complete Torch and Lead Assemblies require a Torch Adapter Kit for proper installation of the Torch.
DescriptionCatalog #
60 - AmpHand Torches with Ergonomic Handle:
SL60 Hand Torch and 20 foot /6.1 m Leads, with O2B Connector7-5200
SL60 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector7-5201
SL60 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector7-5204
SL60 Hand Torch and 50 foot / 15.2 m Leads, with ATC Connector7-5205
100 - Amp
Options
Hand Torches with Ergonomic Handle:
SL100 Hand Torch and 20 foot /6.1 m Leads, with O2B Connector7-5202
SL100 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector7-5203
SL100 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector7-5206
SL100 Hand Torch and 50 foot / 15.2 m Leads, with ATC Connector7-5208
ATC Adapter Kit7-5207
Leads extensions with ATC Connectors, 15 - foot / 4.6 m length7-7544
Leads extensions with ATC Connectors, 25 foot / 7.6 m length7-7545
Leads extensions with ATC Connectors, 50 foot / 15.2 m length7-7552
Leather Leads Cover, 20 foot / 6.1 m length9-1260
Leather Leads Cover, 25 foot / 7.6 m length9-1270
Leather Leads Cover, 50 foot / 15.2 m length9-1280
Straight Line Cutting Guide7-8911
Radius / Roller Kit7-7501
Circle Cutting Guide7-3291
Deluxe Cutting Guide Kit7-8910
Standoff Guide9-8422
NOTE
Every effort has been made to provide complete and accurate information in this manual. However, the
publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused
by errors or omissions in this Manual, whether such errors result from negligence, accident, or any other
cause.
January 3, 200612Manual 0-2880
PATENT INFORMATION
The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512
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 becomes invalid if the product is sold by non-authorized persons.
All SureLok™ RPT Torches have a one year Parts & Labor warranty
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.
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, NH 03784 USA
Telephone: 603-298-5711
www.thermal-dynamics.com
Loading...
+ hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.