Tweco 7-3480 User Manual

Manual 0-2973

82 Benning Street, West Lebanon, NH 03784 USA

[phone] • www.thermal-dynamics.com

General Information

This kit connects Thermal Dynamics 1T orch Models SL60
or SL100 T orches, or the Thermal Dynamics A TC Adapter ,
to Hypertherm* powermax* 600 power supplies with in­ternal torch connections.

These instructions are important for the proper installa­tion of the Torches. Read the instructions thoroughly
before attempting the installation. Only a qualified tech­nician should perform the installation of this kit. Keep
these instructions for reference.

Parts Supplied

The kit includes:

• O2B Adapter Fitting with Wire Harness

• Control W ire Harness

• Barrel Crimp

• Strain Relief

• Instructions

1Torch Adapter

Kit No. 7-3480

Installation Instructions

Installation

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.

1. Remove the Power Supply cover per
manufacturer's instructions.

2. Disconnect and remove the original torch from
the Power Supply per manufacturer's instructions.
Remove the brass fitting from the power supply
solenoid connection. Keep the C-clip which se­cures the brass fitting to the solenoid.

Torch Leads

Assembly or ATC Adapter

Strain Relief

Strain Relief

Securing Nut

Negative /
Plasma Lead

Insulating Sleeve

A-03606

© 2003 by Thermal Dynamics Corp., Printed in USA. *HYPERTHERM and
powermax are registered trademarks of Hypertherm, Inc.

on Pilot Lead

Remove Tie Wrap ,
Remove Insulator,
Disconnect Wires

Small

Torch

Adapter

Gas

Fitting

O-Ring

To

Power Supply

To Power Supply Main
Circuit Board

Pow er Wire
Connector ­to T erminal 5

5

Pilot Lead Connector­to T erminal 3

1

3

Power Supply
Terminal Block

2

6

4

July 7, 2003 1 Manual 0-2973

3. The torch leads or ATC Adapter includes a pilot
wire with a ring-tongue terminal. Slide back the
insulation sleeve covering this wire. Cut the ter­minal off the wire. Strip back approximately
11/16 inch (17 mm) of insulation fr om the end of
the wire. Double the stripped end of the wire back
onto itself. Use a crimping tool to attach the bar­rel crimp included in this kit to the end of the pi­lot wire. Check for a secure connection between
the crimp and the wire.

14. Connect the mating wire connectors on the sepa­rate 4 - wire harness assembly provided in this
kit to the connectors on the torch leads assembly
or A TC Adapter .

15. Connect the receptacle on the 4 - wire harness as­sembly to the power supply main circuit board.
Press the connector into place securely.

16.Reinstall the power supply cover per
manufacturer's instructions.

4. The torch leads or ATC Adapter includes two
wires covered with an insulating sleeve and joined
with mating connectors. Remove the tie wrap
securing the insulating sleeve in place. Remove
the insulating sleeve and disconnect the mating
connectors.

5. Remove the nut from the strain relief assembly.

6. Install the strain relief on the Replacement Torch
leads or A TC Adapter . It may be necessary to twist
the strain relief back and forth while sliding it onto
the leads or ATC Adapter.

7. Pass the T orch Leads or A TC Adapter thr ough the
torch leads access opening in the power supply
front panel. Loosely thread the Strain Relief Nut
onto the Strain Relief. Do not tighten.

8. Connect the O2B Adapter Fitting (with wire har­ness) to the Plasma Fitting on the torch leads or
A TC Adapter . Tighten securely.

9. Ensure that the O-ring is in place on the Adapter
Connector .

10. Press the Adapter Connector into the power sup­ply solenoid connection. Secure the fitting in place
with the C-clip removed to disconnect the origi­nal torch. Test for a secure connection between
the fitting and the solenoid.

17. Check the torch for proper consumables per the
torch manual.

18. Connect primary input power to the power sup­ply. Test the power supply for proper operation.

19. Set gas pressure per the torch manual.

20. T est the torch for proper operation.

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.

11. Tighten the Strain Relief Nut onto the Strain Re­lief securely. Test the torch leads or ATC Adapter
leads assembly to ensure that the strain relief holds
the leads or adapter leads securely.

12. Refer to the illustration. Install the pilot lead wire
(with barrel crimp) in terminal #3 in the terminal
block just above the power supply solenoid.
Tighten the securing screw. Check for a secure
connection.

13. Refer to the illustration. Install the power wire
connector from the torch adapter (4 wires termi­nated in a barrel crimp) in terminal #5 in the ter­minal block just above the power supply solenoid.
Tighten the securing screw. Check for a secure
connection.

July 7, 2003 2 Manual 0-2973