Tweco 7-5227 User Manual

5

(

82 Benning Street, West Lebanon, NH 03784 USA

s

[phone] • www.thermal-dynamics.com

Manual 0-4647

SL60 and SL100 Replacement

Plasma Cutting Hand Torches,

Cat. No. 7-5225, 7-5226, 7-5227

Installation and Operation Instructions

General Information

The 1TorchTM SL60 and SL100 Torches are connected to
power supplies using an Adapter Kit. The torches use
compressed air as both the plasma and secondary gas.

The torches are suitable for standoff cutting.
These instructions are important for the proper installation of

the T orches. Read the instructions thoroughly before attempt­ing the installation. Keep these instructions for reference.

The torches are supplied as follows:

Catalog No. Torch Model

7-5225 SL60 50A
7-5226 SL100 70A
7-5227 SL100 90A

Consumable

Inst alled

Options

The following options are available. Refer to the replace­ment parts list for catalog numbers.

• Leather Leads Covers

• Cutting Guides

• Radius / Roller Kit

• Trigger Guards

• Standoff Cutting Guide

Supplied Parts

The T orches include:

• T or ch W ith Leads

• Control Wire Connectors

• Instructions

• Consumables (Installed on the Torch): Electrode,
Starter Cartridge, Tip, Shield Cup

• Replacement Consumables as follows:

Torch Cat. No. Cutting Tip Electrode

7-5225 (2) No. 9-8209 (50A)
7-5226 (2) No. 9-8231 (70A)
7-5227 (2) No. 9-8212 (90A)

(1) No. 9-821

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.

9.5" (241 mm)

3.75"

95 mm)

1.17" (29 mm)

Art # A-03322

Torch Specifications

B. Torch Leads Lengths

20 foot / 6.1 m

© 2004 by Thermal Dynamics Corp., Printed in USA

July 28, 2004 1 Manual 0-4647

C. Current Rating (Refer to Note)

SL60 & S L100 Cur rent Ratin gs

Temperature

SL60 Torch Ratings

Temperature

h

SL100 Torch Ratings

A

er

F. Gas Requirements

NOTE

Power Supply characteristics will determine ma­terial thickness range.

SL60 Torch & Leads

Up to 60 Amps, DC,
Strai ght P ol a ri ty

SL100 Torch & Leads

Up to 100 Amps, DC,
Strai ght P ol a ri ty

D. Torch Ratings

Ambient

Duty Cy c le

Maximum Current

Volt a ge ( V

peak

)

Arc Striking Vol tage

100% @ 60 Amps @ 400 scfh

104° F

40° C

60 Amps

500V

7kV

SL60 and SL100 Torch Gas Specifications

Gas (Pl asma and Secondary) Compressed Air
Operating Pres sure

Refer to NOTE

60 - 75 psi

4.1 - 5.2 bar

Max im um Input P res s ure 125 psi / 8. 6 bar
Gas Fl ow (Cutt i ng and Gouging)

300 - 500 scfh

(142 - 235 lpm)

W ARNING

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

NOTE

Operating pressure varies with torch model and
operating amperage. Refer to gas pressure settings
chart for each model.

G. Direct Contact Hazard

For exposed tip the recommended standoff is 1/8" - 1/4" (3 - 6.4
mm).

Ambient

104° F

40° C

Duty Cy cle

Maximum Current

Volt a ge ( V

peak

Arc Striking Vol tage

100% @ 100 Amps @ 400 scf

100 Amps

)

500V

7kV

E. Type of Cooling

Combination of ambient air and gas stream through torch.

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

The torch and leads include circuitry called Parts-In-Place
(PIP). This circuit includes a switch located at the torch
head. The shield cup closes this switch when properly
installed. The torch will not operate if this switch is open.

To Control

Torch Switch

Cable Wiring

PIP Switch

-02997

Torch Trigg

Shield Cup

July 28, 2004 2 Manual 0-4647

Connecting Torch

C

A

Torch Parts Selection

The T orch Leads connect to the power supply with an Adapter
Kit consisting of two control wire connectors supplied with the
torch. Connect the torch to the power supply as follows:

W ARNINGS

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. Pass the end of the Torch Leads Assembly through the
access opening on the power supply.

2. Connect the ring tongue terminal on the Tor ch Leads
Assembly pilot lead to the pilot terminal on the power
supply . T ighten secur ely .

Control

Wire

Connectors

To Power Supply
Control Connectors

Refer to the Consumables Selection Chart for the various torch
parts for the application and operation.

W ARNINGS

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 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

ontrol Circuit

Connectors

Pilot
Lead

Negative/Plasma

Torch Lead Assembly

Pilot Lead

Stud

To Power Supply

(-) Fitting

Negative/Plasma

Lead Connection

Lead

Art # A-03959

Starter Cartridge

Tip

Shield Cup

-03645

2. Tilt the torch head to remove the tip and starter car­tridge.

3. Connect the Negative / Plasma lead from the torch to the
power supply . Tighten secur ely . Do not use sealant.

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

4 . The torch leads assembly includes two wires joined to-

gether and covered with an insulating sleeve. These wires
must remain joined and sleeved for proper torch operation.

5. Refer to the illustration. Connect the Control Wire Connec­tors to the torch leads assembly wires as shown.

6. Connect the Control Wire Connectors to the power supply .

7. Reinstall any power supply covers removed for torch in­stallation.

July 28, 2004 3 Manual 0-4647

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

r
r

r

2

3

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.

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.

CAUTION

Do not operate the torch with the torch tip in con­tact with the work at outputs greater than 40 amps
as this can cause irreparable damage to the torch
parts.

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 ar c will
start.

Torch Tip

SL60

Torch

SL100

Torch

50A 65 ps i / 4.5 ba
70A 60 ps i / 4.1 ba

90A 65 ps i / 4.5 ba

Gas P ress ure

Setting

Cuttingtting 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 pr essure on the Power
Supply pressure gauge. Refer to the charts for opti­mum pressure settings for the torch tip in use.

2. Adjust current output on the Power Supply to match
the selected tip and attach the work clamp firmly to the
work.

W ARNING

T rigger

T rigger Release

Art # A-0396

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.

Trigger

1

2

Trigger Release

Maximum current for is 60 Amps for SL60 T or ches,
or 100 Amps for SL100 T or ches. Operation of this
torch at higher outputs may damage the torch, the

3

leads, or the Power Supply. DO NOT operate the
SL60 T orch at mor e than 60 Amps, or the SL100 at
more than 100 Amps.

4

Art # A-0338

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

July 28, 2004 4 Manual 0-4647

7. Follow normal recommended cutting practices as provided

g

U
w
M

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 can damage components.

8. The optional Standoff Guide allows the user to easily
adjust and maintain a consistent standoff height for
most applications.

3. Excessive Dross Formation

a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non-Genuine Thermal Dynamics Parts

4. Short T orch 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

Shield Cup

Standoff Guide

T orch Tip

Workpiece

Art # A-04063

Common Operating Faults

The following are the more common cutting faults and the
possible causes:

1. Insufficient Penetration

a. Cutting speed too fast
b. T or ch 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

f . Non-Genuine Thermal Dynamics Parts

5. Difficult Starting

a. Worn torch consumables
b. Non - Genuine Thermal Dynamics Parts

6. Torch will not pilot when torch switch is activated

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

Art # A-03640

pper Groove
ith V ent Holes

ust Remain Open

Upper O-Ring
in Correct Groove

Threads
Lower O-Rin

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

July 28, 2004 5 Manual 0-4647

Inspection and Replacement of

A

g

Start Cartridge

A

Consumable Torch Parts

A. General Information

3. Check the starter cartridge for excessive wear, plugged gas
holes, discoloration, and for free movement of the lower
end plate. Replace if necessary .

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

Starter Cartridge

Lower End Fittin

Art # A-03621

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

New Electrode

rt # A-03284

Worn Electrode

5. Reinstall the Electrode by pushing it straight into the torch

head until it clicks.

W ARNINGS

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

Tip

Shield Cup

-03645

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

Good Tip

Worn Tip

A-03406

Refer to the consumables selection charts for the
proper combination of torch parts.

The use of any consumable parts other than those
specified by the Manufacturer may cause irrepa­rable damage to the torch head.

6. Reinstall the desired starter cartridge and tip into the torch

head.

7. 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.

July 28, 2004 6 Manual 0-4647

Consumables Selection Chart

e

e

Standard Torch Consumables

The illustration shows standard consumable parts for standoff cutting with SL60 and SL100 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 .

Electrode

9-8215

Starter

Cartridge

9-8213

Art # A-03961

50A

CUTTING

70A

CUTTING

90A

CUTTING

Tip:

50A 9-8209

Tip:

70A 9-8231

Tip:

90A 9-8212

Shield Cup

9-8218

Shield Cup

9-8218

Shield Cup

9-8218

Standoff Guide

9-8422

Standoff Guid

9-8422

Standoff Guid

9-8422

July 28, 2004 7 Manual 0-4647

Replacement Hand Torch Parts

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (include 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 /6.1 m Leads Assembly with O2B connectors 4-7830

1 SL100 / 100 Amp, 20 - foot /6.1 m Leads Assembly with O2B connectors 4-7832

8 1 Switch Kit 9-7031

9 1 Adapter Kit 7-3439

Complete Assembly Replacement

NOTE

All Complete Torch and Lead Assemblies include a Torch Adapter Kit for proper installation of the Torch.

Description Catalog #

Hand Torch with Ergonomic Handle and 50-Amp Cutting Parts:

SL60 Hand Torch and 20 foot /6.1 m Leads, with O2B Connector & Power Supply Adapter 7-5225

Hand Torch with Ergonomic Handle and 70-Amp Cutting Parts:

SL100 Hand Torch and 20 foot /6.1 m Leads, with O2B Connector & Power Supply Adapter 7-5226

Hand Torch with Ergonomic Handle and 90-Amp Cutting Parts:

SL100 Hand Torch and 20 foot /6.1 m Leads, with O2B Connector & Power Supply Adapter 7-5227

Options

Leather Leads Cover, 20 foot / 6.1 m length 9-1260

Straight Line Cutting Guide 7-8911

Radius / Roller Kit 7-7501

Circle Cutting Guide 7-3291

Deluxe Cutting Guide Kit 7-8910

Short Trigger Guard 9-8420

Long Trigger Guard 9-8421

Standoff Guide 9-8422

July 28, 2004 8 Manual 0-4647

1

2

4

5

6

3

9

8

7

Art # A-03960

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.

July 28, 2004 9 Manual 0-4647

Statement of Warranty

LIMITED W ARRANTY: 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 r ecognized
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 manufactur e, sale, delivery, resale, or use of any goods cover ed 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 pr oducts 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

W est Lebanon, NH 03784 USA

Telephone: [phone]

www.thermal-dynamics.com

July 28, 2004 10 Manual 0-4647