Tweco SL100 User Manual

100

100% Duty Cycle

PIP

H/F LV Start

Max Input 125PSI

Op Pres 60-75 PSI

Max Flow 400 scfh

SL60

SL100

PLASMA CUTTING TORCH

Model SL60, SL100 Hand Torch Model SL100 Machine Torch

Instruction Manual

Rev. AB Date: June 20, 2012 Manual # 0-2962 Operating Features:

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 marketleading, 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

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 Revision AB Date: June 20, 2012

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Power Supply Serial #: ____________________________________

Torch Serial #: ____________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ........................................................................... 1-1

1.01 Notes, Cautions and Warnings ........................................................................ 1-1

1.02 Important Safety Precautions ......................................................................... 1-1

1.03 Publications .................................................................................................... 1-2

1.04 Declaration of Conformity ............................................................................... 1-4

1.05 Statement of Warranty .................................................................................... 1-5

SECTION 2:

INTRODUCTION ..................................................................................... 2-1

2.01 Scope of Manual ............................................................................................. 2-1

2.02 General Description ........................................................................................ 2-1

2.03 Speciﬁcations ................................................................................................ 2-1

2.04 Options And Accessories ................................................................................ 2-3

2.05 Introduction to Plasma ................................................................................... 2-3

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Introduction .................................................................................................... 3-1

3.02 Site Location ................................................................................................... 3-1

3.03 Unpacking ....................................................................................................... 3-1

3.04 Setting Up Hand Torch .................................................................................... 3-1

3.05 Setting Up Machine Torch ............................................................................... 3-1

3.06 Connecting Torch ............................................................................................ 3-2

3.07 Gas Connection ............................................................................................... 3-8

SECTION 4:

OPERATION ........................................................................................... 4-1

4.01 Introduction .................................................................................................... 4-1

4.02 Functional Overview ........................................................................................ 4-1

4.03 Getting Started ................................................................................................ 4-1

4.04 Torch Parts Selection ...................................................................................... 4-2

4.05 Cut Quality ...................................................................................................... 4-2

4.06 General Cutting Information ............................................................................ 4-3

4.07 Hand Torch Operation ..................................................................................... 4-4

4.08 Machine Torch Operation ................................................................................ 4-7

4.09 Recommended Cutting Speeds ....................................................................... 4-8

4.10 Gouging .......................................................................................................... 4-8

SECTION 5:

SERVICE ............................................................................................... 5-1

5.01 Introduction .................................................................................................... 5-1

5.02 General Torch Maintenance ............................................................................. 5-1

5.03 Common Operating Faults .............................................................................. 5-2

5.04 Inspection and Replacement of Consumable Torch Parts ............................... 5-3

5.05 Troubleshooting Guide .................................................................................... 5-4

TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS ......................................................................................... 6-1

6.01 Introduction .................................................................................................... 6-1

6.02 Ordering Information ...................................................................................... 6-1

6.03 Replacement Parts for Hand Torch ................................................................ 6-2

6.04 Replacement Parts - for Machine Torches with Unshielded Leads .................. 6-4

6.05 Replacement Shielded Machine Torch Leads Assemblies .............................. 6-6

6.06 Hand Torch Consumables .............................................................................. 6-8

6.07 Hand Torch Spare Parts Kits ........................................................................... 6-8

6.08 Machine Torch Consumables ....................................................................... 6-10

6.09 Machine Torch Spare Parts Kits .................................................................... 6-10

6.10 Automated Torch Consumables .................................................................... 6-12

6.11 Automated Torch Spare Parts Kits ................................................................ 6-12

6.12 Complete Assembly Replacement ................................................................ 6-14

6.13 Options & Accessories .................................................................................. 6-15

PATENT INFORMATION ...................................................................................6-16

APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM .................. A-1

APPENDIX 2: GENERAL APPLICATION NOTES ......................................................... A-3

APPENDIX 3A: CUTMASTER 50 & CUTMASTER 51 SYSTEM DATA (HAND TORCH) ............. A-4

APPENDIX 3B: CUTMASTER 50 & CUTMASTER 51 SYSTEM DATA (MACHINE TORCH) ........ A-6

APPENDIX 4A: CUTMASTER 75 & CUTMASTER 81 SYSTEM DATA (HAND TORCH) ............. A-8

APPENDIX 4B: CUTMASTER 75 & CUTMASTER 81 SYSTEM DATA (MACHINE TORCH) .......A-10

APPENDIX 5: CUTMASTER 100 & 101 SYSTEM DATA (HAND and MACHINE TORCH) ..........A-12

APPENDIX 6: CUTMASTER 151 SYSTEM DATA (HAND and MACHINE TORCH) ..................A-14

APPENDIX 7A: PAKMASTER 50XL PLUS SYSTEM DATA (HAND TORCH) .........................A-16

APPENDIX 7B: PAKMASTER 50XL PLUS SYSTEM DATA (MACHINE TORCH) ....................A-18

APPENDIX 8A: PAKMASTER 75XL PLUS SYSTEM DATA (HAND TORCH) .........................A-20

APPENDIX 8B: PAKMASTER 75XL PLUS SYSTEM DATA (MACHINE TORCH) ....................A-22

APPENDIX 9: PAKMASTER 100XL PLUS SYSTEM DATA (MACHINE TORCH) ....................A-24

APPENDIX 10: HAND TORCH WIRING DIAGRAMS ...................................................A-26

APPENDIX 11: MECHANIZED TORCH WIRING DIAGRAMS .........................................A-27

APPENDIX 12: AUTOMATED TORCH WIRING DIAGRAMS ..........................................A-28

APPENDIX 13: ATC ADAPTER PINOUT DIAGRAM ....................................................A-29

Rear Cover

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 infor mation which requires additional emphasis or is helpful in efﬁcient operation of the system.

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:

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 pacemak ers, 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 1-603-298-5711 or your local distributor if you have any questions.

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.

Manual 0-2962 1-1 GENERAL INFORMATION

• Nevertouchanypartsthatareelectrically“live”or “hot.”

• 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

• 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.

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Besurethereisnocombustibleorammablematerial in the workplace. Any material that cannot be removed must be protected.

• Ventilateallammableorexplosivevaporsfromthe

workplace.

• Donotcutorweldoncontainersthatmayhaveheld

combustibles.

• Provideare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 aluminum 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

• 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.

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.

GENERAL INFORMATION 1-2 Manual 0-2962

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

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT- TING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

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

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

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ammability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 as-

sociated accessories.

* Extensive product design veriﬁcation is conducted at the manufacturing facility as part of the routine design and manu-

facturing 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

victor Europe

Europa Building

Chorley N Industrial Park

Operations Director

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

Australia Terms of Warranty – 2012

Effective 1st January 2012, all warranties against defects (also known as a manufacturer’s warranty) supplied with goods or services must comply with the new Australian consumer law regulations (2010).

This Warranty Statement should be read in conjunction with the Warranty Schedule contained in the operating instructions of the product. This schedule contains the warranty period applicable to the product

Any claim under this warranty must be made within the warranty period which commences on the date of purchase of the product. To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Accredited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.

All costs associated with lodging the warranty claim including the return of goods to Cigweld or our Nominated Accredited Distributor/Accredited Service Provider are the responsibility of the consumer.

This warranty is given. Cigweld Pty Ltd A.B.N. 56007226815 71 Gower Street, Preston Victoria, Australia, 3072 Phone: 1300 654 674 Email: enquiries@thermadyne.com.au Website: www.cigweld.com.au

This warranty is provided in addition to other rights and remedies you have under law: Our goods come with guarantees which cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund for a major failure and to compensation for other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Failures due to incorrect use are not covered by this warranty and consumers are reminded to only use the product in accordance with the Operating Instruction supplied with the product. Additional copies of Operating Instructions are available from Cigweld Customer Care 1300 654 674 or the Website.

GENERAL INFORMATION 1-6 Manual 0-2962

SECTION 2:

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

Art # A-03322_AB

Art # A-02998

1.75" /

44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" / 16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm

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owsthroughthesmalloriceinthetorchtip,which

is focused on the metal to be cut.

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.

2. Machine Torch, Model SL100

The standard machine torch has a positioning tube with rack & pinch block assembly.

A single torch lead provides gas from a single source to be

usedasboththeplasmaandsecondarygas.Theairow

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.

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

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

SL60 and SL100 Torch Gas Specification

Combination of ambient air and gas stream through torch.

F. Torch Ratings

SL60 Torch Ratin

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

Ambient

erature

Tem

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

)

peak

SL100 Torch Ratin

)

peak

100% @ 60 Amps @ 400 scfh

100% @ 100 Amps @ 400 scfh

104° F

40° C

60 Amps

500V

7kV

104° F

40° C

100 Amps

500V

7kV

G. Current Ratings

Current Rating

SL60 Torch & Leads

SL100 Torch & Leads

Up to 60 Amps, DC, Straight Polarity Up to 100 Amps, DC, Straight Polarity

H. Gas Requirements

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

Maximum Input Pressure

Gas Flow (Cutting and Gouging)

WARNING

60 - 75 psi

4.1 - 5.2 bar

125 psi / 8.6

bar

300 - 500 scfh

142 - 235 lpm

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.

I. Direct Contact Hazard

For exposed tip the recommended standoff is 3/16 inches / 4.7 mm.

J. Plasma Power Supply Used With

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 at more than 100 Amps.

NOTE

Power Supply characteristics will determine material thickness range.

• CutMaster50

• CutMaster51

• CutMaster75

• CutMaster81

• CutMaster100

• CutMaster101

• CutMaster151

• PakMaster50XLPlus

• PakMaster75XLPlus

• PakMaster100XLPlus

NOTE

Refer to the Appendix Pages for additional speciﬁcations as related to the Power Supply used.

INTRODUCTION 2-2 Manual 0-2962

2.04 Options And Accessories

A-00002

Workpiece

Power

Supply

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.

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.

• LeadsExtensionsfortorcheswithATCconnectors

• LeatherLeadsCovers

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.

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.

Manual 0-2962 2-3 INTRODUCTION

B. Gas Distribution

A-02997

Torch Trigger

PIP Switch

Shield Cup

To Control

Cable Wiring

Torch Switch

A-03504

PIP Switch

Shield Cup

To Control

Cable Wiring

The single gas used is internally split into plasma and secondary gases.

The plasma gas ows into the torch through the

negative lead, through the starter cartridge, around the electrode, and out through the tip oriﬁce.

Thesecondarygasows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.

Parts - In - Place Circuit Diagram for Hand Torch

Parts - In - Place Circuit Diagram for Machine Torch

INTRODUCTION 2-4 Manual 0-2962

SECTION 3:

A-02585

Workpiece

Square

Pinch Block Assembly

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.

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.

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

Thru-Hole Protector

Nut

Thru-Hole Protector

Torch Leads

Assembly or ATC Adapter

Art # A-03875

Negative / Plasma Lead

Pilot Lead

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 Con-

nectors

C. Mechanized Machine Torch Systems with O2B Con-

nectors

D. Remote Pendant Control (Optional)

E. Automated Machine Torch Systems with ATC Connec-

tors

F. Automated Machine Torch Systems with O2B Connec-

tors

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.

INSTALLATION 3-2 Manual 0-2962

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.

3. Secure the Through - Hole protector with the retain-

Adapter

Plug

Pilot Lead

Torch Leads Assembly or

ATC Adapter

Negative/Plasma

Lead

Adapter

Connector

Pilot Lead Stud

Negative/Plasma Lead

Connection

A-03527

Control Circuit

Connectors

Note: Actual Bulkhead configuration may differ from that shown.

A-03627

ATC Male Connector

ATC Adapter Female Receptacle

Torch Leads

Power Supply

Control Cable Connector (Machine Torches Only)

ATC Male Connector

ATC Female Receptacle (Panel Mounted)

A-03602

ing nut removed earlier.

4. Connect the torch leads or ATC Adapter Negative / Plasma Lead to the bulkhead connection inside the Power Supply as shown.

Bulkhead Connections - ATC Adapter or Hand Torch

Leads with O2B Fittings

Torch Connection - Torch Leads with ATC Male

Connector, Power Supply with ATC Adapter

Manual 0-2962 3-3 INSTALLATION

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.

7. Connect the pilot lead terminal to the stud and secure with the nut and washer removed in the above Step.

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. 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 connection.

Torch Connection - Torch Leads with ATC Male

Connector, Power Supply with Panel-Mounted ATC

Receptacle

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.

B. Mechanized Machine Torch Systems - Torches

Thru-Hole Protector

Nut

Thru-Hole Protector

Torch Leads

Assembly or ATC Adapter

Art # A-03875

Negative / Plasma Lead

Pilot Lead

Adapter

Plug

Pilot Lead

Torch Leads Assembly or

ATC Adapter

Negative/Plasma

Lead

Adapter

Connector

Pilot Lead Stud

Negative/Plasma Lead

Connection

A-03527

Control Circuit

Connectors

Note: Actual Bulkhead configuration may differ from that shown.

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.

1. Remove the Through - Hole protector Nut from the Through - Hole protector.

5. Connect the Control Circuit Connectors on the ATC Adapter to the mating connectors on the Power Supply Adapter.

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.

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.

3. Connect the ATC Adapter as follows:

a. Feed the end of the adapter lead and the

b. Tighten the Through - Hole protector Nut to

4. Connect the Adapter Negative / Plasma Lead to the bulkhead connection inside the Power Supply.

Through - Hole protector into the hole in the unit

secure the Through - Hole protector to the Power Supply.

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.

INSTALLATION 3-4 Manual 0-2962

10. Connect the remote pendant adapter to the Remote

A-03582

Control Cable Connector (Machine Torches Only)

ATC Male Connector

ATC Adapter Female Receptacle

Torch Leads

Power Supply

Control Cable Connector (Machine Torches Only)

ATC Male Connector

ATC Female Receptacle (Panel Mounted)

A-03602

Through - Hole

Protector Nut

Through - Hole

Protector

Torch Leads

Assembly or ATC Adapter

Art # A-03877

Remove Tie Wrap, Remove Insulator, Disconnect Wires

Pilot Lead

Control Cable Connector.

Torch Connection - Torch Leads with ATC Male

Connector, Power Supply with ATC Adapter

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.

1. Remove the Through - Hole protector Nut from the Through - Hole protector.

Connector, Power Supply with Panel-Mounted ATC

11. Check the torch for proper consumable parts.

Torch Connection - Torch Leads with ATC Male

Receptacle

The torch parts must correspond with the type of operation. Refer to Section 4.04, Torch Parts

CAUTION

Selection.

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 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.

5. Connect the Negative / Plasma lead to the bulkhead connection inside the power supply.

Manual 0-2962 3-5 INSTALLATION

6. Connect the control circuit connectors on the Torch

A-03675

Torch Lead

Assembly

Control Circuit

Connectors

Open

Power Supply

Adapter

Pilot LeadNegative/Plasma

Lead

Adapter

Connector

Pilot Lead Stud

Negative/Plasma

Lead Connection

Note: Actual Bulkhead configuration may differ from that shown.

Remote Pendant

Adapter Wire Harness

Remote Pendant

Adapter Wire

Harness

A-03676

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Control Circuit

Connectors

Open

Power Supply

Adapter

Leads to the mating connectors on the Remote Pendant Adapter and Power Supply Adapter (see Warning).

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.

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.

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.

11. Connect the remote pendant to the remote pendant adapter.

12. 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.

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

Strain Relief

Nut

Strain Relief

Shielded ATC Adapter

Pilot Lead

Negative/Plasma

Lead

Torch Control

Connectors

Shield

Connector

Shield

Connector

A-03677

A-03627

ATC Male Connector

ATC Adapter Female Receptacle

Torch Leads

Power Supply

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.

WARNING

The Shielded ATC Adapter includes two connec

tors 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.

Manual 0-2962 3-7 INSTALLATION

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.

6. Connect the pilot lead terminal to the stud and secure with the nut and washer removed previously.

7. Connect the ATC Adapter connectors to the power supply adapter.

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.

F. Automated Machine Torch Systems with O2B

Adapter

Connector

Pilot Lead Stud

Strain Relief

Nut

Strain Relief

Shielded Torch Leads

with O2B Connector

Pilot Lead

Negative/Plasma

Lead

Torch Control

Connectors

Shield

Connectors

A-03678

Power Supply Bulkhead

May Differ from Type Shown

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 mois ture may cause double - arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear.

Bulkhead Connections - Shielded Machine Torch Leads

with O2B Connectors

B. Checking Air Quality

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.

INSTALLATION 3-8 Manual 0-2962

SECTION 4:

OPERATION

4.01 Introduction

This section provides a description of the SL60 and SL100 Torch Assemblies followed by operating procedures.

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ow. Iftheswitchis inRUN positiontherewillbenogasow.

F. RUN - SET - LATCH , RUN - SET or RUN - RAPID

AUTO RESTART Switch

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 informa tion 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.

A. Torch Parts

If the RUN - SET - LATCH , RUN - SET or RUN - RAPID AUTO RESTART - SET switch is in SET position, gas

willow.IftheswitchisinRUNpositiontherewill benogasow.

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

H. Pressure Settings

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 informa tion 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 posi tion where the torch switch can be released after the main arc transfer. The torch remains

activated until the main arc breaks from the workpiece.

Manual 0-2962 4-1 OPERATION

Refer to Appendix 1 for a typical detailed block

Art # A-03417

Electrode

Start Cartridge

Tip

Shield Cup Assembly

Torch Head

Kerf Width

Cut Surface Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

diagram of Sequence of Operation.

3. Install the replacement Electrode by pushing it straight into the torch head until it clicks.

The system is now ready for 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

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 car tridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed.

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

NOTES

Cut quality depends heavily on setup and pa rameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.

Refer to Appendix Pages for additional informa tion 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:

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.

Cut Quality Characteristics

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.

+ 60 hidden pages

Tweco SL100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual