Tweco SL100 User Manual

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Page 1

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:

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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.

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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 #: ____________________________________

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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

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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

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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

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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

Page 8

• 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

Page 9

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

Page 10

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

Page 11

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

Page 12

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

Page 13

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

Page 14

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

Page 15

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

Page 16

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

Page 17

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

Page 18

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.

Page 19

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.

Page 20

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

Page 21

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

Page 22

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

Page 23

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.

Page 24

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

Page 25

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

Page 26

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.

Page 27

C. Bevel Angle

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

A. Piloting

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.

D. Top - Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

E. Bottom Dross Buildup

Molten material which is not blown out of the cut area and resolidiﬁes on the plate. Excessive dross may require secondary cleanup operations after cutting.

F. Kerf Width

The width of the cut (or the width of material removed during the cut).

G. Top Spatter (Dross)

Top spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip whose oriﬁce has become elongated.

4.06 General Cutting Information

WARNINGS

Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.

Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life.

B. Torch Standoff

Improper standoff (the distance between the torch tip and workpiece) can adversely affect tip life as well as shield cup life. Standoff may also signiﬁcantly affect the bevel angle. Reducing standoff will generally result in a more square cut.

C. Edge Starting

For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touching) the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do

notpauseattheedgeandforcethearcto"reach"for

the edge of the metal. Establish the cutting arc as quickly as possible.

D. Direction of Cut

In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.

Frequently review the Important Safety Pre

cautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

Side Characteristics Of Cut

CAUTION

To make a square - edged cut along an inside diameter

Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

NOTE

Handle torch leads with care and protect them from damage.

of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Manual 0-2962 4-3 OPERATION

Page 28

E. Dross

A-00024_AB

Shield Cup

Torch

Standoff Distance

1/8" - 3/8" (3 - 9mm)

When dross is present on carbon steel, it is com-

monlyreferredtoaseither“highspeed,slowspeed, ortopdross”. Drosspresentontopof theplateis

normally caused by too great a torch to plate distance.

"Topdross"isnormallyveryeasytoremoveandcan oftenbewipedoffwithaweldingglove."Slowspeed dross"isnormallypresentonthebottomedgeofthe

plate. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily scrapedoff."Highspeeddross"usuallyformsanarrow bead along the bottom of the cut edge and is very difﬁcult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to

produce"slowspeeddross".Anyresultantcleanupcan

be accomplished by scraping, not grinding.

4.07 Hand Torch Operation

A. Standoff Cutting With Hand Torch

NOTE

2. Depending on the cutting operation, do one of the following:

a. For edge starts, hold the torch perpendicular

to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.

b. For standoff cutting, hold the torch 1/8 - 3/8 in

(3-9 mm) from the workpiece as shown below.

For best performance and parts life, always use the correct parts for the type of operation.

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

NOTE

The tip should never come in contact with the workpiece except during drag cutting opera

tions.

Standoff Distance

3. Hold the torch away from your body.

4. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

Trigger

Trigger Release

A-02986

5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTE

Thegaspreowandpostowareacharacter

istic of the power supply and not a function of the torch.

OPERATION 4-4 Manual 0-2962

Page 29

Art # A-03383

Tr igger

Tr igger Release

Shield Cup

Workpiece

Standoff Guide

Art # A-04034

Torch Tip

A-03539

Non-Conductive

Straight Edge Cutting Guide

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

7. Follow normal recommended cutting practices as provided in the power supply operator's manual.

NOTE

When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.

8. For a consistent standoff height from the workpiece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece.

B. Shield Cup With Straight Edge

The drag shield cup can be used with a nonconductive straight edge to make straight cuts by hand.

WARNING

The straight edge must be non - conductive.

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when cutting 3/16 inch (4.7 mm) solid metal with relatively smooth surface.

C. Drag Cutting With a Hand Torch

Drag cutting works best on metal 3/16" (4.7 mm)

thick or less.

NOTE

For best parts performance and life, always use the correct parts for the type of operation.

1. Install the drag cutting tip and set the output current to 35 amps or less.

2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

4. Keep the torch in contact with the workpiece during the cutting cycle.

5. Hold the torch away from your body.

6. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

Manual 0-2962 4-5 OPERATION

Page 30

Trigger

Art # A-03383

Tr igger

Tr igger Release

Trigger Release

A-02986

7. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTE

Thegaspreowandpostowareacharacter

istic of the power supply and not a function of the torch.

D. Piercing With Hand Torch

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement.

NOTE

The tip should never come in contact with the workpiece except during drag cutting opera tions.

2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete.

3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete.

OPERATION 4-6 Manual 0-2962

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

9. Follow normal recommended cutting practices as provided in the power supply operator's manual.

NOTE

4. Hold the torch away from your body.

5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

Trigger

Trigger Release

A-02986

6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTES

Thegaspreowandpostowareacharacter

istic of the power supply and not a function of the torch.

Page 31

7. Clean spatter and scale from the shield cup and the

A-02585

Workpiece

Square

Pinch Block Assembly

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

4.08 Machine Torch Operation

A. Cutting With Machine Torch

The machine torch can be activated by remote control pendant or by a remote interface device such as CNC.

1. Use a square to check that the torch is perpendicular to the workpiece to obtain a clean, vertical cut.

3. Trailing Arc

The trailing arc is directed in the opposite direction as torch travel.

2. To start a cut at the plate edge, position the center of the torch along the edge of the plate.

B. Travel Speed

Proper travel speed is indicated by the trail of the arc which is seen below the plate. The arc can be one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cut using air plasma on stainless or aluminum.

2. Leading Arc

The leading arc is directed in the same direction as torch travel. A ﬁve degree leading arc is generally recommended for air plasma on mild steel.

Checking Alignment

Machine Torch Operation

For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer.

Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required.

Manual 0-2962 4-7 OPERATION

Page 32

C. Piercing With Machine Torch

To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow back onto the front end of the torch.

Refer to Appendix Pages for cutting speed chart information as related to the Power Supply used.

4.10 Gouging

When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled until the arc penetrates the bottom of the plate. As motion begins, torch standoff should be reduced to the recommended 1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cut quality. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

4.09 Recommended Cutting Speeds

Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance:

• Torchpartswear

• Airquality

• Linevoltageuctuations

• Torchstandoffheight

• Properworkcableconnection

NOTES

This information represents realistic expecta tions using recommended practices and well

- maintained systems. Actual speeds may vary up to 50% from those shown.

WARNINGS

Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions at the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch is activated.

Disconnect primary power to the system be fore disassembling the torch, leads, or power supply.

CAUTIONS

Sparks from plasma gouging can cause damage to coated, painted or other surfaces such as glass, plastic, and metal.

Check torch parts. The torch parts must cor respond with the type of operation. Refer to Section 4.04, Torch Parts Selection.

A. Gouging Parameters

Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff).

B. Torch Travel Speed

NOTE

Refer to Appendix Pages for additional informa

tion as related to the Power Supply used.

Optimum torch travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch).

OPERATION 4-8 Manual 0-2962

Page 33

C. Current Setting

35°

Workpiece

Torch Head

Standoff Height

A-00941_AB

Current settings depend on torch travel speed, mode of operation (hand or machine torch), and the amount of material to be removed.

D. Lead Angle

The angle between the torch and workpiece depends on the output current setting and torch travel speed. At 80 amps, the recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.

E. Standoff Distance

The tip to work distance affects gouge quality and depth. Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows for smooth, consistent metal removal. Smaller standoff distances may result in a severance cut rather than a gouge. Standoff distances greater than 1/4 inch (6 mm) may result in minimal metal removal or loss of transferred main arc.

F. Slag Buildup

Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels, can be removed easily in most cases. Slag does not obstruct the gouging process if it accumulates to the side of the gouge path. However, slag build - up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc. The build - up is most often a result of improper travel speed, lead angle, or standoff height.

Gouging Angle and Standoff Distance

Manual 0-2962 4-9 OPERATION

Page 34

OPERATION 4-10 Manual 0-2962

Page 35

SECTION 5:

5.02 General Torch Maintenance

SERVICE

5.01 Introduction

This section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by other than properly trained personnel.

WARNINGS

Disconnect primary power at the source before disassembling the torch or torch leads.

Frequently review the Important Safety Pre cautions at the front of this Manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

CAUTION

Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

A. Cleaning Torch

Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.

CAUTION

Dry the torch thoroughly before reinstalling.

NOTE

Handle torch leads with care and protect them from damage.

Manual 0-2962 5-1 SERVICE

Page 36

B. O-Ring Lubrication

ATC Male Connector

Art #A-03791

Gas Fitting

O-Ring

5.03 Common Operating Faults

This section applies only to torches withATC connectors.

An o-ring on the Torch ATC Male Connector requires lubrication on a regular basis, depending on how frequently the torch is disconnected and re-connected. This will allow the o-ring to remain pliable and provide a proper seal. The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant is not used on a regular basis. This can lead to potential performance problems.

It is recommended to apply a very light ﬁlm of 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 ele

ments” that may react with the atmosphere. 

This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.

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

1. Insufﬁcient Penetration

a. Cutting speed too fast

b. Torch tilted too much

c. Metal too thick

d. Worn torch parts

e. Cutting current too low

f. Non - Genuine Thermal Dynamics Parts

2. Main Arc Extinguishes

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Cutting current too high

d. Work cable disconnected

e. Worn torch parts

f. Non - Genuine Thermal Dynamics Parts

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 Torch Parts Life

a. Oil or moisture in air source b. Exceeding system capability (material too thick) c. Excessive pilot arc time

d. Airowtoolow(incorrectpressure)

e. Improperly assembled torch

f. Non - Genuine Thermal Dynamics Parts

SERVICE 5-2 Manual 0-2962

Page 37

5.04 Inspection and Replacement of

Art # A-03417

Electrode

Start Cartridge

Tip

Shield Cup Assembly

Torch Head

Drag Shield Cap

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

Good Tip

Worn Tip

Lower End Fitting

Start Cartridge

Art # A-03621

Consumable Torch Parts

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.

Remove the consumable torch parts as follows:

NOTE

3. On torches with a shield cup body and a shield cap or

deector,ensurethatthecapordeectoristhreaded

snugly against the shield cup body. In shielded drag cutting operations (only), there may be an O-ring between the shield cup body and drag shield cap. Do not lubricate the O-ring.

The shield cup holds the tip and starter car

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

1. Unscrew and remove the shield cup from the torch.

NOTE

Slag built up on the shield cup that cannot be removed may effect the performance of the system.

2. Inspect the cup for damage. Wipe it clean or replace if damaged.

4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized oriﬁce). Clean or replace the tip if necessary.

Tip Wear

5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end ﬁtting for free motion. Replace if necessary.

Manual 0-2962 5-3 SERVICE

Consumable Parts

6. Pull the Electrode straight out of the Torch Head. Check the face of the electrode for excessive wear. Refer to the following ﬁgure.

Page 38

Worn Electrode

New Electrode

Art # A-03284

Troubleshooting

Lower O-Ring

Upper O-Ring in Correct Groove

Upper Groove with Vent Holes Must Remain Open

Threads

Art # A-03640

A. Torch will not pilot when torch switch is activated

1. Power Supply RUN / SET switch in SET position

a. Place RUN / SET switch to RUN position.

2. Parts - In - Place (PIP) not satisﬁed.

Electrode Wear

7. Reinstall the Electrode by pushing it straight into the

torch head until it clicks.

8. Reinstall the desired starter cartridge and tip into the

torch head.

9. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.

5.05 Troubleshooting Guide

This subsection covers troubleshooting that requires disassembly and electronic measurements. It is helpful for solving many of the common problems that can arise with this torch assembly.

How to Use This Guide

The following information is a guide to help the Customer / Operator determine the most likely causes for various symptoms.

a. Check that shield cup is properly installed.

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

a. Remove shield cup from torch; check position

of upper O-ring. Correct if necessary.

4. Faulty Torch Switch or PIP Switch

a. Check PIP switch for continuity.

5. Faulty torch parts

This guide is set up as follows:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

Locate your symptom, check the ﬁrst) then remedies. Repair as needed being sure to verify that unit is fully operational after any repairs.

a. Check / Remedy (Text Type)

causes

(easiest listed

a. Inspect torch parts and replace if necessary.

Refer to Section 5.04, Inspection and Replacement Consumable Torch Parts

6. Gas pressure too low

a. Set proper operating gas pressure.

7. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary.

8. Faulty components in power supply

a. Return for repair or have qualiﬁed technician

repair per Service Manual.

SERVICE 5-4 Manual 0-2962

Page 39

B. No cutting output

1. Torch not properly connected to power supply

a. Check that torch leads are properly attached to

power supply

2. Shield cup not properly installed on torch

a. Check that shield cup is fully seated against

torch head (do not overtighten)

3. Parts - In - Place (PIP) not satisﬁed.

a. Check that shield cup is properly installed.

a. Reduce cutting speed (refer to Appendix Page

for the Power Supply being used).

4. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3.2 mm) from clean sur-

face while purging and observe oil or moisture buildup (do not activate torch).

5. Torch tip dragged across workpiece

a. When the tip is dragged across the workpiece,

the amperage automatically cuts back to 35 amps (see Note).

b. Check switch - in hand torch handle or in ma-

chine torch head - for continuity.

4. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary.

5. Faulty components in power supply

a. Return for repair or have qualiﬁed technician

repair per Service Manual.

C. Limited output with no control

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary.

3. Faulty components in power supply

a. Return for repair or have qualiﬁed technician

repair per Service Manual.

D. Erratic or improper cutting output

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Current set too low at power supply

a. Increase current setting.

NOTE

All power supplies may not have this feature.

E. No gas ﬂow

1. Gas not connected or pressure too low

a. Check source for proper operating gas pressure

(refer to Appendix Page for Power Supply used).

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary.

3. Faulty components in power supply

a. Return for repair or have qualiﬁed technician

repair per Service Manual.

F. Torch cuts but not adequately

1. Current set too low at power supply

a. Increase current setting

2. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix Page

for the Power Supply being used).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3.2 mm) from clean sur-

face while purging and observe oil or moisture buildup (do not activate torch).

3. Torch is being moved too fast across workpiece

Manual 0-2962 5-5 SERVICE

Page 40

SERVICE 5-6 Manual 0-2962

Page 41

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all replaceable components. Torch Assemblies are ﬁeld serviceable, so a complete breakdown of parts is provided. The parts lists are arranged as follows:

Section 6.03: Hand Torch Replacement Parts

Section 6.04: Machine Torch Replacement Parts

Section 6.05: Replacement Shielded Leads Assemblies

Section 6.06: Hand Torch Consumable Parts

Section 6.07: Hand Torch Spare Parts Kits

Section 6.08: Machine Torch Consumable Parts

Section 6.09: Machine Torch Spare Parts Kits

Section 6.10: Automated Torch Consumable Parts

Section 6.11: Automated Torch Spare Parts Kits

Section 6.12: Complete Assembly Replacements

Section 6.13: Options & Accessories

NOTE

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns

If a product must be returned for service, contact your authorized distributor. Materials returned without proper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for each type item. Also include the model and serial number of the torch. Address all inquiries to your authorized distributor.

Manual 0-2962 6-1 PARTS LISTS

Page 42

6.03 Replacement Parts for Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030

2 1 Trigger Assembly Replacement Kit 9-7034

 3 1 HandleScrewKit(5each,6-32x1/2"capscrew,andwrench)  9-8062

4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219

5 1 Large O - Ring 8-3487

6 1 Small O - Ring 8-3486

7 Leads Assemblies with O2B connectors (includes switch assemblies)

1 SL60 / 60 Amp, 20 - foot Leads Assembly with O2B connectors 4-7830

1 SL60 / 60 Amp, 50 - foot Leads Assembly with O2B connectors 4-7831

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

1 SL100 / 100 Amp, 50 - foot Leads Assembly with O2B connectors 4-7833

8 Leads Assemblies with ATC connectors (includes switch assemblies)

1 SL60 / 60 Amp, 20 - foot Leads Assembly with ATC connector 4-7834

1 SL60 / 60 Amp, 50 - foot Leads Assembly with ATC connector 4-7835

1 SL100 / 100 Amp, 20 - foot Leads Assembly with ATC connector 4-7836

1 SL100 / 100 Amp, 50 - foot Leads Assembly with ATC connector 4-7837

9 1 Switch Kit 9-7031

10 1 Torch Control Cable Adapter (includes item # 11) 7-3447

11 1 Through - Hole Protector 9-8103

PARTS LISTS 6-2 Manual 0-2962

Page 43

Requires Adapter Kit For Proper Installation

May Require ATC Adapter Kit For Proper Installation

A-03664

Manual 0-2962 6-3 PARTS LISTS

Page 44

6.04 Replacement Parts - for Machine Torches with Unshielded Leads

Item No. Qty Description Catalog No.

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220

2 1 Large O - Ring 8-3487

3 1 Small O - Ring 8-3486

4 1 PIP Switch Kit 9-7036

5 Unshielded Mechanized Leads Assemblies with O2B connectors

1 25 - foot / 7.6 m Leads Assembly with O2B connectors 4-7838*

1 50 - foot / 15.2 m Leads Assembly with O2B connectors 4-7839*

6 Unshielded Automated Leads Assemblies with ATC connectors

1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850

1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851

1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852

1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853

7 Unshielded Mechanized Leads Assemblies with ATC connectors

1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842

1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843

1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844

1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845

 8 1 11"/279mmRack  9-7041

 9 1 11"/279mmMountingTube  9-7043

10 1 End Cap Assembly 9-7044

11 2 Body, Mounting, Pinch Block 9-4513

12 1 Pin, Mounting, Pinch Block 9-4521

13 1 Torch Holder Sleeve 7-2896

14 1 PIP Plunger and Return Spring Kit 9-7045

15 1 Torch Control Cable Adapter for Unshielded Leads (includes item # 16) 7-3447

16 1 Through - Hole Protector 9-8103

1 Pinion Assembly (Not shown) 7-2827

  1 5"/126mmPositioningTube(Notshown)  9-7042

NOTE

* Does not include Control Cable Adapter or Through - Hole Protector.

Refer to Section 6.05 for Replacement Shielded Leads As

semblies.

PARTS LISTS 6-4 Manual 0-2962

Page 45

A-03665

May Require ATC Adapter Kit For Proper Installation

Requires Adapter Kit For Proper Installation

May Require ATC Adapter Kit For Proper Installation

Manual 0-2962 6-5 PARTS LISTS

Page 46

6.05 Replacement Shielded Machine Torch Leads Assemblies

Item No. Qty Description Catalog No.

1 Mechanized Shielded Leads Assemblies with ATC Connectors

1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846

1 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847

1 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848

1 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849

2 Shielded Leads Assemblies with O2B Connectors

1 25 - foot / 7.6 m Leads Assembly with O2B Connector 4-7840

1 50 - foot / 15.2 m Leads Assembly with O2B Connector 4-7841

3 Negative / Plasma Lead

1 25 - foot / 7.6 m Length 9-7969

1 50 - foot / 15.2 m Length 9-7974

4 Shield Lead

1 25 - foot / 7.6 m Length 9-7979

1 50 - foot / 15.2 m Length 9-7980

5 PIP Lead

1 25 - foot / 7.6 m Length 9-7977 *

1 50 - foot / 15.2 m Length 9-7978 *

6 Pilot Lead, 25 - foot / 7.6 m Length

1 25 - foot / 7.6 m Length 9-7975

1 50 - foot / 15.2 m Length 9-7976

7 1 Power Supply Adapter for Shielded Leads (not shown) 7-3479

NOTE

*Does not include Torch continuity (PIP) Switch.

PARTS LISTS 6-6 Manual 0-2962

Page 47

Art #A-03616

Torch Continuity ('PIP') Switch

Torch Connection Fitting

Torch Continuity ('PIP') Switch

Adapter Wire

Manual 0-2962 6-7 PARTS LISTS

Page 48

6.06 Hand Torch Consumables

The illustration shows all consumable parts for the SL60 and SL100 hand torches. Refer to the Appendix pages covering the power supply being used to ensure proper selection for the application.

Various front - end torch parts are available for different applications.

Use the single - piece shield cup for general purpose cutting operations with the torch tip in contact with the work (up to 40 amps). This is the preferred method of cutting

sheetmetalupto3/16"or4.8mmthick.

Also use the single - piece Shield Cup for 'standoff' cut-

ting(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.

6.07 Hand Torch Spare Parts Kits

The Standoff Guide ﬁts Shield Cup No. 9-8218 and enables the user to maintain a consistent standoff height for most applications.

UsetheShieldCupBodywiththeDeectorShieldCapfor extendedpartslifeandimprovedresistancetoreected

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.

Use the Shield Cup Body with the Drag Shield Cap for a consistent standoff distance with the drag shield in contact with the workpiece. This is a simple and operator-friendly method of cutting between 50 and 100 amps.

Use the Shield Cup Body with the Gouging Shield Cap for excellent gouging performance and enhanced torch parts life.

The electrode and starter cartridge are the same for all operations.

Hand Torch Spare Parts Kit Contents

Catalog No.

Item

Electrode9-82153 333

40A Drag Tip9-82075 222

40A Standoff Ti p9-82082

Large O-Ring 8-3487 11

Small O-Ring 8-3486 11

Standoff Guide9-8251 1

40-Amp Kit,

Cat No.

5-0050

60-Amp Kit,

Cat No.

5-0075

50128-9piT ffodnatS A06

15328-9A06-05 ,paC dleihS garD

80-Amp Kit,

Cat No.

5-0110

51128-9piT ffodnatS A08

100-Amp Kit,

Cat No.

5-0170

52128-9piT ffodnatS A001

1117328-9ydoB puC dleihS

116328-9A001-07 ,paC dleihS garD

1111828-9ediuG ffodnatS

PARTS LISTS 6-8 Manual 0-2962

Page 49

Hand Torch Consumables Selection

Start

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:

DRAG TIP

CUTTING

40-100A

GOUGING

CUTTING

Art # A-03662

DRAG SHIELD

CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8281

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Standoff Guide

9-8281

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

9-8251

Gouging Profiles

Tip A40 Amps Max. ShallowNarrow Tip B40-100 Amps Deep Narrow

Manual 0-2962 6-9 PARTS LISTS

Tip C40-100 Amps ModerateModerate Tip D40-100 Amps Shallo

Output RangeDepth Width

ide

Page 50

6.08 Machine Torch Consumables

Automation Torch Spare Parts Kit Contents

The illustration shows all consumable parts for the SL100 machine torches. Refer to the Appendix pages covering the power supply being used to ensure proper selection for the application.

Various front - end torch parts are available for different applications.

Use the single - piece Shield Cup for 'standoff' cutting (with

thetorchtip1/8"to1/4"fromtheworkpiece).Thisisthe

preferredmethodforcuttingmetalthickerthan3/16"/4.8

mm and at current levels above 40 amps. This provides

UsetheShieldCupBodywiththeDeectorShieldCapfor extendedpartslifeand improvedresistancetoreected

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.

Use the Shield Cup Body with the Gouging Shield Cap for excellent gouging performance and enhanced torch parts life.

The electrode and starter cartridge are the same for all operations.

maximum visibility and accessibility.

6.09 Machine Torch Spare Parts Kits

Catalog No.

Item

30A Standoff Ti p9-8206 55

40A Standoff Ti p9-8208 55

Shield Cup Body 9-8237 11

Shield Cap, Deflector9-8243 11

Shield Cap, Machine, 40A 9-8245 11

Large O-Ring 8-3487 11

Small O-Ring 8-3486 1111

Start Cartridge9-82131 111 Ohmic Clip Kit9-8224 11

40-Amp Kit,

Cat No.

5-0054

60-Amp Kit,

Cat No.

5-0079

80-Amp Kit,

Cat No.

5-0122

100-Amp Kit,

Cat No.

5-0174

33335128-9edortcelE

5550128-9piT ffodnatS A06

551128-9piT ffodnatS A08

52128-9piT ffodnatS A001

1118328-9A06 ,enihcaM ,paC dleihS

11 9328-9A001-07 ,enihcaM ,paC dleihS

PARTS LISTS 6-10 Manual 0-2962

Page 51

Machine Torch Consumables Selection

Starter

Cartridge

9-8213

Electrode

9-8215

Shield Cap, Deflector

9-8243

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 Cup, Gouging

9-8241

Shield Cap, Machine

40A 9-8245

20A 9-8205 30A 9-8206 40A 9-8208

Shield

Cup Body,

9-8237

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

Shield Cup

9-8218

Shield

Cup Body,

9-8237

50-60A

Tip:

Tips:

40-100A

GOUGING

CUTTING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine

50-60A 9-8238

Shield Cap, Machine

70-100A 9-8239

Art # A-03663

STANDOFF

CUTTING

STANDOFF

70-100A

CUTTING

STANDOFF

20-40A

Shield Cap, Deflector

9-8243

Ohmic Clip

9-8224

Tip A40 Amps Max. ShallowNarrow Tip B40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Gouging Profiles

Output RangeDepth Width

ide

Manual 0-2962 6-11 PARTS LISTS

Page 52

6.10 Automated Torch Consumables

The illustration shows all consumable parts for the SL100 automated torch. Refer to the Appendix pages covering the power supply being used to ensure proper selection for the application.

Use the Shield Cup Body with the Gouging Shield Cap for excellent gouging performance and enhanced torch parts life.

The electrode and starter cartridge are the same for all

operations. Various front - end torch parts are available for different applications.

The Shield Cup Body with the Deector Shield Cap

provides extended parts life and improved resistance to

reectedheat.Thiscombinationprovideseasychange-

over to gouging or drag shield cutting.

6.11 Automated Torch Spare Parts Kits

Automation Torch Spare Parts Kit Contents

Catalog No.

Item

30A Standoff Ti p9-8206 55

40A Standoff Ti p9-8208 55

Shield Cup Body 9-8237 11

Shield Cap, Deflector9-8243 11

Shield Cap, Machine, 40A 9-8245 11

Large O-Ring 8-3487 11

Small O-Ring 8-3486 1111

Start Cartridge9-82131 111 Ohmic Clip Kit9-8224 11

40-Amp Kit,

Cat No.

5-0054

60-Amp Kit,

Cat No.

5-0079

80-Amp Kit,

Cat No.

5-0122

100-Amp Kit,

Cat No.

5-0174

33335128-9edortcelE

5550128-9piT ffodnatS A06

551128-9piT ffodnatS A08

52128-9piT ffodnatS A001

1118328-9A06 ,enihcaM ,paC dleihS

11 9328-9A001-07 ,enihcaM ,paC dleihS

PARTS LISTS 6-12 Manual 0-2962

Page 53

Automated Torch Consumables Selection

Starter

Cartridge

9-8213

Electrode

9-8215

Shield Cap, Deflector

9-8243

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 Cup, Gouging

9-8241

Shield Cap, Machine

40A 9-8245

20A 9-8205 30A 9-8206 40A 9-8208

Shield

Cup Body,

9-8237

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

Shield Cup

9-8218

Shield

Cup Body,

9-8237

50-60A

Tip:

Tips:

40-100A

GOUGING

CUTTING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine

50-60A 9-8238

Shield Cap, Machine

70-100A 9-8239

Art # A-03663

STANDOFF

CUTTING

STANDOFF

70-100A

CUTTING

STANDOFF

20-40A

Shield Cap, Deflector

9-8243

Ohmic Clip

9-8224

Gouging Profiles

Tip A40 Amps Max. ShallowNarrow Tip B40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Output RangeDepth Width

ide

Manual 0-2962 6-13 PARTS LISTS

Page 54

6.12 Complete Assembly Replacement

NOTE

The Complete Torch & Leads Assembly Replacement does not include the Torch Control Cable Adapter.

Description Catalog #

60 - Amp Hand Torch and Leads Assemblies:

SL60 Hand Torch and 20 foot / 6.1 m Leads, with O2B Connector 7-5200

SL60 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5201

SL60 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector 7-5204

SL60 Hand Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5205

100 - Amp Hand Torch and Leads Assemblies:

SL100 Hand Torch and 20 foot / 6.1 m Leads, with O2B Connector 7-5202

SL100 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5203

SL100 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector 7-5206

SL100 Hand Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5208

100 - Amp Machine Torch and Leads Assemblies, Unshielded Leads:

SL100 Machine Torch and 25 foot / 7.6 m Leads, with O2B Connector 7-5209

SL100 Machine Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5210

SL100 Machine Torch and 5 foot / 1.5 m Leads, with ATC Connector 7-5213

SL100 Machine Torch and 10 foot / 3.05 m Leads, with ATC Connector 7-5214

SL100 Machine Torch and 25 foot / 7.6 m Leads, with ATC Connector 7-5215

SL100 Machine Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5216

100 - Amp Machine Torch and Leads Assemblies, Shielded Leads

SL100 Machine Torch and 25 foot / 7.6 m Leads, with O2B Connector 7-5211

SL100 Machine Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5212

SL100 Machine Torch and 5 foot / 1.5 m Leads, with ATC Connector 7-5219

SL100 Machine Torch and 10 foot / 3 m Leads, with ATC Connector 7-5220

SL100 Machine Torch and 25 foot / 7.6 m Leads, with ATC Connector 7-5221

SL100 Machine Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5222

PARTS LISTS 6-14 Manual 0-2962

Page 55

6.13 Options & Accessories

Qty Description Catalog #

1 ATC Adapter Kit, Unshielded 7-5207

1 ATC Adapter Kit, Shielded 7-3472

1 Unshielded Leads extensions with ATC connectors, 15 - foot / 4.6 m length 7-7544

1 Unshielded Leads extensions with ATC connectors, 25 - foot / 7.6 m length 7-7545

1 Unshielded Leads extensions with ATC connectors, 50 - foot / 15.2 m length 7-7552

1 Shielded Leads extensions with ATC connectors, 25 - foot / 7.6 m length 4-7854

1 Shielded Leads extensions with ATC connectors, 50 - foot / 15.2 m length 4-7855

1 Deluxe Cutting Guide Kit 7-8910

1 Radius / Roller Cutting Guide Kit 7-7501

1 Circle Cutting Guide Kit 7-3291

1 Remote Hand Pendant Control with 20 ft. Cable 7-3460

1 Hand Pendant Extension - 25 ft 7-7744

1 Computer Control (CNC) Cable

25 Foot / 7.6 m length 8-5557

50 Foot / 15.2 m length 8-5558

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

1 Leather Leads Cover, 25 foot / 7.6 m 9-1270

1 Leather Leads Cover, 50 foot / 15.2 m 9-1280

1 Ohmic Clip Kit (for Automated Applications only) 9-8224

Manual 0-2962 6-15 PARTS LISTS

Page 56

PATENT INFORMATION

The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512

Catalog Number Description

9-8235 Shield Cap, Drag 50-60A 9-8236 Sheild Cap, Drag 70-100A

9-8237 Shield Cup, Body 9-8238 Shield Cap, Machine 50-60A 9-8239 Shield Cap, Machine 70-100A 9-8244 Shield Cap, Drag 40A 9-8245 Shield Cap, Machine 40A

PARTS LISTS 6-16 Manual 0-2962

Page 57

APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK

ACTION

ON/OFF-Switch to OFF.

RESULT

All indicators OFF.

Power supply fan(s) off.

ACTION

Mode Switch* to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved within

transfer distance of workpiece.

RESULT

Main arc transfers.

Pilot arc off.

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

Main Arc stops.

(Power supply enable signal removed.)

Gas flows briefly.

NOTE - If torch is activated during

post-flow, pilot arc will immediately restart.

If torch is within transfer distance (3/8 in) of

workpiece, main arc will transfer.

After post-flow:

Gas solenoid closes, gas flow stops.

GAS indicator off.

ACTION

Open external

disconnect switch.

RESULT

No power to system.

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Mode Switch* to SET.

RESULT

Gas Solenoid open, gas

flows to set pressure.

GAS indicator ON.

ACTION

Torch moved away

from work (while still

activated)

RESULT

Main arc stops.

Pilot arc automatically

restarts.

PILOT ARC

ACTION

ON/OFF-Switch to ON.

RESULT

AC indicator blinks for 8

seconds, then steady on.

Fans on.

Power circuit ready.

ACTION

Protect eyes and

activate torch.

RESULT

Gas flows

(2 seconds)

After gas pre-flow:

DC indicator ON.

Pilot relay closes.

Pilot arc established.

Art # A-03779

LATCH

* Mode switch settings in PakMaster Series are RUN / SET / LATCH. * Mode switch settings in CutMaster 50, CutMaster 75 and CutMaster 100 are RUN / SET. * Mode switch settings in CutMaster 51, CutMaster 81 and CutMaster 101 are RUN / RAPID AUTO RESTART / SET.

To rch switch

can be released.

RESULT

Transfer will continue

until torch is removed

from workpiece.

ACTION

DIAGRAM

Manual 0-2962 A-1 APPENDIX

Page 58

This page intentionally blank

APPENDIX A-2 Manual 0-2962

Page 59

APPENDIX 2: GENERAL APPLICATION NOTES

Material Thickness

Speed

Machine Cutting

Speeds

Hand Cutting Speeds

(Shaded Area)

A-02947

A. Hand Cutting Versus Machine (Mechanized) Cutting Speeds

Hand cutting speeds can be much less than those obtained from Machine (Mechanized) Type applications. Hand cutting application speeds mostly depend on operator experience. The cut quality obtained at slower speeds for a Hand application is just as good as those obtained from a Machine application. As the cut speeds increase or decrease from the Machine applications the following may occur:

• Ifcutspeedistoofastthecutmayexhibitoneormoreofthefollowing:InsufcientPenetration,HighSpeed

Dross, Poor Consumable Life, Excessive Bevel Angle.

• Ifcutspeedistooslowthecutmayexhibitoneormoreofthefollowing:MainArcExtinguishes,SlowSpeed

Dross, Wandering (Unstable) Arc, Poor Consumable Life.

Manual 0-2962 A-3 APPENDIX

Page 60

APPENDIX 3A: CUTMASTER 50 & CUTMASTER 51 SYSTEM DATA

(HAND TORCH)

Torch Specifications For

CutMaste r 50 & CutMaster 51 Power Supplies

Cutting Range

Material Mild Steel

Genuine Cut:

Up to 1/2 inch - 12.7 mm

Speed12-14 ipm / 0.3 - 0.36 mpm

Pierce Ra ting

Material Mild Steel

Thickness:

Hand Cutting1/2 inch - 12.7 mm

Machine Cutting1/4 inch - 6.4 mm

Transfer Dist ance Gouging

Width3/16 inch - 4.8 mm Depth1/8 inch - 3.2 mm

Number PassesSingle

Speed20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees0° to 45°

Material Thickness3/8 inch - 9.5 mm

Gas Requirement

Type GasAir

Operating Pressure 75 ps i / 5.2 bar

Max Input Pressure 125 psi / 8.6 bar

Total Flow Rate:

Cutting350 scfh / 165 lpm

Gouging230 scfh / 109 lpm

3/8 inch - 9.5 mm

Cut Quality on Various Materials and Thicknesses

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMater ialGas Char acteristics

Gage

1/2 inch

( 12.7 mm )

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip

oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

Gouging Profiles

Output

Range Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Dept

idth

ide

SL60 - SL100 Hand Torch Consumables for 40-Amp Power Supply

ApplicationElectrode

Drag Cutting9-82159-8213 9-8207 (40A)NoneNone9-8218

9-8215 9-8213 9-8208 (40A)NoneNone9-8218

Standoff Cutting

9-8215 9-8213 9-8208 (40A)9-8237

Gouging9-82159-8213

Starter

Cartridge

Tip

Tip A: 9-8225 (40A Max)

Tip B: 9-8226 (40-100A) Tip C: 9-8227 (40-100A) Tip D: 9-8228 (40-100A)

APPENDIX A-4 Manual 0-2962

Shield

Cup Body

9-8237 9-8241 None

Shield Cap

or Deflector

9-8244 or

9-8243

Shield Cup

None

Page 61

Cutting Speed Charts

00 94

00 94 94

00 94

Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51

Type Torch: SL60 - Drag Type Material: Aluminum

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output Volt sAmperageSpeed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-82078040300 7.62 N/AN/A 75 5.250350 00.0 16 ga 1.59-82078040275 6.99 N/AN/A 75 5.250350 00.1 10 ga 3.49-82078040751.91N/A N/A755.2 50 35000.19 4.8

7 ga 4.69-82078540551.40N/A N/A755.2 50 3500.5 0.19 4. 8 1/4 6.49-82079040401.02N/A N/A755.2 50 3500.5 0.19 4.8 3/8 9.59-8207100 40 18 0.46 N/AN/A 75 5.250350 10.2

1/2 12.7 9-8207 10040100.25N/A N/A755.2 50 3501.5 0.25 6.4

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec) Inches mm

Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51

Type Torch: SL60 - Drag Type Material: Mild Steel

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output Volt sAmperageSpeed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-82078040300 7.62 N/AN/A 75 5.250350 00.0 16 ga 1.59-82078040275 6.99 N/AN/A 75 5.250350 00.1 10 ga 3.49-82078040105 2.67 N/AN/A 75 5.250350 00.1

7 ga 4.69-82078540701.78N/A N/A755.2 50 3500.5 0.19 4. 8 1/4 6.49-82079040390.99N/A N/A755.2 50 3500.5 0.19 4.8 3/8 9.59-8207100 40 20 0.51 N/AN/A 75 5.250350 10.2

1/2 12.7 9-8207 10040100.25N/A N/A755.2 50 3501.5 0.25 6.4

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec) Inches mm

.0 .8

.0 .8 .8

Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51

Type Torch: SL60 - Drag Type Material: Stainless Steel

Thickness TipOutput VoltsAmp erageSpeed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-82078040300 7.62 N/AN/A 75 5.250350 00.0 16 ga 1.59-82078040275 6.99 N/AN/A 75 5.250350 00.1 10 ga 3.49-82078040751.91N/A N/A755.2 50 35000.19 4.8

7 ga 4.69-82078540551.40N/A N/A755.2 50 3500.5 0.19 4.8 1/4 6.49-82079040401.02N/A N/A755.2 50 3500.5 0.19 4.8 3/8 9.59-8207100 40 18 0.46 N/AN/A 75 5.250350 10.2

1/2 12.7 9-8207100 40 10 0.25 N/AN/A 75 5.250350 1.50.2

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi* barPlasma Total** Delay (Sec) Inches mm

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 85 psi / 5.9 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-5 APPENDIX

.0 .8

Page 62

APPENDIX 3B: CUTMASTER 50 & CUTMASTER 51 SYSTEM DATA

Gouging Profiles

(MACHINE TORCH)

Torch Specifications For

CutMaste r 50 & CutMaster 51 Power Supplies

Cutting Range

Material Mild Steel

Genuine Cut:

Up to 1/2 inch - 12.7 mm

Speed 12-14 ipm / 0.3 - 0.36 mpm

Pierce Ra ting

Material Mild Steel

Thickness:

Hand Cutting1/2 inch - 12.7 mm

Machine Cutting1/4 inch - 6.4 mm

Transfer Di stance Gouging

Width3/16 inch - 4.8 mm Depth1/8 inch - 3.2 mm

Number Passes Single

Speed 20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees0° to 45°

Material Thickness3/8 inch - 9.5 mm

Gas Requirement

Ty pe GasAir

3/8 inch - 9.5 mm

Cut Quality on Various Materials and Thicknesses

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMater ialGas Char acteristics

Gage

1/2 inch

( 12.7 mm )

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2

x tip oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2

x tip oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

Operating Pressure 65 psi / 4.5 bar

Max Input Pressure 125 psi / 8.6 bar

Total Flow Rate:

Cutting 350 scfh / 165 lpm

Gouging230 scfh / 109 lpm

SL100 Machine Torch Consumables for 40-Amp Power Supply

ApplicationElectrode

9-82159-82139-8208 (40A)NoneNone 9-8218

Standoff Cutting

9-82159-82139-8208 (40A)9-8237

Gouging9-8215 9-8213

Starter

Cartridge

Tip A: 9-8225 (40 A Max)

Tip B: 9-8226 (40-100 A) Tip C: 9-8227 (40-100 A) Tip D: 9-8228 (40-100 A)

Output

Range Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Tip

Shield

Cup Body

9-8237 9-8241 None

Dept

Shield Cap

or Deflector

9-8245 or

9-8243

idth

ide

Shield Cup

None

APPENDIX A-6 Manual 0-2962

Page 63

Cutting Speed Charts

Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51

munimulA :lairetaM epyT 001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput VoltsAmp erageSpeed (Per Minute) Standoff Plasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.89-82089040350 8.89 0.19 4.8654.5 50 35000.19 4.8 16 ga 1.39-82089440275 6.99 0.19 4.8654.5 50 35000.19 4.8 10 ga 2.69-8208105 40 1002.540.194.8 65 4.550350 00.1

7 ga 3.79-8208100 40 70 1.78 0.19 4.8654.5 50 35000.19 4.8 1/4 6.49-8208107 40 40 1.02 0.19 4.8654.5 50 3500.5 0.19 4.8 3/8 9.59-8208114 40 18 0.46 0.19 4.8654.5 50 3500.5 0.19 4.8

1/2 12.79-8208121 40 10 0.25 0.19 4.8654.5 50 35010.19 4.8

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total** Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51

leetS dliM :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput VoltsAmp erageSpeed (Per Minute) Standoff Plasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-82089040300 7.62 0.13 3.2654.5 50 35000.19 4.8 16 ga 1.59-82089040275 6.99 0.13 3.2654.5 50 35000.19 4.8 10 ga 3.49-82089040115 2.92 0.13 3.2654.5 50 35000.19 4.8

7 ga 4.69-82089540751.910.133.2 65 4.550350 0.50.1 1/4 6.49-8208110 40 45 1.14 0.19 4.8654.5 50 3500.5 0.19 4. 8 3/8 9.59-8208119 40 20 0.51 0.19 4.8654.5 50 35010.25 6.4

1/2 12.79-8208121 40 14 0.36 0.19 4.8654.5 50 3501.5 0.25 6.4

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total** Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51

leetS sselniatS :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput VoltsAmp erageSpeed (Per Minute) Standoff Plasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-82089540300 7.62 0.19 4.8654.5 50 35000.19 4.8 16 ga 1.59-82089540275 6.99 0.19 4.8654.5 50 35000.19 4.8 10 ga 3.59-8208100 40 75 1.91 0.19 4.8654.5 50 35000.19 4.8

7 ga 4.69-8208105 40 55 1.40 0.19 4.8654.5 50 35000.19 4.8 1/4 6.49-8208105 40 40 1.02 0.19 4.8654.5 50 3500.5 0.19 4.8 3/8 9.59-8208110 40 18 0.46 0.19 4.8654.5 50 35010.19 4.8

1/2 12.79-8208119 40 10 0.25 0.19 4.

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total** Delay (Sec)Inchesmm

8654.5 50 3501.5 0.19 4.8

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-7 APPENDIX

Page 64

APPENDIX 4A: CUTMASTER 75 & CUTMASTER 81 SYSTEM DATA

(HAND TORCH)

Torch Specifications For

CutMaster 75 & CutMaster 81 Power Supplies

Cutting Range

Material Most Metals

Up to 3/4 inch - 19 mm

Speed 11 ipm / 0.28 mpm

Pierce Ra ting

Material Carbon Steel

Thickness3/8 inch - 9.5 mm

Transfer Di stance Gouging

Width1/4 inch - 6.3 mm Depth1/8 inch - 3.2 mm

Number PassesSingle

Speed 20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees 0° to 45°

Material Thickness1/4 inch - 6.3 mm

Gas Requirement

Type GasAir

Operating Pressure 70 psi / 4.8 bar

Max Input Pressure 125 psi / 8.6 bar

Cutting & Gouging

Total Flow

3/8 inch - 9.5 mm

350 scfh / 165 lpm

Cut Quality on Various Materials and Thicknesses

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMater ialGas Char acteristics

Gage

3/4 inch

( 19 mm )

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x

tip oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

Gouging Profiles

Output

Range Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Dept

SL60 - SL100 Hand Torch Consumables for 60-Amp Power Supply

ApplicationElectrode

Drag Cutting 9-8215 9-8213 9-8207 (40A )NoneNone9-8218

9-8215 9-8213 9-8210 (60A )NoneNone9-8218

Standoff Cutting

9-8215 9-8213 9-8210 (60A )9-8237

Gouging9-82159-8213

Starter

Cartridge

Tip

Tip A: 9-8225 (40A Max)

Tip B: 9-8226 (40-100A) Tip C: 9-8227 (40-100A) Tip D: 9-8228 (40-100A)

Shield

Cup Body

9-8237 9-8241 None

Shield Cap

or De flector

9-8235 or

9-8243

Shield Cup

None

idth

ide

APPENDIX A-8 Manual 0-2962

Page 65

Cutting Speed Charts

94 94 94 94 94

94 94

94 94 94 94 94

Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81

munimulA :lairetaM epyT06LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output VoltsAmp erage Speed (Per Minute)StandoffPlasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

0.06 1.69-8210 95 60 3508.890.194.8 70 4.880400 00.1

0.125 3.29-8210 98 60 1754.450.194.8 70 4.880 400 00.1 1/46.4 9- 8210 10260802.030.194.8 70 4.880400 00.1 3/89.5 9- 8210 10960441.120.194.8 70 4.880400 00.1 1/2 12.79-8210 11560230.580.194.8 70 4.880400 00.1

3/4 19.19-8210 11760110.280.194.8 70 4.880 400 NR 0.19 4.8

ThicknessTip Output VoltsAmperag eSpeed (Per Minute) Standoff Plasma Gas PressFlow (SCFH) PiercePierce Height

Inches

0.06 1.69-8210 95 60 3508.890.194.8 70 4.880 400 00.1 1/83.2 9- 8210 98 60 1754.450.194.8 70 4.880 400 00.1 1/46.4 9- 8210 102 60 80 2.03 0.19 4.8704.8 80 40000.19 4.8 3/89.5 9- 8210 109 60 44 1.12 0.19 4.8704.8 80 40000.19 4.8 1/2 12. 79-8210 115 60 23 0.58 0.19 4.8704.8 80 40000.19 4.8

3/4 19.19-8210 117 60 11 0.28 0.19 4.8704.8 80 400NR0.1

(Cat. No.) (VDC) (Amp s) Inches Meters Inches mm psi* barPlasmaTotal** Delay (Sec) Inches mm

Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81

leetS dliM :lairetaM epyT06LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec)Inchesmm

.8 .8 .8 .8 .8

.8 .8

Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81

leetS sselniatS :lairetaM epyT06LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output VoltsAmp erage Speed (Per Minute)StandoffPlasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

0.06 1.69-8210 95 60 3508.890.194.8 70 4.880400 00.1 1/83.2 9-8210 98 60 1503.810.194.8 70 4.880400 00.1

1/46.4 9- 8210 10260701.780.194.8 70 4.880400 00.1 3/89.5 9- 8210 10960350.890.194.8 70 4.880400 00.1 1/2 12.79-8210 11560200.510.194.8 70 4.880400 00.1

3/4 19.19-8210 11760100.250.194.8 70 4.880 400 NR 0.19 4.8

(Cat. No.) (VDC) (Amp s) Inches Meters Inches mm psi* barPlasmaTotal** Delay (Sec) Inches mm

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 80 psi / 5.5 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-9 APPENDIX

.8 .8 .8 .8 .8

Page 66

APPENDIX 4B: CUTMASTER 75 & CUTMASTER 81 SYSTEM DATA

(MACHINE TORCH)

Cut Quality on Various Materials and Thicknesses

Torch Specifications For

CutMaster 75 & CutMaster 81 Power Supplies

Cutting Range

Material Most Metals

Up to 3/4 inch - 19 mm

Speed 11 ipm / 0.28 mpm

Pierce Ra ting

Material Carbon Steel

Thickness3/8 inch - 9.5 mm

Transfer Dist ance Gouging

Width1/4 inch - 6.3 mm

Depth1/8 inch - 3.2 mm

Number Passes Single

Speed 20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees 0° to 45°

Material Thickness1/4 inch - 6.3 mm

Gas Requirement

Ty pe GasAir

Operating Pressure 65 psi / 4.5 bar

Max Input Pressure 125 psi / 8.6 bar

Cutting & Gouging

Total Flow

3/8 inch - 9.5 mm

350 scfh / 165 lpm

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMaterialGas Characteristics

Gage

3/4 inch

( 19 mm )

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip

oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

SL100 Machine Torch Consumables for 60-Amp Power Supply

ApplicationElectrode

9-8215 9-8213 9-8210 (60A)None None 9-8218

Standoff Cutting

9-8215 9-8213 9-8210 (60A)9-8237

Gouging 9-8215 9-8213

Starter

Cartridge

Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Tip

Tip A: 9-8225 (40 A Max)

Tip B: 9-8226 (40-100 A) Tip C: 9-8227 (40-100 A) Tip D: 9-8228 (40-100 A)

Gouging Profiles

Output Range

Shield

Cup Body

9-8237 9-8241 None

Dept

Shield Cap

or Deflector

9-8238 or

9-8243

Shield Cup

idth

ide

None

APPENDIX A-10 Manual 0-2962

Page 67

Cutting Speed Charts

94 94 94 94

Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81

munimulA :lairetaM epyT 001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput Vo ltsAmp erageSpeed (Per Minute)Standoff Plasma Gas PressFlo w (SCFH) Pierce Pierce Height

Inches

0.06 1.69-82109560350 8.89 0.19 4.8654.5 80 40000.19 4.8

1/83.2 9-82109860175 4.45 0.19 4.8654.5 80 40000.19 4.8

1/4 6.49-8210102 60 80 2.03 0.19 4.8654.5 80 40000.19 4.8

3/89.5 9-8210109 60 44 1.12 0.19 4.8654.5 80 40000.19 4.8 1/2 12.79-8210115 60 23 0.58 0.19 4.8654.5 80 40000.19 4.8

3/4 19.19-8210117 60 11 0.28 0.19 4.8654.5 80 400NR0.1

Thickness TipOutput Vo ltsAmp erageSpeed (Per Minute)Standoff Plasma Gas PressFlo w (SCFH) Pierce Pierce Height

Inches

0.06 1.69-82109560350 8.89 0.19 4.8654.5 80 40000.19 4.8

1/83.2 9-82109860175 4.45 0.19 65 65 4.580400 00.1 1/46.4 9-8210102 60 80 2.03 0.19 65 65 4.580400 00.1 3/89.5 9-8210109 60 44 1.12 0.19 65 65 4.580400 00.1 1/2 12.79-8210115 60 23 0.58 0.19 65 65 4.580400 00.1

3/4 19.19-8210117 60 11 0.28 0.19 65 65 4.580400 NR 0.19 4.8

(Cat. No.) (VDC)(Amps)InchesMeters Inches mm psi* barPlasmaTotal** Delay (Sec) Inches mm

Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81

leetS dliM :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

(Cat. No.) (VDC)(Amps)InchesMeters Inches mm psi* barPlasmaTotal** Delay (Sec) Inches mm

.8 .8 .8 .8

Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81

leetS sselniatS :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output VoltsAmperageSpeed (Per Minute)Standoff Plasma Gas PressFlo w (SCFH) Pierce Pierce Height

Inches

0.06 1.69-82109560350 8.89 0.19 4.8654.5 80 40000.19 4.8

0.125 3.29-82109860150 3.81 0.19 4.8654.5 80 40000.19 4.8

1/46.4 9-8210102 60 70 1.78 0.19 4.8654.5 80 40000.19 4.8 3/89.5 9-8210109 60 35 0.89 0.19 4.8654.5 80 40000.19 4.8 1/2 12.79-8210115 60 20 0.51 0.19 4.8654.5 80 40000.19 4.8

3/4 19.19-8210117 60 10 0.25 0.19 4.8654.5 80 400NR0.1

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar PlasmaTotal** Delay (Sec)Inchesmm

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-11 APPENDIX

Page 68

APPENDIX 5: CUTMASTER 100 & 101 SYSTEM DATA

(HAND AND MACHINE TORCH)

Cut Quality on Various Materials and Thicknesses

Torch Specifications For

CutMaste r 100 & CutMaster 101 Power Supplies

Cutting Range

Material Most Metals

Up to 1 inch / 25.4 mm

Speed 10 ipm / 0.25 mpm

Pierce Ra ting

Material Carbon Steel

Thickness3/8 inch / 9.5 mm

Transfer Dist ance Gouging

Width1/4 inch - 6.3 mm Depth3/16 inch - 4.8 mm

Number PassesSingle

Speed 20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees 0° to 45°

Material Thickness1/2 inch - 13 mm

Gas Requirement

Type GasAir

Operating Pressure 70 psi / 4.8 bar

Max Input Pressure 125 psi / 8.6 bar

Cutting & Gouging

Total Flow

3/8 inch / 9.5 mm

490 scfh / 231 lpm

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMater ialGas Char acteristics

Gage

1 inch

( 25.4 mm )

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x

tip oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

SL100 Machine Torch Consumables for 80-Amp Power Supply

ApplicationElectrode

9-8215 9-8213 9-8211 (80A)NoneNone9-8218

Standoff Cutting

9-8215 9-8213 9-8211 (80A)9-8237

Gouging9-82159-8213

Starter

Cartridge

Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Tip

Tip A: 9-8225 (40A Max)

Tip B: 9-8226 (40-100A) Tip C: 9-8227 (40-100A) Tip D: 9-8228 (40-100A)

Gouging Profiles

Output Range

Shield

Cup Body

9-8237 9-8241 None

Dept

Shield Cap

or Deflector

9-8239 or

9-8243

Shield Cup

idth

ide

None

APPENDIX A-12 Manual 0-2962

Page 69

Cutting Speed Charts

94 94 94 94

Air Plasma Cutting Speed Data Chart For CutMaster 100 & CutMaster 101

munimulA :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput Vo ltsAmp erageSpeed (Per Minute) St andoff Plasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

0.05 1.39-8211100 80 350 8.89 0.19 4.8704.8 90 49000.19 4.8

0.1253.2 9-8211103 80 230 5.84 0.19 4.8704.8 90 49000.19 4.8 1/46.4 9-8211106 80 112 2.84 0.19 4.8704.8 90 49000.19 4.8 3/89.5 9-8211111 80 55 1.40 0.19 4.8704.8 90 49000.19 4.8 1/212.79-8211112 80 38 0.97 0.19 4.8704.8 90 49000.19 4.8 3/419.19-8211117 80 18 0.46 0.19 4.8704.8 90 490NR0.1

125.49-8211120 80 10 0.25 0.19 4.8704.8 90 490NR0.1

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For CutMaster 100 & CutMaster 101

leetS dliM :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput Vo ltsAmp erageSpeed (Per Minute) Stan doff Plasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

0.05 1.39-8211100 80 350 8.89 0.19 4.8704.8 90 49000.19 4.8

0.1253.2 9-8211103 80 230 5.84 0.19 4.8704.8 90 49000.19 4.8 1/46.4 9-8211 10680112 2.84 0.19 4.8704.8 90 49000.19 4.8 3/89.5 9-8211111 80 55 1.40 0.19 4.8704.8 90 49000.19 4.8 1/212.79-8211112 80 38 0.97 0.19 4.8704.8 90 49000.19 4.8 3/419.19-8211117 80 18 0.46 0.19 4.8704.8 90 490NR0.1

125.49-8211120 80 10 0.25 0.19 4.8704.8 90 490NR0.1

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For CutMaster 100 & CutMaster 101

leetS sselniatS :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput Vo ltsAmp erageSpeed (Per Minute) Stan doff Plasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

0.05 1.39-8211100 80 350 8.89 0.19 4.8704.8 90 49000.19 4.8

0.1253.2 9-8211103 80 200 5.08 0.19 4.8704.8 90 49000.19 4.8 1/46.4 9-8211 10680112 2.84 0.19 4.8704.8 90 4900.250.1 3/89.5 9-8211111 80 55 1.40 0.19 4.8704.8 90 4900.250.1 1/212.79-8211112 80 38 0.97 0.19 4.8704.8 90 4900.250.1 3/419.19-8211117 80 18 0.46 0.19 4.8704.8 90 490NR0.1

125.49-8211120 80 10 0.25 0.19 4.8704.8 90 490NR0.1

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec)Inchesmm

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 80 psi / 5.5 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-13 APPENDIX

.8 .8 .8 .8

Page 70

APPENDIX 6: CUTMASTER 151 SYSTEM DATA

Torch Specifications For

(HAND AND MACHINE TORCH)

Cut Quality on Various Materials and Thicknesses

CutMaste r 151 Power Supply

Cutting Range

Material Most Metals

Up to 1-1/2 inch / 38 mm

Speed11 ipm / 0.28 mpm

Pierce Ra ting

Material Carbon Steel

Thickness1/2 inch / 12.2 mm

Transfer Distance Gouging

Width1/4 inch - 6.3 mm (min) Depth3/16 inch - 4.8 mm (min)

Number Passes Single

Speed20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees0° to 45°

Material Thickness3/4 inch - 19 mm

Gas Requirement

Type GasAir

Operating Pressure 70 ps i / 4.8 bar

Max Input Pressure 125 psi / 8.6 bar

Cutting & Gouging

Total Flow

3/8 inch / 9.5 mm

490 scfh / 231 lpm

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMaterialGas Characteristics

Gage

1.5 inch

( 38 mm )

Carbon Steel

Stainless

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2

x tip oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2

x tip oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight

top edge rounding.

SL100 Machine Torch Consumables for 100-Amp Power Supply

ApplicationElectrode

9-8215 9-8213 9-8212 (100A) None None 9-8218

Standoff Cutting

9-8215 9-8213 9-8212 (100A) 9-8237

Gouging9-8215 9-8213

Start

Cartridge

Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Tip

Tip A: 9-8225 (40A Max)

Tip B: 9-8226 (40-100A) Tip C: 9-8227 (40-100A) Tip D: 9-8228 (40-100A)

Gouging Profiles

Output Range

Shield

Cup Body

9-8237 9-8241 None

Dept

Shield Ca p

or Deflector

9-8239 or

9-8243

Shield Cup

idth

ide

None

APPENDIX A-14 Manual 0-2962

Page 71

Cutting Speed Charts

94 94 94 94

94 94

Air Plasma Cutting Speed Data Chart For CutMaster 151

munimulA :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput VoltsAmperageSpeed (Per Minute)Plasma Gas PressFlow (SCFH) Pierce Pierce He ight

Inches

1/46.4 9-8212 104100 1483.760.1 94.8 70 4.890490 00.1 94.8 3/89.5 9-8212 110100 1183.000.1 94.8 70 4.890490 00.1 94.8 1/212.79-8212113 100792.010.194.8 70 4.890490 00.194.8 3/419.19-8212118 100310.790.194.8 70 4.890490 00.194.8

125.49-8212121 100180.4 60.194.8 70 4.890490 NR 0.19 4.8 1-1/431.89-8212128 100140.360.194.8 70 4.890490 NR 0.19 4.8 1-1/238.19-8212133 100110.280.194.8 70 4.890490 NR 0.19 4.8

(Cat. No.) (VDC )(Am ps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec)Inchesmm

Standoff

Air Plasma Cutting Speed Data Chart For CutMaster 151

leetS dliM :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output VoltsAmperageSpeed (Per Minute) St andoff Plasma Gas PressFlo w (SCFH) Pierce Pierce He ight

Inches

1/46.4 9-8212104 100129 3.28 0.19 4.8704.8 90 49000.19 4.8 3/89.5 9-8212110 100651.6 50.194.8 70 4.890490 00.194.8 1/212.79-8212 113 100491.240.194.8 70 4.890490 00.194.8 3/419.19-8212 118 100240.610.194.8 70 4.890490 00.194.8

125.49-8212 121 100160.410.194.8 70 4.890490 NR 0.19 4.8 1-1/431.89-8212 128 100100.250.194.8 70 4.890490 NR 0.19 4.8 1-1/

238.19-8212 133 10080.20 0.19 4.8704.8 90 490NR0.1

(Cat. No.) (VDC)(Am ps)InchesMetersInchesmmpsi*bar Plas ma Total**Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For CutMaster 151

leetS sselniatS :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput VoltsAmperage

Inches

1/46.4 9-8212 104100 134 3.40 0.19 4.8704.8 90 490 00.1 3/89.5 9-8212 110100 67 1.70 0.19 4.8704.8 90 490 00.1 1/212.79-8212 113 100 40 1.02 0.19 4.8704.8 90 490 00.1 3/419.19-8212 118 100 22 0.56 0.19 4.8704.8 90 490 00.1

1 25.49-8212 123 100120.300.194.8 70 4.890 490 NR 0.19 4.8 1-1/4 31.89-8212 129 10090.23 0.19 4.8704.8 90 490NR0.1 1-1/2 38.19-8212 135 10060.15 0.19 4.8704.8 90 490NR0.1

(Cat. No .) (VDC)

(Amps)

peed (Per Minute)Standoff Plas ma Gas Pr essFlow (SCFH) Pierce Pierce He ight

Inches Meters Inches mm psi* barPlasmaTotal** De lay (Sec)Inchesmm

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 75 psi / 5.2 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-15 APPENDIX

.8 .8 .8 .8

.8 .8

Page 72

APPENDIX 7A: PAKMASTER 50XL PLUS SYSTEM DATA

Torch Specifications For

PakMaster 50XL Plus Power Supply

Cutting Range

Material Mild Steel

Production Cut:

Up to 1/4 inch - 6.3 mm

Speed 45 ipm / 1. 14 mpm

Genuine Cut:

Up to 1/2 inch - 12.7 mm

Speed 12-14 ipm / 0.3 - 0.36 mpm

Severance Cut:

Up to 3/4 inch - 19 mm

Speed 5-7 ipm 0.13 - 0.18 mpm

Pierce Ra ting

Material Mild Steel

Thickness:

Hand Cutting 1/2 inch - 12.7 mm

Machine Cutting 1/4 inch - 6.4 mm

Transfer Di stance Gouging

Width3/16 inch - 4.8 mm Depth1/8 inch - 3.2 mm

Number Passes Single

Speed 20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees 0° to 45°

Material Thickness3/8 inch - 9.5 mm

Gas Requirement

Ty pe GasAir

Operating Pressure 65 psi / 4.5 bar

Max Input Pressure 125 psi / 8.6 bar

Total Flow Rate:

Cutting 350 scfh / 165 lpm

Gouging230 scfh / 108.5 lpm

3/8 inch - 9.5 mm

(HAND TORCH)

Cut Quality on Various Materials and Thicknesses

The following table deﬁnes the cut quality on various materials and thicknesses:

Material Type of Type of Cut

ThicknessMater ialGas Char acteristics

Gage

1/2 inch

( 12.7 mm )

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x

tip oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Cut Quality on Various Materials

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

oriﬁce diameter), little or no dross, smooth cut surface.

Gouging Profiles

Output

Range

Dept

idth

ide

SL60 - SL100 Hand Torch Consumables for 40-Amp Power Supply

ApplicationElectrode

Drag Cutting9-82159-8213 9-8207 (40A)NoneNone9-8218

9-8215 9-8213 9-8208 (40A)NoneNone9-8218

Standoff Cutting

9-8215 9-8213 9-8208 (40A)9-8237

Gouging9-82159-8213

Starter

Cartridge

Tip

Tip A: 9-8225 (40A Max)

Tip B: 9-8226 (40-100A) Tip C: 9-8227 (40-100A) Tip D: 9-8228 (40-100A)

APPENDIX A-16 Manual 0-2962

Shield

Cup Body

9-8237 9-8241 None

Shield Cap

or Deflector

9-8244 or

9-8243

Shield Cup

None

Page 73

Cutting Speed Charts

00 94

94 94

94 94 94

Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus

Type Torch: SL60 - Drag Type Material: Aluminum

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Ou tput VoltsAmperageSpeed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-82078040300 7.62 N/AN/A 65 4.550350 00.0 16 ga 1.59-82078040275 6.99 N/AN/A 65 4.550350 00.1 10 ga 3.49-82078040751.91N/A N/A654.5 50 35000.19 4.8

7 ga 4.69-82078540551.40N/A N/A654.5 50 3500.5 0.19 4.8 1/4 6.49-82079040401.02N/A N/A654.5 50 3500.5 0.19 4.8 3/8 9.59-8207100 40 18 0.46 N/AN/A 65 4.550350 10.2

1/2 12.79-8207100 40 10 0.25 N/AN/A 65 4.550350 1.50.2

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus

Type Torch: SL60 - Drag Type Material: Mild Steel

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output Volt sAmperage Speed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-82078040300 7.6N/A N/A654.5 50 35000.00 0.0 16 ga 1.59-82078040275 7.0N/A N/A654.5 50 35000.19 4.8 10 ga 3.49-82078040105 2.7N/A N/A654.5 50 35000.19 4.8

7 ga 4.69-82078540701.8 N/AN/A 65 4.550350 0.50.1 1/4 6.49-82079040391.0 N/AN/A 65 4.550350 0.50.1 3/8 9.59-8207100 40 20 0.5N/A N/A654.5 50 35010.25 6.4

1/2 12.7 9-8207 10040100.3 N/AN/A 65 4.550350 1.50.2

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec)Inchesmm

.0 .8

.8 .8

Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus

Type Torch: SL60 - Drag Type Material: Stainless Steel

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput VoltsAmperageSpeed (Per Minute) StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-82078040300 7.6N/A N/A654.5 50 35000.00 0.0 16 ga 1.59-82078040275 7.0N/A N/A654.5 50 35000.19 4.8 10 ga 3.49-82078040751.9 N/AN/A 65 4.550350 00.1

7 ga 4.69-82078540551.4 N/AN/A 65 4.550350 0.50.1 1/4 6.49-82079040401.0 N/AN/A 65 4.550350 0.50.1 3/8 9.59-8207100 40 18 0.5N/A N/A654.5 50 35010.25 6.4

1/2 12.79-8207100 40 10 0. 3N/A N/A654.5 50 3501.5 0.25 6.4

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec)Inchesmm

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 75 psi / 5.2 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-17 APPENDIX

.8 .8 .8

Page 74

APPENDIX 7B: PAKMASTER 50XL PLUS SYSTEM DATA

Gouging Profiles

(MACHINE TORCH)

Torch Specifications For

PakMaster 50XL Plus Power Supply

Cutting Range

Material Mild Steel

Production Cut:

Up to 1/4 inch - 6.3 mm

Speed 45 ipm / 1.14 mpm

Genuine Cut:

Up to 1/2 inch - 12.7 mm

Speed 12-14 ipm / 0.3 - 0.36 mpm

Severance Cut:

Up to 3/4 inch - 19 mm

Speed 5-7 ipm 0.13 - 0.18 mpm

Pierce Ra ting

Material Mild Steel

Thickness:

Hand Cutting1/2 inch - 12.7 mm

Machine Cutting1/4 inch - 6.4 mm

Transfer Dist ance Gouging

Width3/16 inch - 4.8 mm Depth1/8 inch - 3. 2 mm

Number PassesSingle

Speed 20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees0° to 45°

Material Thickness3/8 inch - 9.5 mm

Gas Requirement

Type GasAir

Operating Pressure 60 psi / 4.1 bar

Max Input Pressure 125 psi / 8.6 bar

Total Flow Rate:

Cutting 350 scfh / 165 lpm

Gouging230 scfh / 108.5 lpm

3/8 inch - 9.5 mm

Cut Quality on Various Materials and Thicknesses

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMater ialGas Char acteristics

Gage

1/2 inch

( 12.7 mm )

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x

tip oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2 - 1/2 x

tip oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

Output

Range Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Dept

idth

ide

SL100 Machine Torch Consumables for 40-Amp Power Supply

ApplicationElectrode

9-82159-82139-8208 (40A)NoneNone 9-8218

Standoff Cutting

9-82159-82139-8208 (40A)9-8237

Gouging9-8215 9-8213

Starter

Cartridge

Tip

Tip A: 9-8225 (40 A Max)

Tip B: 9-8226 (40-100 A) Tip C: 9-8227 (40-100 A) Tip D: 9-8228 (40-100 A)

APPENDIX A-18 Manual 0-2962

Shield

Cup Body

9-8237 9-8241 None

Shield Cap

or Deflector

9-8245 or

9-8243

Shield Cup

None

Page 75

Cutting Speed Charts

94 94 94 94 94 94

Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus

munimulA :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput Vo ltsAmperageSpeed (Per Minute) St andoff Plasma Gas PressFlow (SCFH) Pi erce Pierce Height

Inches

20 ga 0.89-82089040350 8.89 0.19 4.8604.1 50 35000.19 4.8 16 ga 1.39-82089440275 6.99 0.19 4.8604.1 50 35000.19 4.8 10 ga 2.69-8208105 40 1002.540.194.8 60 4.150350 00.194.8

7 ga 3.79-8208100 40 70 1.78 0.19 4.8604.1 50 35000.19 4.8 1/4 6.49-8208107 40 40 1.02 0.19 4.8604.1 50 3500.5 0.19 4.8 3/8 9.59-8208114 40 18 0.46 0.19 4.8604.1 50 3500.5 0.19 4.8

1/2 12.79-8208121 40 10 0.25 0.19 4.8604.1 50 35010.19 4.8

(Cat. No.) (VDC)(Amps)InchesMeters Inches mm psi* barPlasmaTotal** Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus

leetS dliM :lairetaM epyT 001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output Volt sAmperageSpeed (Per Minute)StandoffPlasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-82089040350 8.89 0.13 3.2604.1 50 35000.19 4. 8 16 ga 1.59-82089040275 6.99 0.13 3.2604.1 50 35000.19 4. 8 10 ga 3.49-82089040115 2.92 0.13 3.2604.1 50 35000.19 4. 8

7 ga 4.69-82089540751.910.133.2 60 4.150350 0.50.1 1/4 6.49-8208110 40 45 1.14 0.19 4.8604.1 50 3500.5 0.19 4.8 3/8 9.59-8208119 40 20 0.51 0.19 4.8604.1 50 35010.25 6.4

1/2 12.7 9-8208 12140140.360.194.8 60 4.150350 1.50.2

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec) Inches mm

Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus

leetS sselniatS :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Ou tput VoltsAmperageSpeed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

20 ga 0.99-8208 95 40 3007.620.194.8 60 4.150350 00.1 16 ga 1.59-8208 95 40 2756.990.194.8 60 4.150350 00.1 10 ga 3.59-8208 10040751.910.194.8 60 4.150350 00.1

7 ga 4.69-8208 10540551.400.194.8 60 4.150350 00.1 1/4 6.49-8208 10540401.020.194.8 60 4.150350 0.50.1 3/8 9.59-8208 11040180.460.194.8 60 4.150350 10.1

1/2 12.7 9-8208 11940100.250.194.8 60 4.150350 1.50.1

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total**Delay (Sec)Inchesmm

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 65 psi / 4.5 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-19 APPENDIX

.8 .8 .8 .8 .8 .8

Page 76

APPENDIX 8A: PAKMASTER 75XL PLUS SYSTEM DATA

Torch Specifications For

(HAND TORCH)

Cut Quality on Various Materials and Thicknesses

Pak Master 75XL Plus Power Supply

Cutting Range

Material Most Metals

Up to 3/ 4 inch - 19 mm

Speed11 ipm / 0.28 mpm

Pierce Ra ting

Material Carbon Steel

Thickness3/8 inch - 9.5 mm

Transfer Di stance Gouging

Width1/4 inch - 6.3 mm Depth1/8 inch - 3. 2 mm

Number PassesSingle

Speed 20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees0° to 45°

Material Thickness1/4 inch - 6.3 mm

Gas Requirement

Type GasAir

Operating Pressure 65 psi / 4.5 bar

Max Input Pressure 125 psi / 8.6 bar

Cutting & Gouging

Total Flow

3/8 inch - 9.5 mm

350 scfh / 165 lpm

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMaterialGas Characteristics

Gage

3/4 inch

( 19 mm )

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf

(2 x tip oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2 -

1/2 x tip oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

Gouging Profiles

Output

Range Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Dept

idth

ide

SL60 - SL100 Hand Torch Consumables for 60-Amp Power Supply

ApplicationElectrode

Drag Cutting 9-8215 9-8213 9-8207 (40A )NoneNone9-8218

9-8215 9-8213 9-8210 (60A )NoneNone9-8218

Standoff Cutting

9-8215 9-8213 9-8210 (60A )9-8237

Gouging9-82159-8213

Starter

Cartridge

Tip

Tip A: 9-8225 (40A Max)

Tip B: 9-8226 (40-100A) Tip C: 9-8227 (40-100A) Tip D: 9-8228 (40-100A)

APPENDIX A-20 Manual 0-2962

Shield

Cup Body

9-8237 9-8241 None

Shield Cap

or De flector

9-8235 or

9-8243

Shield Cup

None

Page 77

Cutting Speed Charts

56 56 56

Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus

munimulA :lairetaM epyT06LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output VoltsAmperageSpeed (Per Minute)StandoffPlasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

1/16 1.69-8210 95 60 350 8.89 0.19 4.8654.5 80 3500.1 0.25 6.4

1/8 3.29-8210 95 60 1754.450.194.8 65 4.580350 0.25 0.25 6.4 1/4 6.49-8210 105 60 80 2.03 0.19 4.8654.5 80 3500.250.2 3/8 9.59-8210 105 60 45 1.14 0.19 4.8654.5 80 3500.250.2 1/2 12.7 9-8210 10560220.560.194.8 65 4.580350 0.50.2

3/4 19.1 9-8210 11560120.300.194.8 65 4.580350 NA NA NA

(Cat. No.) (VDC) (Amps) Inches MetersInchesmmpsi*bar PlasmaTotal** Delay (Sec) Inches mm

Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus

leetS dliM :lairetaM epyT 06LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Ou tput VoltsAmp erageSpeed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

1/16 1.69-8210 90 60 3508.890.194.8 65 4.580350 0.10.256.4

1/8 3.29-8210 95 60 1754.450.194.8 65 4.580350 0.25 0.25 6.4 1/4 6.49-8210 10560802.030.194.8 65 4.580350 0.25 0.25 6.4 3/8 9.59-8210 10560451.140.194.8 65 4.580350 0.25 0.25 6.4 1/2 12.7 9-8210 10560220.560.194.8 65 4.580350 0.50.256.4 3/4 19.1 9-8210 11560110.280.194.8 65 4.580350 NA NA NA

125.49-8210 1156080.20 0.19 4.8654.5 80 350NANANA

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar PlasmaTotal** Delay (Sec)Inchesmm

.4 .4 .4

Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus

leetS sselniatS :lairetaM epyT06LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Output VoltsAmp erageSpeed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pi erce Height

Inches

1/16 1.69-82109560 350 8.89 0.19 4.8654.5 80 3500.1 0.25 6.4

1/8 3.29-82109560 150 3.81 0.19 4.8654.5 80 3500.250.256.4 1/4 6.49-8210105 60 70 1.78 0.19 4.8654.5 80 3500.250.256.4 3/8 9.59-8210105 60 35 0.89 0.19 4.8654.5 80 3500.250.256.4 1/2 12.79-8210105 60 20 0.51 0.19 4.8654.5 80 3500.5 0.25 6.4 3/4 19.1 9- 8210 11560100.250.194.8 65 4.580350 NA NA NA

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total** Delay (Sec)Inchesmm

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 75 psi / 5.2 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-21 APPENDIX

Page 78

APPENDIX 8B: PAKMASTER 75XL PLUS SYSTEM DATA

(MACHINE TORCH)

Cut Quality on Various Materials and Thicknesses

Torch Specifications For

Pak Master 75XL Plus Power Supply

Cutting Range

Material Most Metals

Up to 3/ 4 inch - 19 mm

Speed11 ipm / 0.28 mpm

Pierce Ra ting

Material Carbon Steel

Thickness3/8 inch - 9.5 mm

Transfer Di stance Gouging

Width1/4 inch - 6.3 mm Depth1/8 inch - 3. 2 mm

Number PassesSingle

Speed 20 ipm / 0.5 mpm

Bevel Cut Ca pability

Degrees0° to 45°

Material Thickness1/4 inch - 6.3 mm

Gas Requirement

Type GasAir

Operating Pressure 60 psi / 4.1 bar

3/8 inch - 9.5 mm

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMaterialGas Characteristics

Gage

3/4 inch

( 19 mm )

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x

tip oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2 - 1/2 x

tip oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

Max Input Pressure 125 psi / 8.6 bar

Cutting & Gouging

Total Flow

350 scfh / 165 lpm

SL100 Machine Torch Consumables for 60-Amp Power Supply

ApplicationElectrode

9-8215 9-8213 9-8210 (60A)None None 9-8218

Standoff Cutting

9-8215 9-8213 9-8210 (60A)9-8237

Gouging 9-8215 9-8213

Starter

Cartridge

Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Tip

Tip A: 9-8225 (40 A Max)

Tip B: 9-8226 (40-100 A) Tip C: 9-8227 (40-100 A) Tip D: 9-8228 (40-100 A)

Gouging Profiles

Output

Range

Shield

Cup Body

9-8237 9-8241 None

Dept

Shield Cap

or Deflector

9-8238 or

9-8243

Shield Cup

idth

ide

None

APPENDIX A-22 Manual 0-2962

Page 79

Cutting Speed Charts

56 56 56

Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus

munimulA :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput VoltsAmp erageSpeed (Per Minute) StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

1/16 1.69-8210 95 60 3508.890.194.8 60 4.180350 0.10.2 1/8 3.29-8210 95 60 1754.450.194.8 60 4.180350 0.25 0.25 6.4 1/4 6.49-8210 10560802.030.194.8 60 4.180350 0.25 0.25 6.4 3/8 9.59-8210 10560451.140.194.8 60 4.180350 0.25 0.25 6.4 1/2 12.7 9-8210 10560220.560.194.8 60 4.180350 0.50.256.4

3/4 19.1 9-8210 11560120.300.194.8 60 4.180350 NA NA NA

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total** Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus

leetS dliM :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput VoltsAmp erageSpeed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

1/16 1.69-82109060350 8.89 0.19 4.8604.1 80 3500.1 0.25 6.4 1/8 3.29-82109560175 4.45 0.19 4.8604.1 80 3500.250.256.4 1/4 6.49-8210105 60 80 2.03 0.19 4.8604.1 80 3500.250.256.4 3/8 9.59-8210105 60 45 1.14 0.19 4.8604.1 80 3500.250.256.4 1/2 12.7 9-8210 10560220.560.194.8 60 4.180350 0. 50.256.4 3/4 19.1 9-8210 11560110.280.194.8 60 4.180350 NA NA NA

125.49-8210115 60 80.200.194.8 60 4.180350 NA NA NA

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi*bar Plasma Total** Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus

leetS sselniatS :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

ThicknessTip Ou tput VoltsAmp erageSpeed (Per Minute) St andoffPlasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

1/16 1.69-8210 95 60 350 8.89 0.19 4.8604.1 80 3500.1 0.25 6.4

1/8 3.29-82109560 150 3.81 0.19 4.8604.1 80 3500.250.2 1/4 6.49-8210105 60 70 1.78 0.19 4.8604.1 80 3500.250.2 3/8 9.59-8210105 60 35 0.89 0.19 4.8604.1 80 3500.250.2 1/2 12.7 9-8210105 60 20 0.51 0.19 4.8604.1 80 3500.5 0.25 6.4

3/4 19.1 9-8210 11560100.250.194.8 60 4.180350 NA NA NA

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi* barPlasmaTotal** Delay (Sec) Inches mm

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 65 psi / 4.5 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-23 APPENDIX

.4 .4 .4

Page 80

APPENDIX 9: PAKMASTER 100XL PLUS SYSTEM DATA

(MACHINE TORCH)

Cut Quality on Various Materials and Thicknesses

Torch Specifications For

Pak Master 100XL Plus Power Supply

Cutting Range

Material Most Metals

Up to 1 inch / 25.4 mm

Speed 10 ipm / 0.25 mpm

Pierce Ra ting

Material Carbon Steel

Thickness3/8 inch - 9.5 mm

Transfer Dist ance Gouging

Width1/4 inch - 6.3 mm Depth3/16 inch - 4.8 mm

Number PassesSingle

Speed20 ipm - 0.5 mpm

Bevel Cut Ca pability

Degrees0° to 45°

Material Thickness1/2 inch - 13 mm

Gas Requirement

Type GasAir

Operating Pressure 60 psi / 4.1 bar

Max Input Pressure 125 psi / 8.6 bar

Cutting & Gouging

Total Flow

3/8 inch - 9.5 mm

490 scfh / 231 lpm

The following table deﬁnes the cut quality on various materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

ThicknessMater ialGas Char acteristics

Gage

1 inch

( 25.4 mm )

Carbon Steel

Stainl ess

Aluminum

Air

Good - Excellent

Good

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x

tip oriﬁce diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2 -

1/2 x tip oriﬁce diameter), some dross (easily removed), medium - smooth cut surface, slight top edge rounding.

SL100 Machine Torch Consumables for 80-Amp Power Supply

ApplicationElectrode

9-8215 9-8213 9-8211 (80A)NoneNone9-8218

Standoff Cutting

9-8215 9-8213 9-8211 (80A)9-8237

Gouging9-82159-8213

Starter

Cartridge

Tip A 40 Amps Max. ShallowNarrow Tip B 40-100 Amps Deep Narrow Tip C40-100 Amps Moderate Moderate Tip D40-100 Amps Shallo

Tip

Tip A: 9-8225 (40A Max)

Tip B: 9-8226 (40-100A) Tip C: 9-8227 (40-100A) Tip D: 9-8228 (40-100A)

Gouging Profiles

Output

Range

Shield

Cup Body

9-8237 9-8241 None

Dept

Shield Cap

or Deflector

9-8239 or

9-8243

idth

ide

Shield Cup

None

APPENDIX A-24 Manual 0-2962

Page 81

Cutting Speed Charts

94 94

05 05

Air Plasma Cutting Speed Data Chart For PakMaster 100XL Plus

munimulA :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput Volt sAmp erageSpeed (Per Minute)StandoffPlasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

0.05 1.39-8211 10080 350 8.89 0.19 4.8604.1 90 49000.19 4.8

0.125 3.29-8211 10380 225 5.72 0.19 4.8604.1 90 49000.19 4.8 1/46.4 9- 8211 10680112 2.84 0.19 4.8604.1 90 49000.19 4.8 3/89.5 9- 8211 11180551.400.194.8 60 4.190490 00.1 1/212.79-8211 11580300.760.194.8 60 4.190490 00.1 3/419.19-8211 11780100.250.194.8 60 4.190490 NR 0.19 4.8

125.49-8211120 80 80.200.194.8 60 4.190490 NR 0.19 4.8

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi* barPlasmaTotal** Delay (Sec)Inchesmm

Air Plasma Cutting Speed Data Chart For PakMaster 100XL Plus

leetS dliM :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput Volt sAmp erageSpeed (Per Minute) Standoff Plasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

1/16 1.69-8211 10080350 8.89 0.19 4.8604.1 90 49000.20 5.1 1/8 3.29-8211 10380230 5.84 0.19 4.8604.1 90 4900.1 0.20 5.1 1/4 6.49-8211 10680112 2.84 0.19 4.8604.1 90 4900.1 0.20 5.1 3/8 9.59-8211 11180551.400.194.8 60 4.190490 0.10.2 1/2 12.7 9-8211 11280380.970.194.8 60 4.190490 0.10.2 3/4 19.1 9-8211 11780180.460.194.8 60 4.190490 NA NA NA

125.49-8211 12080100.250.194.8 60 4.190490 NA NA NA

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi* barPlasmaTotal** Delay (Sec)Inchesmm

.8 .8

.1 .1

Air Plasma Cutting Speed Data Chart For PakMaster 100XL Plus

leetS sselniatS :lairetaM epyT001LS :hcroT epyT

hcroT saG elgniS :saG yradnoceS epyTriA :saG amsalP epyT

Thickness TipOutput Volt sAmp erageSpeed (Per Minute) Standoff Plasma Gas PressFlow (SCFH) Pierce Pierce Height

Inches

0.05 1.39-8211 10080 350 8.89 0.19 4.8604.1 90 49000.19 4.8

0.125 3.29-8211 10380 200 5.08 0.19 4.8604.1 90 49000.19 4.8 1/46.4 9-8211 10680112 2.84 0.19 4.8604.1 90 4900.250.1 3/89.5 9-8211 11180551.400.194.8 60 4.190490 0.25 0.19 4.8 1/212.79-8211 11280380.970.194.8 60 4.190490 0.25 0.19 4.8 3/419.19-8211 11780180.460.194.8 60 4.190490 NR 0.19 4.8

125.49-8211120 80 10 0.25 0.19 4.8604.1 90 490NR0.1

(Cat. No.) (VDC)(Amps)InchesMetersInchesmmpsi* barPlasmaTotal** Delay (Sec)Inchesmm

NOTES

* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2 m leads, set gas pressure to 65 psi / 4.5 bar.

**Totalowrateincludesplasmaandsecondarygasow.

Manual 0-2962 A-25 APPENDIX

Page 82

APPENDIX 10: HAND TORCH WIRING DIAGRAMS

PIP

Switch

Torch

Switch

ATC Male

Connector

Orange

Black

Green

White

Torch Leads

Pilot

1 2

Torch Head

Pilot

Negative / Plasma

To Power Supply

Internal Connections

Power Supply

Adapter

Torch & Leads with O2B Connector

White

Black Orange

Green

Power Supply

Front Panel

(Console)

Torch

Switch

SL60 - SL100 Hand Torch

Hand Torch and Leads with O2B Connector

Hand Torch and Leads with ATC Connector, Power Supply with ATC Adapter

PIP

Switch

Torch

Switch

1 2

ATC Male

Connector

ATC Female

Receptacle

Art # A-03679

Orange

Black

Green

White

Pilot

Negative / Plasma

Torch Head

White

Black

Orange

Green

Torch Head

Torch Leads

Pilot

Power Supply

Bulkhead

Pilot

Power Supply

Bulkhead

Negative / Plasma

PIP

Switch

ATC Adapter Female

Receptacle

Negative / Plasma

Torch Leads

Negative / Plasma

Hand Torch & Leads with ATC Connector,

Power Supply with Console - Mounted ATC Receptacle

Power Supply

Adapter

Torch & Leads with

ATC Connector

ATC Adapter

Assembly

Torch & Leads with

ATC Connector

Power Supply with Console-Mounted

ATC Receptacle

APPENDIX A-26 Manual 0-2962

Page 83

APPENDIX 11: MECHANIZED TORCH WIRING DIAGRAMS

Not Used

PIP

Switch

Unshielded SL100 Mechanized (Machine) Torch

Art # A-03680

Orange

Black

Green

White

Torch Head

Not Used

PIP

Switch

AT C

Male

Connector

ATC Adapter

Female

Receptacle

Pilot

Orange

Black

White

Torch Leads

Torch Head

Negative / Plasma

Remote

Pendant

Connector

Not Used

Remote Pendant

Adapter

Green

Black

Pilot

Negative / Plasma

Power Supply

Bulkhead

Pilot

Power Supply

Bulkhead

Negative / Plasma

Green

White

Not Used

PIP

Switch

ATC Male

Connector

Pilot

White

Torch Leads

Torch Head

Negative / Plasma

Green

Black

Pilot

ATC Female

Receptacle

Negative / Plasma

Torch & Unshielded Leads

with O2B Connector

Mechanized Torch &

Unshielded Leads

with ATC Connector

Torch & Unshielded Leads

with ATC Connector, Power Supply

with Unshielded ATC Adapter

ATC Adapter

Assembly

Torch & Unshielded Leads

with ATC Connector, Power Supply

with Console-Mounted ATC Receptacle

O2B Leads

Connector

Power Supply

Adapter

Power Supply

Adapter

Pilot

Torch Leads

Negative / Plasma

Torch & Unshielded Leads with O2B Leads Connector

Remote

Pendant

Connector

Power Supply

Front Panel

Black

Orange

To Power Supply

Internal Connections

Mechanized Torch &

Unshielded Leads

with ATC Connector

Manual 0-2962 A-27 APPENDIX

Page 84

APPENDIX 12: AUTOMATED TORCH WIRING DIAGRAMS

PIP

Switch

Shielded SL100 Automated (Machine) Torch

Female Faston

Male

Faston

Square Socket

Square

Torch and Shielded Leads with O2B Connector

PIP

Switch

ATC Adapter Female Receptacle

Art # A-03681

Pilot

Female Faston

Male

Faston

Square Socket

Square Pin

Black

Red

White

Green

Torch Leads

Torch Head

Not Used

Torch Head

Pilot

Power Supply

Bulkhead

Pilot

Power Supply

Bulkhead

Negative / Plasma

Control Shield

Negative & Pilot Shield

Negative / Plasma

Control Shield

Negative &

Pilot Shield

Torch and Shielded Leads

with O2B Connector

Black

Red

ATC Male Connector

Torch & Shielded Leads with ATC Connector

Shielded ATC Adapter

Power Supply

Adapter

Torch and Shielded Leads

with ATC Connector, Power Supply

with Shielded ATC Adapter

PIP

Switch

Pilot

Shielded

Torch Leads

Torch Head

Negative &

Pilot Shield

ATC Male Connector

Torch & Shielded Leads with ATC Connector

Torch and Shielded Leads with ATC Connector,

Power Supply with Console -Mounted

ATC Receptacle

Pilot

To Power Supply

Internal Connections

ATC Female

Receptacle

Negative / Plasma

Power Supply

Front Panel

Red

Black

Red

Black

Negative / Plasma

Shielded

Torch Leads

O2B

Connector

Control Shield

Negative / Plasma

APPENDIX A-28 Manual 0-2962

Page 85

APPENDIX 13: ATC ADAPTER PINOUT DIAGRAM

ATC Adapter Female Receptacle

Front View

Art # A-03666

ATC Male Connector

Front View

ATC Female Adapter

Receptacle - Front View

ATC Male Connector

Front View

Shielded ATC Adapter -

Female Receptacle Front View

Shielded ATC Male Connector

Front View

Negative / Plasma

3 - White / Switch

Negative / Plasma

Pilot

Negative / Plasma

5 - Open

7 - Open

6 - Neg/Pilot

Shield Drain

8 - Shield Drain*

5 - Open

6 - Neg/Pilot Shield Drain to Square Socket

7 - Open

8 - Shield Drain* to Faston

Pilot

Negative / Plasma

Pilot

Negative / Plasma

6 - Open

7 - Open

5 - Open

8* - Open

Pilot

Negative / Plasma

6 - Open

7 - Open

5 - Open

8 - Open

6 - Open

7 - Open

8 - Open

5 - Open

8 - Open*

5 - White / Not Used

7 - Green / Not Used

HAND TORCH

UNSHIELDED MACHINE TORCH

SHIELDED MACHINE TORCH

* Positions 3,4,8 used for optional remote pendant

* Positions 3 & 4 used for remote pendant in mechanized applications. Pendant drain splices to wire in position 8.

* Positions 3 & 4 used for remote pendant in mechanized applications.

2- Orange / PIP

Pilot

4 - Green / Switch

1 - Black / PIP

3 - White - Switch -

to Large Socket

4 - Green - Switch-

to Small Pin

1 - Black / PIP to Large Pin

2 - Orange /PIP -

to Small Socket

3 - Open*

2 - Orange / PIP

1 - Black / PIP

4- Open*

2 - Orange /PIP -

to Small Socket

1 - Black / PIP to Large Pin

3 - White /

Not Used* -

to Large Socket

4 - Green / Not Used* to Small Pin

3 - Open*

4- Open*

2 - Red / PIP

1 - Black / PIP

3 - White /

Not Used* -

to Large Socket

1 - Black / PIP

to Large Pin

4 - Green / Not Used* to Small Pin

2 - Red / PIP

to Small Socket

6 - Open

Manual 0-2962 A-29 APPENDIX

Page 86

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Tweco SL100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual