Tweco SL80 User Manual

82 Benning Street, West Lebanon, NH 03784 USA

[phone] • www.thermal-dynamics.com

Manual 0-4797

SL80 Plasma Cutting

Hand Torch

Use with Lincoln

Installation and Operation Instructions

®

Pro-Cut® 80

General Information

Pro-Cut® 80

Torch Models

Cutting Capacity 85 Amps
Torc h Leads Lengt hs

Applications
Power Supply

Used W i t h:
Plasma Gas
Secondary Gas

Operating P ressure
Max. Input Pres sure 125 psi / 8.6 bar

Gas Flow (Cutting
and Gouging)

Duty Cycl e
Ambient

Tempera ture
Maximum Current 85 Amps
Volt age (V peak ) 500V
Arc Striking Voltage 7kV

Current Ratin g

Cooling

Catalog No. 7-5257
Ca talo g No. 7-5258

25' / 7.6 m
50' / 15.2 m
Shielded Drag Cutting
St andoff Cutting

®

Lincoln

Compress ed A i r (O nl y)
70 - 75 psi

4.8 - 5.2 bar

250 sc fh
(110 lpm)
100% @ 85 Am ps
@ 250 sc fh
104° F
40° C

Up to 85 Amps, DC,
Straight Polarity

Combinati on of Ambi ent
Air and Gas S tream
Through Torch

Pro-Cut 80

Refer to the Complete Assembly Replacement page for
configurations and catalog numbers.

These instructions are important for the proper installation
of the Torch. Read the instructions thoroughly before
attempting the installation. Keep these instructions for
reference.

Supplied Parts

The Replacement Torches include:

• Torch With Leads - 1 each

• Installation Instructions - 1 each

• Consumables (Installed on the Torch):

Art # A-04743

Electrode

Start Cartridge

Tip

Shield Cup

NOTE

The consumable parts installed in the Torch may
not necessarily be optimized for your Power Supply
or cutting application. For best results, refer to the
selection charts in this manual to choose the proper
consumables for your application.

CAUTION

The start cartridge supplied with this torch cannot
be used with any other 1Torch or on any other power
supply except Lincoln Pro-Cut 80.

Options

The following torch options are available. Refer to the
complete assembly replacement list for catalog numbers.

• Cutting Guide Kits

* Lincoln and Pro-Cut are registered trademarks of Lincoln
Electric.

©

2005,2006 by Thermal Dynamics Corp., Printed in USA.

• Leather Leads Covers

• Standoff Cutting Guide

Manual 0-4797 1 October 20, 2006 Rev. AA.01

Torch Specifications

!

E. Torch Lead Pin Out

A. Torch Configuration and Dimensions

The torch head is at 75° to the torch handle. The torch
includes a torch handle and torch trigger assembly.

9.5" (241 mm)

3.75"

(95 mm)

1.17" (29 mm)

Art # A-03322

B. Operating Notes

WARNING

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 chart for each model.

This pin out is for the torch lead connector that at­taches to the console. It indicates the placement of the
individual lead wires.

Red

Red

Green

9

8

7

6

1

4

5

Empty

White

2

3

Black

Orange

Art # A-07609

Connecting Torch

Torch leads connect directly to the power supply receptacle.
Align the leads connector with the power supply
receptacle. Press the connector into the receptacle fully.
Turn the connector locking ring to secure the connector to
the receptacle. Do not use the locking ring to pull the
connector into the receptacle.

C. Direct Contact Hazard

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

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

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

To Control

Torch Switch

Cable Wiring

PIP Switch

A-04791

Torch Trigger

Shield Cup

Spare Parts Label

Included with the torch is an adhesive label. Apply the
label to the power supply, where the operator can see it for
easy reference.

Torch Parts Selection

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

WARNINGS

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

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

The shield cup (or shield cup body and shield cap or
deflector) holds the tip and start cartridge in place. Position
the torch with the shield cup facing upward to keep these
parts from falling out when the cup is removed.

Change the torch parts as follows:

October 20, 2006 Rev. AA.01 2 Manual 0-4797

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

Operating Gas Pressure

Set gas pressure at the power supply regulator according
to the following charts. These charts are a guide only;
adjust as necessary for best performance.

Torch Head

Electrode

Start Cartridge

Tip

Shield Cup

A-03645

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

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

CAUTION

Gas Pressure Settings

Leads Le ngth

Tip

80A 70 psi / 4. 8 bar 75 psi / 5. 2 bar

25' / 7.6 m 50' / 15.2 m

Cutting

The torch can be held comfortably in one hand or steadied
with two hands. Choose the holding technique that feels
most comfortable and allows good control and movement.

Sequence of Operation

1. Turn on power and adjust gas pressure on the Power
Supply pressure gauge. Refer to the charts for optimum
pressure settings for the combination of torch tip and
total lead lengths in use.

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

CAUTION

The start cartridge supplied with this torch cannot
be used with any other 1Torch or on any other power
supply except Pro-Cut 80.

NOTE

Refer to the consumables selection chart for the proper
combination of torch parts, including shield cups
and tips.

4. Hand tighten the shield cup until it is seated on the
torch head. Do not use tools to tighten the cup. If
resistance is felt when installing the cup, check the
threads before proceeding.

NOTE

When operating the torch in a normal condition, a
small amount of gas vents through the gap between
the shield cup and the torch handle. Do not attempt
to overtighten the shield cup as irreparable damage
to internal components may result.

Do not operate the torch with the torch tip in contact
with the work, as it will cause irreparable damage to
the torch parts.

3. Hold the torch away from your body.

4. Slide the trigger release toward the back of the torch
while simultaneously squeezing the trigger. The pilot
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.

Manual 0-4797 3 October 20, 2006 Rev. AA.01

NOTE

The gas preflow and postflow are a characteristic of
the power supply and not a function of the torch.

Common Operating Faults

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

Trigger

1

2

Trigger Release

3

4

Art # A-03383

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

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

A. Torch will not pilot or is erratic when torch switch is

activated

1. Input air setting improperly set. Input air pressure needs
to be adjusted for proper pilot.

a. If air pressure is too low, erratic or no pilot will

result. Increase air pressure to recommended
level.

b. If air pressure is too high, the pilot arc will stop

working after post flow cycle and the Safety
switch LED will light steady on the power
supply. Press the Safety switch button to reset
and decrease the air pressure to the recommend
level.

2. Wrong start cartridge installed.

a. The start Cartridge (9-8257) is specific to the

Pro-Cut 80. If any other start cartridge is
installed, the pilot arc will not start. Replace
with proper start cartridge, (9-8257).

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

NOTE

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

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

Shield Cup

Standoff Guide

Torch Tip

Workpiece

Art # A-04063

Art # A-03640

Upper Groove
with Vent Holes
Must Remain Open

Upper O-Ring
in Correct Groove

Threads
Lower O-Ring

October 20, 2006 Rev. AA.01 4 Manual 0-4797

B. Difficult Starting Main Arc

1. Torch standoff too high from workpiece

Inspection and Replacement of

Consumable Torch Parts

2. Bad or no connection between work cable and workpiece

C. Main Arc Extinguishes

1. Cutting speed too slow

2. Torch standoff too high from workpiece

3. Bad or no connection between work cable and workpiece

4. Worn torch parts

D. Insufficient Penetration

1 Cutting speed too fast

2. Torch tilted too much

3. Metal too thick

4. Worn torch parts

5. Cutting current too low

E. Excessive Dross Formation

1. Cutting speed too slow

2. Torch standoff too high from workpiece

3. Worn torch parts

4. Improper cutting current

A. General Information

WARNINGS

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

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

Unthread the shield cup assembly to remove the
consumable torch parts.

1. Inspect the cup for damage. Wipe it clean or replace if
damaged. Slag built up on the shield cup that cannot
be removed may affect the performance of the system.

Torch Head

Electrode

F. Short Torch Parts Life

1. Oil or moisture in air source

2. Exceeding system capability (material too thick)

3. Cutting speed too fast

4. Excessive pilot arc time

5. Gas pressure too low

6. Improperly assembled torch

7. Torch tip contacting work piece at or above 40Amps

Start Cartridge

Tip

Shield Cup

A-03645

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

Good Tip

Worn Tip

A-03406

Manual 0-4797 5 October 20, 2006 Rev. AA.01

3. On torches with a shield cup body and a shield cap or
deflector, ensure that the cap or deflector is threaded
snugly against the shield cup body. In shielded drag
cutting operations (only), there may be an O-ring
between the shield cup body and drag shield cap. Do
not lubricate the O-ring.

Drag Shield Cap

6. Reinstall the Electrode by pushing it straight into the

torch head until it clicks.

WARNINGS

Refer to the consumables selection charts for the
proper combination of torch parts, including shield
cups and shield caps.

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

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

Start Cartridge

Lower End Fitting

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

7. Reinstall the start cartridge and tip into the torch head.

Torch Head

Electrode

Start Cartridge

Tip

Shield Cup

Art # A-03621

CAUTION

The start cartridge supplied with this torch cannot
be used with any other 1Torch or on any other power
supply except Lincoln Pro-Cut 80.

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

New Electrode

Art # A-03284

Worn Electrode

A-03645

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

NOTE

When operating the torch in a normal condition, a
small amount of gas vents through the gap between
the shield cup and the torch handle. Do not attempt
to overtighten the shield cup as irreparable damage
to internal components may result.

October 20, 2006 Rev. AA.01 6 Manual 0-4797

Torch Consumables

The illustration shows all consumable parts for this 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' cutting (with the torch tip 1/8" to 1/4" from the workpiece). This
is the preferred method for cutting metal thicker than 3/16" / 4.8 mm and at current levels above 40 amps. This
provides maximum visibility and accessibility.

Use the Shield Cup Body with the Deflector Shield Cap for improved resistance to reflected heat. This combination
provides cutting results similar to the single-piece Shield Cup, as well as easy change-over to gouging or drag shield
cutting.

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.

The Standoff Guide fits both shield cup designs for this torch. The Guide allows the user to easily adjust and maintain
a consistent standoff height for most applications.

The start cartridge will not work for other applications.

Use only Genuine Thermal Dynamics consumables with this torch. The use of any other consumables may irreparably
damage the torch and/or void the warranty.

Electrode

9-8215

Art # A-05545

Start Cartridge

9-8257

DRAG SHIELD

CUTTING

Tip:

80A 9-8211

STANDOFF

CUTTING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Shield Cap, Drag
70-100A 9-8236

Shield Cap, Deflector

9-8243

Standoff Guide

for All Applications

9-8422

Manual 0-4797 7 October 20, 2006 Rev. AA.01

Replacement Hand Torch Parts

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (include items no. 2 & 3) 9-7030

2 1 Trigger Assembly Replacement Kit 9-7034

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

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

5 1 Large O-Ring 8-3487

6 1 Small O-Ring 8-3486

7 Leads Assembly with Lincoln Connectors (includes switch assemblies)

1 SL80 25' (7.6m) Leads Assembly 4-7865

includes valve assembly and Power Supply male connector

1 SL80 50' (15.2m) Leads Assembly 4-7866

includes valve assembly and Power Supply male connector

1

7

2

4

5

6

1

3

7

Art # A-04744

October 20, 2006 Rev. AA.01 8 Manual 0-4797

Complete Assembly Replacement

Description Catalog #

Pro-Cut® 80

Options

Every effort has been made to provide complete and accurate information in this manual. However, the
publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by
errors or omissions in this Manual, whether such errors result from negligence, accident, or any other cause.

Hand Torches with Ergonomic Handle:

SL-80 Hand Torch 25 ft 7.6m 7-5257

SL-80 Hand Torch 50 ft 15.2m 7-5258

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

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

Straight Line Cutting Guide 7-8911

Radius / Roller Kit 7-7501

Circle Cutting Guide 7-3291

Deluxe Cutting Guide Kit 7-8910

Standoff Guide 9-8422

NOTE

Manual 0-4797 9 October 20, 2006 Rev. AA.01

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

October 20, 2006 Rev. AA.01 10 Manual 0-4797

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 becomes invalid if the product is sold by non-authorized persons.

All SureLok™ RPT Torches have a one year Parts & Labor warranty

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal
Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under
this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility
of the customer. All returned goods shall be at the customer’s risk and expense.

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, NH 03784 USA

Telephone: [phone]

www.thermal-dynamics.com

Manual 0-4797 11 October 20, 2006 Rev. AA.01