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