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Thermal Dynamics SL100 HAND TORCH, Instruction Manual

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Thermal Dynamics SL100 HAND TORCH Instruction Manual Download Page 87

Manual 0-2962

A-27

APPENDIX

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

Not Used

PIP

Switch

1

2

3

4

1

2

3

4

ATC

Male

Connector

ATC Adapter

Female

Receptacle

Pilot 

Orange

Black

White

8

5

7

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

Not Used

PIP

Switch

1

2

3

4

1

2

3

4

ATC Male

Connector

Pilot 

White

8

5

7

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

Summary of Contents for SL100 HAND TORCH

Page 1: ...Start Max Input 125PSI Op Pres 60 75 PSI Max Flow 400 scfh 60 PLASMA CUTTING TORCH Rev AA 01 Date October 20 2006 Manual 0 2962 OperatingFeatures Instruction Manual SL60 SL100 Model SL60 SL100 Hand To...

Page 2: ...please take the time to read the entire manual especially the Safety Precautions They will help you to avoid poten tial hazards that may exist when working with this product YOU ARE IN GOOD COMPANY T...

Page 3: ...11 www thermal dynamics com Copyright 2003 2004 2005 2006 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher...

Page 4: ......

Page 5: ...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 m...

Page 6: ...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 a...

Page 7: ...re Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis High...

Page 8: ...2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicabl...

Page 9: ...s 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...

Page 10: ...GENERAL INFORMATION 1 6 Manual 0 2962...

Page 11: ...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 m...

Page 12: ...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 a...

Page 13: ...re Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis High...

Page 14: ...2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicabl...

Page 15: ...s 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...

Page 16: ...GENERAL INFORMATION 1 6 Manual 0 2962...

Page 17: ...rom a single source to be used as both the plasma and secondary gas The air flow is divided inside the torch head Single gas operation provides a smaller sized torch and inexpensive operation NOTE Ref...

Page 18: ...operate the SL60 torch at more than 60 Amps or the SL100 at more than 100 Amps NOTE Power Supply characteristics will determine mate rial thickness range H Gas Requirements Gas Plasma and Secondary Co...

Page 19: ...rLeadsCovers 2 05 Introduction to Plasma A Plasma Gas Flow Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes elec trically conductive The plasma arc...

Page 20: ...tarc capacitivedischargeisalsoused Thehighvoltagejumpsbetweenthetipandelectrodewith theDCfollowing NOTE Not all power supplies have this feature E Main Cutting Arc DC power is also used for the main c...

Page 21: ...ing 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...

Page 22: ...orches 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 sup ply front panel Torches with O2B fittings...

Page 23: ...tud 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...

Page 24: ...ole in the unit b Tighten the Through Hole protector Nut to secure the Through Hole protector to the Power Supply 4 Connect the Adapter Negative Plasma Lead to the bulkhead connection inside the Power...

Page 25: ...chanized torch leads with O2B connectors require a remote pendant adapter to ac cept a remote pendant WARNING Disconnect primary power at the source before dis assembling the torch or torch leads 1 Re...

Page 26: ...h O2B Fittings and Remote Pendant Adapter 9 Connect the Torch Leads connectors and the re mote pendant adapter connector to the power supply adapter as shown Remote Pendant Adapter Wire Harness A 0367...

Page 27: ...ion 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 previ ously 7 Connect theATCAda...

Page 28: ...ay Differ from Type Shown Bulkhead Connections Shielded Machine Torch Leads with O2B Connectors 8 Tighten the Through Hole protector onto theATC Adapter leads 9 Check the torch for proper consumable p...

Page 29: ...N SET LATCH RUN SETorRUN RAPIDAUTORESTART SETSwitchisinSETposition gaswillflow IftheswitchisinRUNpositiontherewillbe nogasflow F RUN SET LATCH RUN SET or RUN RAPID AUTO RESTART Switch IftheRUN SET LAT...

Page 30: ...hield 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 an...

Page 31: ...er surfaces such as glass plastic and metal NOTE Handle torch leads with care and protect them from damage A Piloting Pilotingisharderonpartslifethanactualcuttingbecause thepilotarcisdirectedfromtheel...

Page 32: ...ith 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 hea...

Page 33: ...conductive straightedgetomakestraightcutsbyhand WARNING The straight edge must be non conductive A 03539 Non Conductive Straight Edge Cutting Guide UsingDragShieldCupWithStraightEdge Thecrownshieldcup...

Page 34: ...ws good control and movement NOTE The tip should never come in contact with the work piece except during drag cutting operations 2 Anglethetorchslightlytodirectblowbackparticles away from the torch ti...

Page 35: ...garcisdirectedinthesamedirectionastorch travel Afive degree leading arc is generally recom mendedforairplasmaonmildsteel 3 TrailingArc Thetrailingarcisdirectedintheoppositedirectionas torchtravel Stan...

Page 36: ...those shown Refer to Appendix Pages for cutting speed chart information as related to the Power Supply used 4 10 Gouging WARNINGS Be sure the operator is equipped with proper gloves clothing eye and e...

Page 37: ...cts 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 di...

Page 38: ...OPERATION 4 10 Manual 0 2962...

Page 39: ...rfaces such as glass plastic and metal NOTE Handle torch leads with care and protect them from damage 5 02 General Torch Maintenance A Cleaning Torch Even if precautions are taken to use only clean ai...

Page 40: ...Either of these conditions can lead to inconsistent performance or poor parts life ATC Male Connector Art A 03791 Gas Fitting O Ring 5 03 Common Operating Faults The following lists the more common cu...

Page 41: ...nspect the cup for damage Wipe it clean or replace if damaged Art A 03417 Electrode Start Cartridge Tip Shield Cup Assembly Torch Head Consumable Parts 3 On torches with a shield cup body and a shield...

Page 42: ...use Italic Type a Check Remedy Text Type Locate your symptom check the causes easiest listed first then remedies Repair as needed being sure to verify that unit is fully operational after any repairs...

Page 43: ...put connections 2 Current set too low at power supply a Increase current setting 3 Torch is being moved too fast across workpiece a Reduce cutting speed refer to Appendix Page for the Power Supply bei...

Page 44: ...SERVICE 5 6 Manual 0 2962...

Page 45: ...s 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 Optio...

Page 46: ...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 Lea...

Page 47: ...Manual 0 2962 6 3 PARTS LISTS 8 5 6 3 4 2 7 10 11 Requires Adapter Kit For Proper Installation OR May Require ATC Adapter Kit For Proper Installation A 03664 1 9...

Page 48: ...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 c...

Page 49: ...PARTS LISTS A 03665 May Require ATC Adapter Kit For Proper Installation Requires Adapter Kit For Proper Installation 6 OR May Require ATC Adapter Kit For Proper Installation 1 4 2 3 5 7 8 9 10 11 14...

Page 50: ...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...

Page 51: ...Manual 0 2962 6 7 PARTS LISTS Art A 03616 1 2 3 5 4 6 Torch Continuity PIP Switch Torch Connection Fitting 5 Torch Continuity PIP Switch Adapter Wire 7 6...

Page 52: ...h the Deflector Shield Cap forextendedpartslifeandimprovedresistancetoreflected heat This combination provides cutting results similar to the single piece Shield Cup as well as easy change over to gou...

Page 53: ...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 Ti...

Page 54: ...Shield Cap for extendedpartslifeandimprovedresistancetoreflectedheat Thiscombinationprovidescuttingresultssimilartothesingle pieceShieldCup aswellaseasychange overtogougingor dragshieldcutting Usethe...

Page 55: ...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...

Page 56: ...t gouging performance and enhanced torch parts life Theelectrodeandstartercartridgearethesameforallopera tions 6 11 Automated Torch Spare Parts Kits Item Catalog No 40 Amp Kit Cat No 5 0054 60 Amp Kit...

Page 57: ...s 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...

Page 58: ...ith 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...

Page 59: ...tensions 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 Ki...

Page 60: ...ed 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 Shie...

Page 61: ...nect 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 ACTIO...

Page 62: ...APPENDIX A 2 Manual 0 2962 This page intentionally blank...

Page 63: ...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 de crease from the Machi...

Page 64: ...lication Electrode Starter Cartridge Tip Shield Cup Body Shield Cap or Deflector Shield Cup Drag Cutting 9 8215 9 8213 9 8207 40A None None 9 8218 9 8215 9 8213 9 8208 40A None None 9 8218 9 8215 9 82...

Page 65: ...age Speed Per Minute Standoff Plasma Gas Press Flow SCFH Pierce Pierce Height Inches mm Cat No VDC Amps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 20 ga 0 9 9 8207 80 40 300 7 62...

Page 66: ...slight top edge rounding Application Electrode Starter Cartridge Tip Shield Cup Body Shield Cap or Deflector Shield Cup 9 8215 9 8213 9 8208 40A None None 9 8218 9 8215 9 8213 9 8208 40A 9 8237 9 8245...

Page 67: ...peed Per Minute Standoff Plasma Gas Press Flow SCFH Pierce Pierce Height Inches mm Cat No VDC Amps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 20 ga 0 9 9 8208 90 40 300 7 62 0 13...

Page 68: ...th cut surface slight top edge rounding Application Electrode Starter Cartridge Tip Shield Cup Body Shield Cap or Deflector Shield Cup Drag Cutting 9 8215 9 8213 9 8207 40A None None 9 8218 9 8215 9 8...

Page 69: ...hickness Tip Output Volts Amperage Speed Per Minute Standoff Plasma Gas Press Flow SCFH Pierce Pierce Height Inches mm Cat No VDC Amps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm...

Page 70: ...easily re moved medium smooth cut surface slight top edge rounding Application Electrode Starter Cartridge Tip Shield Cup Body Shield Cap or Deflector Shield Cup 9 8215 9 8213 9 8210 60A None None 9...

Page 71: ...s Torch Thickness Tip Output Volts Amperage Speed Per Minute Standoff Plasma Gas Press Flow SCFH Pierce Pierce Height Inches mm Cat No VDC Amps Inches Meters Inches mm psi bar Plasma Total Delay Sec I...

Page 72: ...ss easily removed medium smooth cut surface slight top edge rounding Application Electrode Starter Cartridge Tip Shield Cup Body Shield Cap or Deflector Shield Cup 9 8215 9 8213 9 8211 80A None None 9...

Page 73: ...ed Per Minute Standoff Plasma Gas Press Flow SCFH Pierce Pierce Height Inches mm Cat No VDC Amps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 05 1 3 9 8211 100 80 350 8 89 0 19 4...

Page 74: ...ious Materials Material Type of Type of Cut Thickness Material Gas Characteristics Gage to Air Air Air Good Excellent Good Good Carbon Steel Stainless Aluminum 1 5 inch 38 mm DescriptionofCutCharacter...

Page 75: ...8 90 490 0 0 19 4 8 3 8 9 5 9 8212 110 100 65 1 65 0 19 4 8 70 4 8 90 490 0 0 19 4 8 1 2 12 7 9 8212 113 100 49 1 24 0 19 4 8 70 4 8 90 490 0 0 19 4 8 3 4 19 1 9 8212 118 100 24 0 61 0 19 4 8 70 4 8...

Page 76: ...Plus Power Supply APPENDIX 7A PAKMASTER 50XL PLUS SYSTEM DATA HAND TORCH Cut Quality on Various Materials and Thicknesses The following table defines the cut quality on vari ous materials and thicknes...

Page 77: ...6 N A N A 65 4 5 50 350 0 0 00 0 0 16 ga 1 5 9 8207 80 40 275 7 0 N A N A 65 4 5 50 350 0 0 19 4 8 10 ga 3 4 9 8207 80 40 105 2 7 N A N A 65 4 5 50 350 0 0 19 4 8 7 ga 4 6 9 8207 85 40 70 1 8 N A N A...

Page 78: ...tions For PakMaster 50XL Plus Power Supply APPENDIX 7B PAKMASTER 50XL PLUS SYSTEM DATA MACHINE TORCH Cut Quality on Various Materials and Thicknesses The following table defines the cut quality on var...

Page 79: ...60 4 1 50 350 0 0 19 4 8 16 ga 1 5 9 8208 90 40 275 6 99 0 13 3 2 60 4 1 50 350 0 0 19 4 8 10 ga 3 4 9 8208 90 40 115 2 92 0 13 3 2 60 4 1 50 350 0 0 19 4 8 7 ga 4 6 9 8208 95 40 75 1 91 0 13 3 2 60 4...

Page 80: ...ls and Thicknesses The following table defines the cut quality on various materialsandthicknesses Cut Quality on Various Materials Material Type of Type of Cut Thickness Material Gas Characteristics G...

Page 81: ...65 4 5 80 350 0 1 0 25 6 4 1 8 3 2 9 8210 95 60 175 4 45 0 19 4 8 65 4 5 80 350 0 25 0 25 6 4 1 4 6 4 9 8210 105 60 80 2 03 0 19 4 8 65 4 5 80 350 0 25 0 25 6 4 3 8 9 5 9 8210 105 60 45 1 14 0 19 4 8...

Page 82: ...Quality on Various Materials and Thicknesses The following table defines the cut quality on vari ous materials and thicknesses Cut Quality on Various Materials Material Type of Type of Cut Thickness...

Page 83: ...60 4 1 80 350 0 1 0 25 6 4 1 8 3 2 9 8210 95 60 175 4 45 0 19 4 8 60 4 1 80 350 0 25 0 25 6 4 1 4 6 4 9 8210 105 60 80 2 03 0 19 4 8 60 4 1 80 350 0 25 0 25 6 4 3 8 9 5 9 8210 105 60 45 1 14 0 19 4 8...

Page 84: ...H Cut Quality on Various Materials and Thicknesses The following table defines the cut quality on vari ous materials and thicknesses Cut Quality on Various Materials Material Type of Type of Cut Thick...

Page 85: ...4 1 90 490 0 0 20 5 1 1 8 3 2 9 8211 103 80 230 5 84 0 19 4 8 60 4 1 90 490 0 1 0 20 5 1 1 4 6 4 9 8211 106 80 112 2 84 0 19 4 8 60 4 1 90 490 0 1 0 20 5 1 3 8 9 5 9 8211 111 80 55 1 40 0 19 4 8 60 4...

Page 86: ...onnector Power Supply with ATC Adapter PIP Switch Torch Switch 1 2 3 4 ATC Male Connector ATC Female Receptacle Art A 03679 Orange Black Green White Pilot Negative Plasma Torch Head White Black Orange...

Page 87: ...itch 1 2 3 4 1 2 3 4 ATC Male Connector Pilot White 8 5 7 Torch Leads Torch Head Negative Plasma Green Black Pilot ATC Female Receptacle Negative Plasma Torch Unshielded Leads with O2B Connector Mecha...

Page 88: ...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 Lead...

Page 89: ...HAND TORCH UNSHIELDED MACHINE TORCH SHIELDED MACHINE TORCH Positions 3 4 8 used for optional remote pendant Positions 3 4 8 used for optional remote pendant Positions 3 4 used for remote pendant in me...

Page 90: ...APPENDIX A 30 Manual 0 2962...

Page 91: ...57 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrat...

Page 92: ...Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St Louis MO 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com...

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