Thermal dynamics 1torch sl60 hand torch User manual

711ERMAL

Original Publication Date: 2002

R.evision Date:

3/22/2017

1vlanual no.: 0-2880

Revision: AE

The

lTorch® SL60,

SL60QDTM

and

SLlOO Torches ·work

with

most

plasn1a

cutting

power

supplies.

The

SL60QDTM

is

for

use

on

non-high

frequency

units

only.

The

Torches

are

equipped

with

either

()2ß

connectors

or

the

Thermal

Dynamics

ATC

connector

and

are

connected

using

vari-

ous

Adapter

Kits

sold

separately.

A

Iabel

on

the

torch

handle

indicates

the

torch

model

number.

The

SL60

and

SL60QD™Torches

provide

cutting

capabilities

of

up

to

80

amperes.

SLlOO

Torches

provide

cutting

capabilities

of

up

to

120

amperes.

The

torches

use

compressed

air

as

both

the

plasma

and

secondary

gas.

The

torches

are

suitable

for

drag

cutting

(with

the

torch

tip

in

contact

with

the

workpiece,

at

up

to

60

Amps

output);

40-100

Amp

shielded

drag

cutting

[with

shielded

torch

parts

(

cap,

etc.)

in

conta.ct wit:h

the

workpiece

]; stan.doff

cutting;

or

gouging.

Refer

to

the

Complete

Assembly

Replacement

page

for

configurations

and

catalog

numbers.

These

instructions

are

important

for

the

proper

instal-

lation.

of

the

Torches.

Read

the

instructions

thorou.ghly

before

attempting

the

installati.on.

Keepthese

instructions

:for refe:rence.

The

Replacement

Torches

include:

• Torch

With

Leads-

1

each

•

Installation

Instructions

- 1

each

•

Consumables

(Installed

on

the

Torch):

Electrode,

Starter

Cartridge,

Tip, Shield

Cup

Body

a.nd

Drag

Shield

Cap)

1Torch®

:.~}<:~····

·w.y••

•

·••

····•

. ••

·•

...

..

··•·

•

•·•··

•·••····

• ' . •

...

'

with

~-.~·

ntchnology

SL60,

SL60QD

and

SL

1

00

Replacement Plasma

Cutting

Hand

Torches

Installation and Operation lnstructions

NOTE!

The

consumable

parts

in-

stalled

in

the

1brch

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.

The

following

options

are

available. Refer

to

the

complete

assernbly

replacement

Iist

for

catalog

numbers.

•

ATCAdapter

Kit (forTorches

withATC

Connectors)

•

Leads

extensions

(

for

Torches

with

ATC

Connectors)

•

Cutting

Guide

Kits

•

Leather

Leads

Covers

•

Standoff

Cutting

Guide

A.

Torch Configurations and Dimensions

The

torch

head

is

at

either

75°

or

90°

to

the

torch

handle.

The

torch

includes

a

torch

handle

and

torch

trigger

as-

sembly.

I~

T

3.75

11

(95 mm

.1_,

10.125

11

(257 mm)

--~•I

1~1.17"

(29 mm)

SL60

and

SLJ 00

Art # A·03322_AB

_M_an_u_al_o_-2_B_a_o

__________________________________________

~~

1

1-4-1•---

10.125" (257 mm)

---~~>I

T

1.17" (29 mm)

SL60QD

B.

Torch Leads Lengths

Art#

A-13246

20 foot I

6.1

m,

or

50 foot I 15.2 m

For torches

with

ATC Connectors, leads extensions

areavail.able toextend the Ieads loa

maximum

of

50

feet I 15.2 m. Total Ieads lengths

must

not

exceed

the

power

supply

manufacturer's recommendations.

C.

Current Rating (Refer to Note)

SLlOO

Torch &

Leads

NOTE!

0

Power

Supply

characteristics

will

determine

material

thick-

ness

range.

D.

Torch Ratings

100%@

60

Maximum

Current

7kV

E.

Type of Cooling

Combination ofambient air

and

gas

stream

through

torch.

F.

Gas Requirements

60-75

psi

4.1-5.2

bar

125 I 8.6

bar

Gas Flow (Cutting

and

Gouging)

~

WARNING

~

This

torch

is

not

to

be

used

with

oxygen

(0

2

).

0

NOTE!

Operatingpressurevarieswith

torchmodel,operatingamper-

age,

and

torch

leads

length.

Refer to gas pressure settings

chart for each model.

G.

Direct Contact Hazard

Forexposed

tip

the

recommended

standoffis

1/8"

-11

4"

(3-6.4mm).

H.

Parts-ln-Piace (PIP) Circuit -12-15 vdc

The torch

and

Ieads include circuitry called Parts-

ln-Piace (PIP). This circuitincludes a switch located

at

the torch head. The shield

cup

closes this switch

when

properly

installed.

The

torch will

not

operate

if this switch is open.

1111(

0

Torch Switch I Torch Trigger

To Control

111(

0 I

Cable Wiring

....

ttti(E-----.

PIP Switch

0 I Shield Cup

A-02997

111(

0 I

2 '\..

Manual

0-2880

'------------------------------

1here

are

two

types of connection for

the

Torch Leads.

One

typeusestheThermalDynamicsATC connector. The

other

uses

02B

connections for gas

and

circuitry. Both

types require

an

adapter

kit

sold

separately.

ATC Connectors

Follow the instructions

provided

with

the

adapter

kit to

connect the

adapter

to

the

power

supply.

Inspect thehalves oftheATC Connector. Align

the

male

connecto.r wi.th

the

female

receptacle

and

push

them

tagether

by

hand

until

they

seat

fully. Turn

the

Locking

Ring until

it

pulls

the

halves

of the connecto.r

tagether

fully.

Do

not

use

tools

to

tighten

the

connector.

If

there

is

any

resistance to

the

ring

tuming,

pull thehalvesofthe

connector

apart,

realign

the

inner

components,

ensure

that

the

threaded

components

are aligned,

and

push

the

halves of

the

connector together again.

028

Connectors

Leads

with

02B

connectors are connected

to

the

power

supply

using

adapter

kits

sold

separately. Follow

the

instructions

provided

with

the

adapter

kit to connect

the

gas

and

electricallines to the

power

supply.

The

new

SL60QDTM

(QuickDisconnect) torch allows

for a

quick

change of

the

torch

handle

assemblyfrom

the

leads.

To

change

the torch

handle

assembly

do

the

following.

1.

Remove

the

torch

handle

assembly

by

grasping

the

torch

handle

in

one

hand

and

the

coupler

nut

and

leads

in

the

other.

2.

Rotate the

nut

a

minimum

of

one

full

turn

to the

left (counterclockwise)

and

pull the torch

handle

assembly

out

from

the

leads

in

a straight line.

3.

To

reattach,

grasp

both

as

before

and

carefully

align

the

intemal

connecting parts.

4.

Carefullypress

the

two

tagether

in

a straightline.

5.

Align

the

mark

on

the

coupler

nut

with

that

on

the

top

of

the

torch

handle

and

rotate to

the

right

(clockwise)

drawing

the

two

tagether

and

seating

theconnectionsinside. Do

not

usetools to tighten.

The

parts

kit

provided

with

the torch

indudes

an

adhe-

sive label. Select

the

small

perforated

section

showing

the

appropriate

pressuresettingfor the

amperage

output

and

Ieads

length

tobe

used

with

this torch. Refer

to

the

charts.

Apply

this section

in

the

'Gas Supply' area

of

the

labelund

er

the

'Recommended

Operating

Pressure' text.

Discard

any

pressure settingsections

of

the

label

that

will

not

be

used.

Apply

the

large label

to

the

power

supply,

where

the

operator

can

see it for

easy

reference.

Refcr

to

the

Consumablcs

Selection

Chart

for

the

various

torch

parts

for

the

application

and

operation.

WARNING

Disconnect

primary

power

to

the

system

before

disassem-

bling

the

torch

or

torch

Ieads.

00

NOT

touch

any

internal

torch

parts

while

the AC indi-

catorlightofthe

Power

Suppl

y

isON.

The

shield

cup

(or shield

cup

body

and

shield

cap

or

de-

t1ector)

holds

the tip

and

starter

cartridge

in

place. Posi-

tion 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:

1. Unscrew

and

remove

the

shield

cup

from the

torch

head.

TorchHead

~

Electrode \

Start Cartridge

~

Art#

A·03417

Tip

-~

Shield Cup

Assembly

~M~an~u~ai~0~-2~8~80~--------------------------------------~~

3

2.

Tut the torch

head

to remove the tip

and

starter car-

tridge.

3.

Inspectthe

two

0-rings

on

thetorchhead. Ensurethey

are

undamaged

and

seated in the

0-ring

grooves.

4.

Fit

the

desired startercartridge

and

tip

onto

the elec-

trode.

0

NOTE!

Refer to the consumables se-

lection

chart

for

the

proper

combinationoftorchparts,in-

cluding shield cups

and

caps.

5.

Hand

tighten the shield

cup

until it is seated

on

the

torch head. Do

not

use tools

to

tighten the cup. Jf

resistance is feit

when

installing the cup, check the

threads before proceeding.

0

NOTE!

When

operating

the

torch

in

a

normal

condition, a small

amount

of gas vents

through

the

gap

between

the

shield

cup

and

the

torchhandle.

Do

not

attempt

to overtightenthe

shield

cup

asirreparabledarn-

age

to

internal

components

mayresult.

Gouging Parts Selection

Selectgougingtips according tothe desiredgougeprofile.

Gougingparameters

shown

are

based

on

a 35° approach

angle.

Setgas

pressure

at

the

power

supply

regulatoraccording

to the following charts. These charts are a

guide

only;

adjust as necessary for

best

performance.

30A,40A,

50155A,

60A,

70A,80A

65 psi I 4.5 bar

60 psi I

4.1

bar

65 psi I 4.5 bar

75 psi I 5.2 bar

65 psi I 4.5

bar

70

15.2

bar

120A 75 psi I 5.2 bar

80

psi

I 5.5 bar

Cuttlng or Gauging

'lhe

torch can

be

held

comfortably

in

one

hand

or

stead-

ied

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

adjustgas pressure

on

the

Power

Supply pressure gauge. Refer

to

the charts for opti-

mum

pressure settings for the combination of torch

tip

and

totalleads

lengths

(induding

extensions) in

use.

2.

Adjust

current

output

on

the

Power

Supply to

match

the

selected tip

and

attach the

work

damp

firmly

to

thework.

WARNINS

Maximum

current is 80

Amps

for SL60

and

SL60QD™Torch-

es,

or

120

Amps

for

SL100

Torches.

Operation

of

this

torch

at

higher

outputs

may

darnage

the

torch, the leads,

or

thePowerSupply.

00

NOT

operatethe

SL60

or

SL60QD™

Torch

at

more

than

80 Amps,

or

the

51.100

at

more

than

120

Amps.

4

"'-

Manual

0-2880

"'-~---------------------------

WARNING

This

Torch

is

not

to

be

used

with

oxygen

(02).

The

SL60QD

torch

shou/d

not

be

used

on

an

HF

system

.

.A\.

CAUTION

~

Do

not

operate

the

torch

with

the

torch

tip

in

contact

with

the

work

at

outputs

greater

than

40

amps,

or

greater

than

60

amps

is

using

the

60

amp

drag

tip.

Drag

cutting

at

higher

output

currents

can

cause

irrepa-

rable

darnage

to

the

torch

parts.

Use

only

shielded

parts

at

output

currents

higher

than

40

amps.

3.

Hold

the

torch

away

from

your

body.

4.

Slide

the

trigger release

toward

the

back of

the

torch

whilesimultaneouslysqueezing

the

trigger.

The

pilot

arc wiJl start.

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

preflow

and

postflow

are a characteristicof

the

pow-

er

supply

and

not

a fW1ction of

the

torch.

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

prop-

erly 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

darnagecomponents.

8.

The

optional

StandoffGui.de allows the user to easily

adjust

and

maintain

a consistent

standoft

height

for

most applications.

--

Shield

Cup

~-=,::J-

Stand~ff

Guide

l;.-.r

-Torch

T1p

Werkpiece

Art

#

A-ü4063

Manual

0-2880

/

----------------------------~

5

The follow:ing are the more com.mon cutting faults

and

the

possible causes:

1.

Insuffident

Penetration

a.

Cutting speed

too

fast

b.

Tarch

tilted

too

much

c.

Meta!

too

thick

d.

Worn torch parts

e.

Cutting current

too

low

f Non-Genuine Thennal Dynamics Parts

2.

Main

Are Extinguishes

a.

Cutting speed

too

slow

b.

1Qrch

standoff

too

highfrom workpiece

c.

Cutting current

too

high

d.

Work

cable

disconnected

e.

Worn torch parts

f Non-Genuine Thermal Dynamics Parts

3.

Exce10sive

Dr4)ss Formation

a.

Cutting speed

too

slow

b.

Torch

standoff

too

highfrom workpiece

c.

Wom

torch parts

d.

Improper cutting current

e.

Non-Genuine Thermal Dynamics Parts

4.

Short

Torch

Parts

Life

a.

Oil

or

maisture in air source

b.

Exceeding system capability (material

too

thick)

c.

Excessive pilot

arc

time

d.

Gas

pressure

too

low

e.

Improperly assembled torch

f Non-(;enuine Thermal Dynamics Parts

5.

Di~cul~

Starting

a.

Worn torch consumables

b.

Non-

Genuine Thermal Dynamics Parts

6.

Torch

will

not

pilot

when

torch

switch

is

activated

a.

Upper

0-ring

on torch

head

is

in wrang position

Art # A-03640

Upper

Groove

with Vent Holes

Must Remain Open

A.

Generalinformation

WARNING

Disconnect

primary

power

to

the

system

before

disassem-

bling the torch

or

torch leads.

DO

NOT

tauch

any

irrtemal

torch

parts

while

the

AC indi-

catorlightof

the

PowerSupply

isON.

Unthreadtheshield

cup

assem.blytoremovetheconsum-

able torch parts.

1.

Inspect

the

cup

for damage. Wipeitclean

or

replaceif

damaged. Slagbuilt

up

on

the shield

cup

that

cannot

be

removed

may

affect theperformanceof thesystem.

TorchHead

~

Electrode

-\

Start

Cartridge

--Q

Art # A-03417

Tip~

Shield

Cup

Assembly

6 "\..

Manual

0-2880

'~-----------------------------

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-Q3406

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

0-ring

between

the

shield

cup

body

and

drag

shield

cap.

Do

not

lubricate

the

0-ring.

Shield

Cup

Body

0-Ring

No.

8-3488

Art

# A-Q3878

Drag

Shield

Cap

4.

Check

the

starter

cartridge

for

excessive

wear,

plugged

gas

holes, discoloration,

and

for free

move-

ment

of

the

lower

end

plate.

Replace

ifnecessary.

Start Cartridge

Lower

End

Fitting

Art

il

A-Q3621

5.

Check

the

end

of

the

electrode

for excessive wear.

rrr-rl~

n-J~Ih-~

~~U-

New

Electrode

Worn Electrode

Art#

A-03284

6.

ReinstaU

the

Eiectrode

by

pushing

it

straight

into

the

torch

head

until

it

clicks.

WARNING

Refer

to

the

consumables

se-

lection

charts

for

the

proper

combination

of

torch

parts,

including

shield

cups

and

shield

caps.

The

use

of

any

consumable

parts

other

than

those

speci-

fied

by

the

Manufacturer

may

cause

irreparable

darnage

to

the

torch

head.

7.

Reinstall

the

desired

starter

cartridge

and

tip

into

the

torch

head.

8.

I-land

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

darn-

age

to

intemal

components

may

result.

8.

0-Ring Lubrication

This

section

applies

only

to

torches

withATC

con-

nectors.

An

o-ring

on

the

TorchATC

Male

Connector

requires

lubrication

on

a

regular

basis,

depending

on

how

fre-

quently

the

torch

is

disconnectcd

and

re-connected.

This

will

allow

the

o-ring

to

remain

pliable

and

pro-

vide

a

proper

seal.

The

o-ring

will

dry

out,

bccoming

hard

and

cracked,

if

the

o-ring

lubricant

is

not

used

on

a

regular

basis.

This

can

lead

to

potential

perfor-

mance

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.

Manual

0-2880

/

~~~--------------------~

7

8

0

NOTE!

Art #A-03791_AB

DO

NOT

use

other

lubricants

or

greasc,

thcy

may

not

be

designed

to

operate

within

high

temperatures

or

may

contain

"unknown

elements"

that

may

react

with

the

at-

mosphere. This reaction can

leave

contaminants

inside the

torch. Either of these condi-

tions

can

lead

to

inconsistent

performance

or

poor

parts

life.

0-Ring

#R-OS?S

The

illustrations

show

all

consumable

parts

for

the

SL60,

SL60QD™

and

SLlOO

torches.

Various front

-end

torch

parts

are available for different

applications.

Drag

Tip Cutting: Use

the

single-

piece shield

cup

for

general

purpose

cutting

operations

with

the

torch

tip

in

contact

with

the

work

(up

to 60 amps). This is the

preferred

method

of

cutting

sheet

metal

up

to

3/16"

or

4.8

mm

thick.

StandoffCutting: Also

usc

the

single-

piece Shield

Cup

for 'standoff'

cutting

(with

thetorch

tip

1/8"

to

1/4"

from

the

workpicce). This is

the

preferred

method

for

cutting

metal

thicker

than

3/16"

I 4.8

mm

and

at

current

levels

above 40 amps. This

provides

maximum

visibility

and

accessibility.

Use

the

Shield

Cup

Bodywith

the

DeflectorShield

Cap

for

extended

parts

life

and

improved

resistance to reflected

heat. Thiscombinationprovides cuttingresultssimilarto

the

single-piece Sh:ield

Cup,

as

well as

easy

change-over

to

gouging

or

drag

shield cutting.

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

40

and

120 amps.

Gouging:

Use

the Shield

Cup

Body

with

the

Gauging

Shield

Cap

for excellent

gouging

performance

and

en-

hanced

torch

parts

life_

TheStandoff

Guide

fits all shield

cup

designsfor theSL60,

SL60QD™

and

SLlOO

RPT

hand

torches. The

Guide

al-

lows

the

user

to easily

adjust

and

maintain

a consistent

standoffheightfor

most

applications. TheStandoff

Guidc

also fits

Thermal

Dynamics PCH-62

and

PCH-102

hand

torches.

The

electrode

and

starter

cartridge are

the

same

for all

applications.

Use

only

Genuine

Thermal

Dynamicsconsumables

with

this torch. The use of

any

other

consumables

may

irrepa-

rably

darnage

the

torch

and/

or

void

the

warranty.

'-

Manual

0-2880

'-~----------------------------

DragTip

Cutting

L 1/8" I 3.2

mm

@ 40A

~

1/8-1/4"

/3.2~

@60A

Drag Shield

'-r----.'

Cutting

Art

# A·07039_AB

~40A

50-

100A I+

60-

120A

~

120A

~M=an~u=ai~0~-2~8~80~----------------------------------------~

9

10

Starter

Cartridge

9-8213

DRAGTIP

CUTTING

Jr..

40A

CUTTING

_ft

50-BOA

CUTTING

_ft

20A 9-8205

30A 9-8206

40A 9-8207

-@

Shield Cap, Deileetor

9-8243

~~~~~~-----------------------------

DRAGSHIELD

0-Ring

No.

8-3488

:-Ji-T~l

Shield Cap, Drag

,

n~

:50-60A 9-8235

L~Q---~~ield

Cap,

Deileetor

~

9-8243

~~Y-~-

~.~~~

Electrode

9-8215

Extended

Life

9-8214

Art # A-04037

...

AB

70-120A

CUTTING

_ft

70A

9-8231

BOA

9-8211

90/lOOA 9-8212

120A 9-8253

ISTANDOFF CUTTING I

0-Ring

No.

8-3488

:-u------:

shield cap, orag

I 0 : 70-100A 9-8236

I

ß~~ietd

1

~::

:e:::or

~

9-8243

~-~~~-----------------------------------

40-120A

:lG

TipA

TipB

TipC

{jr., Shield Cap, Gouging

-w

9-8241

Standoff Guide

40 Amp Tip -9-8251

60 Amp

Tip-

9-8281

for All Applications

9-8422

"\..

Manual

0·2880

"\..~-----------------------------

Thermal Dynamics 1Torch SL60 Hand Torch User manual

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