Thermal Dynamics 1Torch SL60 Hand Torch User manual

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PLASMA CUTTING TORCH
Rev. AB Date: June 20, 2012 Manual # 0-2962
Operating Features:
Instruction Manual
SL60
SL100
Model SL60, SL100 Hand
Torch
Model SL100 Machine Torch

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 World-
wide.
Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through market-
leading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical sup-
port, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically ad-
vanced products to achieve a safer working environment within
the welding industry.

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
[phone]
www.thermal-dynamics.com
Copyright 2003, 2004, 2005, 2006, 2007 by
Thermal Dynamics Corporation
All rights reserved.
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 neg-
ligence, 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 #:____________________________________

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

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