Thermal Dynamics SL60 User manual

January 8, 2009 1 Manual 0-2880 Rev AB
General Information
The 1TorchTM SL60 and SL100 Torches work with most
plasma cutting power supplies. The Torches are equipped
with either O2B connectors or the Thermal Dynamics ATC
connector and are connected using various Adapter Kits
sold separately.
A label on the torch handle indicates the torch model
number. SL60 Torches provide cutting capabilities of up
to 60 amperes. SL100 Torches provide cutting capabili-
ties of up to 100 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 40 Amps out-
put); 40-100 Amp shielded drag cutting (with shielded
torch parts (cap, etc.) in contact with the workpiece);
standoff cutting; or gouging.
Refer to the Complete Assembly Replacement page for
configurations and catalog numbers.
These instructions are important for the proper installa-
tion of the Torches. Read the instructions thoroughly be-
fore 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): Electrode,
Starter Cartridge, Tip, Shield Cup Body and Drag
Shield Cap)
• Standard Shield Cup
NOTE
The consumable parts installed in the Torch may
not necessarily be optimized for your Power Sup-
ply or cutting application. For best results, refer
to the selection charts in this manual to choose the
proper consumables for your application.
Manual 0-2880
SL60 and SL100
Replacement Plasma
Cutting Hand Torches
Installation and Operation Instructions
Options
The following options are available. Refer to the complete
assembly replacement list for catalog numbers.
• ATC Adapter Kit (for Torches withATC Connectors)
• Leads extensions (for Torches with ATC Connectors)
• Cutting Guide Kits
• Leather Leads Covers
• Standoff Cutting Guide
Torch Specifications
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.
10.125" (257 mm)
3.75"
(95 mm)
1.17" (29 mm)
Art # A-03322_AB
B. Torch Leads Lengths
20 foot / 6.1 m, or 50 foot / 15.2 m
For torches withATC Connectors, leads extensions are
available to extend the leads to a maximum of 50 feet / 15.2
m. Total leads lengths must not exceed the power supply
manufacturer's recommendations.
© 2002 by Thermal Dynamics Corp., Printed in USA

January 8, 2009 2 Manual 0-2880 Rev AB
C. Current Rating (Refer to Note)
SL60 & SL100 Current Ratings
SL60 Torch & Leads
SL100 Torch & Leads
Up to 60 Amps, DC,
Straight Polarity
Up to 100 Amps, DC,
Straight Polarity
NOTE
Power Supply characteristics will determine mate-
rial thickness range.
D. Torch Ratings
Ambient
Tem
p
erature
104° F
40° C
Duty Cycle 100% @ 60 Amps @ 400 scfh
Maximum Current 60 Amps
Voltage (Vpeak)500V
Arc Striking Voltage 7kV
SL60 Torch Ratin
g
s
Ambient
Tem
p
erature
104° F
40° C
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum Current 100 Amps
Voltage (Vpeak)500V
Arc Striking Voltage 7kV
SL100 Torch Ratin
g
s
E. Type of Cooling
Combination of ambient air and gas stream through
torch.
F. Gas Requirements
Gas (Plasma and Secondary) Compressed Air
Operating Pressure
Refer to NOTE 60 - 75 psi 4.1 - 5.2 bar
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow (Cutting and Gouging) 300 - 500 scfh
(142 - 235 lpm)
SL60 and SL100 Torch Gas Specifications
!
WARNING
This torch is not to be used with oxygen (O2).
NOTE
Operating pressure varies with torch model, oper-
ating amperage, and torch leads length. Refer to
gas pressure settings chart for each model.
G. Direct Contact Hazard
For exposed tip the recommended standoff is 1/8" - 1/4"
(3 - 6.4 mm).
H. Parts-In-Place (PIP) Circuit - 12 vdc
The torch and leads include circuitry called Parts-In-
Place (PIP). This circuit includes 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.
Connecting Torch
There are two types of connection for the Torch Leads. One
type uses the Thermal Dynamics ATC connector. The other
uses O2B connections for gas and circuitry. Both types require
an adapter kit sold separately.
ATC Connectors
Follow the instructions provided with the adapter kit to con-
nect the adapter to the power supply.
Inspect the halves of theATC Connector. Align the male con-
nector with the female receptacle and push them together by
hand until they seat fully. Turn the Locking Ring until it pulls
the halves of the connector together fully. Do not use tools to
tighten the connector. If there is any resistance to the ring
turning, pull the halves of the connector apart, realign the inner
components, ensure that the threaded components are aligned,
and push the halves of the connector together again.
O2B Connectors
Leads with O2B 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 electrical
lines to the power supply.

January 8, 2009 3 Manual 0-2880 Rev AB
Spare Parts Label
The parts kit provided with the torch includes an adhe-
sive label. Select the small perforated section showing the
appropriate pressure setting for the amperage output and
leads length to be used with this torch. Refer to the charts.
Apply this section in the 'Gas Supply' area of the label
under the 'Recommended Operating Pressure' text. Dis-
card any pressure setting sections 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.
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 dis-
assembling 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 starter 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:
1. Unscrew and remove the shield cup from the torch
head.
Art # A-03417
Electrode
Start Cartridge
Tip
Shield Cup
Assembly
Torch Head
2. Tilt the torch head to remove the tip and starter car-
tridge.
3. Fit the desired starter cartridge and tip onto the electrode.
NOTE
Refer to the consumables selection chart for the proper
combination of torch parts, including shield cups
and caps.
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 pro-
ceeding.
NOTE
When operating the torch in a normal condition,
a small amount of gas vents through the gap be-
tween the shield cup and the torch handle. Do not
attempt to overtighten the shield cup as irrepa-
rable damage to internal components may result.
Gouging Parts Selection
Select gouging tips according to the desired gouge profile.
Gouging parameters shown are based on a 35° approach angle.
Output Range Depth Width
Tip A 40 Amps Max. Shallow Narrow
Tip B 40-100 Amps Deep Narrow
Tip C 40-100 Amps Moderate Moderate
Tip D 40-100 Amps Shallow Wide
Gouging Profiles
Operating Gas Pressure
Set gas pressure at the power supply regulator according to the
following charts. These charts are a guide only; adjust as nec-
essary for best performance.
Tip 20' / 6.1 m 50' / 15.2 m
30A, 40A,
50/55A, 60A 65 psi / 4.5 bar 75 psi / 5.2 bar
Leads Length
SL60 GasPressure Settings
Tip Up to 25' / 7.6 m 50' / 15.2 m
30A, 40A,
50/55A, 60A,
70A, 80A 60 psi / 4.1 bar 65 psi / 4.5 bar
90/100A 65 psi / 4.5 bar 70 psi / 5.2 bar
SL100 Gas Pressure Settings
Leads Length

January 8, 2009 4 Manual 0-2880 Rev AB
Cutting or Gouging
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 Sup-
ply pressure gauge. Refer to the charts for optimum pres-
sure settings for the combination of torch tip and total
leads lengths (including extensions) in use.
2. Adjust current output on the Power Supply to match the
selected tip and attach the work clamp firmly to the
work.
!
WARNING
Maximum current for is 60 Amps for SL60 Torches,
or 100 Amps for SL100 Torches. Operation of this
torch at higher outputs may damage the torch, the
leads, or the Power Supply. DO NOT operate the
SL60 Torch at more than 60 Amps, or the SL100
at more than 100 Amps.
CAUTION
Do not operate the torch with the torch tip in contact
with the work at outputs greater than 40 amps. Drag
cutting at higher output currents can cause irrepa-
rable damage 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
while simultaneously squeezing the trigger. The pi-
lot arc will start.
A-02986
Trigger
Trigger Release
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 characteristic of
the power supply and not a function of the torch.
3
4
Art # A-03383
Trigger
2
1
Trigger Release
6. Cut as usual. Simply release the trigger assembly to
stop cutting.
7. Follow normal recommended cutting practices as pro-
vided in the power supply operator's manual.
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 nor-
mal 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 ad-
just and maintain a consistent standoff height for most ap-
plications.
Art # A-04063
Shield Cup
Standoff Guide
Torch Tip
Workpiece

January 8, 2009 5 Manual 0-2880 Rev AB
Common Operating Faults
The following are the more common cutting faults and the
possible causes:
1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non-Genuine Thermal Dynamics Parts
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts
f. Non-Genuine Thermal Dynamics Parts
3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non-Genuine Thermal Dynamics Parts
4. Short Torch Parts Life
a. Oil or moisture 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-Genuine Thermal Dynamics Parts
5. Difficult Starting
a. Worn torch consumables
b. Non - Genuine Thermal Dynamics Parts
6. Torch will not pilot when torch switch is activated
a. Upper O-ring on torch head is in wrong position
Lower O-Ring
Upper O-Ring
in Correct Groove
Upper Groove
with Vent Holes
Must Remain Open
Threads
Art # A-03640

January 8, 2009 6 Manual 0-2880 Rev AB
Inspection and Replacement of
Consumable Torch Parts
A. General Information
WARNINGS
Disconnect primary power to the system before dis-
assembling 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.
Art # A-03417
Electrode
Start Cartridge
Tip
Shield Cup
Assembly
Torch Head
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
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 be-
tween the shield cup body and drag shield cap. Do not
lubricate the O-ring.
Drag Shield Cap
Shield
Cup Body
O-Ring No. 8-3488
Art # A-03878
4. Check the starter cartridge for excessive wear, plugged gas
holes, discoloration, and for free movement of the lower
end plate. Replace if necessary.
Lower End Fitting
Start Cartridge
Art # A-03621
5. Check the end of the electrode for excessive wear.
Worn Electrode
New Electrode
Art # A-03284

January 8, 2009 7 Manual 0-2880 Rev AB
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.
The use of any consumable parts other than
those specified by the Manufacturer may cause
irreparable damage to the torch head.
7. Reinstall the desired starter cartridge and tip into the
torch head.
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 condi-
tion, 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 compo-
nents may result.
B. O-Ring Lubrication
This section applies only to torches withATC connec-
tors.
An o-ring on the Torch ATC Male Connector requires
lubrication on a regular basis, depending on how fre-
quently the torch is disconnected and re-connected. This
willallow the o-ringto remainpliable and providea proper
seal. The o-ring will dry out, becoming hard and cracked,
if the o-ring lubricant is not used on a regular basis.
This can lead to potential performance 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.
NOTE
DO NOT use other lubricants or grease, they
may not be designed to operate within high tem-
peratures or may contain “unknown elements”
that may react with the atmosphere. This reac-
tion can leave contaminants inside the torch.
Either of these conditions can lead to inconsis-
tent performance or poor parts life.
ATC Male Connector
Art #A-03791
Gas Fitting
O-Ring

January 8, 2009 8 Manual 0-2880 Rev AB
Torch Consumables
The illustrations show all consumable parts for the SL60
and SL100 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 40 amps). This is the pre-
ferred method of cutting sheet metal up to 3/16" or 4.8 mm
thick.
Standoff Cutting: 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
extended parts life and 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.
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.
Gouging: Use the Shield Cup Body with the Gouging
Shield Cap for excellent gouging performance and en-
hanced torch parts life.
The Standoff Guide fits all shield cup designs for the SL60
and SL100 RPT hand torches. The Guide allows the user
to easily adjust and maintain a consistent standoff height
for most applications. The Standoff Guide also fits Ther-
mal Dynamics PCH-62 and PCH-102 hand torches.
The electrode and starter cartridge are the same for all
applications.
Use only Genuine Thermal Dynamics consumables with
this torch. The use of any other consumables may irrepa-
rably damage the torch and/or void the warranty.
Drag Tip
Cutting
Drag Shield
Cutting
Gouging,
40 - 100 A
1/8" / 3.2 mm
@ 40A
3/16" / 4.8 mm
35 - 45
ABCD
40A 50 - 100A
v
v
v
1/8-1/4" / 3.2-6.4mm
@60 A
Standoff
Cutting
3/16" / 4.8 mm
1/8 - 1/4"
(3.2 - 6.4 mm)
v
v
40 A
50 - 100 A
Art # A-07039
v
Art # A-04063
Shield Cup
Standoff Guide
Torch Tip
Workpiece

January 8, 2009 9 Manual 0-2880 Rev AB
Output Range Depth Width
Tip A 40 Amps Max. Shallow Narrow
Tip B 40-100 Amps Deep Narrow
Tip C 40-100 Amps Moderate Moderate
Tip D 40-100 Amps Shallow Wide
Gouging Profiles
Consumables Selection
Starter
Cartridge
9-8213
Electrode
9-8215
Tips:
20A 9-8205
30A 9-8206
40A 9-8207
Tip A 9-8225 (40 Amps Max.)
Tip B 9-8226 (40 - 100 Amps)
Tip C 9-8227 (40 - 100 Amps)
Tip D 9-8228 (40 - 100 Amps)
Shield Cap, Gouging
9-8241
Shield Cap, Drag
40A 9-8244
40A 9-8208
50-55A 9-8209
60A 9-8210
70A 9-8231
80A 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:
Tips:
Tips:
Tips:
DRAG TIP
CUTTING
40-100A
GOUGING
CUTTING
CUTTING
CUTTING
Art # A-04037
DRAG SHIELD
CUTTING
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield
Cup Body,
9-8237
Shield Cup
9-8218
STANDOFF
CUTTING
DRAG SHIELD
CUTTING
STANDOFF
CUTTING
DRAG SHIELD
CUTTING
STANDOFF CUTTING
Shield Cap, Deflector
9-8243
Shield
Cup Body,
9-8237
Shield Cup
9-8218
O-Ring No. 8-3488
Standoff Guide
for All Applications
9-8422
Shield Cap, Deflector
9-8243
O-Ring No. 8-3488
Shield Cap, Deflector
9-8243
O-Ring No. 8-3488

January 8, 2009 10 Manual 0-2880 Rev AB
Replacement Hand Torch Parts
Item # Qty Description Catalog #
11 75° Torch Handle Replacement Kit (include items no. 2 & 3) 9-7030
11 90° Torch Handle Replacement Kit (include items no. 2 & 3) 9-7037
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
41 75° Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
41 90° Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8260
5 1 Large O-Ring 8-3487
6 1 Small O-Ring 8-3486
7Leads Assemblies with O2B Connectors (includes switch assemblies)
1 SL60 / 60 Amp, 20 - foot 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 Leads Assembly with O2B connectors 4-7833
8Leads Assemblies with ATC Connectors (includes switch assemblies)
1 SL60 / 60 Amp, 20 - foot Leads Assembly with ATC connectors 4-7834
1 SL60 / 60 Amp, 50 - foot Leads Assembly with ATC connectors 4-7835
1 SL100 / 100 Amp, 20 - foot Leads Assembly with ATC connectors 4-7836
1 SL100 / 100 Amp, 50 - foot Leads Assembly with ATC connectors 4-7837
9 1 Switch Kit 9-7031
Not Shown:
1 Starter Cartridge Restrictor Pin Kit (for use with certain 8-3440
power supplies with high - volt start circuitry)