Victor SL60 User manual

Manual 0-2880 1
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 Victor Thermal Dy-
namics 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 capabilities
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 output);
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 instal-
lation of the Torches. 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): Electrode,
Starter Cartridge, Tip, Shield Cup Body and Drag
Shield Cap)
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.
Options
The following options are available. Refer to the complete
assembly replacement list for catalog numbers.
• ATCAdapterKit(forTorcheswithATC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withATC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.
C. Current Rating (Refer to Note)
SL60 & SL100 Current Ratings
SL60 Torch & Leads Up to 60 Amps, DC,
Straight Polarity
SL100 Torch & Leads Up to 100 Amps, DC,
Straight Polarity
Original Publication Date: 2002 Manual no.: 0-2880
Revision Date: 2013 Revision: AD
SL60 and SL100
Replacement Plasma
Cutting Hand Torches
Installation Instructions

Manual 0-2880
2
NOTE
Power Supply characteristics will determine material
thickness range.
D. Torch Ratings
SL60 Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 60 Amps @ 400 scfh
MaximumCurrent 60 Amps
Voltage (Vpeak) 500V
Arc Striking Voltage 7kV
SL100 Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 100 Amps @ 400 scfh
MaximumCurrent 100 Amps
Voltage (Vpeak) 500V
Arc Striking Voltage 7kV
E. Type of Cooling
Combination of ambient air and gas stream through
torch.
F. Gas Requirements
SL60 and SL100 Torch Gas Specications
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)
!
WARNING
This torch is not to be used with oxygen (O2).
NOTE
Operating pressure varies with torch model, operat-
ing 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.
A-02997
Torch Trigger
PIP Switch Shield Cup
To Control
Cable Wiring
Torch Switch
Connecting Torch
There are two types of connection for the Torch Leads.
One type uses the Victor Thermal Dynamics ATC connec-
tor. 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
connect the adapter to the power supply.
InspectthehalvesoftheATCConnector.Alignthemale
connector 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.
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.
Discard 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.

Manual 0-2880 3
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 de-
flector) 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.
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 elec-
trode.
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 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.
Gouging Parts Selection
Select gouging tips according to the desired gouge profile.
Gougingparametersshownarebasedona35°approach
angle.
Gouging Proles
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
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.
SL60 Gas Pressure Seings
Leads Length
Tip 20' / 6.1 m 50' / 15.2 m
30A, 40A,
50/55A, 60A 65 psi / 4.5 bar 75 psi / 5.2 bar
SL100 Gas Pressure Seings
Leads Length
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
Cutting or Gouging
The 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 adjust gas pressure on the Power
Supply pressure gauge. Refer to the charts for opti-
mum pressure settings for the combination of torch
tipandtotalleadslengths(includingextensions)in
use.

Manual 0-2880
4
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 pilot
arc will start.
A-02986
Tr igger
Tr igger 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
Tr igger
2
1
Tr igger Release
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 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.
Art # A-04063
Shield Cup
Standoff Guide
Torch Tip
Workpiece

Manual 0-2880 5
Common Operating Faults
The following are the more common cutting faults and
the possible causes:
1. Insufcient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Victor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Victor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Victor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VictorThermalDynamicsParts
5. Difficult Starting
a. Worntorchconsumables
b. Non-GenuineVictor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
Inspection and Replacement of
Consumable Torch Parts
A. General Information
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.
Unthread the shield cup assembly to remove the consum-
able 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.

Manual 0-2880
6
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
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 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.
B. O-Ring Lubrication
This section applies only to torches withATC con-
nectors.
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 will allow the o-ring to remain pliable and pro-
vide a 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 perfor-
mance problems.
Itisrecommendedtoapplyaverylightlm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 tempera-
tures or may contain “unknown elements” that
may react with the atmosphere. This reaction can
leave contaminants inside the torch. Either of these
conditions can lead to inconsistent performance or
poor parts life.

Manual 0-2880 7
ATC Male Connector
Art #A-03791
Gas Fitting
O-Ring
Torch Consumables
The illustrations show all consumable parts for the SL60
and SL100 torches.
Various front - end torch parts are available for differ-
ent 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
preferred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
enhanced torch parts life.
TheStandoffGuidets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tsVictor
Thermal Dynamics PCH-62 and PCH-102 hand torches.
The electrode and starter cartridge are the same for all
applications.
UseonlyGenuineVictorThermalDynamicsconsumables
with this torch. The use of any other consumables may
irreparably 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

Manual 0-2880
8
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
Gouging Proles
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

Manual 0-2880 9
Replacement Hand Torch Parts
 Item# Qty Description  Catalog#
1 1 75° Torch Handle Replacement Kit (include items no. 2 & 3) 9-7030
1 1 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
4 1 75° Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
4 1 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
7 Leads 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
8 Leads 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)

Manual 0-2880
10
Complete Assembly Replacement
NOTE
All Complete Torch and Lead Assemblies require a Torch Adapter Kit for proper installation of the Torch.
Description Catalog #
60 - Amp Hand Torches with Ergonomic Handle 75°:
SL60 Hand Torch and 20 foot /6.1 m Leads, with O2B Connector 7-5200
SL60 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5201
SL60 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector 7-5204
SL60 Hand Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5205
60 - Amp Hand Torches with Ergonomic Handle 90°:
SL60 Hand Torch and 20 foot /6.1 m Leads, with O2B Connector 7-5261
SL60 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5262
SL60 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector 7-5260
100 - Amp Hand Torches with Ergonomic Handle 75°:
SL100 Hand Torch and 20 foot /6.1 m Leads, with O2B Connector 7-5202
SL100 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5203
SL100 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector 7-5206
SL100 Hand Torch and 50 foot / 15.2 m Leads, with ATC Connector 7-5208
100 - Amp Hand Torches with Ergonomic Handle 90°:
SL100 Hand Torch and 20 foot /6.1 m Leads, with O2B Connector 7-5264
SL100 Hand Torch and 50 foot / 15.2 m Leads, with O2B Connector 7-5265
SL100 Hand Torch and 20 foot / 6.1 m Leads, with ATC Connector 7-5263
Options
ATC Adapter Kit 7-5207
LeadsextensionswithATCConnectors,15-foot/4.6mlength  7-7544
 LeadsextensionswithATCConnectors,25foot/7.6mlength  7-7545
 LeadsextensionswithATCConnectors,50foot/15.2mlength  7-7552
Leather Leads Cover, 20 foot / 6.1 m length 9-1260
Leather Leads Cover, 25 foot / 7.6 m length 9-1270
Leather Leads Cover, 50 foot / 15.2 m length 9-1280
 StraightLineCuttingGuide  7-8911
Radius / Roller Kit 7-7501
 CircleCuttingGuide   7-3291
 DeluxeCuttingGuideKit  7-8910
 StandoffGuide    9-8422