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July 28, 2004 1 Manual 0-4647

Manual 0-4647

SL60 and SL100 Replacement

Plasma Cutting Hand Torches,

Cat. No. 7-5225, 7-5226, 7-5227

Installation and Operation Instructions

Supplied Parts

The Torches include:

• Torch With Leads

• Control Wire Connectors

• Instructions

• Consumables (Installed on the Torch):

Electrode,

Starter Cartridge, Tip, Shield Cup

• Replacement Consumables as follows:

Torch Cat. No. Cutting Tip Electrode

7-5225 (2) No. 9-8209 (50A)

7-5226 (2) No. 9-8231 (70A)

7-5227 (2) No. 9-8212 (90A)

(1) No. 9-821

Torch Specifications

A. Torch Configurations and Dimensions

The torch head is at 75° to the torch handle. The torch

includes a torch handle and torch trigger assembly.

9.5" (241 mm)

3.75"

(

95 mm)

1.17" (29 mm)

Art # A-03322

Torch Specifications

B. Torch Leads Lengths

20 foot / 6.1 m

82 Benning Street, West Lebanon, NH 03784 USA

(603) 298-5711 • www.thermal-dynamics.com

General Information

The 1Torch

SL60 and SL100 Torches are connected to

power supplies using an Adapter Kit. The torches use

compressed air as both the plasma and secondary gas.

The torches are suitable for standoff cutting.

These instructions are important for the proper installation of

the Torches. Read the instructions thoroughly before attempt-

ing the installation. Keep these instructions for reference.

The torches are supplied as follows:

Catalog No. Torch Model

Consumable

Installed

7-5225 SL60 50A

7-5226 SL100 70A

7-5227 SL100 90A

Options

The following options are available. Refer to the replace-

ment parts list for catalog numbers.

• Leather Leads Covers

• Cutting Guides

• Radius / Roller Kit

• Trigger Guards

• Standoff Cutting Guide

Summary of content (10 pages)

PAGE 1
Manual 0-4647 SL60 and SL100 Replacement Plasma Cutting Hand Torches, Cat. No. 7-5225, 7-5226, 7-5227 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation and Operation Instructions General Information Supplied Parts The 1TorchTM SL60 and SL100 Torches are connected to power supplies using an Adapter Kit. The torches use compressed air as both the plasma and secondary gas.
PAGE 2
C. Current Rating (Refer to Note) F. Gas Requirements SL60 and SL100 Torch Gas Specifications NOTE Power Supply characteristics will determine material thickness range. SL60 & SL100 Current Ratings SL60 Torch & Leads SL100 Torch & Leads Up to 60 Amps, DC, Straight Polarity Up to 100 Amps, DC, Straight Polarity Gas (Plasma and Secondary) Compressed Air Operating Pressure Refer to NOTE Maximum Input Pressure 60 - 75 psi 4.1 - 5.2 bar 125 psi / 8.
PAGE 3
Connecting Torch Torch Parts Selection The Torch Leads connect to the power supply with an Adapter Kit consisting of two control wire connectors supplied with the torch. Connect the torch to the power supply as follows: Refer to the Consumables Selection Chart for the various torch parts for the application and operation. WARNINGS WARNINGS Disconnect primary power to the system before disassembling the torch or torch leads.
PAGE 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. CAUTION Do not operate the torch with the torch tip in contact with the work at outputs greater than 40 amps as this can cause irreparable damage to the torch parts. 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.
PAGE 5
7. Follow normal recommended cutting practices as provided in the power supply operator's manual. 3. Excessive Dross Formation a. Cutting speed too slow NOTE b. Torch standoff too high from workpiece 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. c.
PAGE 6
Inspection and Replacement of Consumable Torch Parts 3. Check the starter cartridge for excessive wear, plugged gas holes, discoloration, and for free movement of the lower end plate. Replace if necessary. A. General Information Start Cartridge WARNINGS Lower End Fitting 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.
PAGE 7
Consumables Selection Chart Standard Torch Consumables The illustration shows standard consumable parts for standoff cutting with SL60 and SL100 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 irreparably damage the torch and/or void the warranty.
PAGE 8
Replacement Hand Torch Parts Item # Qty Description 1 1 Torch Handle Replacement Kit (include items no. 2 & 3) 9-7030 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 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219 5 1 Large O-Ring 8-3487 6 1 Small O-Ring 8-3486 7 Catalog # Leads Assemblies with O2B Connectors (includes switch assemblies) 1 SL60 / 60 Amp, 20 - foot /6.
PAGE 9
1 2 4 5 6 3 8 7 9 Art # A-03960 NOTE Every effort has been made to provide complete and accurate information in this manual. However, the publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by errors or omissions in this Manual, whether such errors result from negligence, accident, or any other cause.
PAGE 10
Statement of Warranty LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material.