Thermal Dynamics SL60 Instruction Manual
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Thermal Dynamics SL60 Instruction Manual

Plasma cutting torch
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SL60
SL100
Instruction Manual
PLASMA CUTTING TORCH
Model SL60, SL100 Hand
Torch
Model SL100 Machine Torch
Rev. AA.01
Date: October 20, 2006
Operating Features:
60
100
Manual # 0-2962
100%
Max
H/F
Op Pres
Duty
Flow
LV
60-75
Start
400 scfh
Cycle
PSI
Max
Input
PIP
125PSI

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Summary of Contents for Thermal Dynamics SL60

  • Page 1 SL60 SL100 PLASMA CUTTING TORCH Model SL60, SL100 Hand Torch Model SL100 Machine Torch Instruction Manual Rev. AA.01 Date: October 20, 2006 Manual # 0-2962 Operating Features: 100% Op Pres Duty Flow Input 60-75 Start 400 scfh 125PSI Cycle...
  • Page 2 This Operating Manual has been designed to instruct you on the cor- rect use and operation of your Thermal Dynamics product. Your sat- isfaction with this product and its safe operation is our ultimate con- cern.
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judge- ment, 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.

  • Page 5: Section 1: General Information

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.
  • Page 6 • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...
  • Page 7 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS- TIBLES, obtainable from American Welding Society, 550 N.W.

  • Page 8: Declaration Of Conformity

    Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

  • Page 9: Statement Of Warranty

    None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer.
  • Page 10 GENERAL INFORMATION Manual 0-2962...
  • Page 11 SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.
  • Page 12 • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...
  • Page 13 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS- TIBLES, obtainable from American Welding Society, 550 N.W.
  • Page 14 Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
  • Page 15 None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer.
  • Page 16 GENERAL INFORMATION Manual 0-2962...

  • Page 17: Section 2: Introduction

    The hand torches include a torch handle and torch This manual contains descriptions, operating instructions trigger assembly. and maintenance procedures for the 1Torch Models SL60 and SL100 Plasma Cutting Torches. Service of this equip- 9.5" (241 mm) ment is restricted to properly trained personnel; unquali-...
  • Page 18 • PakMaster 50XL Plus leads, the components, or the Power Supply. DO • PakMaster 75XL Plus NOT operate the SL60 torch at more than 60 Amps, • PakMaster 100XL Plus or the SL100 at more than 100 Amps. NOTE...

  • Page 19: Options And Accessories

    2.04 Options And Accessories 2.05 Introduction to Plasma These items can adapt a standard system to a particular A. Plasma Gas Flow application or further enhance performance (refer to Sec- Plasma is a gas which has been heated to an extremely tion 6 for ordering information).
  • Page 20 B. Gas Distribution The single gas used is internally split into plasma and sec- ondary gases. The plasma gas flows into the torch through the negative lead, through the starter cartridge, around the electrode, and out through the tip orifice. The secondary gas flows down around the outside of the torch starter cartridge, and out between the tip and shield cup around the plasma arc.

  • Page 21: Section 3: Installation

    SECTION 3: 3.05 Setting Up Machine Torch INSTALLATION WARNING 3.01 Introduction Disconnect primary power at the source before dis- assembling the torch or torch leads. This section describes installation of the Torch. These instructions apply to the Torch and Leads Assemblies only;...

  • Page 22: Connecting Torch

    A. Hand Systems 3.06 Connecting Torch Torches with ATC connectors connect either to an ATC The Torch Leads must be properly connected to the Power Adapter which connects to the power supply bulkhead, Supply for proper operation. If the torch leads or ATC or to an ATC Receptacle which mounts to the power sup- Adapter were not factory - installed, make all torch con- ply front panel.
  • Page 23 3. Secure the Through - Hole protector with the re- taining nut removed earlier. Torch Leads 4. Connect the torch leads or ATC Adapter Negative ATC Male Connector / Plasma Lead to the bulkhead connection inside the Power Supply as shown. Note: Actual Bulkhead Adapter Power Supply...
  • Page 24 B. Mechanized Machine Torch Systems - 5. Connect the Control Circuit Connectors on the ATC Adapter to the mating connectors on the Power Torches with ATC Connectors Supply Adapter. Torches with ATC connectors connect either to an ATC Adapter which connects to the power supply bulkhead, or to a panel-mounted ATC Receptacle.
  • Page 25 10. Connect the remote pendant adapter to the Remote C. Mechanized Machine Torch Systems - Control Cable Connector. Torches with O2B Connectors Torches with O2B connectors connect directly to the power supply bulkhead. Mechanized torch leads with Torch Leads Control Cable O2B connectors require a remote pendant adapter to ac- Connector (Machine cept a remote pendant.
  • Page 26 6. Connect the control circuit connectors on the Torch Leads to the mating connectors on the Remote Pendant Adapter and Power Supply Adapter (see Power Supply Adapter Warning). Control Circuit Connectors WARNING Open Remote Pendant There are two additional connectors that are not Adapter Wire used and must be taped out of the way to prevent Open...
  • Page 27 E. Automated Machine Torch Systems with 7. Connect the ATC Adapter connectors to the power supply adapter. ATC Connectors Torches with shielded leads and ATC connectors connect to a shielded ATC Adapter which connects to the power WARNING supply bulkhead. The Shielded ATC Adapter includes two connec- tors that are not used and must be taped out of the WARNING...

  • Page 28: Gas Connection

    F. Automated Machine Torch Systems with 8. Tighten the Through - Hole protector onto the ATC Adapter leads. O2B Connectors 9. Check the torch for proper consumable parts. Torches with shielded leads and O2B connectors connect directly to the power supply bulkhead. CAUTION 1.

  • Page 29: Section 4: Operation

    If the switch is in RUN position there will be 4.01 Introduction no gas flow. This section provides a description of the SL60 and SL100 F. RUN - SET - LATCH , RUN - SET or RUN - Torch Assemblies followed by operating procedures.

  • Page 30: Torch Parts Selection

    3. Install the replacement Electrode by pushing it straight into 4.04 Torch Parts Selection the torch head until it clicks. Depending on the type of operation to be done determines the 4 . Install the starter cartridge and desired tip for the op- torch parts to be used.

  • Page 31: General Cutting Information

    C. Bevel Angle A. Piloting The angle between the surface of the cut edge and a plane Piloting is harder on parts life than actual cutting because perpendicular to the surface of the plate. A perfectly per- the pilot arc is directed from the electrode to the tip rather pendicular cut would result in a 0°...

  • Page 32: Hand Torch Operation

    E. Dross 2. Depending on the cutting operation, do one of the following: When dross is present on carbon steel, it is commonly a. For edge starts, hold the torch perpendicular referred to as either “high speed, slow speed, or top to the workpiece with the front of the tip on dross”.
  • Page 33 B. Shield Cup With Straight Edge The drag shield cup can be used with a nonconductive Trigger straight edge to make straight cuts by hand. WARNING Trigger Release The straight edge must be non - conductive. Non-Conductive Straight Edge Cutting Guide Art # A-03383 A-03539 6.
  • Page 34 D. Piercing With Hand Torch 1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the Trigger back end for maximum heat protection.

  • Page 35: Machine Torch Operation

    4.08 Machine Torch Operation A. Cutting With Machine Torch The machine torch can be activated by remote control pen- dant or by a remote interface device such as CNC. 1. Use a square to check that the torch is perpendicular to the workpiece to obtain a clean, vertical cut.

  • Page 36: Recommended Cutting Speeds

    C. Piercing With Machine Torch 4.10 Gouging To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above the WARNINGS plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow back onto the front end of the torch.

  • Page 37: Standoff Distance

    D. Lead Angle The angle between the torch and workpiece depends on the output current setting and torch travel speed. At 80 amps, the recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch.
  • Page 38 OPERATION 4-10 Manual 0-2962...

  • Page 39: Section 5: Service

    SECTION 5: 5.02 General Torch Maintenance SERVICE A. Cleaning Torch Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch be- 5.01 Introduction comes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of This section describes basic maintenance procedures per- the torch.

  • Page 40: O-Ring Lubrication

    Cutting current too low It is recommended to apply a very light film of o- ring lubricant (Catalog # 8-4025) to the o-ring on a f. Non - Genuine Thermal Dynamics Parts weekly basis. 2. Main Arc Extinguishes NOTE a.

  • Page 41: Inspection And Replacement Of Consumable Torch Parts

    3. On torches with a shield cup body and a shield cap or 5.04 Inspection and Replacement of deflector, ensure that the cap or deflector is threaded Consumable Torch Parts 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.

  • Page 42: Troubleshooting Guide

    6. Pull the Electrode straight out of the Torch Head. Check Troubleshooting the face of the electrode for excessive wear. Refer to the A. Torch will not pilot when torch switch is activated following figure. 1. Power Supply RUN / SET switch in SET position a.
  • Page 43 B. No cutting output 4. Excessive oil or moisture in torch 1. Torch not properly connected to power supply a. Hold torch 1/8 inch (3.2 mm) from clean sur- face while purging and observe oil or moisture a. Check that torch leads are properly attached to buildup (do not activate torch).
  • Page 44 SERVICE Manual 0-2962...

  • Page 45: Ordering Information

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all replaceable components. Torch Assemblies are field serviceable, so a complete breakdown of parts is provided. The parts lists are arranged as follows: Section 6.03: Hand Torch Replacement Parts Section 6.04: Machine Torch Replacement Parts Section 6.05: Replacement Shielded Leads Assemblies...

  • Page 46: Replacement Parts For Hand Torch

    8-3487 Small O - Ring 8-3486 Leads Assemblies with O2B connectors (includes switch assemblies) SL60 / 60 Amp, 20 - foot Leads Assembly with O2B connectors 4-7830 SL60 / 60 Amp, 50 - foot Leads Assembly with O2B connectors 4-7831...
  • Page 47 Requires Adapter Kit For Proper Installation May Require ATC Adapter A-03664 Kit For Proper Installation Manual 0-2962 PARTS LISTS...

  • Page 48: Replacement Parts - For Machine Torches With Unshielded Leads

    6.04 Replacement Parts - for Machine Torches with Unshielded Leads Item No. Qty Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O - Ring 8-3487 Small O - Ring 8-3486 PIP Switch Kit 9-7036 Unshielded Mechanized Leads Assemblies with O2B connectors 25 - foot / 7.6 m Leads Assembly with O2B connectors...
  • Page 49 Requires Adapter Kit For Proper Installation May Require ATC Adapter Kit For Proper Installation May Require ATC Adapter Kit For Proper Installation A-03665 Manual 0-2962 PARTS LISTS...

  • Page 50: Replacement Shielded Machine Torch Leads Assemblies

    6.05 Replacement Shielded Machine Torch Leads Assemblies Item No. Qty Description Catalog No. Mechanized Shielded Leads Assemblies with ATC Connectors 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848...
  • Page 51 Torch Connection Fitting Torch Continuity Torch Continuity Adapter Wire ('PIP') Switch ('PIP') Switch Art #A-03616 Manual 0-2962 PARTS LISTS...

  • Page 52: Hand Torch Consumables

    The illustration shows all consumable parts for the SL60 and SL100 hand torches. Refer to the Appendix Use the Shield Cup Body with the Deflector Shield Cap pages covering the power supply being used to ensure for extended parts life and improved resistance to reflected proper selection for the application.
  • Page 53 Hand Torch Consumables Selection Shield Tips: DRAG TIP Cup Body, Shield Cap, Deflector 9-8237 9-8243 CUTTING 20A 9-8205 Shield Cup 30A 9-8206 9-8218 40A 9-8207 O-Ring No. 8-3488 Shield Cap, Drag DRAG SHIELD 40A 9-8244 CUTTING Shield Cup Body, Shield Cap, Deflector Tip: CUTTING 9-8237...

  • Page 54: Machine Torch Consumables

    6.08 Machine Torch Consumables The illustration shows all consumable parts for the Use the Shield Cup Body with the Deflector Shield Cap for SL100 machine torches. Refer to the Appendix pages extended parts life and improved resistance to reflected heat. covering the power supply being used to ensure proper This combination provides cutting results similar to the single- selection for the application.
  • Page 55 Machine Torch Consumables Selection Ohmic Clip 9-8224 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243 9-8218 9-8208 Shield 50-60A Tips: Shield Cap, Machine Cup Body, STANDOFF 50-60A 9-8238 9-8237 CUTTING 50-55A...
  • Page 56 6.10 Automated Torch Consumables Use the Shield Cup Body with the Gouging Shield Cap for The illustration shows all consumable parts for the SL100 automated torch. Refer to the Appendix pages excellent gouging performance and enhanced torch parts life. covering the power supply being used to ensure proper selection for the application.
  • Page 57 Automated Torch Consumables Selection Ohmic Clip 9-8224 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243 9-8218 9-8208 Shield 50-60A Tips: Shield Cap, Machine Cup Body, STANDOFF 50-60A 9-8238 9-8237 CUTTING 50-55A...

  • Page 58: Complete Assembly Replacement

    The Complete Torch & Leads Assembly Replacement does not include the Torch Control Cable Adapter. Description Catalog # 60 - Amp Hand Torch and Leads Assemblies: 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...
  • Page 59 6.13 Options & Accessories Description Catalog # ATC Adapter Kit, Unshielded 7-5207 ATC Adapter Kit, Shielded 7-3472 Unshielded Leads extensions with ATC connectors, 15 - foot / 4.6 m length 7-7544 Unshielded Leads extensions with ATC connectors, 25 - foot / 7.6 m length 7-7545 Unshielded Leads extensions with ATC connectors, 50 - foot / 15.2 m length 7-7552...

  • Page 60: Patent Information

    PATENT INFORMATION The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512 Catalog Number Description 9-8235 Shield Cap, Drag 50-60A 9-8236 Sheild Cap, Drag 70-100A 9-8237 Shield Cup, Body 9-8238 Shield Cap, Machine 50-60A 9-8239 Shield Cap, Machine 70-100A 9-8244 Shield Cap, Drag 40A 9-8245...

  • Page 61: Appendix 1: Typical System Sequence Of Operation Block Diagram

    APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM LATCH ACTION ACTION ACTION ACTION ON/OFF-Switch to ON. Close external Mode Switch* to RUN. Mode Switch* to SET. disconnect switch. RESULT RESULT RESULT RESULT Gas Solenoid open, gas AC indicator blinks for 8 Gas flow stops.
  • Page 62 This page intentionally blank APPENDIX Manual 0-2962...

  • Page 63: Appendix 2: General Application Notes

    APPENDIX 2: GENERAL APPLICATION NOTES A. Hand Cutting Versus Machine (Mechanized) Cutting Speeds A-02947 Hand Cutting Speeds (Shaded Area) Machine Cutting Speeds Material Thickness Hand cutting speeds can be much less than those obtained from Machine (Mechanized) Type applications. Hand cutting application speeds mostly depend on operator experience.

  • Page 64: Appendix 3A: Cutmaster 50 & Cutmaster 51 System Data (Hand Torch)

    40-100 Amps Deep Narrow Tip C 40-100 Amps Moderate Moderate Tip D 40-100 Amps Shallow Wide SL60 - SL100 Hand Torch Consumables for 40-Amp Power Supply Starter Shield Shield Cap Application Electrode Shield Cup Cartridge Cup Body or Deflector Drag Cutting...

  • Page 65: Cutting Speed Charts

    Cutting Speed Charts Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51 Type Torch: SL60 - Drag Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute)
  • Page 66 APPENDIX 3B: CUTMASTER 50 & CUTMASTER 51 SYSTEM DATA (MACHINE TORCH) Cut Quality on Various Materials and Torch Specifications For Thicknesses CutMaster 50 & CutMaster 51 Power Supplies The following table defines the cut quality on vari- Cutting Range ous materials and thicknesses: Material Mild Steel Genuine Cut:...
  • Page 67 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For CutMaster 50 & CutMaster 51 Type Torch: SL100 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height...

  • Page 68: Appendix 4A: Cutmaster 75 & Cutmaster 81 System Data (Hand Torch)

    40-100 Amps Deep Narrow Tip C 40-100 Amps Moderate Moderate Tip D 40-100 Amps Shallow Wide SL60 - SL100 Hand Torch Consumables for 60-Amp Power Supply Starter Shield Shield Cap Application Electrode Shield Cup Cartridge Cup Body or Deflector Drag Cutting...
  • Page 69 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81 Type Torch: SL60 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press...
  • Page 70 APPENDIX 4B: CUTMASTER 75 & CUTMASTER 81 SYSTEM DATA (MACHINE TORCH) Cut Quality on Various Materials and Torch Specifications For Thicknesses CutMaster 75 & CutMaster 81 Power Supplies The following table defines the cut quality on vari- Cutting Range ous materials and thicknesses: Material Most Metals Up to...
  • Page 71 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For CutMaster 75 & CutMaster 81 Type Torch: SL100 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height...

  • Page 72: Appendix 5: Cutmaster 100 & 101 System Data

    APPENDIX 5: CUTMASTER 100 & 101 SYSTEM DATA (HAND and MACHINE TORCH) Cut Quality on Various Materials and Thicknesses Torch Specifications For CutMaster 100 & CutMaster 101 Power Supplies The following table defines the cut quality on vari- Cutting Range ous materials and thicknesses: Material Most Metals...
  • Page 73 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For CutMaster 100 & CutMaster 101 Type Torch: SL100 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height...

  • Page 74: Appendix 6: Cutmaster 151 System Data

    APPENDIX 6: CUTMASTER 151 SYSTEM DATA (HAND and MACHINE TORCH) Cut Quality on Various Materials and Torch Specifications For Thicknesses CutMaster 151 Power Supply Cutting Range The following table defines the cut quality on vari- ous materials and thicknesses: Material Most Metals Up to 1-1/2 inch / 38 mm...
  • Page 75 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For CutMaster 151 Type Torch: SL100 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Standoff Thickness Output Volts Am perage Speed (Per Minute) Plasm a Gas Press Flow (SCFH) Pierce Pierce Height...

  • Page 76: Appendix 7A: Pakmaster 50Xl Plus System Data

    Moderate Cutting 350 scfh / 165 lpm Tip D 40-100 Amps Shallow Wide Gouging 230 scfh / 108.5 lpm SL60 - SL100 Hand Torch Consumables for 40-Amp Power Supply Starter Shield Shield Cap Application Electrode Shield Cup Cartridge Cup Body...
  • Page 77 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus Type Torch: SL60 - Drag Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press...
  • Page 78 APPENDIX 7B: PAKMASTER 50XL PLUS SYSTEM DATA (MACHINE TORCH) Torch Specifications For Cut Quality on Various Materials and PakMaster 50XL Plus Power Supply Thicknesses Cutting Range The following table defines the cut quality on vari- Material Mild Steel ous materials and thicknesses: Production Cut: Up to 1/4 inch - 6.3 mm...
  • Page 79 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus Type Torch: SL100 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height...

  • Page 80: Appendix 8A: Pakmaster 75Xl Plus System Data

    40-100 Amps Deep Narrow Tip C 40-100 Amps Moderate Moderate Tip D 40-100 Amps Shallow Wide SL60 - SL100 Hand Torch Consumables for 60-Amp Power Supply Starter Shield Shield Cap Application Electrode Shield Cup Cartridge Cup Body or Deflector Drag Cutting...
  • Page 81 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus Type Torch: SL60 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press...
  • Page 82 APPENDIX 8B: PAKMASTER 75XL PLUS SYSTEM DATA (MACHINE TORCH) Cut Quality on Various Materials and Torch Specifications For Thicknesses Pak Master 75XL Plus Power Supply Cutting Range The following table defines the cut quality on vari- Material Most Metals ous materials and thicknesses: Up to 3/4 inch - 19 mm Speed...
  • Page 83 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For PakMaster 75XL Plus Type Torch: SL100 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height...

  • Page 84: Appendix 9: Pakmaster 100Xl Plus System Data

    APPENDIX 9: PAKMASTER 100XL PLUS SYSTEM DATA (MACHINE TORCH) Cut Quality on Various Materials and Torch Specifications For Thicknesses Pak Master 100XL Plus Power Supply Cutting Range The following table defines the cut quality on vari- Material Most Metals ous materials and thicknesses: Up to 1 inch / 25.4 mm Speed...
  • Page 85 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For PakMaster 100XL Plus Type Torch: SL100 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height...

  • Page 86: Appendix 10: Hand Torch Wiring Diagrams

    APPENDIX 10: HAND TORCH WIRING DIAGRAMS SL60 - SL100 Hand Torch Hand Torch and Leads with O2B Connector Torch & Leads with O2B Connector Power Supply Power Supply Torch Leads Torch Head Bulkhead Adapter Black Switch Orange Green Torch White...

  • Page 87: Appendix 11: Mechanized Torch Wiring Diagrams

    APPENDIX 11: MECHANIZED TORCH WIRING DIAGRAMS Unshielded SL100 Mechanized (Machine) Torch Remote Torch & Unshielded Leads Torch & Unshielded Leads Pendant with O2B Connector with O2B Leads Connector Adapter Torch Head Power Supply Torch Leads Bulkhead Orange Black Switch Power Supply Green Adapter O2B Leads...

  • Page 88: Appendix 12: Automated Torch Wiring Diagrams

    APPENDIX 12: AUTOMATED TORCH WIRING DIAGRAMS Shielded SL100 Automated (Machine) Torch Torch and Shielded Leads with O2B Connector Torch and Shielded Leads with O2B Connector Torch Head Torch Leads Power Supply Bulkhead Switch Black Control Shield Female Male Faston Faston Negative &...

  • Page 89: Appendix 13: Atc Adapter Pinout Diagram

    APPENDIX 13: ATC ADAPTER PINOUT DIAGRAM ATC Adapter Female Receptacle ATC Male Connector HAND TORCH Front View Front View Negative / Plasma Negative / Plasma 4 - Green - Switch- to Small Pin 4 - Green / 8 - Open 8 - Open Switch 3 - White - Switch -...
  • Page 90 APPENDIX A-30 Manual 0-2962...

  • Page 91: Global Customer Service Contact Information

    Global Customer Service Contact Information Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 800-426-1888 West Malaysia Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 92 Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...

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