Thermal Dynamics A80 Operating Manual
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Thermal Dynamics A80 Operating Manual

Plasma cutting power supply for sl100 1torch
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A80
AUTOMATED PLASMA CUTTING SYSTEM
Operating
Manual
®
100
Revision: AS Issue Date: 10/03/2020
208-
380-
460V
230V
400V
Manual No.: 0-4985
Thermal-Dynamics.com
600V
Art # A-08954_AD

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  • Page 1 ® 208- 380- 460V 600V 230V 400V AUTOMATED PLASMA CUTTING SYSTEM Operating Manual Art # A-08954_AD Revision: AS Issue Date: 10/03/2020 Manual No.: 0-4985 Thermal-Dynamics.com...
  • Page 2 ® 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 lo- cate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at www.thermal-dynamics.com.
  • Page 3 Manufacturer assumes no liability for its use. Plasma Cutting Power Supply SL100 1Torch™ Operating Manual Number 0-4985 Published by: Thermal Dynamics Corporation 2800 Airport Rd. Denton, Texas 76207 Phone: +01 800 426 1888, FAX +01 603 298 7402 www.thermal-dynamics.com...
  • Page 4 Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,”...
  • Page 5 ASSUREZ-VOUS QUE CE DOCUMENT D’INFORMATION EST DISTRIBUÉ À L’OPÉRATEUR. DES COPIES SUPPLÉMENTAIRES SONT DISPONIBLES CHEZ VOTRE FOURNISSEUR. MISE EN GARDE Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualifiés seulement. Si vous n’avez pas une connaissance approfondie des principes de fonctionnement et des règles de sécurité...
  • Page 6 This page intentionally blank...
  • Page 7 The RoHS Directive 2011/65/EU, entering into force 2 January 2013 Type of equipment PLASMA CUTTING POWER SUPPLY Type designation etc. A80 w SL100 SV Torch, from serial number 845-XXX-XXXX Brand name or trade mark Thermal Dynamics Manufacturer or his authorised representative established within the EEA...

  • Page 8: Table Of Contents

    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 Note, Attention et Avertissement ........................1-3 1.05 Precautions De Securite Importantes ......................1-3 1.06 Documents De Reference ..........................
  • Page 9 TABLE OF CONTENTS SECTION 4 TORCH: OPERATION............................4T-1 4T.01 Machine and Automated Torch Operation ....................4T-1 4T.02 Automation Torch Parts Selection ....................... 4T-1 4T.03 Machine and Hand Torch Parts Selection ....................4T-2 4T.04 Cut Quality ................................4T-3 4T.05 General Cutting Information ......................... 4T-3 4T.06 Hand Torch Operation............................
  • Page 10 TABLE OF CONTENTS This Page Intentionally Blank...

  • Page 11: General Information

    SECTION 1: GENERAL INFORMATION GASES AND FUMES 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 are Keep your head out of the welding fume plume.
  • Page 12 ELECTRIC SHOCK NOISE Electric Shock can injure or kill. The plasma arc process uses Noise can cause permanent hearing loss. Plasma arc pro- and produces high voltage electrical energy. This electric cesses can cause noise levels to exceed safe limits. You must energy can cause severe or fatal shock to the operator or protect your ears from loud noise to prevent permanent others in the workplace.

  • Page 13: Publications

    1.03 Publications 1.04 Note, Attention et Avertissement Refer to the following standards or their latest revisions for Dans ce manuel, les mots “note, ” “attention, ” et “avertissement” more information: sont utilisés pour mettre en relief des informations à caractère important.

  • Page 14: Precautions De Securite Importantes

    1.05 Precautions De Securite Importantes • Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS AVERTISSEMENTS contiennent des renseignements quant à la quantité et la L’OPÉRATION ET LA MAINTENANCE DU nature de la fumée et des gaz pouvant poser des dangers MATÉRIEL DE SOUDAGE À...
  • Page 15 Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro Numéro INCENDIE ET EXPLOSION Moins de 300* Les incendies et les explosions peuvent résulter des scories 300 - 400* chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories 400 - 800* chaudes pouvant mettre le feu aux matières combustibles * Ces valeurs s’appliquent ou l’arc actuel est...

  • Page 16: Documents De Reference

    1.06 Documents De Reference 12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOU- DAGE ET LA COUPE, disponible auprès de l’Association Consultez les normes suivantes ou les révisions les plus des Normes Canadiennes, Standards Sales, 178 Rexdale récentes ayant été faites à celles-ci pour de plus amples Boulevard, Rexdale, Ontario, Canada, M9W 1R3 renseignements : 13.

  • Page 17: Statement Of Warranty

    This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose. Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
  • Page 18 This page intentionally blank GENERAL INFORMATION 0-4985...

  • Page 19: Section 2 System: Introduction

    Additional copies of this manual may be purchased by contacting Thermal Dynamics at the address and phone number in your area listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

  • Page 20: Power Supply Specifications

    Output Current 30 - 100 Amps, Continuously Adjustable Power Supply Gas Particulates to 5 Microns Filtering Ability A80 Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Operating Range 0° - 50° C Duty Cycle...

  • Page 21: Input Wiring Specifications

    2.05 Input Wiring Specifications A80 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Flexible Cord Flexible Cord Volts I max Fuse (amps) (Min. AWG) (Min. mm 20.6 4 Type W 25 Type W 1 Phase 21.9...

  • Page 22: Power Supply Features

    2.06 Power Supply Features Art # A-08460 Control Panel Torch Leads Receptacle Mounting Rails Work Cable and Clamp Automation Interface Cable Port Input Power Selection Filter Assembly Gas Inlet Port Input Power Cord Art # A-08461 INTRODUCTION 0-4985...

  • Page 23: Section 2 Torch: Introduction

    SECTION 2 TORCH: 18.875" / 479 mm 12.285" / 312 mm INTRODUCTION 2.875” / 73 mm 2T.01 Scope of Manual 1.375" / 35 mm 1.175" / 30 mm 1.75" / 4.95" / 126 mm 0.625" / This manual contains descriptions, operating instructions 44.5 mm 16 mm Art # A-07402_AC...

  • Page 24: 04 Options And Accessories

    D. Parts - In - Place (PIP) H. Direct Contact Hazard Torch Head has built - in switch For standoff tip the recommended standoff is 3/16 inches / 4.7 mm. 12 VDC circuit rating 2T.04 Options And Accessories E. Type Cooling For options and accessories, see section 6.
  • Page 25 E. Parts - In - Place (PIP) By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration of The torch includes a 'Parts - In - Place' (PIP) circuit. When heat to a small area. The stiff, constricted plasma arc is the shield cup is properly installed, it closes a switch.
  • Page 26 This Page Intentionally Blank INTRODUCTION 0-4985 2T-4...

  • Page 27: Section 3 System: Installation

    SECTION 3 SYSTEM: 3. Remove the unit and using these markings, prepare holes for mounting hardware. INSTALLATION 4. Insert proper hardware. If using hardware that screws into the mounting surface, leave all four loose enough for the thickness of the rail to slide under 3.01 Unpacking the head and washer if used.
  • Page 28 A. Cover Removal C. Input Power Selection 1. Remove the upper and lower screws which secure Set the Input Voltage Selection Switch at the rear of the unit the cover to the main assembly. Do not loosen the based on the primary input voltage it is connected to. Low lower screws inside the cut out slots in the bottom is 208/230 VAC and high is 460 VAC.
  • Page 29 5. Pass the cable being used through the access open- CAUTION ing in the back panel of the power supply. Refer to The primary power source and power cable Section 2 for power cable specifications. must conform to local electrical code and the recommended circuit protection and wiring CAUTION requirements (refer to table in Section 2).

  • Page 30: Gas Connections

    Installing Optional Single - Stage Air Filter 3.06 Gas Connections An optional filter kit is recommended for improved filter- Connecting Gas Supply to Unit ing with compressed air, to keep moisture and debris out The connection is the same for compressed air or high of the torch.
  • Page 31 Using High Pressure Air Cylinders Installing Optional Two - Stage Air Filter Kit When using high pressure air cylinders as the air supply: This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture and 1.
  • Page 32 Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: 1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any dust which may be present.

  • Page 33: Section 3 Torch: Installation

    1. Locate the interface connection port on the rear of If necessary, connect the torch to the Power Supply. Connect the power supply. only the Thermal Dynamics model SL100SV / Automation, SL100 / Mechanical or SL60 / Manual Torch to this power Automation Interface supply.
  • Page 34 FULL FEATURED AUTOMATION INTERFACE PCB OPTION To configure DIVIDED ARC VOLTS signal output No jumper installed for ARC VOLTS /16.67 Jumper pins 1 & 2 for ARC VOLTS / 30 Jumper pins 2 & 3 for ARC VOLTS / 50 To -V OUT 1 on PCB1 +12VDC...

  • Page 35: 03 Setting Up Automation Or Machine Torch

    3T.03 Setting Up Automation or Machine Torch NOTE! An adapter is required to be installed in the power supply if converting a hand torch system to operate a machine or automation torch. WARNING Disconnect primary power at the source before disassembling the torch or torch leads. The Automation and Machine torch include a positioning tube with rack and pinch block assembly.
  • Page 36 This Page Intentionally Blank INSTALLATION 0-4985 3T-4...

  • Page 37: Section 4 System: Operation

    SECTION 4 SYSTEM: OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification 1. Output Current Control Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or higher for standoff cutting.

  • Page 38: Preparations For Operation

    (10) minute period once Check that the torch is properly connected. Only the condition is cleared. Thermal Dynamics model SL100 / Manual or SL100 / Mechanical Torches may be connected to this Power Supply. See Section 3T of this manual.
  • Page 39 Cutting Operation STANDOFF A80 Gas Pressure Settings When the torch leaves the workpiece during cutting operations with the Function Control Knob in the RUN SL100 position, there is a brief delay in restarting the pilot Leads SL100 (Mechanized Torch) arc. With the knob in the RAPID AUTO RESTART posi-...
  • Page 40 This Page Intentionally Blank OPERATION 0-4985...

  • Page 41: Section 4 Torch: Operation

    SECTION 4 TORCH: For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the OPERATION arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer.

  • Page 42: 03 Machine And Hand Torch Parts Selection

    1. If attached, remove the ohmic clip then unscrew NOTE! and remove the shield cup assembly from the torch Refer to Sections 4T.08 and following for ad- head. Wipe it clean or replace if damaged ditional information on torch parts. 2.

  • Page 43: 04 Cut Quality

    Top Spatter (Dross) 4T.04 Cut Quality Top spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip NOTE! whose orifice has become elongated. Cut quality depends heavily on setup and parameters such as torch standoff, align- 4T.05 General Cutting Information ment with the workpiece, cutting speed, gas...

  • Page 44: 06 Hand Torch Operation

    Direction of Cut NOTE! In the torches, the plasma gas stream swirls as it leaves The tip should never come in contact with the torch to maintain a smooth column of gas. This swirl the workpiece except during drag cutting effect results in one side of a cut being more square than operations.
  • Page 45 Trigger WARNING T h e s t r a i g h t e d g e m u s t b e n o n - conductive. Trigger Release Non-Conductive Straight Edge Cutting Guide A-03539 Using Drag Shield Cup With Straight Edge Art # A-03383 The crown shield cup functions best when cutting 3/16 6.
  • Page 46 NOTE! The tip should never come in contact with the workpiece except during drag cutting operations. Trigger 2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete. Trigger Release A-02986 3.

  • Page 47: 07 Gouging

    Lead Angle 4T.07 Gouging The angle between the torch and workpiece depends WARNING on the output current setting and torch travel speed. Be sure the operator is equipped with proper The recommended lead angle is 35°. At a lead angle gloves, clothing, eye and ear protection greater than 45°...

  • Page 48: 08 Recommended Cutting Speeds For Machine And Automated Torches With Exposed Tip

    4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Material Gas Pressure...
  • Page 49 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3990 2920 1810 1470 4.8 (7.6m) 1345 5.2 (15.2m) 1100 BOLD TYPE indicates maximum piercing parameters.
  • Page 50 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness...
  • Page 51 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 1670 1140 5.2 (7.6) 5.5 (15.2) Edge Start BOLD TYPE indicates maximum piercing parameters.
  • Page 52 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air)
  • Page 53 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7620 3500 2350 4.8 (7.6m) 2170 1740 5.2 (15.2m) 1015 Edge Start 10.0...
  • Page 54 Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness...
  • Page 55 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7540 7015 0.10 4570 0.10 3650 0.20 2465 0.20 5.9 (7.6m) 2145...
  • Page 56 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness...
  • Page 57 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 10890 0.00 7560 0.10 4365 0.10 2865 0.20 2195 0.20 5.9 (7.6m)
  • Page 58 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air)
  • Page 59 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 17010 0.00 7680 0.10 6410 0.10 5230 0.20 4010 0.20 5.9 (7.6m)
  • Page 60 Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness...
  • Page 61 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8915 0.00 7415 0.10 5915 0.10 4095 0.30 3325 0.30 5.9 (7.6m)
  • Page 62 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness...
  • Page 63 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 9020 0.00 8380 0.00 7730 0.10 5865 0.20 3410 0.20 5.9 (7.6m)
  • Page 64 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8213 9-8218 9-8243 9-8211 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air)
  • Page 65 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 8890 8420 0.00 0.10 7170 5710 0.20 0.20 4315 5.9 (7.6m)
  • Page 66 Mild Steel 100A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8212 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness...
  • Page 67 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2200 0.10 2030 0.10 1790 0.20 5.2 (7.6m) 1310 0.40 0.60...
  • Page 68 Stainless Steel 100A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8212 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness...
  • Page 69 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2630 0.00 2080 0.10 1575 0.20 5.2 (7.6m) 1255 0.30 5.2 (15.2m)
  • Page 70 Aluminum 100A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8212 9-8232 9-8237 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness...
  • Page 71 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2630 0.00 2080 0.10 1575 0.20 5.2 (7.6m) 1255 0.30 5.2 (15.2m)

  • Page 72: 09 Recommended Cutting Speeds For Machine And Automated Torches With Shielded Tip

    4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width...
  • Page 73 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3266 2239 1794 1651 5.2 (7.6) 1578 5.5 (15.2) 1256 BOLD TYPE indicates maximum piercing parameters.
  • Page 74 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air) Height...
  • Page 75 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed Bar (torch lead (mm) Volts (mm) (mm/min) (mm) (sec) (mm) length) 1670 1140 5.2 (7.6) 5.5 (15.2) BOLD TYPE indicates maximum piercing parameters. 0-4985 OEPRATION 4T-35...
  • Page 76 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air) Height...
  • Page 77 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7660 3490 2350 5.2 (7.6) 2170 1630 5.5 (15.2) 10.0 BOLD TYPE indicates maximum piercing parameters.
  • Page 78 Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air) Height...
  • Page 79 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 6804 5942 0.10 5080 0.10 3316 0.20 2794 0.20 5.9 (7.6m) 2230...
  • Page 80 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air) Height...
  • Page 81 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 4590 0.00 3925 0.10 3285 0.10 1985 0.20 1850 0.20 5.9 (7.6m)
  • Page 82 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air) Height...
  • Page 83 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8890 0.00 8890 0.10 7070 0.10 5095 0.20 3335 0.20 5.9 (7.6m)
  • Page 84 Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Material Gas Pressure Initial Piercing Kerf Width Arc Voltage Working Travel Speed Pierce Delay Thickness (Air) Height...
  • Page 85 Torch Material Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Working Travel Speed Pierce Delay Thickness Height @ Rec. Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 7895 6395 0.10 4895 0.10 4025 0.30 3300 0.30 5.9 (7.6m)
  • Page 86 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Material Gas Pressure Initial Piercing Kerf Width Arc Voltage Working Travel Speed Pierce Delay Thickness (Air) Height...
  • Page 87 Torch Material Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Working Travel Speed Pierce Delay Thickness Height @ Rec. Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 9410 8120 0.00 6830 0.10 5635 0.20 4010 0.20 5.9 (7.6m)
  • Page 88 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Material Gas Pressure Initial Piercing Kerf Width Arc Voltage Working Travel Speed Pierce Delay Thickness (Air) Height...
  • Page 89 Torch Material Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Working Travel Speed Pierce Delay Thickness Height @ Rec. Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 9020 0.00 7595 0.10 6165 0.20 5045 5.9 (7.6m) 3955 0.20...
  • Page 90 Mild Steel 100A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8233 9-8232 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air)
  • Page 91 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2210 0.00 1960 0.10 1665 0.20 1185 0.30 0.40 0.80 Edge Start...
  • Page 92 Stainless Steel 100A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8212 9-8232 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air)
  • Page 93 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2900 0.00 2265 0.10 1685 0.20 5.2 (7.6m) 1285 0.30 5.2 (15.2m)
  • Page 94 Aluminum 100A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8212 9-8232 9-8277 Material Gas Pressure Torch Working Initial Piercing Kerf Width Arc Voltage Travel Speed Pierce Delay Thickness (Air) Height...
  • Page 95 Material Torch Working Initial Piercing Kerf Width Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay Thickness Height Height @ Rec. Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2920 0.00 2135 0.10 1470 0.20 5.2 (7.6m) 1230 0.30 5.2 (15.2m)

  • Page 96: Patent Information

    PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S. and Foreign Patents as follows: Catalog # Description Patent(s) 9-8215 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8232 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8213 Cartridge US Pat No(s) 6903301;...
  • Page 97 Catalog # Description Patent(s) 9-8239 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8244 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512: Catalog # Description 9-8235...
  • Page 98 This Page Intentionally Blank OPERATION 0-4985 4T-58...

  • Page 99: Section 5 System: Service

    SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the cables and leads. Replace as needed Visually inspect the torch body tip, electrode, start cartridge and shield cup 3 Months...

  • Page 100: Maintenance Schedule

    Daily Operational Checks or Every Six Cutting Hours: 4. Worn torch parts 5. Cutting current too low. 1. Check torch consumable parts, replace if damaged 6. Non - Genuine Thermal Dynamics or worn. parts used 7. Incorrect gas pressure 2. Check plasma and secondary supply and pressure/ flow.

  • Page 101: Fault Indicator

    5.04 Fault Indicator At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7.

  • Page 102: Basic Troubleshooting Guide

    5.05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Problem - Possible Cause Recommended Action Symptom ON / OFF Switch...
  • Page 103 Problem - Possible Cause Recommended Action Symptom FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten. indicators flashing. 2. Torch tip, electrode or starter 2. Turn OFF power supply. Remove shield cup. Install missing Gas flow is cycling cartridge missing.

  • Page 104: Power Supply Basic Parts Replacement

    C. Filter Element Assembly Replacement 5.06 Power Supply Basic Parts Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be checked WARNING per the Maintenance Schedule (Subsection 5.02), and either Disconnect primary power to the system cleaned or replaced.
  • Page 105 Optional Single-Stage Filter Element Replacement 5. Remove the fitting from the filter element assembly by inserting a 6 mm hex wrench into the internal These instructions apply to power supplies where the op- hex fitting and turning it counter clock-wise (left). tional Single-Stage Filter has been installed.
  • Page 106 Optional Two-Stage Filter Element Replacement 6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in The Two-Stage Air Filter has two Filter Elements. When the Step 4 above. Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable.

  • Page 107: Section 5 Torch: Service

    SECTION 5 TORCH: SERVICE 5T.01 General Maintenance Upper Groove with Vent Holes Must Remain Open NOTE! Upper O-Ring Refer to Previous "Section 5 System" for com- in Correct Groove mon and fault indicator descriptions. Threads Lower O-Ring Cleaning Torch Art # A-03725 Torch Head O-Ring Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated...

  • Page 108: 02 Inspection And Replacement Of Consumable Torch Parts

    4. Remove the tip. Check for excessive wear (indicated 5T.02 Inspection and Replacement of by an elongated or oversized orifice). Clean or re- Consumable Torch Parts place the tip if necessary. Good Tip Worn Tip WARNING Disconnect primary power to the system be- fore disassembling the torch or torch leads.

  • Page 109: Parts Lists

    208/230 single phase input power cable and plug 3-1334-1 with 460V single phase input power cable 3-1334-2 A80 Non CE Power Supply with 400VAC, 3 phase input power cable 3-1334-3 A80 CE Power Supply with 400VAC, 3 phase input power cable...

  • Page 110: Replacement Power Supply Parts

    6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115 Filter Assembly Replacement Element 9-0116 Input Power Cord for 208 / 230 V Power Supply 8-4384 Input Power Cord for 400 V Power Supply 9-0216 6.05 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter &...
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  • Page 112: Torch Replacement Parts Sl100Sv Torch (With Solenoid On Mounting Tube)

    6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) Item No. 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 PIP Plunger and Return Spring Kit 9-7045 Automated Leads Assemblies with ATC connectors 25 - foot / 7.6 m Leads Assembly with ATC connector...
  • Page 113 Art # A-07113 0-4985 PARTS LIST...

  • Page 114: Torch Consumable Parts (Sl100 Sv)

    6.07 Torch Consumable Parts (SL100 SV) Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 20A 9-8205 Shield Cap, De ector Shield Cup 30A 9-8206 9-8243 9-8218 40A 9-8208 Drag Shield Cup...

  • Page 115: Replacement Parts For Hand Torch

    6.08 Replacement Parts for Hand Torch Item # Description Catalog # Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 Trigger Assembly Replacement Kit 9-7034 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 Torch Head Assembly Replacement Kit (includes items No.
  • Page 116 This Page Intentionally Blank PARTS LIST 0-4985...

  • Page 117: Appendix 1: Sequence Of Operation (Block Diagram

    APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: RUN / Rapid Auto Restart / ON / OFF switch to ON Close external RUN / SET / LATCH disconnect switch. Rapid Auto Restart / switch to RUN RESULT: SET / LATCH switch RESULT: to SET...

  • Page 118: Appendix 2: Data Tag Information

    APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and ® Revision Level, Serial Number Model: and Production Code Date of Mfr: Made in USA Type of Power Regulatory Standard Covering Supply (Note 1) This Type of Power Supply Output Current Type Duty Cycle Factor...

  • Page 119: Appendix 3: Torch Pin - Out Diagrams

    APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Open 4 - Green / Switch 4 - Switch 3 - Switch...

  • Page 120: Appendix 4: Torch Connection Diagrams

    APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power Torch Supply Torch Head Leads Black To Power Supply Switch...
  • Page 121 This Page Intentionally Blank 0-4985 APPENDIX...

  • Page 122: Appendix 5: System Schematic, 208/460V Units

    PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1 MTH2 MTH2 /INRUSH +12VDC BIAS SUPPLY C3,C4,C7,C8* C3,C4,C7,C8* * CM102 & A80 MTH7 MTH7 C7 & C10 not installed MTH4 MTH4 80A_AC1 80A_AC1 80A_AC2 80A_AC2 PRIMARY AC INPUT 80A_AC3 80A_AC3...
  • Page 123 PILOT IGBT WORK1 WORK1 WORK WORK /PIP /START 24VAC RETURN CNC INTERFACE STANDARD ON A80 & A120 UNITS 24VAC SUPPLY CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS OK TO MOVE CNC PINOUT OK-TO-MOVE (5A @ 250VAC / 30VDC) +12VDC...

  • Page 124: Appendix 6: System Schematic, 400V/600V Units

    40A_AC3 PMTH1 PMTH1 PMTH1 PMTH1 C16-17 C16-17 PMTH2 PMTH2 PMTH2 PMTH2 PMTH3 PMTH3 PMTH3 PMTH3 PCB2 INPUT CAPACITOR PCB *CM102/35mm/A80 C7 & C10 may not be installed C12-13 C12-13 PMTH4 PMTH4 PMTH4 PMTH4 PCB5 40/50 AMP PCB A-09130_AD APPENDIX 0-4985...
  • Page 125 PILOT IGBT WORK1 WORK1 WORK WORK /PIP /START 24VAC RETURN CNC INTERFACE STANDARD ON A80 & A120 UNITS 24VAC SUPPLY CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS OK TO MOVE CNC PINOUT OK-TO-MOVE (5A @ 250VAC / 30VDC) +12VDC...

  • Page 126: Appendix 7: Raw Arc Voltage

    APPENDIX 7: RAW ARC VOLTAGE If raw arc voltage is necessary for the torch height control, the customer must supply an 18 AWG (1.0 mm2), single pair, unshielded cable rated for 300V or greater. All work must be performed following applicable local and national codes. 1.
  • Page 127 Art # A-10288_AB 5. Tighten the strain relief. Work2 (+) Polarity -V_out2 (-) Polarity 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control. 0-4985 APPENDIX A-11...
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  • Page 129 This Page Intentionally Blank...
  • Page 130 I N N O V A T I O N T O S H A P E T H E W O R L D ™ U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 Canada Customer Care: 905-827-4515 / FAX 800-588-1714 International Customer Care: 940-381-1212 / FAX 940-483-8178 © 2012 Thermal Dynamics Corp. www.thermal-dynamics.com...

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