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Thermadyne Thermal Dynamics 1Torch SL60 Installation And Operation Instruction Manual

Replacement plasma cutting hand torches
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Replacement Plasma Torches
Hand Torches
SL60™
4/15/04
SL100™
Machine Torches
SL100™
Torch and Adapter installations
on most Manufacturers' Units
• Esab
• L-Tec
• Lincoln
• Miller
• Hypertherm
• Hobart
• Smith
• Harris
...and more!
Literature No. 0-2935

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Summary of Contents for Thermadyne Thermal Dynamics 1Torch SL60

  • Page 1 Replacement Plasma Torches Hand Torches Machine Torches SL100™ SL100™ SL60™ Torch and Adapter installations on most Manufacturers’ Units • Esab • Hypertherm • L-Tec • Hobart • Lincoln • Smith • Miller • Harris …and more! 4/15/04 Literature No. 0-2935...
  • Page 2 Section Section Torches Contents SL60/SL100 RPT...
  • Page 3 Torch and Lead Selection Listed below are the Torch and Lead selection charts for the SL60 and SL100 Hand 1 Torch RPT torches. ™ ™ ORDERING INFORMATION Hand Torches SL60 SL100 ™ ™ Light/Medium Duty Torch Medium/Heavy Duty Torch 20-60 Amps 30-100 Amps C AT N O .
  • Page 4 Manual 0-2880 SL60 and SL100 RPT Replacement Plasma 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Cutting Hand Torches Installation and Operation Instructions Options General Information The following options are available. Refer to the complete The 1Torch SL60 and SL100 Torches work with most assembly replacement list for catalog numbers.
  • Page 5 D. Torch Ratings H. Parts - In - Place (PIP) Circuit - 12 vdc The torch and leads include circuitry called Parts - SL60 Torch Ratings In - Place (PIP). This circuit includes a switch lo- 104° F Ambient cated at the torch head. The shield cup closes this Temperature 40°...
  • Page 6 4. Hand tighten the shield cup until it is seated on the Torch Parts Selection torch head. Do not use tools to tighten the cup. If resistance is felt when installing the cup, check the Refer to the Consumables Selection Chart for the vari- threads before proceeding.
  • Page 7 Cutting or Gouging 5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot The torch can be held comfortably in one hand or stead- arc will shut off. ied with two hands. Choose the holding technique that NOTE feels most comfortable and allows good control and movement.
  • Page 8 Common Operating Faults Inspection and Replacement of Consumable Torch Parts The following are the more common cutting faults and the possible causes: 1. Insufficient Penetration WARNINGS a. Cutting speed too fast Disconnect primary power to the system before b. Torch tilted too much disassembling the torch or torch leads.
  • Page 9 3. Check the starter cartridge for excessive wear, Torch Consumables plugged gas holes, discoloration, and for free move- The illustrations show all consumable parts for the ment of the lower end plate. Replace if necessary. SL60 and SL100 torches. Refer to the Appendix pages covering the power supply being used to ensure proper Starter Cartridge selection for the application.
  • Page 10 Consumables Selection (All Applications) Use only Genuine Thermal Dynamics consumables with this torch. The use of any other consumables may irrepara- bly damage the torch. DRAG CUTTING Tips: Shield Cup 20A 9-8205 9-8218 Shield Cap, Drag 30A 9-8206 40A 9-8244 40A 9-8207 50-60A 9-8235 70-100A 9-8236...
  • Page 11 Replacement Hand Torch Parts 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. 5 & 6) 9-8219 Large O - Ring 8-3487...
  • Page 12 Requires Adapter Kit For Proper Installation May Require ATC Adapter A-03323 Kit For Proper Installation February 28, 2003 Manual 0-2880...
  • Page 13 Complete Assembly Replacement NOTE All Complete Torch and Lead Assemblies require a Torch Adapter Kit for proper installation of the Torch. Description Catalog No. 60 - Amp Hand Torches with Ergonomic Handle: 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...
  • Page 14 Statement of Warranty ® LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantia- tion that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifica- tions, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of...
  • Page 15 Torch and Lead Selection Listed below are the Torch and Lead selection charts for the SL100 Machine 1 Torch RPT torch. ™ ORDERING INFORMATION Machine Torch SL100 ™ Medium/Heavy Duty Torch 30-100 Amps Standard Shielded C AT N O . D E S C R I P T I O N C AT N O .
  • Page 16 Manual 0-2937 Model SL100 RPT Replacement Plasma Cutting 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Machine Torches Installation and Operation Instructions General Information Options The SL100 SureLok ® Torch works with most plasma cut- The following options are available. Refer to the parts ting power supplies.
  • Page 17 B. Torch Leads Lengths F. Parts - In - Place (PIP) Circuit - 12 vdc The torch is available with leads as follows: The torch and leads include circuitry called Parts - In - Place (PIP). This circuit includes a switch lo- cated at the torch head.
  • Page 18 Connections with Adapter Kits Spare Parts Label Leads with ATC Connectors The parts kit provided with this torch includes an adhe- sive label. Select the small perforated section showing Connect the torch leads to the power supply per the in- the appropriate pressure setting for the amperage out- structions provided with the appropriate adapter kit.
  • Page 19 2. Fit the starter cartridge and desired tip onto the elec- 2. Adjust current output on the Power Supply to match trode. the selected tip and attach the work clamp firmly to the work or to the cutting table. NOTE Refer to the consumables selection chart for the WARNING proper combination of torch parts, including shield...
  • Page 20 2. Main Arc Extinguishes a. Cutting speed too slow b. Torch standoff too high from workpiece Torch Head c. Cutting current too high Electrode d. Work cable disconnected e. Worn torch parts f. Non - Genuine Thermal Dynamics Parts Starter Cartridge 3.
  • Page 21 5 . Reinstall the Electrode by pushing it straight into the Consumables Selection torch head until it clicks. Various front - end torch parts are available for different applications. WARNINGS Use the single - piece Shield Cup for ‘standoff’ cutting (with the torch tip 1/8"...
  • Page 22 Consumables Selection Use only Genuine Thermal Dynamics consumables with this torch. The use of any other consumables may irrepara- bly damage the torch. Shield Cap, Machine 40A 9-8245 50-60A 9-8238 70-100A 9-8239 STANDOFF CUTTING Shield Cap, Deflector Shield 9-8243 Cup Body, MaximumLife Tips: 9-8237...
  • Page 23 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 24 Requires Adapter Kit For Proper Installation May Require ATC Adapter Kit For Proper Installation A-03404 February 28, 2003 Manual 0-2937...
  • Page 25 Replacement Shielded Machine Torch Leads Assemblies and Components 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 26 Torch Connection Fitting Torch Connection Fitting Strain Relief Half Securing Ring Remote Torch Torch Strain Pendant Continuity Continuity Relief Half Connector Switch Switch A-03616 NOTES NOTES Item 3 does not include torch continuity switch. Item 7 includes Torch Connection Fitting. Item 5 includes Torch Connection Fitting.
  • Page 27 Complete Torch and Leads Assembly Replacement NOTE All Complete Torch and Lead Assemblies require a Torch Adapter Kit for proper installation of the Torch. Description Catalog No. 100 - Amp Mechanized Torches, Unshielded Leads, O2B Connectors SL100 Machine Torch, 25 foot / 7.6 m Leads, with O2B Connector 7-5209 SL100 Machine Torch, 50 foot / 15.2 m Leads, with O2B Connector 7-5210...
  • Page 28 Standard Torch Control Cable for Start / Stop Only Mechanized Systems To Torch Control Device Torch Control Torch Control Cable Connectors To Power Supply Torch Control Connectors Adapter Not Used Pilot Lead A-03428 Torch Lead Assembly Optional Torch Control Cable For CNC / Remote Pendant Systems Control Connector Torch Control Torch Control...
  • Page 29 Statement of Warranty ® LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantia- tion that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifica- tions, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of...
  • Page 30 Section Section Adapter Kits Contents 7-3434 7-3425 7-3443 7-3455 7-3481 7-3426 7-3435 7-3444 7-3456 7-3483 7-3427 7-3436 7-3445 7-3457 7-3484 7-3446 7-3461 7-3428 7-3437 7-3485 7-3438 7-3447 7-3462 7-3429 7-3430 7-3439 7-3449 7-3476 7-3431 7-3440 7-3450 7-3477 7-3441 7-3478 7-3432 7-3451 7-3480 7-3442...
  • Page 31 The Revolution in Plasma Torches The Revolution in Plasma Torches Has Begun Has Begun Adapter Kit Selection Listed below is the Adapter Kit selection charts for the Hand 1 Torch RPT torch. Torch Adapter Kits The model of the plasma cutting system must be known to determine the adapter kit required. Manufacturer Manufacturer Catalog...
  • Page 32 1Torch Reference Guide ® Components Required to upgrade THERMAL DYNAMICS to a 1Torch RPT Torch Plasma Systems Adapter Spare OEM Torch Current Torch Parts Kit Model Rating System Model SL60™ 7-3443 5-2550 Drag-Gun 38 PCH25/38 SL60™ 7-3446 5-2550 PAK 3XR PCH-51 SL60™...
  • Page 33 1Torch Reference Guide ® Components Required to upgrade ESAB / LTEC to a 1Torch RPT Torch Plasma Systems Adapter Spare OEM Torch Current Torch Parts Kit Model Rating System Model PCH-42 7-3425 5-4202 PCM-SMi PT-31/31XL SL60™ 7-3425 5-2550 PCM-31 PT-31/31XL SL60™...
  • Page 34 1Torch Reference Guide ® Components Required to upgrade HARRIS to a 1Torch RPT Torch Plasma Systems Adapter Spare OEM Torch Current Torch Parts Kit Model Rating System Model SL60™ 7-3439 5-2552 System 50 SL60™/SL100™ 7-3439 5-2554 System 65 SL100™ 7-3439 5-2556 System 100 ®...
  • Page 35 1Torch Reference Guide ® Components Required to upgrade LINCOLN to a 1Torch RPT Torch Plasma Systems Adapter Spare OEM Torch Current Torch Parts Kit Model Rating System Model SL60™ 7-3431 5-2551 Procut 40 PCT-40 SL60™ 7-3431 5-2553 Procut 60 PCT-60 ®...
  • Page 36 1Torch Reference Guide ® Components Required to upgrade POWCON to a 1Torch RPT Torch Plasma Systems Adapter Spare OEM Torch Current Torch Parts Kit Model Rating System Model SL100™ 7-3430 5-2556 Starcut ® Components Required to upgrade SMITH to a 1Torch RPT Torch Plasma Systems Adapter Spare...
  • Page 37 1Torch Reference Guide ® Components Required to upgrade INNERLOGIC to a 1Torch RPT Torch Plasma Systems Adapter Spare OEM Torch Current Torch Parts Kit Model Rating System Model SL100™ 7-3451 5-2552 SR45i ® Components Required to upgrade AIRCO/BOC to a 1Torch RPT Torch Plasma Systems Adapter Spare...
  • Page 38 1Torch Reference Guide ® Components Required to upgrade SNAP-ON to a 1Torch RPT Torch Plasma Systems Adapter Spare OEM Torch Current Torch Parts Kit Model Rating System Model 7-3476 SL60™ 5-2550 YA-2230 7-3476 SL60™ 5-2552 YA-5550 SL60™ 7-3476 5-2552 YA-5550A SL100™...
  • Page 39 9/7/03 Adapter Kit Numerical List Catalog Description Manufacturer Systems PCS-43 BOC(Airco) PCM-SMi, 500i, 625i, PCS-43 Esab RPT Torch Adapter Kit 7-3425 Smoothcut 30, 625 Hobart PCM-31, SMi, 32i/34i, Vpi, PCM-500i, 625i, PCS-80i L-Tec ESP-100i Esab RPT Torch Adapter Kit 50 (single gas), 100 7-3426 Hobart PCM-50A, 70, 80, 52i/54i, 82i/84i,ESP-100i, PCM-50, PCM-100 (Single Gas), PCM-50, PCM-100 (Dual Gas)
  • Page 40 9/7/03 Adapter Kit Numerical List Catalog Description Manufacturer Systems RPT Torch Adapter Kit PakMaster® 50 w/ Smart Torch (Q.D.) 7-3445 Thermal Dynamics RPT Torch Adapter Kit PAK® 3XR, 5XT, 5XR, 6XR, 7XR, 625XR, 750XR 7-3446 Thermal Dynamics RPT Torch Adapter Kit PakMaster®...
  • Page 41 Manual 0-2766 RPT Adapter Kit Catalog # 7-3425 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: •...
  • Page 42 6. The Pilot Adapter Fitting is only used on Pilot Arc Sys- tems. Do one of the following: • On Pilot Arc Systems install the the Pilot Adapter Fitting onto the Power Supply Pilot Connection. • For HF Torch Start Systems the Pilot Adapter Fit- ting is not used.
  • Page 43 7-3425 RPT Adapter Kit Protective Boot Control Plug Connector Negative Adaptor Pilot Connector Pilot Connector (un-assembled)
  • Page 44 Manual 0-2733 RPT Adapter Kit Catalog # 7-3426 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: •...
  • Page 45 6. The Pilot Adapter Fitting is only used on Pilot Arc Sys- tems. Do one of the following: • On Pilot Arc Systems install the the Pilot Adapter Fitting onto the Power Supply Pilot Connection. • For HF Torch Start Systems the Pilot Adapter Fit- ting is not used.
  • Page 46 7-3426 RPT Adapter Kit Control Plug Connector Negative Adaptor Protective Boot Pilot Connector Pilot Connector (un-assembled)
  • Page 47 Manual 0-2760 RPT Adapter Kit Catalog # 7-3427 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: •...
  • Page 48 7. Connect the Control Connector Plug, with two connec- NOTE tors, to the two mating connectors on the replacement For Mechanized Systems refer to the Torch Control torch leads, see NOTE. Cable Wiring Diagrams in the Manual supplied with 8. Connect the Control Connector Plug to the Power Sup- the RPT Torch.
  • Page 49 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Plug with Connectors Torch Control Cable Connectors A-02488 Torch Lead Assembly 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 50 7-3427 RPT Adapter Kit Protective Boot (not shown) Control Plug Connector...
  • Page 51 Manual 0-2769 RPT Adapter Kit Catalog # 7-3428 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: •...
  • Page 52 7. Connect the pilot wire (+) from the replacement torch to the Power Supply Pilot Adapter Fitting. Secure the wire with the bolt and washers provided. NOTE 8. Connect the Negative / Plasma Lead from the replace- For Mechanized Systems refer to the Torch Control ment torch to the Power Supply.
  • Page 53 7-3428 RPT Adapter Kit Protective Boot (not shown) Negative Adaptor Control Plug Connector Pilot Connector...
  • Page 54 Manual 0-2715 RPT Adapter Kit Catalog # 7-3429 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: •...
  • Page 55 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Plug with Connectors Torch Control Cable Connectors A-02272 Torch Lead Assembly 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 56 7-3429 RPT Adapter Kit Protective Boot Negative Adaptor Pilot Connector...
  • Page 57 Manual 0-2763 RPT Adapter Kit Catalog # 7-3430 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: •...
  • Page 58 8. Connect the Negative / Plasma Lead from the replacement torch to the Power Supply. Slide the protective boot over the lead connection. 9. Connect the Control Connector Plug, with two connectors, to the two mating connectors on the replacement torch leads, see NOTE.
  • Page 59 Installation on Power Supplies With Quick Disconnect Install the Adapter Kit as follows: 1. Turn OFF the power supply. 2. Disconnect the main input power to the power supply. 3. Remove the existing torch from the power supply at the quick disconnect. 4.
  • Page 60 WARNING Replacing Original Machine Torch with TDC RPT Mechanized Torch Thermal Dynamics RPT mechanized torches have two control wires that are used for Parts-In-Place, PIP, only. Do not connect these PIP connections di- rectly into any start input because when the torch parts are in place, the start signal will always be energized.
  • Page 61 7-3430 RPT Adapter Kit Insulation Sleeve Butt Connector Negative Adaptor Control Plug Connectors Pilot Connector Pilot Connector (un-assembled)
  • Page 62 Manual 0-2735 RPT Adapter Kit Catalog # 7-3431 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: Lincoln PROCUT 60 Parts Supplied The following parts are included in this kit: •...
  • Page 63 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Plug with Connectors Torch Control Cable Connectors A-01648 Torch Lead Assembly 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 64 7-3431 RPT Adapter Kit Negative Adaptor Control Plug Connector...
  • Page 65 Manual 0-2764 RPT Adapter Kit 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Catalog No. 7-3432 Installation Instructions General Information This Replacement Torch Adapter Kit connects the Thermal Dynamics Plasma RPT Series Cutting Torch to the follow- ing equipment: DAIHEN SC-60P MILLER Plazcut 60 / Zipcut...
  • Page 66 9. Reinstall any covers removed (see WARNING). 10. Install the proper torch consumables for the Power Supply amperage. 11. Reconnect input power to the Power Supply and ON turn the unit. 12. Set gas pressure and flow according to directions in the torch manual. 13.
  • Page 67 7-3432 RPT Adapter Kit Negative Adaptor Control Plug Connector...
  • Page 68 Manual 0-2759 RPT Adapter Kit Catalog # 7-3433 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: MILLER* SPECTRUM* 250, 500 and 750 Parts Supplied...
  • Page 69 6. Connect the Control Connector Wires (see NOTE), with two connectors, to the two mating connectors on the replacement torch leads. Spade Lugs Control Connector Wires with Connectors Torch Control Connectors Pilot Lead Negative/Plasma Lead A-02485 Torch Lead Assembly NOTE For Mechanized Systems refer to the Torch Control Cable Wiring Diagram on the last page of this Manual.
  • Page 70 7-3433 RPT Adapter Kit Control Connector...
  • Page 71 Manual 0-2757 RPT Adapter Kit Catalog # 7-3434 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: •...
  • Page 72 Control Connector Plug with Connectors Torch Control Connectors Pilot Lead Negative/Plasma Lead A-02482 Torch Lead Assembly 5. Connect the pilot wire (+) from the replacement torch to the Power Supply and tighten securely. 6. Connect the Negative / Plasma Lead from the replace- ment torch to the Power Supply.
  • Page 73 7-3434 RPT Adapter Kit Control Plug Connector Pilot Connector Pilot Connector (un-assembled)
  • Page 74 Manual 0-2730 RPT Adapter Kit Catalog # 7-3435 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: •...
  • Page 75 6. Cut the ring terminal off the pilot lead of the replace- ment torch. 7. Remove the two screws from the Pilot Connector Plug. Open the connector and insert the end of the Torch Pi- lot Lead wire into either one of the outside terminals. DO NOT insert pilot wire into center terminal.
  • Page 76 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Plug with Connectors Torch Control Cable Connectors A-02272 Torch Lead Assembly 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 77 7-3435 RPT Adapter Kit Jumper connector Negative Adaptor Control Plug Connector Pilot Connector...
  • Page 78 Manual 0-2762 RPT Adapter Kit Catalog # 7-3436 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: • L-TEC PCM-101 • Thermal Dynamics PAK 10 Parts Supplied The following parts are included in this kit: •...
  • Page 79 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Plug with Connectors Torch Control Cable Connectors A-02272 Torch Lead Assembly 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 80 7-3436 RPT Adapter Kit Control Plug Connector Pilot Connector Pilot Connector (un-assembled)
  • Page 81 Manual 0-2761 RPT Adapter Kit Catalog # 7-3437 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: • MULTIQUIP MQ PCX50SS • OTC D-5000 and D-7000 •...
  • Page 82 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Plug with Connectors Torch Control Cable Connectors A-02488 Torch Lead Assembly 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 83 7-3437 RPT Adapter Kit Control Plug Connectors...
  • Page 84 Manual 0-2770 RPT Adapter Kit Catalog # 7-3438 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: CEBORA 50 NU-TECSYS OMNICUT 375 Parts Supplied The following parts are included in this kit: •...
  • Page 85 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Wires with Connectors Torch Control Cable Connectors A-02484 Torch Lead Assembly 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 86 7-3438 RPT Adapter Kit Negative Adaptor Control Plug Connector...
  • Page 87 Manual 0-2758 RPT Adapter Kit Catalog # 7-3439 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: HARRIS System 50, 65 and 100 Parts Supplied The following parts are included in this kit: •...
  • Page 88 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Wires with Connectors Torch Control Cable Connectors A-02484 Torch Lead Assembly 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 89 7-3439 RPT Adapter Kit Tie Wrap Control Plug Connector...
  • Page 90 Manual 0-2765 RPT Adapter Kit Catalog # 7-3440 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: HOBART FAB SHOP Parts Supplied The following parts are included in this kit: •...
  • Page 91 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Wires with Connectors Torch Control Cable Connectors A-02484 Torch Lead Assembly 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 92 7-3440 RPT Adapter Kit Negative Adaptor Control Plug Connector...
  • Page 93 Manual 0-2767 RPT Adapter Kit Catalog # 7-3441 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: NU-TECSYS PCA-30/60 and 65 Parts Supplied The following parts are included in this kit: •...
  • Page 94 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Wires with Connectors Torch Control Cable Connectors A-02484 Torch Lead Assembly 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 95 7-3441 RPT Adapter Kit Negative Adaptor Control Plug Connector...
  • Page 96 Manual 0-2768 RPT Adapter Kit Catalog # 7-3442 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: SMITH SPC-30, 20-50 and 40-80 Parts Supplied The following parts are included in this kit: •...
  • Page 97 Torch Control Cable Wiring Diagram For Mechanized Systems Control Connector Torch Control Plug with Connectors Torch Control Cable Connectors A-02497 Torch Lead Assembly 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 98 7-3442 RPT Adapter Kit Pilot Connector Negative Adaptor Ring Terminal Control Plug Connector...
  • Page 99 Manual 0-2771 RPT Adapter Kit Catalog # 7-3443 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: Thermal Dynamics PAK-4Xi, 6Xi, 2XT-220 and DynaPak 110 Thermal Dynamics Pak Master 25 and 38XL Thermal Dynamics EconoPak 25 Thermal Dynamics Drag-Gun 38...
  • Page 100 8. Connect the Control Connector Wire (see NOTE) to the two mating connectors NOTE on the replacement torch leads per one of the following procedures: For PAK-4Xi, 6Xi, 2XT-220 and DynaPak 110: For Mechanized Systems refer to the Connect the Control Connector Wires (8” long), with two connectors, to the Torch Control Cable Wiring Diagram two mating connectors on the replacement torch leads.
  • Page 101 7-3443 RPT Adapter Kit Control Plug Connector Negative Adaptor Hole Grommet Control Plug Connector Terminal Connector...
  • Page 102 Manual 0-2772 RPT Adapter Kit Catalog # 7-3444 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: • Thermal Dynamics PAK 5 Parts Supplied The following parts are included in this kit: •...
  • Page 103 7-3444 RPT Adapter Kit Control Plug Connector Negative Adaptor Pilot Connector Pilot Connector (un-assembled)
  • Page 104 Manual 0-2773 RPT Adapter Kit Catalog # 7-3445 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: • Thermal Dynamics Pak Master 50 with Smart Torch NOTE Parts Supplied For Mechanized Systems refer to the...
  • Page 105 4. Pull the protective boot and inner retaining ring from the quick disconnect body. Protective Boot Quick Disconnect Body Inner Retaining Ring Outer Retaining Nut Rubber Cover & A-00029 Tie Wrap Disassembly Of Connector 5. Slide the protective boot and inner retaining ring back over the torch leads to expose the leads connections. 6.
  • Page 106 Negative/Plasma Lead Connection Pilot Lead Connection A-00031 Disconnecting Leads 11. Remove the protective boot, inner retaining ring and outer retaining nut from the old leads. 12. Discard the old leads and Signal Pin Connector. B. Reassembling New Quick Disconnect 1. Slide the protective boot, inner retaining ring and outer Quick Disconnect retaining nut from the old torch onto the replacement Body...
  • Page 107 7. Insert the Signal Pin Connector in the quick disconnect body and install the two white locking tabs on both sides. The bevel must be towards the signal connector. Quick Disconnect Body Signal Pin Connector A-00164 White Tabs Installing The White Locking Tabs 8.
  • Page 108 7-3445 RPT Adapter Kit Control Plug Connector Protective Boot Negative Adapter Pilot Connector (un-assembled) Tie Wrap Pilot Connector...
  • Page 109 Manual 0-2831 RPT Adapter Kit Catalog # 7-3446 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: Thermal Dynamics PAK 3XR, 5XR, 5XT, 6XR, 7XR, 625XR and 750XR Parts Supplied The following parts are included in this kit: •...
  • Page 110 11. Reinstall any covers removed (see WARNING). WARNING 12. Install the proper torch consumables for the Power Supply amperage. Make sure that the Control Connector Plug wires DO NOT contact the Adapter Fitting after 13. Reconnect main input power to the Power Supply and turn the unit ON. all leads are connected.
  • Page 111 7-3446 RPT Adapter Kit Negative Control Plug Adapter Connector Pilot Connector (un-assembled) Pilot Connector...
  • Page 112 Manual 0-2828 RPT Adapter Kit Catalog # 7-3447 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: •...
  • Page 113 Control Connector Plug with Connectors Torch Control Connectors Pilot Lead Negative/Plasma Lead A-02482 Torch Lead Assembly 5. Connect the pilot wire (+) from the replacement torch NOTE to the Power Supply and tighten securely. For Mechanized Systems refer to the Torch Control 6.
  • Page 114 7-3447 RPT Adapter Kit Control Plug Connector...
  • Page 115 Manual 0-2832 RPT Adapter Kit Catalog # 7-3449 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: Thermal Dynamics EconoPak 50 Parts Supplied The following parts are included in this kit: •...
  • Page 116 9. Connect the fastons of the Control Connector Wires to the Power Supply. Install the two replacement tie-wraps in the same location as WARNING noted in Step 3 above to secure the control and pilot leads to the existing wiring. Make sure that the Control Connector Wires DO NOT contact the Adapter Fitting after all leads 10.
  • Page 117 7-3449 RPT Adapter Kit Control Plug Connector Negative Adaptor Control Plug Connector Hole Grommet Tie Wraps Pilot Connector...
  • Page 118 Manual 0-2834 RPT Adapter Kit Catalog # 7-3450 Installation Instructions General Information This Replacement Torch Adapter Kit is to be used to connect the Thermal Dynamics Plasma RPT Series Cutting Torch to the following equipment: Thermal Dynamics EconoPak 100 Parts Supplied The following parts are included in this kit: •...
  • Page 119 7-3450 RPT Adapter Kit Control Plug Connector Pilot Connector...
  • Page 120 Manual 0-2891 RPT Adapter Kits Catalog # 7-3454, 7-3457 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information These Replacement Torch Adapter Kits connect the Thermal Dynamics SL60 and SL100 Torch Leads with O2B fit- tings, or ATC Adapter Kit No.
  • Page 121 5. Slide the large insulating sleeve onto the Negative / Plasma lead (only) on the ATC adapter or torch leads. All wiring must remain outside this insulating sleeve. Fold back approximately one third of the length of the sleeve for access to the Negative / Plasma lead fitting. Connect the Negative / Plasma lead on the ATC Adapter or torch leads to the fitting on the RPT Adapter Kit.
  • Page 122 Installation and Use 1. Use the connecting ring on the ATC Adapter Kit to secure the male connector in place in the receptacle. Do not use tools. If resistance is felt, unthread the connecting ring, check the alignment of the connector and receptacle, and reassemble.
  • Page 123 Manual 0-2892 RPT Adapter Kits Catalog # 7-3455, 7-3456 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information These Replacement Torch Adapter Kits connect the Thermal Dynamics SL60 or SL100 Torch Leads, or the ATC Adapter Kit No.
  • Page 124 3. Slide the rubber boot, small end first, onto the torch leads or ATC Adapter. Slide the boot up far enough to allow access to the fittings and connections. 4. Cut the plastic tie wrap off the sleeved wires connected to each other on the torch leads or ATC Adapter. Remove the insulating sleeve.
  • Page 125 Installation and Use 1. Press the male connector on the torch leads into the female receptacle on the ATC Adapter. Use the connecting ring on the torch leads connector to secure the male connector in place in the receptacle. Do not use tools. If resistance is felt, unthread the connecting ring, check the alignment of the connector and receptacle, and reassemble.
  • Page 126 Manual 0-2927 RPT Adapter Kit Catalog # 7-3461 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This Replacement Torch Adapter Kit is used to connect Thermal Dynamics RPT 1Torch Plasma Torches to the follow- ing equipment: •...
  • Page 127 Torch Lead Strain Relief Assembly Insert Halves Strain Relief Shell Half ATC Adapter Kit Sleeve and Tie Wrap Removed Large Insulating Sleeve Torch Control Strain Relief Connectors Shell Half Negative/Plasma Butt Splice Lead A-03447 Pilot Lead Small Insulating Sleeve Ring Terminal (Removed) Gas Fitting 11.
  • Page 128 Manual 0-2928 RPT Torch Adapter Kit 82 Benning Street, West Lebanon, NH 03784 USA Catalog # 7-3462 (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This kit connects Thermal Dynamics Torches equipped with O2B connectors, or the ATC Adapter Kit, to the follow- ing Power Supplies: •...
  • Page 129 B. Installation 1. Thread the large gas fitting from this adapter kit onto the ATC Adapter or Torch Leads O2B fitting. Tighten securely. Do not use sealant. 2. Connect the large adapter fitting to the gas connector on the Power Supply. Tighten securely. Do not use sealant.
  • Page 130 C. Operation 1. Install the proper torch consumables. 2. Connect primary input power. Turn on the gas supply. 3. Set proper gas pressure and flow per the Torch Instruction Manual. 4. Test for proper operation. 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 131 Manual 0-2958 Torch Adapter Kit Catalog # 7-3476 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information These instructions cover Thermal Dynamics RPT Adapter Kit No. 7-3476. The kit connects 1Torch SL60 or SL100 Torches equipped with O2B connectors, or the ATC Adapter Kit, to the following Power Supplies: •...
  • Page 132 B. Installation 1. Pass the end of the leads or ATC Adapter through the torch leads opening in the Power Supply. 2. Inside the Power Supply, slide the Strain Relief securing nut onto the Leads or Adapter. Tighten the securing nut onto the Strain Relief to secure the strain relief to the Power Supply.
  • Page 133 9. In 4-wire Power Supply applications only, remove the insulating sleeve covering two joined wire connec- tors with mating connectors on the Torch Leads or the ATC Adapter if not previously removed. Separate the connectors. In 2-wire Power Supply applications, reconnect and insulate the two Torch Leads or ATC Adapter wires which were originally joined with mating connectors if they were disconnected for any reason.
  • Page 134 Manual 0-2951 Torch Adapter Kit Catalog # 7-3477 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information These instructions cover Thermal Dynamics RPT Adapter Kit No. 7-3477. The kit connects 1Torch SL60 or SL100 Torches equipped with O2B connectors, or the ATC Adapter Kit, to the following Power Supplies: •...
  • Page 135 B. Installation 1. Pass the end of the leads or ATC Adapter through the torch leads opening in the Power Supply front panel. 2. Slide the Strain Relief securing nut over the Leads or Adapter. Tighten the securing nut onto the Strain Relief to secure the strain relief to the Power Supply front panel.
  • Page 136 C. Operation 1. Connect primary input power. Turn on the gas supply. 2. Set proper gas pressure and flow per the Torch Instruction Manual. 3. Test for proper operation. 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 137 Manual 0-2951 Torch Adapter Kit Catalog # 7-3477 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information These instructions cover Thermal Dynamics RPT Adapter Kit No. 7-3477. The kit connects 1Torch SL60 or SL100 Torches equipped with O2B connectors, or the ATC Adapter Kit, to the following Power Supplies: •...
  • Page 138 B. Installation 1. Pass the end of the leads or ATC Adapter through the torch leads opening in the Power Supply front panel. 2. Slide the Strain Relief securing nut over the Leads or Adapter. Tighten the securing nut onto the Strain Relief to secure the strain relief to the Power Supply front panel.
  • Page 139 C. Operation 1. Connect primary input power. Turn on the gas supply. 2. Set proper gas pressure and flow per the Torch Instruction Manual. 3. Test for proper operation. 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 140 Manual 0-2973 1Torch Adapter Kit 82 Benning Street, West Lebanon, NH 03784 USA 7-3480 (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information Installation This kit connects Thermal Dynamics 1Torch Models SL60 or SL100 Torches, or the Thermal Dynamics ATC Adapter, WARNINGS to Hypertherm* powermax* 600 power supplies with in- ternal torch connections.
  • Page 141 3. The torch leads or ATC Adapter includes a pilot 15. Connect the mating wire connectors on the sepa- wire terminated with a ring-tongue terminal. Cut rate 4-wire harness assembly provided in this kit this terminal off the wire. Strip back approxi- to the connectors on the torch leads assembly or mately 11/16 inch (17 mm) of insulation from the ATC Adapter.
  • Page 142 Manual 0-2978 1Torch Adapter Kit 82 Benning Street, West Lebanon, NH 03784 USA Catalog No. 7-3481 (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information 5. Loosen the screw securing the red wire from the This kit connects Thermal Dynamics 1Torch Models SL60 quick disconnect fitting to the bottom left corner or SL100, or the Thermal Dynamics ATC Adapter Kit, to of the power supply pilot relay.
  • Page 143 5. Refer to the illustration. Place the lead support Installing Adapter Kit bracket on the RPT Adapter fitting (with power supply transformer lead). Position the fitting and 1. On the torch leads or adapter leads, remove the bracket diagonally into the opening in the power tie wrap and insulation sleeve covering two wires supply chassis just above the relay.
  • Page 144 9. Connect the mating connectors on the control wire harness supplied in this kit to the connectors on the end of the torch leads or adapter leads. 10. Crimp the butt splices on the control wire har- ness to the blue and purple power supply wires cut when removing the original quick-disconnect fitting.
  • Page 145 Manual 0-2988 RPT Adapter Kit No. 7-3483 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information These instructions cover Thermal Dynamics No. 7-3483 Replacement Torch Adapter Kit. This kit connects Thermal Dynamics SL60 or SL100 Torch leads with O2B fittings, or the Thermal Dynamics ATC Adapter Kit, to Hypertherm* powermax* 1650 power supplies.
  • Page 146 4. Disconnect and remove the torch per the power supply manufacturer's instructions. 5. Slide back the insulating sleeve covering the wire terminated with a ring terminal on the ATC Adapter or torch leads assembly. Cut the ring terminal off the wire. Strip back the insulation on the wire approximately 1/4"...
  • Page 147 15. Securely crimp the butt splice on the Adapter Kit wire harness to the ATC Adapter or torch leads pilot wire. Check for a secure connection. Slide the insulating sleeve over the butt splice. Connect the torch control connectors on the ATC Adapter Kit or Torch Leads to the RPT Adapter Kit wire harness. 16.
  • Page 148 Pinout Diagram for RPT Hand Torch with ATC Adapter ATC Female Receptacle ATC Male Connector HAND TORCH Front View Front View Pilot Pilot 1 - Black / PIP 1 - Black / to Large Pin 5 - Open 5 - Open 2 - Orange /PIP - 2- Orange / 6 - Open...
  • Page 149 Manual 0-2993 RPT Adapter Kit 82 Benning Street, West Lebanon, NH 03784 USA No. 7-3484 (603) 298-5711 • www.thermal-dynamics.com Installation Instructions Procedure General Information This kit connects Thermal Dynamics 1Torch Adapters or SL60 / SL100 Torch leads to Hypertherm* powermax* WARNING 350 Power Supplies.
  • Page 150 7. Install the black plastic Adapter Fitting included 12. Slide back the insulating sleeve covering the pi- in this kit in the solenoid outlet port. Do not lot lead (terminated with a ring terminal) on the tighten yet. ATC Adapter or torch leads assembly. Cut the ring terminal off the lead.
  • Page 151 16. Slide the strain relief securing nut onto the ATC 22. In installations with the ATC Adapter, connect the Adapter Leads or torch leads assembly. Thread torch ATC male connector to the ATC Adapter the nut onto the strain relief securely. Do not receptacle.
  • Page 152 Manual 0-2994 RPT Adapter Kit 82 Benning Street, West Lebanon, NH 03784 USA No. 7-3485 (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information Procedure This kit connects Thermal Dynamics 1Torch Adapters or SL60 / SL100 Torch leads to Hypertherm* powermax* WARNING 190C Power Supplies.
  • Page 153 6. Refer to the illustration. Pass the end of the ATC 11. Attach the hose union included in this kit to the Adapter Leads or torch leads assembly through Adapter fitting. Simply press the union onto the the torch access opening in the front panel of the Adapter Fitting until it seats securely.
  • Page 154 17. Tighten the strain relief dome nut onto the strain relief assembly. Check for a secure fit. 18. Use the wire ties included in this kit to secure the torch wire leads and work cable to the leads as- sembly 19.
  • Page 155 Section Section ATC Lead Extensions/Adapters Contents 7-5207 7-7544 7-7545 7-7552 7-3474 9/10/02...
  • Page 156 Manual 0-2883 ATC Adapter Kit (Female Receptacle) 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Catalog # 7-5207 Installation Instructions General Information The ATC Adapter Kit (Female Receptacle) is used to connect the ATC Style RPT Torch to a plasma power supply. This kit is connected to a Torch Adapter Kit which is required to complete the installation.
  • Page 157 8. Connect the ATC Adapter lead connections to the Torch Adapter Kit parts installed onto the Power Supply as de- scribed in the instructions supplied with the Torch Adapter Kit. 9. Tighten the Strain Relief onto the ATC Adapter Leads. 10.
  • Page 158 Manual 0-2887 ATC Leads Extension Kits Catalog # 7-7544, 7-7545 & 7-7552 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions 3. Disconnect the torch from the ATC Adapter Kit con- General Information nector, see NOTE, installed on the power supply. The ATC Leads Extension Kits are used to extend the to- NOTE tal torch lead length of Thermal Dynamics Plasma RPT...
  • Page 159 Manual 0-2954 Remote Interface Adapter Catalog # 7-3474 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information These instructions cover the Thermal Dynamics ATC Remote Interface Adapter Kit No. 7-3474. This adapter is only for Thermal Dynamics torches or Lead Extensions with ATC torch connectors.
  • Page 160 B. Installation 1. Align the male connector on the ATC Remote Interface Adapter with the ATC female receptacle. Press the con- nector into the receptacle. The connectors should push together with a small amount of pressure. Secure the connection by turning the locking nut clockwise until it stops. DO NOT use the locking nut to pull the connection together.
  • Page 161 Section Section Remote Interface Kits Contents 7-3452 7-3470 1/10/03...
  • Page 162 Manual 0-2876 Remote Pendant Interface RPT Adapter Kit 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Catalog # 7-3452 Installation Instructions General Information 4. On the RPT Torch remove the Strain Relief Nut from the Strain Relief. This kit allows any RPT Torch Adapter Kit to be inter- faced with a Remote Pendant Control.
  • Page 163 6. Connect the pilot lead (+) from the replacement c. For two-wire Torch & Lead Assemblies: torch to the Power Supply and tighten securely. Connect the Torch & Lead wires to the Con- 7. Connect the Negative / Plasma Lead from the re- trol Connector and Remote Pendant Adapter placement torch to the Power Supply.
  • Page 164 Manual 0-2929 Remote Pendant Adapter Kit Catalog # 7-3470 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information This kit connects a Thermal Dynamics Remote Pendant to SL60 or SL100 Torches equipped with the ATC connector. Supplied Parts The kit includes: •...
  • Page 165 B. Installation on Unshielded ATC Connectors A-03501 1. Refer to the illustration. Unfold Torch Leads individual wires as needed for access to sockets in the ATC male connector. The Remote Pendant Adapter wire harness includes three wires ter- minated with pins. Insert the pins in sockets in the ATC male connector as follows: •...
  • Page 166 To Remote Pendant To Torch Alignment Key Shell half Shell half Locking Ring Alignment Alignment Key Notches Alignment Notches ATC Male Connector Bend Relief Shell half ATC Female Receptacle To Power Supply A-03492 Ground Wire (Refer to Instructions) Adapter Installation, Unshielded Leads February 24, 2003 / 24 Février, 2003 Manual / Manuel 0-2929...
  • Page 167 D. Installation on Shielded ATC Connectors 1. Refer to the illustration. Unfold individual wires in the ATC male connector as needed for access to sockets. 2. Cut the wire connected to the pin in socket #8 in the ATC male connector, 1.5 inch / 38 mm from the flange at the end of the male connector (inner) center assembly.
  • Page 168 Pendant Adaper Wires To Torch to ATC Connector Insulating Boot To Remote Pendant Tie Wrap Sockets 3 & 4 Shield Alignment Key Shield Wire Shell half Locking Ring Leads ATC Male Connector Center Assembly Shield Wire to Connector Socket 8 Alignment Notches ATC Male...
  • Page 169 Section Section Replacement Kits Contents 9-7030 9-7031 9-7034 9-8218 9/10/02...
  • Page 170 Manual 0-2922 Torch Handle Replacement Kit 82 Benning Street, West Lebanon, NH 03784 USA for SL60 & SL100 Hand Torches (603) 298-5711 • www.thermal-dynamics.com Catalog No. 9-7030 Installation Instructions B. Disassembly General Information Disassemble the torch as follows: These instructions cover the Torch Handle Replacement Kit No.
  • Page 171 C. Reassembly 1. Position the replacement right handle half as A-03415 shown in the illustration. 2. Check the colors of the switch wires. Position the switches in the same arrangement as the original placement. Position the switches carefully on the mounting pins, with the activating blades oriented the same way as the originals.
  • Page 172 A-03431 1 Right Handle Half 6 Left Handle Half 11 Torch Lead Fitting 7 Torch Head 2 PIP Switch 12 Handle Screw 8 Pilot Lead Terminal 3 Torch Trigger Switch 13 Leads Connection (O2b) 9 Internal Star Washer 4. Trigger Assembly 14 Leads Connection (ATC) 10 Screw 5 Trigger Return Spring...
  • Page 173 Manual 0-2894 Replacement Switch Kit for SL60 & SL100 Torches 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Catalog No. 9-7031 Installation Instructions General Information These instructions cover Switch Replacement Kit No. A-03415 9-7031 for Thermal Dynamics Model SL60 and SL100 Plasma Cutting Torches.
  • Page 174 6. Check the Trigger Assembly against the illustra- NOTE tion. Ensure that the trigger release is fully against Every effort has been made to provide com- the trigger and slides freely along the trigger, and plete and accurate information in this manual. that the springs are in place.
  • Page 175 A-03430 1 Right Handle Half 11 Torch Lead Fitting 6 Left Handle Half 2 PIP Switch 12 Handle Screw 7 Torch Head 3 Torch Trigger Switch 13 Leads Connection (O2b) 8 Pilot Lead Terminal 4. Trigger Assembly 14 Leads Connection (ATC) 9 Internal Star Washer 5 Trigger Return Spring 15 Bushing (SL60 Torches only)
  • Page 176 Manual 0-2897 Torch Trigger Replacement Kit 82 Benning Street, West Lebanon, NH 03784 USA for SL60 & SL100 Hand Torches (603) 298-5711 • www.thermal-dynamics.com Catalog No. 9-7034 Installation Instructions General Information These instructions cover Torch Trigger Replacement Kit A-03415 No. 9-7034 for Thermal Dynamics Model SL60 and SL100 Plasma Cutting Hand Torches.
  • Page 177 C. Torch Assembly 1. Check that wires do not impede the motion of the Trigger Assembly. 2. Position the left handle half against the right half. Adjust as needed to ensure that the pivot pin on the Trigger Assembly engages its mating socket in the left handle half.
  • Page 178 A-03430 1 Right Handle Half 6 Left Handle Half 11 Torch Lead Fitting 2 PIP Switch 7 Torch Head 12 Handle Screw 3 Torch Trigger Switch 8 Pilot Lead Terminal 13 Leads Connection (O2b) 4. Trigger Assembly 9 Internal Star Washer 14 Leads Connection (ATC) 5 Trigger Return Spring 10 Screw...
  • Page 179 Manual 0-2923 SL60 and SL100 Hand Torch Replacement Head Kit 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com and Replacement Leads Kits Installation Instructions Replacement Procedures General Information Disassembly and reassembly of the torch handle is the These instructions cover the following Replacement Kits same for all kits covered by these instructions.
  • Page 180 5. Carefully lift the leads, torch head, and switches engages a socket on the upper (inner) surface of out of the right handle half. Set the right handle the trigger. Put the back end of the Assembly in half aside. place first.
  • Page 181 A-03430 6 Left Handle Half 1 Right Handle Half 11 Torch Lead Fitting 7 Torch Head 2 PIP Switch 12 Handle Screw 8 Pilot Lead Terminal 3 Torch Trigger Switch 13 Leads Connection (O2b) 9 Internal Star Washer 4. Trigger Assembly 14 Leads Connection (ATC) 10 Screw 5 Trigger Return Spring...
  • Page 182 Manual 0-2889 82 Benning Street, West Lebanon, NH 03784 USA Replacement Machine Torch (603) 298-5711 • www.thermal-dynamics.com Head or Leads Kits Installation Instructions General Information 2. Remove the end cap assembly from the top of the positioning tube. These instructions cover Replacement Torch Head or Re- 3.
  • Page 183 C. Installing Replacement Parts Install the replacement component as follows: Bend Relief Spring 1. If replacing the torch leads, pass the torch end of the replacement leads through the positioning tube. Torch Connect the power supply end of the leads assembly End Cap Leads to the power supply bulkhead, the power supply ATC...
  • Page 184 Manual 0-2930 Replacement Switch Kit Catalog #9-7036 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information B. Switch Removal and Replacement 1. Cut the original switch wires above the butt splices These instructions cover the replacement PIP switch kit and as close as possible to the butt splices.
  • Page 185 C. Torch Reassembly NOTE Every effort has been made to provide com- 1. Hold the torch head assembly stationary. Rotate plete and accurate information in this manual. the mounting tube to connect the tube to the torch However, the publisher does not assume and head.
  • Page 186 Manual 0-2963 82 Benning Street, West Lebanon, NH 03784 USA Replacement PIP Plunger (603) 298-5711 • www.thermal-dynamics.com & Spring Kit, No. 9-7045 Installation Instructions General Information 5. Pull the Torch Head Assembly straight down from the positioning tube, far enough to expose the PIP return These instructions cover the Replacement PIP Plunger and spring and PIP Switch on the torch head assembly.
  • Page 187 B. Installing Replacement Parts 1. Press the replacement plunger into the torch head. Push it up as far as it will go, so that the notch in the torch head keeps the plunger in position. End Cap Half Bend Relief Spring 2.

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Thermal dynamics 1torch sl100 rpt