Tweco SL100 User Manual

100100%DutyCyclePIP H/F LVStart Max Input 125PSIOp Pres 60-75 PSI Max Flow400 scfh 60PLASMA CUTTING TORCH Rev. AB Date: J

GENERAL INFORMATION 1-4 Manual 0-29621.04 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning Street West L

Manual 0-2962 1-5 GENERAL INFORMATION1.05 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics®Corporation(hereinafter“Thermal”)warrantsth

GENERAL INFORMATION 1-6 Manual 0-2962Australia Terms of Warranty – 2012Effective 1st January 2012, all warranties against defects (also known as a

Manual 0-2962 2-1 INTRODUCTION SECTION 2: INTRODUCTION 2.01 Scope of ManualThis manual contains descriptions, operating instructions and maintenanc

INTRODUCTION 2-2 Manual 0-2962E. Type CoolingCombination of ambient air and gas stream through torch.F. Torch RatingsAmbientTemperature104° F40°

Manual 0-2962 2-3 INTRODUCTION 2.04 Options And AccessoriesThese items can adapt a standard system to a particular application or further enhance p

INTRODUCTION 2-4 Manual 0-2962B. Gas DistributionThe single gas used is internally split into plasma and secondary gases.The plasma gas ows i

Manual 0-2962 3-1 INSTALLATION SECTION 3: INSTALLATION 3.01 IntroductionThis section describes installation of the Torch. These instructions apply

INSTALLATION 3-2 Manual 0-29623.06 Connecting TorchThe Torch Leads must be properly connected to the Power Supply for proper operation. If the to

Manual 0-2962 3-3 INSTALLATION 3. Secure the Through - Hole protector with the retain-ing nut removed earlier.4. Connect the torch leads or ATC Ad

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

INSTALLATION 3-4 Manual 0-2962B. Mechanized Machine Torch Systems - Torches with ATC Connectors Torches with ATC connectors connect either to an

Manual 0-2962 3-5 INSTALLATION 10. Connect the remote pendant adapter to the Remote Control Cable Connector.A-0358212Control CableConnector (Machine

INSTALLATION 3-6 Manual 0-29626. Connect the control circuit connectors on the Torch Leads to the mating connectors on the Remote Pendant Adapter

Manual 0-2962 3-7 INSTALLATION E. Automated Machine Torch Systems with ATC ConnectorsTorches with shielded leads and ATC connectors connect to a s

INSTALLATION 3-8 Manual 0-2962F. Automated Machine Torch Systems with O2B ConnectorsTorches with shielded leads and O2B connectors connect direct

Manual 0-2962 4-1 OPERATIONSECTION 4: OPERATION4.01 IntroductionThis section provides a description of the SL60 and SL100 Torch Assemblies followed

OPERATION 4-2 Manual 0-2962Refer to Appendix 1 for a typical detailed block diagram of Sequence of Operation.The system is now ready for operation.4

Manual 0-2962 4-3 OPERATIONC. Bevel AngleThe angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A per

OPERATION 4-4 Manual 0-2962E. DrossWhen dross is present on carbon steel, it is com-monlyreferredtoaseither“highspeed,slowspeed,ortopdros

Manual 0-2962 4-5 OPERATION34Art # A-03383Tr igger21Tr igger Release6. Cut as usual. Simply release the trigger assembly to stop cutting.7. Follo

WARNINGSRead and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.While the

OPERATION 4-6 Manual 0-2962A-02986 Tr igger Tr igger Release 7. Bring the torch within transfer distance to the work. The main arc will transfer t

Manual 0-2962 4-7 OPERATION7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti - spatte

OPERATION 4-8 Manual 0-2962C. Piercing With Machine TorchTo pierce with a machine torch, the arc should be started with the torch positioned as hig

Manual 0-2962 4-9 OPERATIONC. Current SettingCurrent settings depend on torch travel speed, mode of operation (hand or machine torch), and the amou

OPERATION 4-10 Manual 0-2962

Manual 0-2962 5-1 SERVICESECTION 5: SERVICE5.01 IntroductionThis section describes basic maintenance procedures per-formable by operating personnel

SERVICE 5-2 Manual 0-2962B. O-Ring Lubrication This section applies only to torches withATC connec-tors. An o-ring on the Torch ATC Male Connector

Manual 0-2962 5-3 SERVICE5.04 Inspection and Replacement of Consumable Torch PartsWARNINGSDisconnect primary power to the system before disassembl

SERVICE 5-4 Manual 0-2962Worn ElectrodeNew ElectrodeArt # A-03284Electrode Wear7. Reinstall the Electrode by pushing it straight into the torch he

Manual 0-2962 5-5 SERVICEB. No cutting output1. Torch not properly connected to power supplya. Check that torch leads are properly attached to p

TABLE OF CONTENTSSECTION 1: GENERAL INFORMATION ... 1-11.01 Notes, Cautions an

SERVICE 5-6 Manual 0-2962

Manual 0-2962 6-1 PARTS LISTSSECTION 6: PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provides a breakdown of all replaceable c

PARTS LISTS 6-2 Manual 0-29626.03 Replacement Parts for Hand Torch Item # Qty Description Catalog # 1 1 Torch Handle Replacement Kit (inc

Manual 0-2962 6-3 PARTS LISTS85634271011Requires Adapter KitFor Proper InstallationORMay Require ATC Adapter Kit For Proper InstallationA-036641 9

PARTS LISTS 6-4 Manual 0-29626.04 Replacement Parts - for Machine Torches with Unshielded Leads Item No. Qty Description Catalog No. 1 1

Manual 0-2962 6-5 PARTS LISTSA-03665May Require ATC Adapter KitFor Proper InstallationRequires Adapter KitFor Proper Installation6ORMay Require ATC

PARTS LISTS 6-6 Manual 0-29626.05 Replacement Shielded Machine Torch Leads Assemblies Item No. Qty Description Catalog No. 1 Mechanized

Manual 0-2962 6-7 PARTS LISTSArt #A-03616123546Torch Continuity ('PIP') SwitchTorch Connection Fitting5Torch Continuity ('PIP')

PARTS LISTS 6-8 Manual 0-2962 6.06 Hand Torch ConsumablesThe illustration shows all consumable parts for the SL60 and SL100 hand torches. Refer to

Manual 0-2962 6-9 PARTS LISTSHand Torch Consumables SelectionStartCartridge9-8213Electrode9-8215Tips:20A 9-820530A 9-820640A 9-8207Tip A 9-

TABLE OF CONTENTS (continued)SECTION 6: PARTS LISTS ... 6-16.01

PARTS LISTS 6-10 Manual 0-29626.08 Machine Torch ConsumablesThe illustration shows all consumable parts for the SL100 machine torches. Refer to t

Manual 0-2962 6-11 PARTS LISTS Machine Torch Consumables SelectionStarterCartridge9-8213Electrode9-8215Shield Cap, Deflector9-8243Tip A 9-8225 (4

PARTS LISTS 6-12 Manual 0-29626.10 Automated Torch ConsumablesThe illustration shows all consumable parts for the SL100 automated torch. Refer to

Manual 0-2962 6-13 PARTS LISTSAutomated Torch Consumables SelectionStarterCartridge9-8213Electrode9-8215Shield Cap, Deflector9-8243Tip A 9-8225

PARTS LISTS 6-14 Manual 0-29626.12 Complete Assembly Replacement NOTEThe Complete Torch & Leads Assembly Replacement does not include the Torch

Manual 0-2962 6-15 PARTS LISTS6.13 Options & Accessories Qty Description Catalog # 1 ATC Adapter Kit, Unshielded 7-5207 1 ATC A

PARTS LISTS 6-16 Manual 0-2962PATENT INFORMATIONThe following parts are licensed under U.S. Patent No(s). 5120930 and 5132512 Catalog Number Descr

Manual 0-2962 A-1 APPENDIXAPPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM ACTIONON/OFF-Switch to OFF. RESULTAll indicators

APPENDIX A-2 Manual 0-2962This page intentionally blank

Manual 0-2962 A-3 APPENDIXAPPENDIX 2: GENERAL APPLICATION NOTESA. Hand Cutting Versus Machine (Mechanized) Cutting SpeedsMaterial ThicknessSpeedMa

APPENDIX 11: MECHANIZED TORCH WIRING DIAGRAMS ...A-27APPENDIX 12: AUTOMATED TORCH WIRING DIAGRAMS ...

APPENDIX A-4 Manual 0-2962APPENDIX 3A: CUTMASTER 50 & CUTMASTER 51 SYSTEM DATA (HAND TORCH)Cut Quality on Various Materials and ThicknessesThe

Manual 0-2962 A-5 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

APPENDIX A-6 Manual 0-2962APPENDIX 3B: CUTMASTER 50 & CUTMASTER 51 SYSTEM DATA (MACHINE TORCH)Cut Quality on Various Materials and Thicknesses

Manual 0-2962 A-7 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

APPENDIX A-8 Manual 0-2962APPENDIX 4A: CUTMASTER 75 & CUTMASTER 81 SYSTEM DATA (HAND TORCH) Cut Quality on Various Materials and ThicknessesThe

Manual 0-2962 A-9 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

APPENDIX A-10 Manual 0-2962APPENDIX 4B: CUTMASTER 75 & CUTMASTER 81 SYSTEM DATA (MACHINE TORCH)Cut Quality on Various Materials and Thicknesses

Manual 0-2962 A-11 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

APPENDIX A-12 Manual 0-2962APPENDIX 5: CUTMASTER 100 & 101 SYSTEM DATA (HAND AND MACHINE TORCH)Cut Quality on Various Materials and Thicknesses

Manual 0-2962 A-13 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

Manual 0-2962 1-1 GENERAL INFORMATIONSECTION 1: GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, and wa

APPENDIX A-14 Manual 0-2962APPENDIX 6: CUTMASTER 151 SYSTEM DATA (HAND AND MACHINE TORCH)Cut Quality on Various Materials and ThicknessesThe follow

Manual 0-2962 A-15 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

APPENDIX A-16 Manual 0-2962APPENDIX 7A: PAKMASTER 50XL PLUS SYSTEM DATA (HAND TORCH)Cut Quality on Various Materials and ThicknessesThe following t

Manual 0-2962 A-17 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

APPENDIX A-18 Manual 0-2962APPENDIX 7B: PAKMASTER 50XL PLUS SYSTEM DATA (MACHINE TORCH)Cut Quality on Various Materials and ThicknessesThe followin

Manual 0-2962 A-19 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

APPENDIX A-20 Manual 0-2962APPENDIX 8A: PAKMASTER 75XL PLUS SYSTEM DATA (HAND TORCH)Cut Quality on Various Materials and ThicknessesThe following t

Manual 0-2962 A-21 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

APPENDIX A-22 Manual 0-2962APPENDIX 8B: PAKMASTER 75XL PLUS SYSTEM DATA (MACHINE TORCH)Cut Quality on Various Materials and ThicknessesThe followin

Manual 0-2962 A-23 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

GENERAL INFORMATION 1-2 Manual 0-2962• Nevertouchanypartsthatareelectrically“live”or“hot.”• Weardryglovesandclothing.Insulateyours

APPENDIX A-24 Manual 0-2962APPENDIX 9: PAKMASTER 100XL PLUS SYSTEM DATA (MACHINE TORCH)Cut Quality on Various Materials and ThicknessesThe followi

Manual 0-2962 A-25 APPENDIXCutting Speed ChartsNOTES* Gas pressure shown is for torches with leads up to 25' / 7.6 m long. For 50' / 15.2

APPENDIX A-26 Manual 0-2962APPENDIX 10: HAND TORCH WIRING DIAGRAMSPIPSwitchTorchSwitch1234ATC MaleConnectorOrangeBlackGreenWhiteTorch LeadsPilot 123

Manual 0-2962 A-27 APPENDIXAPPENDIX 11: MECHANIZED TORCH WIRING DIAGRAMSNot UsedPIPSwitchUnshielded SL100 Mechanized (Machine) TorchArt # A-03680Ora

APPENDIX A-28 Manual 0-2962APPENDIX 12: AUTOMATED TORCH WIRING DIAGRAMSPIPSwitchShielded SL100 Automated (Machine) TorchFemaleFastonMaleFastonSquare

Manual 0-2962 A-29 APPENDIXAPPENDIX 13: ATC ADAPTER PINOUT DIAGRAMATC Adapter Female ReceptacleFront ViewArt # A-03666ATC Male ConnectorFront ViewAT

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Manual 0-2962 1-3 GENERAL INFORMATION1.03 PublicationsRefer to the following standards or their latest revisions for more information:1. OSHA, SAF