Plasma Arc Cutting - LJ Welding and Machine Rentals

Plasma Arc Cutting
MANUAL SYSTEMS, TORCHES &
ACCESSORIES
with Added Condensation Removal Feature
®
DRAG-GUN
PLUS
Ask Us About the NEW
82 Benning Street
West Lebanon, NH 03784
QUICK REFERENCE
PRODUCT GUIDE
Introducing:
The NEW Portable Drag-Gun Plus
Now Faeaturing Condensation Removal
(see page 5)
www.thermal-dynamics.com
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Plasma Gas – What is it?
Advantages of Plasma Cutting
Thermal Dynamics® Plasma Terminology
Selecting a Thermal Dynamics Plasma Cutting System
Systems
Drag-Gun® & Drag-Gun Plus (NEW) Systems . . . . . . . . . . . . . . . . . . 5
CUTMASTER® 1Series™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
PakMaster® XL PLUS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PakMaster 150XL System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torches
1Torch RPT Torches (see NEW Lincoln Compatible 1Torch) . . . 10
®
®
®
1Torch Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1Torch Consumables Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
About Us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19
Sales
Literature Requests
Technical & Product Application Services
Service & Repair
Introduction
Contents
Plasma Cutting Systems, Torches & Access ories
Introduction
Plasma Gas – What is it?
Plasma gas is gas heated to an extremely high temperature and ionized so
that it becomes electrically conductive. The plasma arc cutting and gouging
processes use plasma to transfer an electrical arc to the work piece. The
metal to be cut or removed is melted by the heat of the arc and then blown
away. A plasma arc creates a very clean, dross free cut with minimal heat
input, usually requiring very little rework or cleanup.
Advantages of Plasma Cutting
Plasma arc cutting is an excellent choice for most cutting applications but
it is particularly well suited for applications where speed and excellent cut
quality are important. Because of the intense heat of the plasma arc –
around 40,000° F (22,000° C) compared to 5,700° F (3150° C), with gases
used with Oxy-Fuel torches – the cut is very clean with little or no dross.
The plasma arc also cuts ferrous and non-ferrous metals much faster than
an Oxy-Fuel torch or abrasive saws, with low or no heat affected zone,
especially on thinner metals. A clean cut with little or no dross means less
time and money is required to finish the work piece. Parts are virtually
weld-ready.
With plasma cutting, less preparation work is required. A plasma arc is hot
enough to burn through most surface coatings such as paint and rust and
still provide excellent cutting results.
For applications where difficult shapes are being handled or cut, such as
ventilation ductwork (HVAC), tanks or vessels, plasma cutting offers
considerable advantage since no fixturing is required. All you need is a
place on the metal to attach the work clamp. And with plasma cutting,
there is also minimal heat input and distortion of the metal as there is with
jigsaws or cutting shears.
Thermal Dynamics® Plasma Terminology
• Genuine Cut – at Thermal Dynamics, our standard cut is called a
‘Genuine Cut’. A ‘Genuine Cut’ is an excellent, smooth cut surface with
little or no dross, requiring little or no rework or grinding. It is achieved
when cutting at 10” (254mm) and above per minute.
• Dross Buildup – molten material which is not blown out of the cut
area and solidifies on the bottom of the plate.
• Drag Cutting – with drag cutting you actually drag the tip of the torch
along the work piece to cut the metal. This works particularly well on
metal 3/16” (4.7mm) thick or less. This is often the easiest way to cut
and minimize heat input and kerf width.
How to Contact Us
• Standoff Cutting – suitable where material thickness is 3/16” (5mm) or
greater, the torch tip is held a distance of 1/8” (3mm) to 3/8” (10mm)
from the work piece to achieve the desired cut. Special devices such as
standoff guides and cutting guides can help make cutting easier. Cutting
guides are particularly useful for cutting thinner metals.
Cover Photo: Auto Body Repair using the new Drag-Gun Plus
page 2
U.S Customer Care: 800-752-7621
• Gouging – plasma gouging produces a very smooth, clean surface which
is often weld-ready. Plasma gouging can also be successfully used to
separate two welds with less noise and less smoke than traditional
gouging methods.
www.thermal-dynamics.com
page 3
• Piercing – piercing with plasma produces a quick hole through the plate
and is recommended on thickness up to 50% of the cutting system’s rating.
• Front End Parts Visibility – no matter if you are drag cutting or
standoff cutting, it is important to be able to see your work while
you are cutting. Thermal Dynamics®
Kerf Width
is known in the plasma cutting
Cut Surface
Bevel Angle
business for designing torches with
Top
excellent visibility.
Spatter
• Consumables Parts – generally refers
to the torch tip and torch electrode.
These parts must withstand the
intense heat of the plasma arc and
must be replaced periodically.
Top Edge
Rounding
Dross
Build-Up
Cut Surface
Drag Lines
A-00007
Systems
Introduction
Plasma Cutting Systems, Torches & Access ories
The Drag-Gun® Series
Designed for complete portability and ease of use,
the Drag-Gun and Drag-Gun Plus systems come with a
built-in air compressors. Excellent machines for a wide range of cutting
applications including expanded metal, HVAC spiral ducting, metal studs,
construction and home shop use.
Drag-Gun
(Brochure #63-2209)
• 1/8” (3.2mm) Genuine Cut Capacity
• 12 Amps Fixed Output
Selecting a Thermal Dynamics Plasma Cutting System
• Input Power – 1ph 120V or 220V
These basic questions will help you decide which system best fits
your needs:
• Duty Cycle – 30% @ 12A
• How thick is the metal you want to cut?
We offer a wide range of systems that can handle metal thickness from
gauge to 11⁄2”. For production applications you’ll want to refer to our
literature for automated plasma cutting systems.
• What cut quality do you require?
The cut quality you require will be an important factor in deciding which
system is right for you. Cut quality is based on a number of factors –
material type, thickness, and gas source. These factors need to be
weighed to determine the best system for your needs.
• What type of metal are you cutting?
Plasma can be used for cutting mild steel, stainless, and aluminum as well
as most other metals, with excellent results.
• What is your primary input power?
This refers to power at the wall or power source. Each plasma system
will have a required input current (single or three phase) rated at
maximum output based on your input voltage.
• Gas Supply
Thermal Dynamics manual cutting systems require either air or nitrogen
as a gas source – either from a high pressure gas cylinder or most often
an air compressor. An air compressor draws on shop air so it is very
important to control the air quality and keep it free from contaminants.
We recommend purchasing an optional filtering accessory for your plasma
system to ensure your system performs at its best.
• Torch Lead Length
Our plasma systems are usually offered in either 20’ (6.1m) or 50’ (15.2m)
lead lengths. (Our 1Torch® RPT® Torch is offered with Lead Extensions
in 15’/4.6m, 25’/7.6m, and 50’/15.2m lengths.) How far away from your
power source do you intend to operate your plasma cutter?
Feature:
Built-In
Air Compressor
s
• Built-In Air Compressor
• PCH-10 Torch
• Applications – Expanded Metal, HVAC
Spiral Ducting, Metal Studs and Any Other
Light Industrial Construction
NEW
Drag-Gun Plus
Condensation
Remo
Feature Availab val
le
(Brochure #63-2519)
• 1/2” (12mm) Genuine Cut Capacity
• 15-35 Amps, Continuously Variable
• Input Power – 1ph 220/230V ±10%,
50/60 Hz., leff: 18 Amps
• Duty Cycle – 35% @ 35A
• Built-In Air Compressor
• New Condensation Removal Feature
• SureLok® PCH-42ER Torch
• Applications – Expanded Metal, HVAC
Spiral Ducting, Metal Studs, General Duty Construction,
Auto Body, Roofing and any General Duty Portable Applications
NOTES:
• Price
Price is always an important consideration. How much money do you
want to spend? Thermal Dynamics is committed to providing customers
with quality product at the best value possible. We back our systems and
torches with excellent warranties and the best customer and technical
service in the industry.
page 4
U.S Customer Care: 800-752-7621
www.thermal-dynamics.com
page 5
The CUTMASTER® 1Series™
This family of products builds on the solid reputation earned by the CUTMASTER
line as reliable, rugged systems with excellent cut characteristics. In fact,
CUTMASTERs provide the best cut quality in the marketplace on thin gauge
metal, especially stainless steel.
Our CUTMASTER 1Series offers excellent value and a great introduction
into the plasma cutting market. If you are looking for a value-packed cutting
system, the CUTMASTER is an excellent choice.
Systems
Systems
Plasma Cutting Systems, Torches & Access ories
CUTMASTER ® 81
(Brochure #63-2316)
• 7/8” (22mm) Genuine Cut Capacity
11⁄4” (32mm) Severance Capacity
• 20-60 Amps, Adjustable
• Input Power – 1ph 208/230V, 3ph 400V,
3ph 400V CE, 3ph 415V, 1/3ph 460V, 3ph 600V
(Dedicated Voltage Design)
• Duty Cycle – 50% @ 60A, 100% @ 45A
The 1Series includes the universal 1Torch® with built-in ATC® (Advanced
Technology Connector), Spare Parts Kit, Input Power Cable, and Operating
Manual. Optional accessories include Torch Leads Extensions in 15 ft. (4.6m),
25 ft. (7.6m) and 50 ft. (15.2m) lengths and a new power supply wheel kit.
An automation interface kit is available to convert CUTMASTER 51-151 to
mechanized systems or systems can be ordered as fully automated models.
• 1Torch® SL60® Torch with Built-in ATC®
Quick Disconnect (Optional Lead Extensions
Available)
• Non HF (High Frequency) Start
• Auto Pilot Restart for Cutting Expanded Metal
• Applications – Heavy Fabrication, Manufacturing, Contractors
All CUTMASTER 1Series Systems come with a 3-year (Power Supply) /
1-year (Torch) Parts and Labor Warranty.
CUTMASTER 101
(Brochure #63-2317)
CUTMASTER 38
(Brochure #63-2203)
• 1” (25mm) Genuine Cut Capacity
11⁄2” (38mm) Severance Capacity
• 3/8” (10mm) Genuine Cut Capacity
5/8” (16mm) Severance Capacity
• 20-80 Amps, Adjustable
• 20-30 Amps, Adjustable
• Input Power – 1ph 120-230V
(Auto Voltage Selection)
• Input Power – 1ph 208/230V, 3ph 400V,
3ph 400V CE, 3ph 415V, 1/3ph 460V, 3ph 600V
(Dedicated Voltage Design)
• Duty Cycle – 40% @ 80A, 100% @ 45A
• Duty Cycle – 35% @ 30A
• 1Torch SL60® with Built-in ATC
Quick Disconnect (Optional Lead Extensions
Available)
• Non HF (High Frequency) Start
• Auto Pilot Restart for Cutting Expanded Metal
• Applications – Auto Body Repair, HVAC, Metal Stud Construction,
Home Shop, Metal Building & Roofing Construction, Plumbing,
Marine Repair and Rental Fleets
• 1Torch SL100® with Built-in ATC Quick
Disconnect (Optional Lead Extensions Available)
• Non HF (High Frequency) Start
• Auto Pilot Restart for Cutting Expanded Metal
• Applications – Heavy Fabrication, Manufacturing
CUTMASTER 151
(Brochure #63-2504)
• 11⁄4” (32mm) Genuine Cut Capacity
13⁄4” (45mm) Severance Capacity
CUTMASTER 51
(Brochure #63-2315)
• 1/2” (13mm) Genuine Cut Capacity
3/4” (20mm) Severance Capacity
• 20-40 Amps, Adjustable
• Input Power – 1ph 208/230V, 3ph 400V,
3ph 400V CE, 3ph 415V, 1/3ph 460V
(Dedicated Voltage Design)
• 25-100 Amps, Adjustable
• Input Power – 1ph 208/230V ±10%,
1ph 208/230V ±10% CE, 3ph 400V ±10%,
3ph 400V ±10% CE, 3ph 415V ±10%,
1/3ph 460V ±10%, 3ph 600V ±10%
(Dedicated Voltage Design)
• 1Torch SL60 with Built-in ATC Quick
Disconnect (Optional Lead Extensions Available)
• Duty Cycle – 104°F (40°C)
40% @ 100A @ 120VDC,
100% @ 50A @ 98VDC
68°F (20°C)
75% @ 100A @ 120VDC
• Non HF (High Frequency) Start
• 1Torch SL100 with Built-in ATC Quick Disconnect (Optional Lead Extensions Available)
• Auto Pilot Restart for Cutting Expanded Metal
• Non HF (High Frequency) Start
• Applications – Construction, Maintenance/Repair, Fabrication
• Auto Pilot Restart for Cutting Expanded Metal
• Duty Cycle – 40% @ 40A
• Applications – Heavy Fabrication, Manufacturing
page 6
U.S Customer Care: 800-752-7621
www.thermal-dynamics.com
page 7
The PakMaster® XL PLUS Series
The XL PLUS Series is designed for the user who wants a little more from
a cutting system. This series features the universal 1Torch® with ATC® Quick
Disconnect as standard. (Systems can also be ordered with the SureLok® Torch
upon request. See brochure #63-9901.) It also offers multi-voltage selection,
Smart Start™ auto pilot restart, tip saver circuitry for consumable parts
protection and a latch feature which acts as a trigger lock to prevent hand
fatigue during long cutting sessions. Standard are the built-in Leads Wrap and
parts storage, Spare Parts Kit, Work Cable & Clamp, and Operating Manual.
Optional Transformer (600VAC) available.
PakMaster 50XL PLUS
(Brochure #63-2424)
• 1/2” (12.7mm) Genuine Cut Capacity
3/4” (19.1mm) Severance Capacity
Systems
Systems
Plasma Cutting Systems, Torches & Access ories
The PakMaster® 150XL System
The Thermal Dynamics® PakMaster 150XL System has a liquid-cooled torch
for 6-8 times longer parts life as compared to similar gas-cooled systems.
This system provides high performance, low cost operation and dual gas
capability. With MaximumLife® parts, energy efficient inverter technology
and a 60% duty cycle, the PakMaster 150XL keeps you cutting all day long.
The PakMaster 150XL has multi-voltage selection, Smart Start™ auto pilot
restart, tip saver circuitry for consumable parts protection and a latch feature
which acts as a trigger lock and is designed to prevent hand fatigue during
long cutting sessions.
System comes complete with Spare Parts Kit and Box, Work Cable and
Clamp, Torch Coolant, Wheels and Handle. Transformer for 600V operation
also available.
• 15-40 Amps, Adjustable
PakMaster 150XL
• Input Power – 1/3ph 208-460V
(Multi-Voltage Capable)
(Brochure #63-2202)
• Duty Cycle – 100% @ 40A
• Auto Pilot Restart for Cutting Expanded Metal
• 1Torch SL60® Plasma Cutting Torch
• Trigger Latch Preventing Hand Fatigue
• 11⁄2” (38.1mm) Genuine Cut Capacity
13⁄4” (44.5mm) Severance Capacity
• 30-120 Amps, Adjustable
• Applications – Construction, Maintenance/Repair, General Fabrication
• Input Power – 3ph 208-230/460V,
3ph 380/415V CE
(Multi-Voltage Capable)
PakMaster 75XL PLUS
• Duty Cycle – 60% @ 120A, 100% @ 100A
(Brochure #63-2424)
• Auto Pilot Restart for Cutting Expanded Metal
• 3/4” (19.1mm) Genuine Cut Capacity
1” (25.4mm) Severance Capacity
• PCH/M-120 Liquid-Cooled Torch
• 15-60 Amps, Adjustable
• Trigger Latch Preventing Hand Fatigue
• Input Power – 1/3ph 208-460V
(Multi-Voltage Capable)
• Applications – General Fabrication of Carbon
Steel, Stainless Steel & Aluminum; Over the
Road Transport Trailers; Railroad Maintenance;
Vessel Manufacturing; Pipe Beveling &
Fabrication; Petroleum Refineries; Foundries;
Chemical Plants; Mining Operations;
Ship Building
• Duty Cycle – 65% @ 60A, 100% @ 55A
• Auto Pilot Restart for Cutting Expanded Metal
• 1Torch SL60 Plasma Cutting Torch
• Trigger Latch Preventing Hand Fatigue
• Applications – Construction, Maintenance/Repair, General Fabrication
PakMaster 100XL PLUS
NOTES:
(Brochure #63-2424)
• 1” (25.4mm) Genuine Cut Capacity
11⁄4” (31.8mm) Severance Capacity
• 15-80 Amps, Adjustable
• Input Power – 1/3ph 208-460V
(Multi-Voltage Capable)
• Duty Cycle – 40% @ 80A, 100% @ 60A
• Auto Pilot Restart for Cutting Expanded Metal
• 1Torch SL100® Plasma Cutting Torch
• Trigger Latch Preventing Hand Fatigue
• Applications – Construction, Maintenance/Repair, General Fabrication
page 8
U.S Customer Care: 800-752-7621
www.thermal-dynamics.com
page 9
1Torch® RPT® Torches
NOW
Compatible wi
th Lincoln®
Pro-Cut® 55
Pro-Cut® 80
1Torch - the most innovative, reliable, high
performance replacement torch available today.
No other torch performs so well with so many major brands of power
supplies, often with cutting results better than the original manufacturer’s torch:
- easily attached to virtually all manufacturers’ systems with
superlative performance
- includes the SureLok electrode locking system permitting quick,
precise changes of consumables
- out-of-the-box ready for all modes of operation including Drag
Shield Cutting, Standoff Cutting and Drag Tip Cutting
- no moving consumable parts
- standard set of consumables for all power supplies
All you need is the 1Torch RPT torch and the appropriate Adapter Kit.
Each torch comes complete with easy-to-install instructions.
ATC®
Quick Disconnect Option
If you need additional flexibility, the 1Torch RPT
torch is also available with ATC (Advanced Torch
Connector). This quick disconnect enables you to
change out a damaged torch, convert from a hand to machine torch, or put on
a different sized torch in a matter of seconds. And no tools are required to
complete the task. You can also customize the length of your leads by adding
on ATC Lead Extensions in 15 ft. (4.6m), 25 ft. (7.6m) or 50 ft. (15.2m) lengths.
1Torch SL60 ®/ SL55 ™ (Lincoln Pro-Cut 55 Compatible)
(Brochure #63-2217 / 63-2530 for SL55)
• 30-60 Amp Capacity
• SL55 Compatible with
Lincoln Pro-Cut 55 (60 Amps)
• Available in 75° Torch Head Configuration
• Standard Connection or ATC Quick Disconnect Available (not for SL55)
1Torch SL100 / SL80 ™
(Lincoln Pro-Cut 80 Compatible)
(Brochure #63-2217 / 63-2530 for SL80)
• Medium / Heavy Duty Torch
• 40-100 Amp Capacity
• SL80 Compatible with Lincoln
Pro-Cut 80 (85 Amps)
• Available in 75° or 180° (not for SL80)
Torch Head Configurations
• Standard Connection or ATC Quick Disconnect
Available (not for SL80)
Lincoln and Pro-Cut are registered trademarks of Lincoln Electric Co. and are in no way affiliated with Thermal Dynamics or Thermadyne Industries, Inc.
page 10
Torch Adapter Kits
The model of the plasma cutting system must be known
to determine the adapter kit required.
Manufacturer
Power Supply Model
Manufacturer
Cat No.
U.S Customer Care: 800-752-7621
Power Supply Model
7-3425
7-3435
LINCOLN®
Pro-Cut® 40
Pro-Cut® 55
Pro-Cut® 60
Pro-Cut® 80
50
Pocket 25
7-3438
7-3476
MARQUETTE®
CENTURY®
82020*, 82050*, M2050*
82100
7-3476
7-3430
DAIHEN®
SC-60P
MRAT-70
7-3432
7-3437
DAYTON®
3W722A*, 5Z031B*
7-3476
ESAB® (yellow)
PCM-SMi, 500i, 625i, PCS-43
PCS-53, 80, 90
ESP-100i
PCM-750i, 875, 1000i, 1125
Sidewinder 30, 55, 105
Powercut® 650
Powercut® 875, 1125
Powercut® 1250, 1500
7-3425
7-3435
7-3426
7-3429
7-3434
7-3464
7-3465
7-3462
HARRIS®
System 50, 65, 100
HOBART®
Smoothcut 30, 625
Smoothcut 50 (single gas), 100
Smoothcut 50 (dual gas)
Smoothcut II 35A, 60A, 100A
Fab Shop
Cybercut 2050*
AIRCO®/BOC®
PCS-43
PCS-53, PCS-80, PCS-90
CEBORA®
7-3431
see 63-2530 for details
7-3476
7-3432
7-3433
7-3430
7-3456
7-3457
7-3476
7-3477
7-3478
MULTIQUIP MQ®
PCX50SS
7-3437
NU-TECSYS®
Omnicut 375
PCA-30/60, 65
7-3438
7-3441
OTC
Panasonic® D-5000, D-7000
7-3437
7-3439
P-TRON®
P-Tron 75, 100
7-3437
7-3425
7-3426
7-3428
7-3427
7-3440
7-3457
POWCON®
Starcut
7-3430
SMITH®
Powerpro 55, 75
SPC-30, 20-50, 40-80
7-3487
7-3442
7-3476
SNAP-ON®
7-3430
Max® 42*, 43*, 40cs*,
powermax® 600*, 800*, 900* w/ Q.D.
7-3454
powermax®
7-3455
7-3461
7-3476
7-3477
7-3480
7-3481
7-3483
7-3484
7-3485
®
L TEC (green)
PCM-31, SMi, 32i/34i, VPi,
PCM-500i, 625i, PCS-80i
7-3486
see 63-2530 for details
MATCO®
2020*, 2050*
MILLER®
Plazcut 60†/Zipcut
Spectrum® 250D, 500, 750
Spectrum® 700, 1000‡, 1250, PLUS
Spectrum® 3080*
Spectrum® 650*, 701*, 2050*
Spectrum® 300*
Spectrum® 375*
Spectrum® 625*
Max® 40, HT® 40 (H/F Start), Max® 70,
Max® 80, Max® 100 w/ & w/o Q.D.
1100*
powermax® 1000*, 1250*
Max® 40cs* (w/o Q.D.)
powermax® 380*
powermax® 600* w/o Q.D.
powermax® 800*, 900* w/o Q.D.
powermax® 1650*
powermax® 350*
powermax® 190C*
Cat No.
12/150, 12/200
HYPERTHERM®
• Light / Medium Duty Torch
®
Adapters
Torches
Plasma Cutting Systems, Torches & Access ories
7-3425
PCM-50A, 70, 80, 52i/54i, 82i/84i,
ESP-100i, PCM-50, PCM-100 (Single Gas)
PCM-50, PCM-100 (Dual Gas)
7-3426
PCS-40
PCM-750i, 1000i
PCM-101
7-3430
7-3435
7-3436
YA-3230, YA-3440
YA-2230*, YA-5550*, YA-5550A*
7-3430
7-3476
SOLAR®
SOL 2020* (118-009, 118-010),
SOL 2050* (118-015,118-016)
SOL 2105, SOL 2106
7-3430
THERMAL DYNAMICS®
PAK® 3XR, 5XT, 5XR, 6XR, 7XR,
625XR, 750XR
PAK® 8XR, 10XR, 1000XR, 1250XR,
PakMaster® 75, 100
PakMaster® 50XL/XLP, 75XL/XLP,
PakMaster® 100XL/XLP,
CUTMASTER® 50, 75, 80XL, 100
PakMaster® 25, 38XL,
EconoPAK® 25, Drag-Gun® 38,
PAK® 4Xi, 6Xi, 2XT, Dynapak® 110
PakMaster® 50
w/ Smart Torch (Q.D.)
EconoPAK® 50
EconoPAK® 100
PAK® 5
PAK® 10
7-3476
7-3446
7-3434
7-3447
7-3443
7-3445
7-3449
7-3450
7-3444
7-3436
*Non-HF Systems.
†The Miller PlazCut 60 machines with Serial Numbers beginning JE are not compatible with 1Torch® RPT® Torches.
‡The Miller Spectrum 1000 machines with Serial Numbers beginning LF are not compatible with 1Torch RPT Torches.
NOTES: Each Adapter Kit includes connection fitting, electrical connectors and installation instruction sheets for the selected power supply.
AIRCO/BOC are registered trademarks of The BOC Group plc; CEBORA is a registered trademark of Cebora S.p.A.; DAIHEN is a registered trademark of Daihen Inc.; ESAB,
L-TEC and POWER-CUT are registered trademarks of ESAB AB; HARRIS, PRO-CUT and LINCOLN are registered trademarks of Lincoln Electric Co.; HOBART is a registered
trademark of Hobart Brothers Co.; HYPERTHERM, MAX and POWERMAX are registered trademarks of Hypertherm, Inc.; MILLER and SPECTRUM are registered trademarks
of Illinois Tool Works, Inc.; MULTIQUIP is a registered trademark of Multiquip, Inc.; NU-TECSYS is a registered trademark of Nu-Tecsys, Inc.; PANASONIC is a registered
trademark of Matsushita Electric Industrial Co., Ltd.; P-TRON is a registered trademark of P-Tron Plasma/Tech Systems; SMITH is a registered trademark of Smith Equipment
Co.; INNERLOGIC is a trademark of Innerlogic; None of the afore mentioned registered trademarks are in any way affiliated with Thermal Dynamics or Thermadyne Industries,
Inc.; THERMAL DYNAMICS, PAK, CUTMASTER, PAKMASTER, ECONOPAK, DYNAPAK and DRAG-GUN are registered trademarks of Thermal Dynamics Corp.
www.thermal-dynamics.com
page 11
Consumables
Plasma Cutting Systems, Torches & Access ories
1Torch® Consumable Parts Application Guide
For SL60® / SL100® Manual Cutting and Gouging Operations.
Gouging Profiles
Drag Tip Cutting
The preferred method of cutting light gauge metal up to 3/16” (4.8mm) thickness. Produces the best
cut quality, narrowest kerf width, fastest cutting speeds, with little to no distortion. For best results,
use the Shield Cup with the torch tip in direct contact with the work (up to 40 amps).
Standoff Cutting
The preferred method for cutting metal thicker than 3/16” (4.8mm) and at current levels above 40 amps.
Provides maximum visibility and accessibility. Use the single-piece Shield Cup for ‘standoff’ cutting
(with the torch tip 1/8” to 1/4” from the workpiece). Use the Shield Cup Body together with the
Deflector for extended parts life and improved resistance to reflected heat. This combination provides
cutting results similar to the single piece Shield Cup, as well as easy changeover to gouging or drag
shield cutting.
Output
Range
Depth
Width
Tip A
40 Amps (MAX)
Shallow
Narrow
Tip B
50-100 Amps
Deep
Narrow
Tip C
50-100 Amps
Moderate
Moderate
Tip D
50-100 Amps
Shallow
Wide
Drag Tip
Cutting
Standoff
Cutting
Profile
Drag Shield Cutting
This is an operator-friendly method of cutting between 50 to 100 amps while maintaining a constant
standoff distance. For metal thicknesses greater than 3/16” (4.8mm) simply drag the Shield Cap in
contact with the workpiece. Use the Shield Cup Body with the appropriate Drag Shield Cap matching
the current level being used. This method is not recommended for cutting light-gauge sheetmetal.
Drag
Shield
Cutting
Gouging
A simple method of metal removal by angling the torch to a lead angle of 35-45 degrees and using a
gouging tip. While maintaining a constant standoff distance, this allows for only a partial penetration into
the work, thus removing metal from the surface. The amount of current, travel speed, standoff distance,
lead angle and tip size will determine the amount of material removed and the profile of the gouge. Can
use the Shield Cup Body with either the Gouging Shield Cap or the Shield Deflector. Can also use the
single piece Shield Cup.
1Torch Consumable Parts Selection Guide
Gouging
1TORCH, a trademark of Thermal Dynamics Corporation, is registered with the U.S. Patent and Trademark Office, and is
the subject of trademark registrations and pending applications in numerous other countries. For information on trademark
registrations of Thermal Dynamics Corporation, contact the local trademark offices in the countries of interest.
For SL60 / SL100 Manual Cutting and Gouging Operations. Various front-end parts are available for different applications. The electrode and start cartridge remain the same for all applications.
Current
Range
20 - 40
Amps
50 - 60
Amps
70 - 100
Amps
page 12
Mode of
Operation
Amps
20A
30A
40A
20A
30A
40A
40A
Standoff Cutting
40A
Gouging
40A TIP A
50-55A
60A
Standoff Cutting
50-55A
60A
Drag Shield Cutting 50-55A
60A
40-60A TIP B
Gouging
40-60A TIP C
40-60A TIP D
70A
80A
90-100A
Standoff Cutting
70A
80A
90-100A
70A
Drag Shield Cutting
80A
90-100A
40-100A TIP B
Gouging
40-100A TIP C
40-100A TIP D
Electrode
Start
Cartridge
Drag Tip /
Standoff Cutting
9-8215
9-8215
9-8215
9-8213
9-8213
9-8213
Tip
9-8205
9-8206
9-8207
9-8205
9-8206
9-8207
9-8208
9-8208
9-8225
9-8209
9-8210
9-8209
9-8210
9-8209
9-8210
9-8226
9-8227
9-8228
9-8231
9-8211
9-8212
9-8231
9-8211
9-8212
9-8231
9-8211
9-8212
9-8226
9-8227
9-8228
U.S Customer Care: 800-752-7621
Shield
Cup
Shield
Cup Body
Drag
Shield Cap
Deflector
Gouging
Shield Cap
9-8218
9-8218
9-8218
9-8237
9-8237
9-8237
9-8243
9-8243
9-8243
9-8237
9-8237
9-8243
9-8218
9-8241
9-8218
9-8218
9-8237
9-8237
9-8237
9-8237
9-8237
9-8237
9-8237
9-8243
9-8243
9-8235
9-8235
9-8241
9-8241
9-8241
9-8218
9-8218
9-8218
9-8237
9-8237
9-8237
9-8237
9-8237
9-8237
9-8237
9-8237
9-8237
9-8243
9-8243
9-8243
9-8236
9-8236
9-8236
www.thermal-dynamics.com
9-8241
9-8241
9-8241
page 13
Accessories
Thermal Dynamics® offers accessories to help improve cutting performance.
TORCH CUTTING GUIDES / GUIDE KITS
Cutting Guide Kit (Deluxe)
Cat. No. 7-8910
Cuts circles from 2.125” (54mm) to 41.5” (1054mm) with proper
cutting attachments.
This kit includes easy add-on attachments to fit most Thermal
Dynamics torches for precise straight line, circle cutting and
beveling. Includes Carrying Case, Radius/Roller Kit (7-7501),
Circle Cutting Guide Kit (7-3291), Magnetic Pivot, Suction Pivot.
Circle Cutting Guide Kit
Accessories
Accessories
Plasma Cutting Systems, Torches & Access ories
TORCH CUTTING GUIDES (CONT.)
Universal Standoff Cutting Guide
Cat. No. 9-8422
A great new standoff guide specifically designed
to fit all shield cup designs for the PCH-62, PCH-102,
SL60® and SL100® RPT® torches. Adjustable
standoff height.
CUTMASTER ® 1Series ™
Standoff Cutting Guides
Cat. No. 9-8251 (CUTMASTER 51)
Cat. No. 9-8281 (CUTMASTER 81, 101 & 151)
New standoff guides designed to fit the SL60 & SL100 torches specific
to the CUTMASTER 1Series systems. The standoff is preset.
Cat. No 7-3291
MISCELLANEOUS TORCH ACCESSORIES
Cuts 2.125” (54mm) to 27.75” (705mm) circles (using
magnetic attachment) when cutting or beveling is required.
For use with most Thermal Dynamics torches. Guide shown
with optional pivot (7-3148).
Leather Leads Cover
Radius / Roller Cutting Guide Kit
Cat. No. 7-7501
This easy-to-use guide cut circles from 3” (76mm) up to
28.75” (730mm). Maintains a consistent height off the work
piece whether you are using the circle cutting attachment
for cutting circles or the roller guide feature to improve your
straight-line cutting.
Both novices and experts will see noticeable improvement
in quality, speed and parts life. Can be used with most
Thermal Dynamics torches.
15 ft. (4.6m)
20 ft. (6.1m)
25 ft. (7.6m)
50 ft. (15.2m)
9-1258
9-1260
9-1270
9-1280
These leads covers are suitable for both 1Torch® and
SureLok® leads. Snaps make it easy to install. For wider
torches, consider snapping two covers together widthwise.
Torch Protector
Cat No. 9-8135 for 70° Torch,
Cat No. 9-8136 for 90° Torch
For use with the PCH-120 Torch, this rugged protector easily
snaps onto the torch providing excellent protection
against damage caused by excessive heat or metal sparks.
Great accessory for your gouging project.
Torch Guide / Circle Cutting Attachment
Cat. No. 7-7505
Trigger Guard Kits
Cuts 3.5” (89mm) to 29” (737mm) circles. Designed for use
with the PCH/M-120 Torch, this accessory can be used as
either a Roller Guide or a Circle Cutting Guide.
SureLok Torches (PCH-62 & PCH-102)
Cat No. 9-8418 - Short Trigger Guard,
Cat No. 9-8419 - Long Trigger Guard
1Torch (SL60 & SL100)
Cat No. 9-8420 - Short Trigger Guard,
Cat No. 9-8421 - Long Trigger Guard
These guards offer additional protection from accidental activation or damage to the torch switch.
Straight Line Cutting Guide
Cat. No 7-8911
Remote Pendant Control
Cat No. 7-3460 - 20 ft. (6.1m)
Remote Pendant Control for your mechanized application.
Introducing a new cutting guide accessory suitable for all
hand torches, PCH-10 through PCH-102. This versatile,
straight line cutter is for hand held systems and it cuts
vertical, 90°, or bevel cuts. Its consistent standoff improves
cut quality and maximizes overall performance. Produces
more efficient straight line cuts. Lightweight, minimum
set up time and no power required. Magnetic mounts
ensure placement and ease of use. Optional suction plates
available for non-magnetic applications (i.e. aluminum
and stainless steel). The Cutting Guide Kit includes: 4 ft.
(1.2m) standard rail Torch Holder and Busing Heavy Duty
Magnets (2 ea.) Slide Assembly Wheels and Fasteners.
Optional 4 ft. (1.2m) extensions (7-7971) available.
Hand Pendant Extension
Cat No. 7-7744 - 25 ft. (7.6m)
ATC ® Lead Extensions
15 ft. (4.6m)
25 ft. (7.6m)
50 ft. (15.2m)
7-7544
7-7545
7-7552
Available for any system using 1Torch with ATC Quick
Disconnect. Leads Extensions enable you to customize
your lead length to suit the cutting job.
SPARE PARTS KITS
page 14
U.S Customer Care: 800-752-7621
www.thermal-dynamics.com
page 15
Accessories
Accessories
Plasma Cutting Systems, Torches & Access ories
SPARE PARTS KITS
Optional VIP Consumable Spare Parts Kits
Various Cat. Nos.
Although a Spare Parts Kit is provided with each
CUTMASTER® and PakMaster® Cutting System, Thermal
Dynamics® also offers Value Incentive Packages (VIP) which
are an excellent value and provide an ample supply of
genuine consumable parts. Each VIP Kit offers a good
selection of tips, electrodes, o-rings, and shield cups.
Reduce the risk of shutting your business down or not being
able to finish a job. Most VIP Kits will save you 30% or more.
PORTABLE GEAR
Multi-Purpose Cart
Cat. No. 7-8888
Designed for most portable manual cutting systems such
as the PakMaster® or CUTMASTER®, or any other similar
sized systems.
This rugged steel cart has easy rolling 8” (203mm)
diameter wheels along with 3” (76mm) front mounted casters.
This cart also serves as an excellent showroom display stand.
Wheel Kits
Cat. No. 9-8510 (not shown)
AIR FILTER/AIR FILTER KITS
For CUTMASTER 51 Systems
For improved consumable parts life and overall performance, Thermal Dynamics
recommends Air Filter Kits be used on all plasma cutting systems.
Cat. No. 9-8331
For CUTMASTER 81, 101 and 151 Systems
Single Stage Air Filter Kit
Cat. No. 7-7507 (Filter Body 9-7740, Hose 9-7742, Filter Element 9-7741)
MISCELLANEOUS ACCESSORIES
For use with shop compressed air systems, this in-line filter
will not allow moisture or water to pass through the filter
element even if it becomes completely saturated. This hi-tech
filter element actually blocks the absorption of water to increase
performance and improve consumable parts life.
Dust Covers
Cat. No. 9-7070 (for CUTMASTER 38 Systems)
Cat. No. 9-7071 (for PakMaster 50XL & 50XL PLUS and
CUTMASTER 51 Systems)
Cat. No. 9-7072 (for PakMaster 75/100XL & 75/100XL PLUS
and CUTMASTER 81, 101 & 151 Systems)
Two Stage Air Filters
Cat. No. 7-7502
For PakMaster 150XL Systems
Leads Wrap
Cat. No. 7-7500
For CUTMASTER and PakMaster Systems
For use with the Drag-Gun®, this convenient accessory
allows storage and safeguarding of your leads.
Cat. No. 9-7865
The Two Stage Air Filter will remove moisture and
contaminants from the air stream when using compressed
air. The filter is capable of filtering to at least 5 microns.
The filter assembly is pre-assembled at the factory and
need only be installed on the power supply.
First Stage Element
Cat. No. 9-1021
Second Stage Element
Cat. No. 9-1022
TORCH COOLANT
Extra Cool ™ Coolant
Tool Boxes
Cat. No. 8-3141 - Small, Cat. No. 9-4173 - Large
Plastic boxes with handy compartments for storage of
your torch consumables. Small (8.375” x 4.25” x 1.75”
/ 213mm x 108mm x 44mm), Large (17.5” x 7.75” x 3” /
445mm x 197mm x 76mm)
Cat. No. 7-3580
Welding Gloves
Resists freezing down to +10°F (-12°C)
Cat. No. 9-1250
Ultra Cool ™ Coolant
Cat. No. 7-3581
Resists freezing down to -27°F (-33°C)
Extreme Cool ™ Coolant
AUTOMATION ACCESSORIES
Cat. No. 7-3582
Automation Interface Kit
Resists freezing down to -65°F (-51°C)
Cat. No. 9-8310 - For CUTMASTER 51, 81, 101 and 151
De-I
Cool ™
CNC Interface Cable
Coolant
Cat. No. 7-3583
De-ionized water mixture for use where freezing protection is not required.
25 ft. (7.6m)
50 ft. (15.2m)
9-8312
9-8313
Pinion Assembly
Cat. No. 7-2827
page 16
U.S Customer Care: 800-752-7621
www.thermal-dynamics.com
page 17
Sales
At Thermal Dynamics®, we work hard to provide the product information,
product demonstrations, technical expertise, and service your business
expects. Thermal Dynamics’ District Business Managers work closely with
welding distributors across the country to provide product information,
demos and training. When you need product information or want to order
our products, contact your local Thermal Dynamics Authorized Distributor.
For a list of distributors in your area, call our Customer Care Center at
1-800-PLASMA1 (1-800-752-7621) or visit us on the web.
Literature Requests
Product literature, operating manuals, and service manuals are all available
through our distributorships or on our web site. You can also order directly
through our Copy Center at 1-800-PLASMA1 (1-800-752-7621).
Technical & Application
Product Services
Our Technical Service specialists are some of the most valued and experienced
in the industry. The can provide assistance with both troubleshooting
day-to-day technical issues and provide cutting process expertise. Contact
Technical Service at 1-800-PLASMA2 (1-800-752-7622).
In addition, we have Technical Training Field Managers available to
conduct sales and service training schools. Contact your Thermadyne
District Business Manager or call our Customer Care Center to arrange
for training.
About Us
About Us
Plasma Cutting Systems, Torches & Access ories
How to Contact Us
Main Phone Number:
1-603-298-5711
Customer Care Center: 1-800-PLASMA1 (1-800-752-7621)
FAX 1-800-221-4401 (or 1-603-298-5720)
8:00am - 5:30pm EST, Monday - Friday
Automation Customer
Care Center:
1-866-279-2628
FAX 1-316-941-4491
International Customer
Care Center:
1-905-827-9777
FAX 1-905-827-9797
Technical & Application
Product Services:
1-800-PLASMA2 (1-800-752-7622)
8:00am - 5:30pm EST, Monday - Friday
Copy Center: 1-800-752-7621
E-Mail: tdctech@thermadyne.com
Website: www.thermal-dynamics.com or www.thermadyne.com
Thermadyne Industries, Inc.
West Lebanon Operations Center
82 Benning St.
West Lebanon, NH 03784
NOTES:
Service & Repair
Thermal Dynamics products either meet or exceed industry standards, and
our torches and power supplies are backed with excellent warranties. With
each system or torch, we include an Operating or Instruction Manual which
includes basic troubleshooting procedures and parts replacement procedures.
Service Manuals are also available by request to service technicians familiar
with high voltage high power electronic equipment. Service Manuals cover
complex troubleshooting procedures and include schematics.
Your local Distributor may also provide on-site service for the products they
sell. Additionally, we have a network of authorized independent service
centers across the country where you can take your equipment for service.
For the service center nearest you, contact Thermal Dynamics’ Customer
Care Center at 1-800-PLASMA1 (1-800-752-7621).
1TORCH, ATC, RPT, SL60 and SL100, trademarks of Thermal Dynamics Corporation, are registered
with the U.S. Patent and Trademark Office, and are the subject of trademark registrations and
pending applications in numerous other countries. For information on trademark registrations of
Thermal Dynamics Corporation, contact the local trademark offices in the countries of interest.
Form No. 63-2205 (4/2/07)
page 18
U.S Customer Care: 800-752-7621
www.thermal-dynamics.com
© Thermadyne Industries, Inc., 2007
page 19
Plasma Arc Cutting
MANUAL SYSTEMS, TORCHES &
ACCESSORIES
with Added Condensation Removal Feature
®
DRAG-GUN
PLUS
Ask Us About the NEW
82 Benning Street
West Lebanon, NH 03784
QUICK REFERENCE
PRODUCT GUIDE
Introducing:
The NEW Portable Drag-Gun Plus
Now Faeaturing Condensation Removal
(see page 5)
www.thermal-dynamics.com