Summary of Contents for ESAB Cutmaster 100 SL100 1Torch
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Cutmaster ® Plasma Cutting system sL100 1Torch Operating Manual Art # A-12775 380/400V Revision: Issue Date: Manual No.: April 8, 2015 0-5404 esab.com.cn...
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WE APPRECIATE YOUR BUSINESS! Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To lo- cate your nearest distributor or service agency, visit us on the web at www.esab.com.cn.
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While the information contained in this Manual represents the Manufacturer's best judge- ment, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply ESAB Cutmaster 100 with SL100 1Torch™ ® Operating Manual Number 0-5404...
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be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INsTRUCTIONs are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and safe Practices for arc Welding, Cutting, and Gouging,”...
SECTION 1: SAFETY Safety Precautions Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
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ESAB CuTmASTEr 100 Arc welding and cutting can be injurious to yourself and others. WARNING Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill.
Warnings will be enclosed in a box such as this. Additional copies of this manual may be purchased by contacting ESAB at the address and phone num- ber in your area listed on back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.
ESAB CuTmASTEr 100 2.06 Power Supply Features Handle and Leads Wrap Control Panel Torch Leads Receptacle Art # A-08359 Work Cable and Clamp Port for Optional Automation Interface Cable Filter Assembly Gas Inlet Port Art # A-08547 Input Power Cord...
ESAB CuTmASTEr 100 SECTION 2 TORCH: 2T.03 Specifications INTRODUCTION A. Torch Configurations 1. Hand/Manual Torch, Models 2T.01 Scope of Manual The hand torch head is at 75° to the torch handle. The hand torches include a torch This manual contains descriptions, operating instruc- handle and torch trigger assembly.
ESAB CuTmASTEr 100 F. Torch Ratings 2T.05 Introduction to Plasma manual Torch ratings A. Plasma Gas Flow Ambient 104° F Temperature 40° C Plasma is a gas which has been heated to an extremely high temperature and ionized so that it...
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ESAB CuTmASTEr 100 B. Gas Distribution E. Parts - In - Place (PIP) The single gas used is internally split into plasma The torch includes a 'Parts - In - Place' (PIP) cir- and secondary gases. cuit. When the shield cup is properly installed, it closes a switch.
ESAB CuTmASTEr 100 SECTION 3 SYSTEM: 3.03 Primary Input Power Connections INSTALLATION CAUTION Check your power source for correct voltage before plugging in or connecting the unit. The primary 3.01 Unpacking power source, fuse, and any extension cords used must conform to local electrical code and the 1.
ESAB CuTmASTEr 100 Installing Optional Single - Stage Air Filter 6. Connect the wires as follows. • Wiring to L1, L2 and L3 input. See the previ- An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and ous illustration and power label. It does not matter what order these wires are attached.
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ESAB CuTmASTEr 100 Installing Optional Two - Stage Air Filter Kit This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns. Connect the air supply as follows: 1.
If necessary, connect the torch to the Power Sup- WARNING ply. Connect only the ESAB model SL100 / Manual Disconnect primary power at the source before or SL100 / Mechanical Torch to this power supply. disassembling the torch or torch leads.
ESAB CuTmASTEr 100 SECTION 4 SYSTEM: OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification 1. Output Current Control Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or higher for standoff cutting.
(10) minute period once the condition is Check that the torch is properly connected. Only cleared. ESAB model SL100 / Manual or SL100 / Mechani- cal Torches may be connected to this Power Sup- ply. See Section 3T of this manual.
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ESAB CuTmASTEr 100 Typical Cutting Speeds STANDOFF ESAB Cutmaster 100 Gas Pressure Settings Cutting speeds vary according to torch output ® amperage, the type of material being cut, and Leads SL100 SL100 operator skill. Refer to Section "4T.08 Length (Hand Torch)
ESAB CuTmASTEr 100 SECTION 4 TORCH: 3. Install the replacement Electrode by pushing it straight into the torch head until it clicks. OPERATION 4. Install the starter cartridge and desired tip for the operation into the torch head. 4T.01 Torch Parts Selection 5.
ESAB CuTmASTEr 100 4T.02 Cut Quality Kerf Width The width of the cut (or the width of material re- NOTE! moved during the cut). Cut quality depends heavily on setup and pa- rameters such as torch standoff, alignment with Top Spatter (Dross)
ESAB CuTmASTEr 100 Left Side 4T.03 General Cutting Information Cut Angle Right Side WARNING Cut Angle Disconnect primary power at the source before dis- assembling the power supply, torch, or torch leads. Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection.
ESAB CuTmASTEr 100 4T.04 Hand Torch Operation Standoff Cutting With Hand Torch NOTE! For best performance and parts life, always use the Trigger correct parts for the type of operation. 1. The torch can be comfortably held in one hand Trigger Release or steadied with two hands.
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ESAB CuTmASTEr 100 5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start. Shield Cup Standoff Guide Trigger Torch Tip Workpiece Art # A-04034 Trigger Release Shield Cup With Straight Edge...
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ESAB CuTmASTEr 100 Piercing With Hand Torch shield cup in anti - spatter compound will minimize the amount of scale which adheres 1. The torch can be comfortably held in one hand to it. or steadied with two hands. Position the hand to press the Trigger on the torch handle.
ESAB CuTmASTEr 100 4T.05 Gouging Torch Head WARNING Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions at the front of this manual have 35° been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch is activated.
ESAB CuTmASTEr 100 Travel speed also affects the bevel angle of a cut. 4T.06 Mechanized Torch Operation When cutting in a circle or around a corner, slow- Cutting With Mechanized Torch ing down the travel speed will result in a squarer cut.
ESAB CuTmASTEr 100 4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff...
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ESAB CuTmASTEr 100 Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC)
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ESAB CuTmASTEr 100 Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC)
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ESAB CuTmASTEr 100 Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC)
ESAB CuTmASTEr 100 4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff...
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ESAB CuTmASTEr 100 Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC)
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ESAB CuTmASTEr 100 Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat.
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ESAB CuTmASTEr 100 Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches (Cat. No.)
ESAB CuTmASTEr 100 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S. and Foreign Patents as follows: Catalog # Description Patent(s) 9-8215 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8277 Cartridge US Pat No(s) 6903301; 6717096; 6936786; 6703581; D496842; D511280; D492709; D499620; D504142 Other Pat(s) Pending 9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending...
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ESAB CuTmASTEr 100 Catalog # Description Patent(s) 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512: Catalog # Description 9-8235 Shield Cap 9-8236 Shield Cap 9-8237 Shield Cup 9-8238 Shield Cap...
ESAB CuTmASTEr 100 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the cables and leads.
4. Worn torch parts Daily Operational Checks or Every Six Cutting 5. Cutting current too low. Hours: 6. Non - Genuine ESAB parts used 1. Check torch consumable parts, replace if dam- 7. Incorrect gas pressure aged or worn. Main Arc 1.
ESAB CuTmASTEr 100 5.04 Fault Indicator At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7.
ESAB CuTmASTEr 100 5.05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Problem - Symptom Possible Cause...
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ESAB CuTmASTEr 100 Problem - Symptom Possible Cause recommended Action FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten. indicators flashing. 2. Torch tip, electrode or starter 2. Turn OFF power supply. Remove shield cup. Install Gas flow is cycling cartridge missing.
ESAB CuTmASTEr 100 5.06 Power Supply Basic Parts C. Filter Element Assembly Replacement Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should WARNING be checked per the Maintenance Schedule (Section Disconnect primary power to the system before 5.02), and either cleaned or replaced.
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ESAB CuTmASTEr 100 5. Remove the fitting from the filter element as- Optional Single-Stage Filter Element sembly by inserting a 6 mm hex wrench into Replacement the internal hex fitting and turning it counter These instructions apply to power supplies where the clock-wise (left). Numbers 4 and 5 in the previ- optional Single-Stage Filter has been installed.
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ESAB CuTmASTEr 100 Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replace- ment filter element catalog number. 1. Shut OFF primary input power. 2. Shut OFF air supply and bleed down system.
ESAB CuTmASTEr 100 SECTION 5 TORCH: SERVICE Upper Groove 5T.01 General Maintenance with Vent Holes Must Remain Open NOTE! Refer to Previous "Section 5: System Service" for Upper O-Ring common and fault indicator descriptions. in Correct Groove Cleaning Torch Threads...
ESAB CuTmASTEr 100 4. Remove the tip. Check for excessive wear 5T.02 Inspection and Replacement of (indicated by an elongated or oversized orifice). Consumable Torch Parts Clean or replace the tip if necessary. Good Tip Worn Tip WARNING Disconnect primary power to the system before disassembling the torch or torch leads.
ESAB CuTmASTEr 100 SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows: 6.03 Power Supply Replacement 6.04 Replacement Power Supply Parts 6.05 Options and Accessories 6.06 Replacement Parts for Hand Torch 6.07 Replacement Parts - for Machine Torches with Unshielded Leads 6.08...
ESAB CuTmASTEr 100 APPENDIX 1: SEQuENCE OF OPErATION (BLOCK DIAGrAm) ACTION: ACTION: ACTION: ACTION: RUN / Rapid Auto Restart / ON / OFF switch to ON Close external RUN / SET / LATCH disconnect switch. Rapid Auto Restart / switch to RUN...
ESAB CuTmASTEr 100 APPENDIX 2: DATA TAG INFOrmATION Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Regulatory Standard Covering Type of Power This Type of Power Supply Supply (Note 1)
ESAB CuTmASTEr 100 APPENDIX 3: TOrCH PIN - OuT DIAGrAmS A. Hand Torch Pin - Out Diagram ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Ground 4 - Green /...
ESAB CuTmASTEr 100 APPENDIX 4: TOrCH CONNECTION DIAGrAmS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Receptacle Power Connector Torch Supply...
ESAB CuTmASTEr 100 APPENDIX 5: SYSTEM SCHEMATIC, 380/400V UNITS PRI 3 PRI 3 PRI 3 PRI 3 PRI 4 PRI 4 PRI 4 PRI 4 BIAS BIAS SUPPLY SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 PRI 2 PRI 2...