Page 1
ESAB Cutmaster ® PLASMA CUTTING SYSTEM SL100 1Torch™ Operating Manual Art # A-12769_AB 208/230V 400V 460V Revision: AB Issue Date: April 15, 2015 Manual No.: 0-5380 esab.com.br...
Page 2
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.
Page 3
ESAB 2800 Airport Rd. Denton, TX 76208 www.esab.com.br Copyright 2015 by ESAB All rights reserved. Reproduction of this work, in whole or in part, without written permission of the pub- lisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Page 4
Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equip- ment, 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.
Page 8
ESAB CUTMASTER 120 Arc welding and cutting can be injurious to yourself and others. Take WARNING precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill.
Additional copies of this manual may be purchased by contacting ESAB at the address and phone number in your area listed on back cover of this manual. Include the Owner’s Manual number and equipment identifica- tion numbers.
ESAB CUTMASTER 120 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 Input Power Selection Filter Assembly Gas Inlet Port Art # A-08360...
ESAB CUTMASTER 120 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 handle and This manual contains descriptions, operating instruc- torch trigger assembly.
ESAB CUTMASTER 120 2T.05 Introduction to Plasma F. Torch Ratings Manual Torch Ratings A. Plasma Gas Flow Ambient 104° F Plasma is a gas which has been heated to an Temperature 40° C extremely high temperature and ionized so that it...
Page 15
ESAB CUTMASTER 120 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) circuit. and secondary gases. When the shield cup is properly installed, it closes a switch.
ESAB CUTMASTER 120 SECTION 3 SYSTEM: 3.03 Opening the Contactor Cover INSTALLATION The input power cord is connected to the main contactor, the contactor is located inside a box with a snap on cover. The cover is held in place with two or more snap lock tabs. To remove the 3.01...
Page 18
ESAB CUTMASTER 120 B. Connections to Three Phase Input Power A. Connections to Single Phase Input Power WARNING WARNING Disconnect input power from the power Disconnect input power from the power supply and input cable before attempting supply and input cable before attempting this procedure.
ESAB CUTMASTER 120 3.05 Gas Connections Installing Optional Single - Stage Air Filter An optional filter kit is recommended for improved filtering with Connecting Gas Supply to Unit compressed air, to keep moisture and debris out of the torch. The connection is the same for compressed air or high pressure 1.
Page 20
ESAB CUTMASTER 120 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 Supply. WARNING Connect only the ESAB model SL100 / Manual or SL100 / Mechanical Torch to this power supply. Maximum Disconnect primary power at the source be- torch leads length is 100 feet / 30.5 m, including exten-...
ESAB CUTMASTER 120 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.
Check that the torch is properly connected. Only exists and for a ten (10) minute period once ESAB model SL100 / Manual or SL100 / Mechanical the condition is cleared. Torches may be connected to this Power Supply.
Page 25
ESAB CUTMASTER 120 2. Set the output current to desired amperage with the Output Current Control Knob. Cutting Operation When the torch leaves the workpiece during cut- ting operations with the Function Control Knob in the RUN position, there is a brief delay in restarting the pilot arc.
ESAB CUTMASTER 120 SECTION 4 TORCH: Torch Parts (Drag Shield Cap & Shield Cup Body Shown) OPERATION 3. Install the replacement Electrode by pushing it straight into the torch head until it clicks. 4T.01 Torch Parts Selection 4 . Install the starter cartridge and desired tip for Depending on the type of operation to be done deter- the operation into the torch head.
ESAB CUTMASTER 120 Piloting Bevel Angle Piloting is harder on parts life than actual cutting The angle between the surface of the cut edge and because the pilot arc is directed from the electrode a plane perpendicular to the surface of the plate.
ESAB CUTMASTER 120 Dross b. For standoff cutting, hold the torch 1/8 - 3/8 in (3-9 mm) from the workpiece as shown When dross is present on carbon steel, it is com- below. monly referred to as either “high speed, slow speed, or top dross”.
Page 30
ESAB CUTMASTER 120 Shield Cup With Straight Edge Trigger The drag shield cup can be used with a non conduc- tive straight edge to make straight cuts by hand. WARNING The straight edge must be non-conductive. Trigger Release Non-Conductive Straight Edge...
Page 31
ESAB CUTMASTER 120 Piercing With Hand Torch 5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the 1. The torch can be comfortably held in one hand trigger. The pilot arc will start. or steadied with two hands. Position the hand to press the Trigger on the torch handle.
ESAB CUTMASTER 120 Torch Travel Speed 7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield NOTE! cup in anti - spatter compound will minimize the Refer to Appendix Pages for additional amount of scale which adheres to it.
ESAB CUTMASTER 120 Slag Buildup Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels, can be removed easily in most cases. Slag does not obstruct the gouging process if it accumulates to the side of the gouge path.
Page 34
ESAB CUTMASTER 120 D i r e c t i o n o f T o r c Standoff Distance r a v Straight Arc Trailing Arc A-02586 Leading Arc Mechanized Torch Operation For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut.
ESAB CUTMASTER 120 4T.08 Recommended Cutting Speeds for SL100 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...
Page 37
ESAB CUTMASTER 120 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 (Cat. No.)
Page 38
ESAB CUTMASTER 120 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 (Cat. No.)
Page 39
ESAB CUTMASTER 120 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 (Cat. No.)
ESAB CUTMASTER 120 Type Torch: SL100 With Exposed Tip Type Material: Stainless 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.)
Page 41
ESAB CUTMASTER 120 Type Torch: SL100 With Shielded Tip Type Material: Stainless 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.)
Page 42
ESAB CUTMASTER 120 Type Torch: SL100 With Shielded Tip Type Material: Stainless 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.)
Page 43
ESAB CUTMASTER 120 Type Torch: SL100 With Shielded Tip Type Material: Stainless 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.)
Page 44
ESAB CUTMASTER 120 Type Torch: SL100 With Shielded Tip Type Material: Stainless 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.)
Page 45
ESAB CUTMASTER 120 Type Torch: SL100 With Shielded Tip Type Material: Stainless 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 120 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 9-8213 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...
Page 47
ESAB CUTMASTER 120 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...
ESAB CUTMASTER 120 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 7. Incorrect gas pressure 1. Check torch consumable parts, replace if dam- aged or worn. Main Arc Extinguishes 1. Cutting speed too slow.
ESAB CUTMASTER 120 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 120 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...
Page 53
ESAB CUTMASTER 120 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 missing parts.
ESAB CUTMASTER 120 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 (Subsection Disconnect primary power to the system 5.02), and either cleaned or replaced.
Page 55
ESAB CUTMASTER 120 Optional Single-Stage Filter Element Replacement 5. Remove the fitting from the filter element as- sembly by inserting a 6 mm hex wrench into These instructions apply to power supplies where the the internal hex fitting and turning it counter optional Single-Stage Filter has been installed.
Page 56
ESAB CUTMASTER 120 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 replacement filter element catalog number. 1. Shut OFF primary input power. 2. Shut OFF air supply and bleed down system.
ESAB CUTMASTER 120 SECTION 5 TORCH: SERVICE Upper Groove 5T.01 General Maintenance with Vent Holes Must Remain Open NOTE! Refer to Previous "Section 5: System" for Upper O-Ring in Correct Groove common and fault indicator descriptions. Threads Cleaning Torch Lower O-Ring...
ESAB CUTMASTER 120 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. WARNING Good Tip Worn Tip Disconnect primary power to the system before disassembling the torch or torch leads.
The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / filter, and operating manual. Description Catalog # ESAB Cutmaster® 120 Power Supply with 400VAC, 3 phase input power cable 0559317302 Manual 0-5380...
ESAB CUTMASTER 120 6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115 Filter Assembly Replacement Element 9-0116 Input Power Cord for 208 / 230 V Power Supply 9-0191 460/600V Power Supply 9-0209 6.05 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter &...
ESAB CUTMASTER 120 6.07 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...
ESAB CUTMASTER 120 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 120 APPENDIX 2: DATA TAG INFORMATION Manufacturer's Name and/or Logo, Location, Model and M odel : Revision Level, Serial Number and Production Code Dat e of M f r : Type of Power Regulatory Standard Covering 1/ 3...
ESAB CUTMASTER 120 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 120 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 Female ATC Leads Connector Receptacle Power Torch Torch...
ESAB CUTMASTER 120 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS PRI 3 PRI 3 PRI 4 PRI 4 BIAS SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 INRUSH +12VDC RESISTORS PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1...
Need help?
Do you have a question about the Cutmaster 120 and is the answer not in the manual?
Questions and answers