ESAB Cutmaster 100 Operating Manual
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ESAB Cutmaster 100 Operating Manual

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ESAB Cutmaster
PLASMA CUTTING SYSTEM
SL100 1Torch™
Operating
Manual
Revision: AD
Issue Date: July 1, 2019
OUTPUT
MAX OUTPUT
100
AMPS
Manual No.: 300X5397
100
®
Art # A-12775_AB
VOLTAGE
INPUT POWER
400V
PHASE
esab.eu

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  • Page 1 ESAB Cutmaster ® PLASMA CUTTING SYSTEM SL100 1Torch™ Operating Manual Art # A-12775_AB OUTPUT MAX OUTPUT VOLTAGE INPUT POWER 400V PHASE AMPS esab.eu Revision: AD Issue Date: July 1, 2019 Manual No.: 300X5397...
  • 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. To locate your nearest distributor or service agency, visit us on the web at www.esab.eu.
  • Page 3 2800 Airport Rd. Denton, TX 76208 (940) 566-2000 www.esab.eu Copyright 2015, 2019 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,”...
  • Page 5 The RoHS Directive 2011/65/EC, entering into force 2 January 2013 Type of equipment PLASMA CUTTING SYSTEM Type designation etc. ESAB Cutmaster® 100, from serial number MX1518xxxxxx Brand name or trade mark ESAB Manufacturer or his authorised representative established within the EEA Name, address, telephone No: ESAB Group Inc.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY .......................1-1 Safety Precautions ..................1-1 SECTION 2 SYSTEM: INTRODUCTION ................2-1 2.01 How To Use This Manual ................2-1 2.02 Equipment Identification ................2-1 2.03 Receipt Of Equipment ................2-1 2.04 Power Supply Specifications ..............2-2 2.05 Input Wiring Specifications ...............2-3 2.06 Power Supply Features ................2-4 SECTION 2 TORCH: INTRODUCTION ................
  • Page 7 TABLE OF CONTENTS SECTION 5 SYSTEM: SERVICE .....................5-1 5.01 General Maintenance ................5-1 5.02 Maintenance Schedule ................5-2 5.03 Common Faults..................5-2 5.04 Fault Indicator ....................5-3 5.05 Basic Troubleshooting Guide ..............5-4 5.06 Power Supply Basic Parts Replacement ..........5-6 SECTION 5 TORCH: SERVICE .................... 5T-9 5T.01 General Maintenance ................

  • Page 8: Section 1: Safety

    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 9 ESAB CUTMASTER 100 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.

  • Page 10: Section 2 System: Introduction

    Include the Owner’s Manual number and equipment identifica- tion numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the ESAB web site listed below http://www.esab.eu 300X5397...

  • Page 11: Power Supply Specifications

    30 - 100 Amps, Continuously Adjustable Power Supply Gas Particulates to 5 Microns Filtering Ability ESAB Cutmaster 100 Power Supply Duty Cycle * Ambient Tempera- Duty Cycle Ratings @ 40° C (104° F) ture Operating Range 0° - 50° C...

  • Page 12: Input Wiring Specifications

    ESAB CUTMASTER 100 2.05 Input Wiring Specifications ESAB Cutmaster 100 Power Supply Input Cable Wiring Requirements Power Input voltage Freq Suggested Sizes Input Flexible Flexible Fuse Volts I eff Cord (Min. Cord (amps) AWG) (Min. mm 18.7 Phase Line Voltages with Suggested Circuit Protection and Wire Sizes...

  • Page 13: Power Supply Features

    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...

  • Page 14: Section 2 Torch: Introduction

    ESAB CUTMASTER 100 SECTION 2 TORCH: 10.125" (257 mm) INTRODUCTION 2T.01 Scope of Manual 3.75" This manual contains descriptions, operating instructions (95 mm) and maintenance procedures for the 1Torch Models Art # A-03322_AB SL100/Manual and SL100/Mechanized Plasma Cutting 1.17" (29 mm) Torches.

  • Page 15: 04 Options And Accessories

    ESAB CUTMASTER 100 2T.05 Introduction to Plasma F. Torch Ratings 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...
  • Page 16 ESAB CUTMASTER 100 B. Gas Distribution Remote Pendant The single gas used is internally split into plasma and secondary gases. The plasma gas flows into the torch through the PIP Switch Shield Cup negative lead, through the starter cartridge, around To ATC the electrode, and out through the tip orifice.
  • Page 17 ESAB CUTMASTER 100 This Page Intentionally Blank 2T-4 INTRODUCTION 300X5397...

  • Page 18: Section 3 System: Installation

    ESAB CUTMASTER 100 SECTION 3 SYSTEM: 3.03 Primary Input Power Connections INSTALLATION CAUTION Check your power source for cor- 3.01 Unpacking rect voltage before plugging in or connecting the unit. The primary 1. Use the packing lists to identify and account for each item.

  • Page 19: Gas Connections

    ESAB CUTMASTER 100 Regulator/Filter CAUTION Assembly The primary power source and pow- er cable must conform to local elec- trical code and the recommended Inlet Port circuit protection and wiring require- ments (refer to table in Section 2). Hose Clamp 6.
  • Page 20 ESAB CUTMASTER 100 NOTE! For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch. Connect as follows:...
  • Page 21 ESAB CUTMASTER 100 Regulator/Filter Assembly 2-Stage Filter Inlet Port (IN) Regulator Input Outlet Port (OUT) Two Stage Filter Hose Clamp Assembly Gas Supply Hose 1/4 NPT to 1/4” (6mm) Fitting Art # A-07945_AC Optional Two - Stage Filter Installation Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: 1.

  • Page 22: Section 3 Torch: Installation

    3T.02 Setting Up Mechanical Torch If necessary, connect the torch to the Power Supply. NOTE! Connect only the ESAB model SL100 / Manual or SL100 An adapter is required to be installed / Mechanical Torch to this power supply. Maximum torch in the power supply if converting leads length is 100 feet / 30.5 m, including extensions.
  • Page 23 ESAB CUTMASTER 100 This Page Intentionally Blank 3T-2 INSTALLATION 300X5397...

  • Page 24: Section 4 System: Operation

    ESAB CUTMASTER 100 SECTION 4 SYSTEM: nect input power, correct the fault, and restart the unit. Refer to Section 5 for details. OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification 1. Output Current Control Sets the desired output current. Output settings...

  • Page 25: Preparations For Operation

    Check that the torch is properly connected. Only run while the condition exists and for ESAB model SL100 / Manual or SL100 / Mechani- a ten (10) minute period once the cal Torches may be connected to this Power Supply.
  • Page 26 Art# A-07946 Cutting speeds vary according to torch output am- perage, the type of material being cut, and operator STANDOFF skill. Refer to Section 4T.08 and following for greater ESAB Cutmaster 100 Gas Pressure Settings details. SL100 SL100 Leads Length...
  • Page 27 ESAB CUTMASTER 100 This Page Intentionally Blank OPERATION 300X5397...

  • Page 28: Section 4 Torch: Operation

    ESAB CUTMASTER 100 SECTION 4 TORCH: 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 the operation into the torch head.

  • Page 29: 03 General Cutting Information

    ESAB CUTMASTER 100 Bevel Angle Piloting The angle between the surface of the cut edge and Piloting is harder on parts life than actual cutting a plane perpendicular to the surface of the plate. because the pilot arc is directed from the electrode A perfectly perpendicular cut would result in a 0°...

  • Page 30: 04 Hand Torch Operation

    ESAB CUTMASTER 100 normally caused by too great a torch to plate dis- Torch tance. "Top dross" is normally very easy to remove and can often be wiped off with a welding glove. "Slow speed dross" is normally present on the bottom edge of the plate.
  • Page 31 ESAB CUTMASTER 100 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- Trigger Release conductive. Non-Conductive...
  • Page 32 ESAB CUTMASTER 100 Piercing With Hand Torch 1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to...

  • Page 33: 05 Gouging

    ESAB CUTMASTER 100 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 addi- amount of scale which adheres to it.

  • Page 34: 06 Mechanized Torch Operation

    ESAB CUTMASTER 100 Slag Buildup Slag generated by gouging on materials such as car- bon 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 D i r side of the gouge path.

  • Page 35: 07 Parts Selection For Sl100 Torch Cutting

    ESAB CUTMASTER 100 4T.07 Parts Selection for SL100 Torch Cutting Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206...

  • Page 36: 08 Recommended Cutting Speeds For Sl100 Torch With Exposed Tip

    ESAB CUTMASTER 100 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 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 (Cat. No.) Volts(VDC)
  • Page 38 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 (Cat. No.) Volts(VDC)
  • Page 39 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 (Cat. No.) Volts(VDC)
  • Page 40 ESAB CUTMASTER 100 4T.09 Recommended Cutting Speeds for SL100 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...
  • Page 41 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.) Volts(VDC)
  • Page 42 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.)
  • Page 43 ESAB CUTMASTER 100 Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Plasma Gas Thickness Output Amperage Speed (Per Minute) Standoff Flow (CFH) Pierce Pierce Height Press Inches (Cat. No.)
  • Page 44 ESAB CUTMASTER 100 This Page Intentionally Blank 4T-17 300X5397 OPERATION...

  • Page 45: Patent Information

    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 9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786;...
  • Page 46 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...
  • Page 47 ESAB CUTMASTER 100 This Page Intentionally Blank 4T-20 OPERATION 300X5397...

  • Page 48: Section 5 System: Service

    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.

  • Page 49: Maintenance Schedule

    4. Worn torch parts 5. Cutting current too low. Daily Operational Checks or Every Six Cutting 6. Non - Genuine ESAB parts used Hours: 7. Incorrect gas pressure 1. Check torch consumable parts, replace if dam- aged or worn.

  • Page 50: Fault Indicator

    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.

  • Page 51: Basic Troubleshooting Guide

    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 measure- ment and troubleshooting techniques.
  • Page 52 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 missing Gas flow is cycling cartridge missing.

  • Page 53: Power Supply Basic Parts Replacement

    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 be checked per the Maintenance Schedule (Subsection WARNING 5.02), and either cleaned or replaced.
  • Page 54 ESAB CUTMASTER 100 5. Remove the fitting from the filter element as- 4. Turn the Filter Housing Cover counter-clockwise sembly by inserting a 6 mm hex wrench into the and remove it. The Filter Element is located internal hex fitting and turning it counter clock- inside the Housing.
  • Page 55 ESAB CUTMASTER 100 WARNING Always turn OFF the air supply and bleed the system before disassembling the Filter As- sembly as injury could result. 3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

  • Page 56: Section 5 Torch: Service

    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: Sys- Upper O-Ring in Correct Groove tem" for common and fault indicator descriptions. Threads Lower O-Ring...

  • Page 57: 02 Inspection And Replacement Of Consumable Torch Parts

    ESAB CUTMASTER 100 5T.02 Inspection and Replacement 4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). of 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.

  • Page 58: Section 6: Parts Lists

    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 100 CE Power Supply with 400VAC, 3 phase 50/60 Hz, with input power cable 0559317304 6.04 Replacement Power Supply Parts...

  • Page 59: Options And Accessories

    ESAB CUTMASTER 100 6.05 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter & Hose) 7-7507 Replacement Filter Body 9-7740 Replacement Filter Hose (not shown) 9-7742 Replacement Filter Element 9-7741 Two - Stage Filter Kit (includes Hose & Mounting Screws)

  • Page 60: Replacement Parts For Hand Torch

    ESAB CUTMASTER 100 6.06 Replacement Parts for Hand Torch 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.

  • Page 61: Replacement Parts - For Machine Torches With Unshielded Leads

    ESAB CUTMASTER 100 6.07 Replacement Parts - for Machine Torches with Unshielded Leads Item No. Qty Description Catalog # 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...
  • Page 62 ESAB CUTMASTER 100 5 & 6 A-07994_AB 300X5397 PARTS LIST...

  • Page 63: Torch Consumable Parts (Sl100)

    ESAB CUTMASTER 100 6.08 Torch Consumable Parts (SL100) Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243 9-8218...
  • Page 64 ESAB CUTMASTER 100 This Page Intentionally Blank 300X5397 PARTS LIST...
  • Page 65 ESAB CUTMASTER 100 This Page Intentionally Blank PARTS LIST 300X5397...

  • Page 66: Appendix 1: Sequence Of Operation (Block Diagram

    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...

  • Page 67: Appendix 2: Data Tag Information

    ESAB CUTMASTER 100 APPENDIX 2: DATA TAG INFORMATION Manufacturer's Name and/or Logo, Location, Model and Serial Number M odel : and Production Code Dat e of M f r : Type of Power Regulatory Standard Covering 1/ 3 Supply (Note 1)

  • Page 68: Appendix 3: Torch Pin - Out Diagrams

    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 - Open 4 - Green /...

  • Page 69: Appendix 4: Torch Connection Diagrams

    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 Power Connector Receptacle Torch Supply...
  • Page 70 ESAB CUTMASTER 100 This Page Intentionally Blank 300X5397 APPENDIX...

  • Page 71: Appendix 5: System Schematic, 400V Units

    ESAB CUTMASTER 100 APPENDIX 5: SYSTEM SCHEMATIC, 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...
  • Page 72 Chk: Chk: App: App: App: App: App: App: Sheet Sheet Sheet Sheet Sheet Sheet SCHEMATIC, ESAB Cutmaster 100/120 20'/50' SL100 400V/208-460V SCHEMATIC, ESAB Cutmaster 100/120 20'/50' SL100 400V/208-460V TITLE: TITLE: TITLE: TITLE: TITLE: TITLE: Size Size Size Size Size Size...

  • Page 73: Revision History

    ESAB CUTMASTER 100 Revision History Date Description 01/15/2015 Manual release Updated art on cover, Updated DoC, added duty cycle values, removed Shielded 08/14/2015 Machine Torch Leads Assemblies 11/14/2015 Revised DoC, removed Printed in text 01/07/2019 APPENDIX 300X5397...
  • Page 74 ESAB CUTMASTER 100 This Page Intentionally Blank 300X5397 APPENDIX...
  • Page 75 ESAB CUTMASTER 100 This Page Intentionally Blank A-10 APPENDIX 300X5397...
  • Page 76 This Page Intentionally Blank...
  • Page 77 THE NETHERLANDS SINGAPORE ESAB Nederland B.V. ESAB Asia/Pacific Pte Ltd Amersfoort Singapore Tel: +31 33 422 35 55 Tel: +65 6861 43 22 Fax: +31 33 422 35 44 Fax: +65 6861 31 95 www.esab.eu ©2015 ESAB Welding and Cutting Products...

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