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ESAB Cutmaster 40 SL60 1Torch Operating Manual

Plasma cutting system
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ESAB Cutmaster
PLASMA CUTTING SYSTEM
SL60 1Torch™
Operating
Manual
Révision : AA Issue Date: January 15, 2015
Art # A-12777_AA
Manual No.: 0-5376
®
40
120V
230V
esab.eu
40

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Summary of Contents for ESAB Cutmaster 40 SL60 1Torch

  • Page 1 ESAB Cutmaster ® PLASMA CUTTING SYSTEM SL60 1Torch™ Operating Manual Art # A-12777_AA 120V 230V esab.eu Révision : AA Issue Date: January 15, 2015 Manual No.: 0-5376...
  • 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 2800 Airport Rd. Denton, TX 76208 (940) 566-2000 www.esab.eu Copyright 2015 by ESAB All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher 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: Table Of Contents

    Introduction ........................6-1 6.02 Power Supply Replacement Parts ..................6-2 6.03 SL60 Torch Consumable Parts ..................6-3 6.04 Optional Accessories .......................6-4 APPENDIX 1: ESAB CUTMASTER 40 CIRCUIT DIAGRAM ................A-1 ® APPENDIX 2: SL60 TORCH PIN-OUT DIAGRAM ....................A-2 Revision History .............................. A-3...
  • Page 6 TABLE OF CONTENTS...
  • Page 7 TABLE OF CONTENTS This Page Intentionally Blank...

  • 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 40 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

    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 identification numbers.

  • Page 11: Working Principle

    ESAB CUTMASTER 40 2.04 Working Principle Inverter Transformer Rectifier Rectifier Compressed air Reduce pressure, filter Gas valve Cutting torch Workpiece Art # A-09204_AB 2.05 Power Supply Specifications ESAB Cutmaster 40 Power Supply Specifications ® Input Power 120 VAC (+ - 10%), 1Phase, 50/60Hz...

  • Page 12: Input Wiring Specifications

    ESAB CUTMASTER 40 9" (228.6mm) 120V 15A 120V 20A 230V 20A 18.5" (469.9mm) Art# A-12781_AA 7" (177mm) 26lb / 11.8kg Figure 2-1: Power Supply Dimensions & Weight NOTE! Weight includes torch & leads, input power cord, and work cable with clamp.

  • Page 13: Power Supply Features

    ESAB CUTMASTER 40 2.07 Power Supply Features 120/230 VAC Power Source Air Inlet Control Panel 120V 15A 120V 20A 230V 20A Art # A-12779_AA Torch Lead Work Cable and Clamp On/Off Switch Air Inlet Power Cord Art# A-09335 INTRODUCTION Manual 0-5376...

  • Page 14: Section 2 Torch: Introduction

    ESAB CUTMASTER 40 SECTION 2 TORCH: Torch Ratings INTRODUCTION SL60 Torch Ratings Ambient 104° F Temperature 40° C 2T.01 Scope of Manual Duty Cycle 100% @ 60 Amps @ 193 scfh This manual contains descriptions, operating instructions and main- Maximum Current 60 Amps tenance procedures for the SL60 Plasma Cutting Torch.

  • Page 15: 03 Introduction To Plasma

    ESAB CUTMASTER 40 B. Gas Distribution 2T.03 Introduction to Plasma The single gas used is internally split into plasma and second- A. Plasma Gas Flow ary gases. Plasma is a gas which has been heated to an extremely high The plasma gas flows into the torch through the negative lead,...

  • Page 16: Section 3: Installation

    ESAB CUTMASTER 40 SECTION 3: INSTALLATION 3.01 Unpacking 1. Use the packing lists to identify and account for each item. 2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation.
  • Page 17 ESAB CUTMASTER 40 Connect the gas line to the compressed air inlet port at the appropriate pressure. On/Off Switch Air Inlet Art# A-09337 Figure 3-2: Gas Connection to Compressed Air input B. Using Industrial Compressed Air In Gas Cylinders When using Industrial compressed air in gas cylinders as the gas supply: 1.

  • Page 18: Section 4 System: Operation

    ESAB CUTMASTER 40 SECTION 4 SYSTEM: OPERATION 4.01 Control Panel On/Off Air Inlet Switch AC Indicator Power Cord DC Indicator (Ready) Air Indicator Overheat Indicator 120V 15A 120V 20A 230V 20A Art# A-12788_AA The Front Panel The Rear Panel 1. ON / OFF Switch (Power Switch/Lamp) Controls input power to the power supply.

  • Page 19: Preparations For Operating

    Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type of operation, and with the amperage output of this power supply (60 amps maximum). Use only genuine ESAB parts with this torch.
  • Page 20 ESAB CUTMASTER 40 NOTE! When operating the torch in a normal condition, some gas vents through the gap between the shield cup and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.
  • Page 21 ESAB CUTMASTER 40 G. Select Current Output Level Set the desired current output level. 120V 15A 120V 20A 230V 20A 27 7 4 4 0 27 7 4 4 0 120V, 15A 120V, 20A 230V, 20A A#09697_AA OPERATION Manual 0-5376...

  • Page 22: Sequence Of Operation

    ESAB CUTMASTER 40 4.03 Sequence of Operation b) For standoff cutting, hold the torch tip on the work piece, pull the trigger. After the arc is The following is a typical sequence of operation for this power initiated lift the tip to 1/8" - 3/8" (3-4mm) off supply.
  • Page 23 ESAB CUTMASTER 40 Trigger NOTE! When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close Trigger Release this gap.

  • Page 24: Cut Quality

    ESAB CUTMASTER 40 Kerf Width 4.04 Cut Quality The width of the cut (or the width of material removed during NOTE! the cut). Cut quality depends heavily on setup and Top Spatter (Dross) parameters such as torch standoff, align- Top spatter or dross on the top of the cut caused by slow travel...
  • Page 25 ESAB CUTMASTER 40 Direction of Cut In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other.

  • Page 26: Section 5 System: Service

    ESAB CUTMASTER 40 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Warning! There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson and you have had training in power measurements Maintain more often and troubleshooting techniques.

  • Page 27: Basic Troubleshooting Guide

    ESAB CUTMASTER 40 B. AC indicator blinking A. Every three months 1. Indicator blinking (1 sec ON/1 Sec OFF, Gas may also Check external air filter, replace if necessary. pulse 3 times). 1. Shut off input power; turn off the gas supply. Bleed down a.
  • Page 28 ESAB CUTMASTER 40 H. Output is restricted, and can not be controlled. E. Torch will not pilot, when torch trigger is activated. 1. Input or output connection is poor. 1. Faulty parts in torch a. Check all input and output connection leads.
  • Page 29 ESAB CUTMASTER 40 K. Arc goes out while operating. Arc can’t be restarted when torch trigger is activated. 1. Power Supply is overheated (TEMP indicator ON). a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond duty cycle limit.

  • Page 30: Section 5 Torch: Service

    ESAB CUTMASTER 40 SECTION 5 TORCH: 5T.02 Inspection and Replacement of Consumable Torch Parts SERVICE WARNING 5T.01 General Maintenance Disconnect primary power to the system before disassembling the torch or torch NOTE! leads. Refer to Previous "Section 5: System" for DO NOT touch any internal torch parts common and fault indicator descriptions.
  • Page 31 ESAB CUTMASTER 40 3. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if neces- sary. Good Tip Worn Tip A-09791 Tip Wear 4. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end fitting for free motion.

  • Page 32: Section 6: Parts Lists

    ESAB CUTMASTER 40 SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all replaceable components. B. Returns If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted.

  • Page 33: Power Supply Replacement Parts

    ESAB CUTMASTER 40 6.02 Power Supply Replacement Parts Item # Qty. Description Catalog # Control PCB assembly 9-0077 Front Control PCB assembly 9-0076 Main PCB assembly 9-0079 Regulator 9-0081 Solenoid assembly 9-0082 Pressure Switch 9-0075 Front Panel with Label 9-0071E...

  • Page 34: Sl60 Torch Consumable Parts

    ESAB CUTMASTER 40 6.03 SL60 Torch Consumable Parts Tips: Shield DRAG TIP Cup Body, Shield Cap, Deflector 9-8237 9-8243 CUTTING 20A 9-8205 30A 9-8206 Shield Cup 40A 9-8207 9-8218 60A 9-8252 O-Ring No. 8-3488 Shield Cap, Drag DRAG SHIELD 40A 9-8244...

  • Page 35: Optional Accessories

    ESAB CUTMASTER 40 6.04 Optional Accessories Description Cat. No. Circle Cutting Guide Kit, 7-3291 Radius/Roller Cutting Guide Kit 7-7501 Filter Body, single stage air filter 7-7507 Hose, single stage air filter 9-7742 Filter Element, single stage air filter 9-7741 Two Stage Air Filter...

  • Page 36: Circuit Diagram

    ESAB CUTMASTER 40 APPENDIX 1: ESAB CUTMASTER 40 CIRCUIT DIAGRAM ® A-09396 Art # A-12780_AA Manual 0-5376 APPENDIX...

  • Page 37: Appendix 2: Sl60 Torch Pin-Out Diagram

    ESAB CUTMASTER 40 APPENDIX 2: SL60 TORCH PIN-OUT DIAGRAM 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 /...

  • Page 38: Revision History

    ESAB CUTMASTER 40 Revision History Date Rev Description 01/15/2015 Manual release Manual 0-5376 APPENDIX...
  • Page 39 ESAB CUTMASTER 40 This Page Intentionally Blank APPENDIX Manual 0-5376...
  • Page 40 This page left blank intentionally.
  • Page 41 ESAB Asia/Pacific Pte Ltd ESAB Nederland B.V. Singapore Amersfoort Tel: +65 6861 43 22 Tel: +31 33 422 35 55 Fax: +65 6861 31 95 Fax: +31 33 422 35 44 www.esab.eu ©2015 ESAB Welding and Cutting Products Printed in Mexico...

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