ESAB Cutmaster® 100
PLASMA CUTTING SYSTEM
SL100 1Torch™
Operating
Manual
OUTPUT
MAX OUTPUT
100
AMPS
Revision: AD Issue Date: July 1, 2019 Manual No.: 300X5397
Art # A-12775_AB
INPUT POWER
PHASE
VOLTAGE
400V
esab.eu
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.
This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB product. Your satisfaction with this product and its safe operation is
our ultimate concern. Therefore please take the time to read the entire manual, especially
the Safety Precautions. They will help you to avoid potential hazards that may exist when
working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable
products that have stood the test of time. We pride ourselves on technical innovation,
competitive prices, excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve
a safer working environment within the welding industry.
WARNING
!
Read and understand this entire Manual and your employer’s safety
practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
ESAB Cutmaster® 100
SL100 1Torch™
Operating Manual Number 300X5397
Published by:
ESAB Group Inc.
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 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.
Original Publication Date: January 15, 2015
Revision Date: July 1, 2019
Record the following information for Warranty purposes:
Where Purchased:_______________________________ ________________
Purchase Date:__________________________________ ________________
Power Supply Serial #:___________________________ ________________
Torch Serial #:___________________________________ ________________
i
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,” Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be
sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with
the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained
equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be
replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends
that a telephone or written request for service advice be made to the Authorized Distributor from whom it
was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from
improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!
DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016
The EMC Directive 2014/30/EU, entering into force 20 April 2016
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.
2800 Airport Rd
Denton TX 76207
Phone: +01 800 426 1888, FAX +01 603 298 7402
The following harmonised standard in force within the EEA has been used in the design:
IEC/EN 60974-1:2017 / AMD1:2019 Arc Welding Equipment - Part 1: Welding power sources.
IEC/EN 60974-10:2014 / AMD1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10: Electromagnetic
compatibility (EMC) requirements
Additional Information: Restrictive use, Class A equipment, intended for use in location other than residential.
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety requirements stated above.
Date Signature Position
1 March 2019
Flavio Santos General Manager
Accessories and Adjacencies
2019
TABLE OF CONTENTS
SECTION 1: SAFETY ...............................................................................................................1-1
1.0 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 .............................................................................. 2T-1
2T.01 Scope of Manual ..................................................................................... 2T-1
2T.02 General Description ................................................................................ 2T-1
2T.03 Specifications ........................................................................................ 2T-1
2T.04 Options And Accessories ....................................................................... 2T-2
2T.05 Introduction to Plasma ........................................................................... 2T-2
SECTION 3 SYSTEM: INSTALLATION .................................................................................3-1
3.01 Unpacking ..................................................................................................3-1
3.02 Lifting Options ...........................................................................................3-1
3.03 Primary Input Power Connections ............................................................3-1
3.04 Gas Connections .......................................................................................3-2
SECTION 3 TORCH: INSTALLATION ................................................................................. 3T-1
3T.01 Torch Connections ................................................................................. 3T-1
3T.02 Setting Up Mechanical Torch ................................................................. 3T-1
SECTION 4 SYSTEM: OPERATION .......................................................................................4-1
4.01 Front Panel Controls / Features ................................................................4-1
4.02 Preparations for Operation ........................................................................4-2
SECTION 4 TORCH: OPERATION ...................................................................................... 4T-1
4T.01 Torch Parts Selection ............................................................................. 4T-1
4T.02 Cut Quality .............................................................................................. 4T-1
4T.03 General Cutting Information ................................................................... 4T-2
4T.04 Hand Torch Operation ............................................................................ 4T-3
4T.05 Gouging ................................................................................................... 4T-6
4T.06 Mechanized Torch Operation ................................................................. 4T-7
4T.07 Parts Selection for SL100 Torch Cutting ............................................... 4T-8
4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip ... 4T-9
4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip . 4T-13
PATENT INFORMATION .................................................................................................... 4T-18
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 ............................................................................. 5T-9
5T.02 Inspection and Replacement of Consumable Torch Parts ................. 5T-10
SECTION 6: PARTS LISTS .....................................................................................................6-1
6.01 Introduction ................................................................................................6-1
6.02 Ordering Information .................................................................................6-1
6.03 Power Supply Replacement ......................................................................6-1
6.04 Replacement Power Supply Parts ............................................................6-1
6.05 Options and Accessories ..........................................................................6-2
6.06 Replacement Parts for Hand Torch .........................................................6-3
6.07 Replacement Parts - for Machine Torches with Unshielded Leads ........6-4
6.08 Torch Consumable Parts (SL100) .............................................................6-6
APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ...................................... A-1
APPENDIX 2: DATA TAG INFORMATION ........................................................................... A-2
APPENDIX 3: TORCH PIN - OUT DIAGRAMS .................................................................... A-3
APPENDIX 4: TORCH CONNECTION DIAGRAMS ............................................................. A-4
APPENDIX 5: SYSTEM SCHEMATIC, 400V UNITS ............................................................ A-6
Revision History ..................................................................................................................... A-8
ESAB CUTMASTER 100
SECTION 1: SAFETY
1.0 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.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator
and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, flame proof
clothing, safety gloves.
- Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualified electrician.
- Appropriate fire extinguishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its
implementation in accordance with national law, electrical and/or electronic equipment that has reached the
end of its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary cutting protection and accessories.
300X5397 GENERAL INFORMATION
1-1
ESAB CUTMASTER 100
Arc welding and cutting can be injurious to yourself and others. Take
WARNING
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with
applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your
breathing zone and the general area.
ARC R AYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and filter
lens and wear protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable
materials nearby.
precautions when welding and cutting. Ask for your employer's safety
practices which should be based on manufacturers' hazard data.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmuffs or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
Do not use the power source for thawing frozen pipes.
WARNING
Class A equipment is not intended for use in residential locations
CAUTION
CAUTION
CAUTION
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.
This product is solely intended for metal removal. Any other use
may result in personal injury and / or equipment damage.
Read and understand the instruction manual before
installing or operating.
!
1-2
GENERAL INFORMATION 300X5397
ESAB CUTMASTER 100
!
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specication or part
numbers listed on page i.
To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.
Throughout this manual, the words DANGER, WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these
headings. These special annotations are easily recognized as follows:
NOTE!
An operation, procedure, or background information which requires
additional emphasis or is helpful in
efcient operation of the system.
CAUTION
!
A procedure which, if not properly
followed, may cause damage to the
equipment.
2.02 EquipmentIdentication
The unit’s identication number (specication or part
number), model, and serial number usually appear on
a data tag attached to the rear panel. Equipment which
does not have a data tag such as torch and cable as-
semblies are identied only by the specication or part
number printed on loosely attached card or the shipping
container. Record these numbers on the bottom of page
i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to le a
claim. Furnish complete information concerning damage
claims or shipping errors to the location in your area listed
in the inside back cover of this manual.
Include all equipment identication numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
WARNING
A procedure which, if not properly
followed, may cause injury to the
operator or others in the operating
area.
WARNING
Gives information regarding possible
electrical shock injury. Warnings will
be enclosed in a box such as this.
DANGER
Means immediate hazards which, if
!
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 identication 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
not avoided, will result in immediate,
serious personal injury or loss of life.
http://www.esab.eu
300X5397 INTRODUCTION
2-1
ESAB CUTMASTER 100
150 mm
2.04 PowerSupplySpecications
ESABCutmaster100PowerSupplySpecications
Input Power 400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 100 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability
ESAB Cutmaster 100 Power Supply Duty Cycle *
Ambient Tempera-
ture
All Units
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or
the output voltage (DC) is higher than shown in this chart.
Particulates to 5 Microns
Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
Duty Cycle 60% 80% 100%
Ratings IEC CE IEC CE IEC CE
Current
DC Voltage
100A -- 80A 80A 70A 70A
120 -- 112 112 92 108
NOTE!
IEC Rating is determined as specied by the International Electro-Technical Commission.
These specications include calculating an output voltage based upon power supply rated
current. To facilitate comparison between power supplies, all manufacturers use this output voltage to determine duty cycle.
Power Supply Dimensions & Weight Ventilation Clearance Requirements
12"
305 mm
Art # A-12887
15"
381 mm
Art # A-07925_AB
6"
150 mm
24"
610 mm
6"
150 mm
6"
30"
63 lb / 28.6 kg
2-2
INTRODUCTION 300X5397
762 mm
2.05 InputWiringSpecications
ESAB Cutmaster 100 Power Supply Input Cable Wiring Requirements
Power
Input
3
Phase
Input voltage Freq
Volts Hz kVA
400 50 18.7 27 24 32 10 6
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTE!
Refer to Local and National Codes or local authority having jurisdiction for proper wiring
requirements.
The suggested sizes are based on exible power cable with power plug installations. For
hard-wired installations refer to local or national codes.
I1max is taken at TDC rated minimum duty cycle.
I
max
I eff
Fuse
(amps)
ESAB CUTMASTER 100
Suggested Sizes
Flexible
Cord (Min.
AWG)
Flexible
Cord
(Min. mm2)
I1eff is taken at TDC 100% rated duty cycle.
300X5397 INTRODUCTION
2-3
ESAB CUTMASTER 100
Handle and Leads Wrap
e
Ar
and Clamp
Input Power Cord
Gas Inlet
2.06 Power Supply Features
t # A-08359
Control Panel
To rch Leads Receptacl
Filter Assembly
Port
Work Cable
Port for Optional Automation
Interface Cable
Art # A-08547
2-4
INTRODUCTION 300X5397
ESAB CUTMASTER 100
(95 mm)
t # A-02998
15.875" / 403 mm
16 mm
SECTION 2 TORCH:
INTRODUCTION
2T.01 Scope of Manual
This manual contains descriptions, operating instructions
and maintenance procedures for the 1Torch Models
SL100/Manual and SL100/Mechanized Plasma Cutting
Torches. Service of this equipment is restricted to prop-
erly trained personnel; unqualied personnel are strictly
cautioned against attempting repairs or adjustments not
covered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding
of the characteristics and capabilities of this equipment
will assure the dependable operation for which it was
designed.
2T.02 General Description
Plasma torches are similar in design to the automotive
spark plug. They consist of negative and positive sections separated by a center insulator. Inside the torch,
the pilot arc starts in the gap between the negatively
charged electrode and the positively charged tip. Once
the pilot arc has ionized the plasma gas, the superheated
column of gas ows through the small orice in the torch
tip, which is focused on the metal to be cut.
10.125" (257 mm)
3.75"
1.17" (29 mm)
2. Mechanized Torch, Model
The standard machine torch has a positioning
tube with rack & pinch block assembly.
9.285" / 236 mm
1.375" / 35 mm
1.75" /
44.5 mm
0.625" /
4.95" / 126 mm
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20 ft / 6.1 m, with ATC connectors
• 50 ft / 15.2 m, with ATC connectors
Machine Torches are available as follows:
Art # A-03322_AB
1.175" / 30 mm
Ar
A single torch lead provides gas from a single source to
be used as both the plasma and secondary gas. The
air ow is divided inside the torch head. Single - gas
operation provides a smaller sized torch and inexpensive
operation.
NOTE!
Refer to Section "2T.05 Introduction to
Plasma", for a more detailed description
of plasma torch operation.
Refer to the Appendix Pages for ad-
ditional specications as related to the
Power Supply used.
2T.03Specications
A. TorchCongurations
1. Hand/Manual Torch, Models
The hand torch head is at 75° to the torch handle.
The hand torches include a torch handle and torch
trigger assembly.
• 5 foot / 1.5 m, with ATC connectors
• 10 foot / 3.05 m, with ATC connectors
• 25 foot / 7.6 m, with ATC connectors
• 50 foot / 15.2 m, with ATC connectors
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch Head has built - in switch
12 VDC circuit rating
E. Type Cooling
Combination of ambient air and gas stream through
torch.
300X5397 INTRODUCTION
2T-1
ESAB CUTMASTER 100
F. Torch Ratings
Manual Torch Ratings
Ambient
Temperature
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum Current 100 Amps
Voltage (V
Arc Striking Voltage 7kV
Ambient
Temperature
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum Current 120 Amps
Voltage (V
Arc Striking Voltage 7kV
) 500V
peak
Mechanized Torch Ratings
) 500V
peak
104° F
40° C
104° F
40° C
G. Gas Requirements
Manual and Mechanized Torch Gas
Specications
2T.05 Introduction to Plasma
A. Plasma Gas Flow
Plasma is a gas which has been heated to an
extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma to
transfer an electrical arc to the workpiece. The metal
to be cut or removed is melted by the heat of the arc
and then blown away.
While the goal of plasma arc cutting is separation of
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.
In a Plasma Cutting Torch a cool gas enters Zone B,
where a pilot arc between the electrode and the torch
tip heats and ionizes the gas. The main cutting arc
then transfers to the workpiece through the column
of plasma gas in Zone C.
Gas (Plasma and Secondary) Compressed Air
Operating Pressure
Refer to NOTE
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow (Cutting and
Gouging)
60 - 95 psi
4.1 - 6.5 bar
300 - 500 scfh
142 - 235 lpm
WARNING
!
This torch is not to be used with
oxygen (O2)
NOTE!
Operating pressure varies with torch
model, operating amperage, and
torch leads length. Refer to gas
pressure settings charts for each
model.
H. Direct Contact Hazard
For standoff tip the recommended standoff is 3/16
inches / 4.7 mm.
2T.04 Options And Accessories
_
Power
Supply
A
+
B
Workpiece
C
Typical Torch Head Detail
By forcing the plasma gas and electric arc through a
small orice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
arc is shown in Zone C. Direct current (DC) straight
polarity is used for plasma cutting, as shown in the
illustration.
Zone A channels a secondary gas that cools the
torch. This gas also assists the high velocity plasma
gas in blowing the molten metal out of the cut allowing for a fast, slag - free cut.
A-00002
For options and accessories, see section 6.
2T-2
INTRODUCTION 300X5397
B. Gas Distribution
A-02997
r
up
To
up
up
Remote Pendant
To
The single gas used is internally split into plasma
and secondary gases.
ESAB CUTMASTER 100
The plasma gas ows into the torch through the
negative lead, through the starter cartridge, around
the electrode, and out through the tip orice.
The secondary gas ows down around the outside
of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot arc
creates a path for the main arc to transfer to the work.
D. Main Cutting Arc
DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
through the torch lead. The positive output is connected to the workpiece via the work cable and to
the torch through a pilot wire.
E. Parts - In - Place (PIP)
The torch includes a 'Parts - In - Place' (PIP) circuit.
When the shield cup is properly installed, it closes
a switch. The torch will not operate if this switch is
open.
AT C
AT C
To AT C
PIP Sw itch
CNC Start
PIP Sw itch
Automation To rch
PIP Sw itch
Sh ield C
Sh ield C
Art # A-08168
Sh ield C
Parts - In - Place Circuit Diagram for Machine Torch
To Control
Cable Wiring
Parts - In - Place Circuit Diagram for Hand Torch
Torch Switch
PIP Switch
Torch Trigge
Shield Cup
300X5397 INTRODUCTION
2T-3
ESAB CUTMASTER 100
This Page Intentionally Blank
2T-4
INTRODUCTION 300X5397
ESAB CUTMASTER 100
!
SECTION 3 SYSTEM:
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.
3. Record Power Supply and Torch model and serial
numbers, purchase date and vendor name, in the
information block at the front of this manual.
3.02 Lifting Options
The Power Supply includes a handle for hand lifting
only. Be sure unit is lifted and transported safely and
securely.
WARNING
Do not touch live electrical parts.
Disconnect input power cord before
moving unit.
3.03 Primary Input Power Connections
CAUTION
!
The following illustration and directions are for wiring
three phase input power.
Check your power source for correct voltage before plugging in or
connecting the unit. The primary
power source, fuse, and any extension cords used must conform to
local electrical code and the recommended circuit protection and wiring
requirements as specied in Section
2.
Input Power Cable Connections
Three-Phase (3ø)
L1
L2
L3
L4
GND
Three Phase Input Power Wiring
Art # A-08548
WARNING
FALLING EQUIPMENT can cause
serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.
• Only persons of adequate physical strength should
lift the unit.
• Lift unit by the handles, using two hands. Do not
use straps for lifting.
• Use optional cart or similar device of adequate
capacity to move unit.
• Place unit on a proper skid and secure in place
before transporting with a fork lift or other vehicle.
A. Connections to Three Phase Input Power
WARNING
Disconnect input power from the
power supply and input cable before
attempting this procedure.
These instructions are for replacing the input power and
or cable for 400 VAC Power Supply to Three - Phase
input power.
1. Remove the Power Supply cover per instructions
found in section 5.
2. Disconnect the original input power cable from
the main input contactor and the chassis ground
connection.
3. Loosen the through - hole protector on the back
panel of the power supply. Pull the original power
cable out of the power supply.
4. Using a customer supplied four - conductor input
power cable for the voltage desired, strip back
the insulation on the individual wires.
5. Pass the cable being used through the access
300X5397 INSTALLATION
opening in the back panel of the power supply.
Refer to Section 2 for power cable specications.
3-1
ESAB CUTMASTER 100
Regulator/Filter
Gas Supply
Hose
to 1/4” (6mm) Fitting
CAUTION
!
The primary power source and power cable must conform to local electrical code and the recommended
circuit protection and wiring require-
ments (refer to table in Section 2).
6. Connect the wires as follows.
• Wires to L1, L2 and L3 input. It does not
matter what order these wires are attached.
See previous illustration and on label in the
power supply.
• Green / Yellow wire to Ground.
7. With a little slack in the wires, tighten the through
- hole protector to secure the power cable.
8. Reinstall the Power Supply cover per instructions
found in section 5.
9. Connect the opposite end of individual wires to
a customer supplied plug or main disconnect.
10. Connect the input power cable (or close the main
disconnect switch) to supply power.
Assembly
Inlet Port
Hose Clamp
1/4 NPT or ISO-R
Art # A-07943
Air Connection to Inlet Port
Installing Optional Single - Stage Air Filter
An optional lter kit is recommended for improved ltering with compressed air, to keep moisture and debris
out of the torch.
1. Attach the Single - Stage Filter Hose to the Inlet
Port.
3.04 Gas Connections
Connecting Gas Supply to Unit
The connection is the same for compressed air or high
pressure cylinders. Refer to the following two subsec-
tions if an optional air line lter is to be installed.
1. Connect the air line to the inlet port. The illustra-
tion shows typical ttings as an example.
NOTE!
For a secure seal, apply thread
sealant to the tting threads, according to manufacturer's instructions.
Do not use Teon tape as a thread
sealer, as small particles of the tape
may break off and block the small air
passages in the torch.
2. Attach the Filter Assembly to the lter hose.
3. Connect the air line to the Filter. The illustration
shows typical ttings as an example.
INSTALLATION 300X5397
3-2
ESAB CUTMASTER 100
t # A-07944
Hose Clam
Regulator/Filter
NOTE!
For a secure seal, apply thread sealant to the tting threads, according to the maker's
instructions. Do Not use Teon 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:
Assembly
Inlet Port
Ar
p
Gas Supply
Hose
1/4 NPT to 1/4"
(6mm) Fitting
Optional Single - Stage Filter Installation
Installing Optional Two - Stage Air Filter Kit
This optional two - stage air line lter 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. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the lter
assembly.
NOTE!
For a secure seal, apply thread sealant to the tting threads according to manufacturer's
instructions. Do Not use Teon tape as a thread sealer as small particles of the tape may
break off and block the small air passages in the torch.
2. Connect the two stage lter outlet hose to the inlet port of the Regulator / Filter Assembly.
3. Use customer - supplied ttings to connect the air line to the Filter. A 1/4 NPT to 1/4" hose barbed tting is
shown as an example.
300X5397 INSTALLATION
3-3
ESAB CUTMASTER 100
Regulator/Filter
wo Stage
Art # A-07945_AC
Hose Clamp
Assembly
Regulator
Input
Gas Supply
Hose
1/4 NPT to 1/4”
(6mm) Fitting
2-Stage Filter
Inlet Port (IN)
Outlet Port
(OUT)
T
Filter
Assembly
Optional Two - Stage Filter Installation
Using High Pressure Air Cylinders
When using high pressure air cylinders as the air supply:
1. Refer to the manufacturer’s specications for installation and maintenance procedures for high pressure
regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briey
open each cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up
to 100 psi (6.9 bar) maximum and ows of at least 300 scfh (141.5 lpm).
4. Connect supply hose to the cylinder.
NOTE!
Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the tting threads, according to manufacturer's
instructions. Do Not use Teon tape as a thread sealer, as small particles of the tape may
break off and block the small air passages in the torch.
INSTALLATION 300X5397
3-4
SECTION 3 TORCH:
Wo
INSTALLATION
ESAB CUTMASTER 100
3. Place a welding lter lens in front of the torch and
turn on the air. Do not start an arc!
Any oil or moisture in the air will be visible on the lens.
3T.01 Torch Connections
If necessary, connect the torch to the Power Supply.
Connect only the ESAB model SL100 / Manual or SL100
/ Mechanical Torch to this power supply. Maximum torch
leads length is 100 feet / 30.5 m, including extensions.
WARNING
Disconnect primary power at the
1. Align the ATC male connector (on the torch lead)
2. Secure the connection by turning the locking nut
source before connecting the torch.
with the female receptacle. Push the male connector into the female receptacle. The connectors should push together with a small amount
of pressure.
clockwise until it clicks. DO NOT use the locking
nut to pull the connection together. Do not use
tools to secure the connection.
3T.02 Setting Up Mechanical Torch
NOTE!
An adapter is required to be installed
in the power supply if converting
a hand torch system to operate a
machine torch.
WARNING
Disconnect primary power at the
The mechanical torch includes a positioning tube with
rack and pinch block assembly.
1. Mount the torch assembly on the cutting table.
2. To obtain a clean vertical cut, use a square to
source before connecting the torch.
align the torch perpendicular to the surface of
the workpiece.
Pinch Block
Assembly
2
1
Art # A-07885
Connecting the Torch to the Power Supply
3. The system is ready for operation.
Check Air Quality
To test the quality of air:
1. / Put the ON / OFF switch in the ON (up)
position.
2. Put the Function Control switch in the SET posi-
tion.
Square
rkpiece
A-02585
Mechanical Torch Set - Up
3. The proper torch parts (shield cup, tip, start cartridge, and electrode) must be installed for the
type of operation. Refer to Section 4T.07, Torch
Parts Selection for details.
300X5397 INSTALLATION
3T-1
ESAB CUTMASTER 100
This Page Intentionally Blank
3T-2
INSTALLATION 300X5397
SECTION 4 SYSTEM:
+
12
3
5
6
7
9
10
!
OPERATION
4.01 Front Panel Controls / Features
SeeIllustrationfornumberingIdentication
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.
2. Function Control
ESAB CUTMASTER 100
nect input power, correct the fault, and restart the
unit. Refer to Section 5 for details.
4
MAX
MIN
A
PSI BAR
MAXMAX
MINMIN
!
+
Function Control Knob, Used to select between the
different operating modes.
and torch and leads and to adjust gas pressure.
restarting of the Pilot Arc for uninterrupted cutting.
Once a cutting arc is established, the torch switch
can be released. The cutting arc will remain ON until
the torch is lifted away from the work piece, the torch
leaves the edge of the work piece the torch switch
is activated again or if one of the system interlocks
is activated.
3. ON OFF Power Switch
/ ON / OFF Switch controls input power to
the power supply. Up is ON, down is OFF.
4. Air/Gas Pressure Control
SET Used to purge the air through the unit
RUN Used for general cutting operations
RAPID AUTO RESTART Allows for faster
LATCH Used for longer hand held cuts.
Art# A-07886
8
6. Temp Indicator
Indicator is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Let the
unit cool before continuing operation.
7. Gas Indicator
Indicator is ON when minimum input gas pressure
for power supply operation is present. Minimum
pressure for power supply operation is not sufcient
for torch operation.
8. DC Indicator
Indicator is ON when DC output circuit is active.
9.
Fault Error Indicator
Indicator is ON when Fault circuit is active. See section 5 for explanations of fault lights.
The Pressure Control is used in the "SET"
mode to adjust the air/gas pressure. Pull the knob
out to adjust and push in to lock.
5. AC Indicator
Steady light indicates power supply is ready for operation. Blinking light indicates unit is in protective
interlock mode. Shut unit OFF, shut OFF or discon-
300X5397 OPERATION
4-1
Loading...