ESAB Cutmaster 100 Plasma Cutting System Instruction manual

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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

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 #:___________________________________ ________________

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

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 specication 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

efcient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

2.02 EquipmentIdentication

The unit’s identication number (specication 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 identied only by the specication 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 identication 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 identication 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 PowerSupplySpecications

ESABCutmaster100PowerSupplySpecications

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 specied by the International Electro-Technical Commission. These specications 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

150 mm

24"

610 mm

150 mm

30"

63 lb / 28.6 kg

2-2

INTRODUCTION 300X5397

762 mm

2.05 InputWiringSpecications

ESAB Cutmaster 100 Power Supply Input Cable Wiring Requirements

Power

Input

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.

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

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; unqualied 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 orice 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

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 specications as related to the

Power Supply used.

2T.03Specications

A. TorchCongurations

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

Specications

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

Workpiece

Typical Torch Head Detail

By forcing the plasma gas and electric arc through a

small orice, 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

Remote Pendant

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 orice.

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

To AT C

PIP Sw itch

CNC Start

PIP Sw itch

Automation To rch

PIP Sw itch

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 specied in Section

Input Power Cable Connections

Three-Phase (3ø)

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 specications.

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 Teon 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 Teon 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

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 Teon 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 specications 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. Briey

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 Teon 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:

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

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:

OPERATION

4.01 Front Panel Controls / Features

SeeIllustrationfornumberingIdentication

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.

MAX

MIN

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

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 sufcient

for torch operation.

8. DC Indicator

Indicator is ON when DC output circuit is active.

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

ESAB CUTMASTER 100

Art # A-08170

Art # A-04509

10. Pressure Indicators

Connect Work Cable

PSI BAR

MAX MAX

90 6.3

85 5.9

MINMIN

The Indicators will illuminate according to the pres-

sure set by the Pressure Control Knob (number 4).

5.5

5.2

4.8

4.5

4.02 Preparations for Operation

At the start of each operating session:

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.

Torch Parts Selection

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 (100 amps maximum). Refer to

Section 4T.07 and following for torch parts selection.

Torch Connection

Check that the torch is properly connected. Only ESAB model SL100 / Manual or SL100 / Mechanical Torches may be connected to this Power Supply. See Section 3T of this manual.

Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off.

Power ON

Place the Power Supply ON / OFF switch to the ON

(up) position. AC indicator turns ON.

Gas indicator turns ON if there is sufcient gas

pressure for power supply operation and the cooling fans turn ON.

NOTE!

Minimum pressure for power supply operation is lower than minimum for torch operation. The cooling fans will turn ON as soon as the unit is turned ON. After

the unit is idle for ten (10) minutes

the fans will turn OFF. The fans will come back ON as soon as the torch

switch (Start Signal) is activated or if

the unit is turned off, then turned ON again. If an over temperature condition occurs, the fans will continue to run while the condition exists and for

a ten (10) minute period once the

condition is cleared.

Check Primary Input Power Source

1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per Section

2, Specications.

2. Connect the input power cable (or close the main

disconnect switch) to supply power to the system.

Air Source

Ensure source meets requirements (refer to Section

2). Check connections and turn air supply ON.

4-2

OPERATION 300X5397

Set Operating Pressure

1. Place the Power Supply Function Control knob

to the SET position. Gas will ow.

2. For Standoff cutting, adjust gas pressure from 70

- 85 psi / 4.8 - 5.9 bar (LED's in center of control

panel). Refer to the Standoff chart for pressure setting details.

MIN

MAX

PSI BAR

MAXMAX

MINMIN

Art# A-07946

STANDOFF

ESAB Cutmaster 100 Gas Pressure Settings

Leads Length

Up to 25' (7.6 m)

Each additional

25' (7.6 m)

SL100

(Hand Torch)

80 psi

5.5 bar

Add 5 psi 0.4

bar

SL100

(Mechanized Torch)

80 psi

5.5 bar

Add 5 psi 0.4 bar

ESAB CUTMASTER 100

Cutting Operation

When the torch leaves the workpiece during cutting operations with the Function Control Knob in the RUN position, there is a brief delay in restarting the pilot arc. With the knob in the RAPID AUTO RESTART position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arc contacts the

workpiece. (Use the 'Rapid Auto Restart' position

when cutting expanded metal or gratings, or in gouging or trimming operations when an uninterrupted restart is desired). And with the knob in the LATCH position the main cutting arc will be maintained after the torch switch is released.

Typical Cutting Speeds

Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill. Refer to Section 4T.08 and following for greater details.

Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, or using a template or cutting guide while still producing cuts of excellent quality.

Postow

3. For Drag cutting, adjust gas pressure from 75 -

95 psi / 5.2 - 6.5 bar (LED's in center of control

panel). Refer to the Drag Cutting chart for pressure setting details.

Drag (60 Amps or less)

ESAB Cutmaster 100 Gas Pressure

Settings

Leads Length

Up to 25' (7.6 m)

Each additional

25' (7.6 m)

SL100

(Hand Torch)

80 psi

5.5 bar

Add 5 psi

0.4 bar

tinues to ow for approximately 20 seconds. During post - ow, if the user moves the trigger release to

the rear and presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece.

Shutdown

/ Turn the ON / OFF switch to OFF (down).

All Power Supply indicators shut OFF. Unplug the input power cord or disconnect input power. Power is removed from the system.

Select Current Output Level

1. Place the Function Control Knob in one of the three operating positions available:

RUN,

Release the trigger to stop the cutting arc. Gas con-

RAPID AUTO RESTART,

or LATCH. Gas ow stops.

2. Set the output current to desired amperage with the Output Current Control Knob.

300X5397 OPERATION

4-3

ESAB CUTMASTER 100

This Page Intentionally Blank

4-4

OPERATION 300X5397

SECTION 4 TORCH:

A-03510_AB

Kerf Width

Cut Surface Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

ESAB CUTMASTER 100

Shown)

OPERATION

4T.01 Torch Parts Selection

Depending on the type of operation to be done determines the torch parts to be used.

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter Cartridge

NOTE!

Refer to Section 4T.07 and following for additional information on torch parts.

Change the torch parts for a different operation as follows:

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.

NOTE!

The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed.

3. Install the replacement Electrode by pushing it straight into the torch head until it clicks.

4. Install the starter cartridge and desired tip for the

operation into the torch head.

5. Hand tighten the shield cup assembly until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.

4T.02 Cut Quality

NOTE!

Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.

Cut quality requirements differ depending on application. For instance, nitride build - up and bevel angle may be major factors when the surface will be welded after cutting. Dross - free cutting is important when nish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are

illustrated in the following gure:

1. Unscrew and remove the shield cup assembly from the torch head.

2. Remove the Electrode by pulling it straight out of the Torch Head.

Large O-Ring

Torch Head

Electrode

Small O-Ring

Cut Surface

Start Cartridge

Tip

Shield Cup

Torch Parts (Drag Shield Cap & Shield Cup Body

300X5397 OPERATION

The desired or specied condition (smooth or rough)

of the face of the cut.

Nitride Build - Up

Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream.

These buildups may create difculties if the material

is to be welded after the cutting process.

Cut Quality Characteristics

4T-1

ESAB CUTMASTER 100

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.

Top - Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

Bottom Dross Buildup

Molten material which is not blown out of the cut area

and resolidies on the plate. Excessive dross may

require secondary cleanup operations after cutting.

Kerf Width

The width of the cut (or the width of material removed

during the cut).

Top Spatter (Dross)

Piloting

Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life.

Torch Standoff

Improper standoff (the distance between the torch tip

and workpiece) can adversely affect tip life as well as

shield cup life. Standoff may also signicantly affect

the bevel angle. Reducing standoff will generally result in a more square cut.

Edge Starting

For edge starts, hold the torch perpendicular to the

workpiece with the front of the tip near (not touching)

the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to "reach" for the edge of the metal. Establish the cutting arc as quickly as possible.

Top spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting

tip whose orice has become elongated.

4T.03 General Cutting Information

WARNING

Disconnect primary power at the source before disassembling 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. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

CAUTION

Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

NOTE!

Handle torch leads with care and protect them from damage.

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. Viewed along the direction of travel, the right side of the cut is more square than the left.

Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Dross

When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is

4T-2

OPERATION 300X5397

normally caused by too great a torch to plate dis-

A-00024_AB

Shield Cup

Torch

Standoff Distance

1/8" - 3/8" (3 - 9mm)

A-02986

Trigger

Trigger Release

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. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily scraped off. "High speed dross" usually forms a narrow bead along the bottom of

the cut edge and is very difcult to remove. When

cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not grinding.

4T.04 Hand Torch Operation

ESAB CUTMASTER 100

Standoff Cutting With Hand Torch

NOTE!

For best parts performance and life, always use the correct parts for the type of operation.

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 the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

NOTE!

The tip should never come in contact with the workpiece except during drag cutting operations.

2. Depending on the cutting operation, do one of the following:

a. For edge starts, hold the torch perpendicular

to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.

Standoff Distance

3. Hold the torch away from your body.

4. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTE!

The gas preow and postow are a

characteristic of the power supply and not a function of the torch.

b. For standoff cutting, hold the torch 1/8 - 3/8

in (3-9 mm) from the workpiece as shown

below.

300X5397 OPERATION

4T-3

ESAB CUTMASTER 100

Art # A-03383

Tr igger

Tr igger Release

Art # A-04034

A-03539

Non-Conductive

Straight Edge Cutting Guide

4T-4

OPERATION 300X5397

6. Cut as usual. Simply release the trigger assembly to stop cutting.

7. Follow normal recommended cutting practices as provided in the power supply operator's manual.

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 this gap. Forcing the shield cup against the torch head or torch handle can damage components.

8. For a consistent standoff height from the workpiece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece.

Shield Cup

Standoff Guide

Torch Tip

Workpiece

Shield Cup With Straight Edge

The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand.

WARNING

The straight edge must be nonconductive.

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when cutting

3/16 inch (4.7 mm) solid metal with relatively smooth

surface.

Drag Cutting With a Hand Torch

Drag cutting works best on metal 1/4" (6 mm) thick

or less.

NOTE!

Drag cutting can only be performed at 60 amps or less. For best parts performance and life, always use the correct parts for the type of operation.

1. Install the drag cutting tip and set the output current.

2. 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 the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

3. Keep the torch in contact with the workpiece during the cutting cycle.

4. Hold the torch away from your body.

5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

ESAB CUTMASTER 100

A-02986

Trigger

Trigger Release

Art # A-03383

Tr igger

Tr igger Release

A-02986

Trigger

Trigger Release

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 the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement.

6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTE!

The gas preow and postow are a

characteristic of the power supply and not a function of the torch.

NOTE!

The tip should never come in contact with the workpiece except during drag cutting operations.

2. Angle the torch slightly to direct blowback par-

ticles away from the torch tip (and operator)

rather than directly back into it until the pierce is complete.

3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete.

4. Hold the torch away from your body.

5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

7. Cut as usual. Simply release the trigger assembly to stop cutting.

8. Follow normal recommended cutting practices as provided in the power supply operator's manual.

NOTE!

When the shield cup is properly in-

the shield cup and the torch handle. Gas vents through this gap as part

stalled, there is a slight gap between

of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.

300X5397 OPERATION

6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTE!

The gas preow and postow are a

characteristic of the power supply and not a function of the torch 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 this gap. Forcing the shield cup against the torch head or torch handle can damage components.

4T-5

ESAB CUTMASTER 100

35°

Workpiece

Torch Head

Standoff Height

A-00941_AB

7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance:

• Torch parts wear

• Air quality

• Line voltage uctuations

• Torch standoff height

• Proper work cable connection

4T.05 Gouging

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 been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch is activated. Disconnect primary power to the system before disassembling the torch, leads, or power supply.

Torch Travel Speed

NOTE!

Refer to Appendix Pages for additional information as related to the Power Supply used.

Optimum torch travel speed is dependent on current

setting, lead angle, and mode of operation (hand or

machine torch).

Current Setting

Current settings depend on torch travel speed,

mode of operation (hand or machine torch), and the

amount of material to be removed.

Pressure Setting

Even though the setting is within the specied range,

if the torch does not pilot well the pressure may need to be reduced.

Lead Angle

The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the

torch. If the lead angle is too small (less than 35°),

less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.

CAUTION

Sparks from plasma gouging can cause damage to coated, painted or other surfaces such as glass, plastic, and metal. Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 4T.07, Torch Parts Selection.

Gouging Parameters

Gouging performance depends on parameters such

as torch travel speed, current level, lead angle (the

angle between the torch and workpiece), and the dis-

tance between the torch tip and workpiece (standoff).

CAUTION

Touching the torch tip or shield cup to the work surface will cause excessive parts wear.

Gouging Angle and Standoff Distance

Standoff Distance

The tip to work distance affects gouge quality and

depth. Standoff distance of 1/8 - 1/4 inch (3 - 6

mm) allows for smooth, consistent metal removal. Smaller standoff distances may result in a severance cut rather than a gouge. Standoff distances greater

than 1/4 inch (6 mm) may result in minimal metal

removal or loss of transferred main arc.

4T-6

OPERATION 300X5397

Slag Buildup

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

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. However, slag build - up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc. The build - up is most often a result of improper travel speed, lead angle, or standoff height.

4T.06 Mechanized Torch Operation

Cutting With Mechanized Torch

The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC.

ESAB CUTMASTER 100

1. To start a cut at the plate edge, position the center of the torch along the edge of the plate.

Travel Speed

Proper travel speed is indicated by the trail of the arc which is seen below the plate. The arc can be one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cut using air plasma on stainless or aluminum.

2. Leading Arc

The leading arc is directed in the same direction as torch travel. A ve degree leading arc is generally recommended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direction as torch travel.

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. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer.

Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required.

Piercing With Machine Torch

To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow back onto the front end of the torch.

300X5397 OPERATION

When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled until the arc penetrates the bottom of the plate. As motion begins, torch standoff should be

reduced to the recommended 1/8 - 1/4 inch (3-6 mm)

distance for optimum speed and cut quality. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

4T-7

ESAB CUTMASTER 100

, Deflector

, Machine

, Deflector

, Machine

4T.07 Parts Selection for SL100 Torch Cutting

Ohmic Clip

Manual Torch

9-8259

Ohmic Clip

Automation To rch

9-8224

Electrode

Auto 9-8232

Manual 9-8215

Starter

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Starter Cartridge

Non HF Only 9-8277

70-120A

STANDOFF

CUTTING

Tip:

20A 9-8205 30A 9-8206 40A 9-8208

Tips:

50-55A 9-8209

60A 9-8210

Tips:

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap 40A 9-8245

Shield Cap 9-8243

Drag Shield Cup 9-8235

Shield Cap 50-60A 9-8238

Shield Cap 9-8243

Drag Shield Cup 70-100A 9-8236

Drag Shield Cup 120A 9-8258

Shield Cap 70-100A 9-8239

Shield Cap 120A 9-8256

Shield Cap 9-8243

40-120A

GOUGING

Tips:

Tip A 9-8225 (40 Amps Max.)

Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Art # A-08066_AG

4T-8

OPERATION 300X5397

Tip E 9-8254 (60 - 120 Amps)

Shield

Cup Body,

9-8237

Shield Cup, Gouging

9-8241

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 Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,036 0,9 9-8208 104 40 340 8,64 0,19 4,8 65 4,5 55 170 0,00 0,2 5,1

0,06 1,5 9-8208 108 40 250 6,35 0,19 4,8 65 4,5 55 170 0,10 0,2 5,1

0,075 1,9 9-8208 108 40 190 4,83 0,19 4,8 65 4,5 55 170 0,30 0,2 5,1

0,135 3,4 9-8208 110 40 105 2,67 0,19 4,8 65 4,5 55 170 0,40 0,2 5,1

0,188 4,8 9-8208 113 40 60 1,52 0,19 4,8 65 4,5 55 170 0,60 0,2 5,1

0,25 6,4 9-8208 111 40 40 1,02 0,19 4,8 65 4,5 55 170 1,00 0,2 5,1

0,375 9,5 9-8208 124 40 21 0,53 0,19 4,8 65 4,5 55 170 NR NR NR

0,500 12,7 9-8208 123 40 11 0,28 0,19 4,8 65 4,5 55 170 NR NR NR

0,625 15,9 9-8208 137 40 7 0,18 0,19 4,8 65 4,5 55 170 NR NR NR

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,036 0,9 9-8208 103 40 355 9,02 0,125 3,2 65 4,5 55 170 0,00 0,2 5,1

0,05 1,3 9-8208 98 40 310 7,87 0,125 3,2 65 4,5 55 170 0,00 0,2 5,1

0,06 1,5 9-8208 98 40 240 6,10 0,125 3,2 65 4,5 55 170 0,10 0,2 5,1

0,078 2,0 9-8208 100 40 125 3,18 0,125 3,2 65 4,5 55 170 0,30 0,2 5,1

0,135 3,4 9-8208 120 40 30 0,76 0,187 4,8 65 4,5 55 170 0,40 0,2 5,1

0,188 4,8 9-8208 124 40 20 0,51 0,187 4,8 65 4,5 55 170 0,60 0,2 5,1

0,25 6,4 9-8208 122 40 15 0,38 0,187 4,8 65 4,5 55 170 1,00 0,2 5,1

0,375 9,5 9-8208 126 40 10 0,25 0,187 4,8 65 4,5 55 170 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Type Torch: SL100 With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,032 0,8 9-8208 110 40 440 11,18 0,187 4,8 65 4,5 55 170 0,00 0,2 5,1

0,051 1,3 9-8208 109 40 350 8,89 0,187 4,8 65 4,5 55 170 0,10 0,2 5,1

0,064 1,6 9-8208 112 40 250 6,35 0,187 4,8 65 4,5 55 170 0,10 0,2 5,1

0,079 2,0 9-8208 112 40 200 5,08 0,19 4,8 65 4,5 55 170 0,30 0,2 5,1

0,125 3,2 9-8208 118 40 100 2,54 0,19 4,8 65 4,5 55 170 0,40 0,2 5,1

0,188 4,8 9-8208 120 40 98 2,49 0,187 4,8 65 4,5 55 170 0,60 0,2 5,1

0,250 6,4 9-8208 123 40 50 1,27 0,187 4,8 65 4,5 55 170 1,00 0,2 5,1

0,375 9,5 9-8208 134 40 16 0,41 0,187 4,8 65 4,5 55 170 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

300X5397 OPERATION

4T-9

ESAB CUTMASTER 100

Type Torch: SL100 With Exposed Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,060 1,5 9-8210 11 0 60 290 7,37 0,19 4,8 70 4,8 90 245 0,00 0,19 4,8

0,075 1,9 9-8210 120 60 285 7,24 0,19 4,8 70 4,8 90 245 0,10 0,19 4,8

0,120 3,0 9-8210 120 60 180 4,57 0,19 4,8 70 4,8 90 245 0,10 0,19 4,8

0,135 3,4 9-8210 11 9 60 170 4,32 0,19 4,8 70 4,8 90 245 0,10 0,19 4,8

0,188 4,8 9-8210 121 60 100 2,54 0,19 4,8 70 4,8 90 245 0,20 0,19 4,8

0,250 6,4 9-8210 11 9 60 80 2,03 0,19 4,8 70 4,8 90 245 0,30 0,19 4,8

0,375 9,5 9-8210 124 60 50 1,27 0,19 4,8 70 4,8 90 245 0,50 0,19 4,8

0,500 12,7 9-8210 126 60 26 0,66 0,19 4,8 70 4,8 90 245 0,75 0,19 4,8

0,625 15,9 9-8210 127 60 19 0,48 0,19 4,8 70 4,8 90 245 NR NR NR

0,750 19,1 9-8210 134 60 14 0,36 0,19 4,8 70 4,8 90 245 NR NR NR

1,000 25,4 9-8210 140 60 6 0,15 0,19 4,8 70 4,8 90 245 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,06 1,5 9-8210 119 60 350 8,91 0,19 4,8 70 4,8 90 245 0,00 0,20 5,1

0,075 1,9 9-8210 116 60 300 7,64 0,19 4,8 70 4,8 90 245 0,10 0,20 5,1

0,120 3,0 9-8210 123 60 150 3,82 0,19 4,8 70 4,8 90 245 0,10 0,20 5,1

0,135 3,4 9-8210 118 60 125 3,18 0,19 4,8 70 4,8 90 245 0,10 0,20 5,1

0,188 4,8 9-8210 122 60 90 2,29 0,19 4,8 70 4,8 90 245 0,20 0,20 5,1

0,250 6,4 9-8210 120 60 65 1,65 0,19 4,8 70 4,8 90 245 0,30 0,20 5,1

0,375 9,5 9-8210 130 60 30 0,76 0,19 4,8 70 4,8 90 245 0,50 0,20 5,1

0,500 12,7 9-8210 132 60 21 0,53 0,19 4,8 70 4,8 90 245 0,75 0,20 5,1

0,625 15,9 9-8210 130 60 15 0,38 0,19 4,8 70 4,8 90 245 NR NR NR

0,750 19,1 9-8210 142 60 12 0,31 0,25 6,4 70 4,8 90 245 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Type Torch: SL100 With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,060 1,5 9-8210 11 0 60 440 11,18 0,25 6,4 70 4,8 90 245 0,00 0,25 6,4

0,075 1,9 9-8210 11 0 60 440 11,18 0,25 6,4 70 4,8 90 245 0,10 0,25 6,4

0,120 3,0 9-8210 11 6 60 250 6,35 0,25 6,4 70 4,8 90 245 0,10 0,25 6,4

0,188 3,4 9-8210 11 6 60 170 4,32 0,25 6,4 70 4,8 90 245 0,20 0,25 6,4

0,250 6,4 9-8210 132 60 85 2,16 0,25 6,4 70 4,8 90 245 0,30 0,25 6,4

0,375 9,5 9-8210 140 60 45 1,14 0,25 6,4 70 4,8 90 245 0,50 0,25 6,4

0,500 12,7 9-8210 143 60 30 0,76 0,25 6,4 70 4,8 90 245 0,80 0,25 6,4

0,625 15,9 9-8210 145 60 20 0,51 0,25 6,4 70 4,8 90 245 NR NR NR

0,750 19,1 9-8210 145 60 18 0,46 0,25 6,4 70 4,8 90 245 NR NR NR

4T-10

OPERATION 300X5397

ESAB CUTMASTER 100

Type Torch: SL100 With Exposed Tip

Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,060 1,5 9-8211 11 3 80 320 8,13 0,19 4,8 65 4,5 11 5 340 0,00 0,19 4,8

0,120 3,0 9-8211 11 3 80 230 5,84 0,19 4,8 65 4,5 11 5 340 0,10 0,19 4,8

0,135 3,4 9-8211 11 5 80 180 4,57 0,19 4,8 65 4,5 11 5 340 0,10 0,19 4,8

0,188 4,8 9-8211 11 4 80 140 3,56 0,19 4,8 65 4,5 11 5 340 0,20 0,19 4,8

0,250 6,4 9-8211 11 4 80 100 2,54 0,19 4,8 65 4,5 11 5 340 0,30 0,19 4,8

0,375 9,5 9-8211 11 7 80 42 1,07 0,19 4,8 65 4,5 115 340 0,40 0,19 4,8

0,500 12,7 9-8211 120 80 33 0,84 0,19 4,8 65 4,5 115 340 0,60 0,19 4,8

0,625 15,9 9-8211 133 80 22 0,56 0,19 4,8 65 4,5 115 340 0,75 0,19 4,8

0,750 19,1 9-8211 128 80 18 0,46 0,19 4,8 65 4,5 115 340 NR NR NR

0,875 22,2 9-8211 133 80 10 0,25 0,19 4,8 65 4,5 115 340 NR NR NR

1,000 25,4 9-8211 132 80 9 0,23 0,19 4,8 65 4,5 115 340 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,060 1,5 9-8211 120 80 340 8,64 0,25 6,4 65 4,5 115 340 0,00 0,25 6,4

0,120 3,0 9-8211 120 80 300 7,62 0,25 6,4 65 4,5 115 340 0,10 0,25 6,4

0,135 3,4 9-8211 120 80 280 7,11 0,25 6,4 65 4,5 115 340 0,10 0,25 6,4

0,188 4,8 9-8211 120 80 140 3,56 0,25 6,4 65 4,5 115 340 0,20 0,25 6,4

0,250 6,4 9-8211 120 80 100 2,54 0,25 6,4 65 4,5 115 340 0,30 0,25 6,4

0,375 9,5 9-8211 126 80 50 1,27 0,25 6,4 65 4,5 115 340 0,40 0,25 6,4

0,500 12,7 9-8211 129 80 28 0,71 0,25 6,4 65 4,5 115 340 0,80 0,25 6,4

0,625 15,9 9-8211 135 80 20 0,51 0,25 6,4 65 4,5 115 340 1,00 0,25 6,4

0,750 19,1 9-8211 143 80 10 0,25 0,25 6,4 65 4,5 115 340 NR NR NR

0,875 22,2 9-8211 143 80 9 0,23 0,25 6,4 65 4,5 115 340 NR NR NR

1,000 25,4 9-8211 146 80 8 0,20 0,25 6,4 65 4,5 115 340 NR NR NR

Type Torch: SL100 with Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,06 1,5 9-8211 120 80 350 8,89 0,25 6,4 65 4,5 11 5 340 0,00 0,25 6,4

0,12 3,0 9-8211 124 80 300 7,62 0,25 6,4 65 4,5 11 5 340 0,10 0,25 6,4

0,188 4,8 9-8211 124 80 180 4,57 0,25 6,4 65 4,5 11 5 340 0,20 0,25 6,4

0,250 6,4 9-8211 128 80 110 2,79 0,25 6,4 65 4,5 11 5 340 0,30 0,25 6,4

0,375 9,5 9-8211 136 80 55 1,40 0,25 6,4 65 4,5 115 340 0,40 0,25 6,4

0,500 12,7 9-8211 139 80 38 0,97 0,25 6,4 65 4,5 11 5 340 0,60 0,25 6,4

0,625 15,9 9-8211 142 80 26 0,66 0,25 6,4 65 4,5 11 5 340 0,75 0,25 6,4

0,750 19,1 9-8211 145 80 24 0,61 0,25 6,4 65 4,5 11 5 340 NR NR NR

0,875 22,2 9-8211 153 80 10 0,25 0,25 6,4 65 4,5 11 5 340 NR NR NR

1,000 25,4 9-8211 162 80 6 0,15 0,25 6,4 65 4,5 11 5 340 NR NR NR

300X5397 OPERATION

4T-11

ESAB CUTMASTER 100

Type Torch: SL100 With Exposed Tip

Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,250 6,4 9-8212 110 100 105 2,65 0,190 4,8 75 5,2 130 390 0,4 0,200 5,1

0,375 9,5 9-8212 117 100 70 1,75 0,190 4,8 75 5,2 130 390 0,5 0,200 5,1

0,500 12,7 9-8212 120 100 50 1,25 0,190 4,8 75 5,2 130 390 0,6 0,200 5,1

0,625 15,9 9-8212 125 100 35 0,90 0,190 4,8 75 5,2 130 390 1,0 0,200 5,1

0,750 19,0 9-8212 131 100 18 0,45 0,190 4,8 75 5,2 130 390 2,0 0,250 6,4

1,000 25,4 9-8212 135 100 10 0,25 0,190 4,8 75 5,2 130 390 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,250 6,4 9-8212 11 8 100 90 2,30 0,190 4,8 75 5,2 130 390 0,5 0,250 6,4

0,375 9,5 9-8212 122 100 55 1,40 0,190 4,8 75 5,2 130 390 0,8 0,250 6,4

0,500 12,7 9-8212 126 100 30 0,75 0,190 4,8 75 5,2 130 390 1,0 0,250 6,4

0,625 15,9 9-8212 133 100 20 0,50 0,190 4,8 75 5,2 130 390 1,5 0,250 6,4

0,750 19,0 9-8212 138 100 15 0,40 0,190 4,8 75 5,2 130 390 NR NR NR

1,000 25,4 9-8212 139 100 10 0,25 0,190 4,8 75 5,2 130 390 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Type Torch: SL100 with Exposed Tip

Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,250 6,4 9-8212 108 100 120 3,05 0,190 4,8 65 4,5 120 360 0,2 0,225 5,7

0,375 9,5 9-8212 117 100 65 1,65 0,190 4,8 65 4,5 120 360 0,4 0,225 5,7

0,500 12,7 9-8212 120 100 45 1,15 0,190 4,8 65 4,5 120 360 0,5 0,225 5,7

0,625 15,9 9-8212 125 100 30 0,75 0,190 4,8 65 4,5 120 360 0,8 0,225 5,7

0,750 19,0 9-8212 131 100 25 0,65 0,190 4,8 65 4,5 120 360 1,0 0,225 5,7

1,000 25,4 9-8212 140 100 10 0,25 0,190 4,8 65 4,5 120 360 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

NOTE!

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to Section "Set Operating Pressure" on page <?>.

** Total ow rate includes plasma and secondary gas ow.

4T-12

OPERATION 300X5397

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 Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,036 0,9 9-8208 11 4 40 170 4,32 0,19 4,8 65 4,5 55 170 0,00 0,2 5,1

0,06 1,5 9-8208 120 40 90 2,29 0,19 4,8 65 4,5 55 170 0,10 0,2 5,1

0,075 1,9 9-8208 121 40 80 2,03 0,19 4,8 65 4,5 55 170 0,30 0,2 5,1

0,135 3,4 9-8208 122 40 75 1,91 0,19 4,8 65 4,5 55 170 0,40 0,2 5,1

0,188 4,8 9-8208 123 40 30 0,76 0,19 4,8 65 4,5 55 170 0,60 0,2 5,1

0,25 6,4 9-8208 125 40 25 0,64 0,19 4,8 65 4,5 55 170 1,00 0,2 5,1

0,375 9,5 9-8208 138 40 11 0,28 0,19 4,8 65 4,5 55 170 NR NR NR

0,500 12,7 9-8208 142 40 7 0,18 0,19 4,8 65 4,5 55 170 NR NR NR

0,625 15,9 9-8208 152 40 3 0,08 0,19 4,8 65 4,5 55 170 NR NR NR

(Cat. No.) Volts (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff

Inches

0,036 0,9 9-8208 109 40 180 4,57 0,125 3,2 65 4,5 55 170 0,00 0,2 5,1

0,05 1,3 9-8208 105 40 165 4,19 0,125 3,2 65 4,5 55 170 0,00 0,2 5,1

0,06 1,5 9-8208 115 40 120 3,05 0,125 3,2 65 4,5 55 170 0,10 0,2 5,1

0,078 2,0 9-8208 120 40 65 1,65 0,187 4,8 65 4,5 55 170 0,30 0,2 5,1

0,135 3,4 9-8208 125 40 25 0,64 0,187 4,8 65 4,5 55 170 0,40 0,2 5,1

0,188 4,8 9-8208 132 40 20 0,51 0,187 4,8 65 4,5 55 170 0,60 0,2 5,1

0,25 6,4 9-8208 130 40 15 0,38 0,187 4,8 65 4,5 55 170 1,00 0,2 5,1

0,375 9,5 9-8208 130 40 10 0,25 0,187 4,8 65 4,5 55 170 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Plasma Gas

Press

Flow (CFH) Pierce Pierce Height

Type Torch: SL100 With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff

Inches

0,032 0,8 9-8208 116 40 220 5,59 0,187 4,8 65 4,5 55 170 0,00 0,2 5,1

0,051 1,3 9-8208 116 40 210 5,33 0,187 4,8 65 4,5 55 170 0,00 0,2 5,1

0,064 1,6 9-8208 118 40 180 4,57 0,187 4,8 65 4,5 55 170 0,10 0,2 5,1

0,079 2,0 9-8208 116 40 150 3,81 0,19 4,8 65 4,5 55 170 0,30 0,2 5,1

0,125 3,2 9-8208 130 40 75 1,91 0,19 4,8 65 4,5 55 170 0,40 0,2 5,1

0,188 4,8 9-8208 132 40 60 1,52 0,187 4,8 65 4,5 55 170 0,60 0,2 5,1

0,250 6,4 9-8208 134 40 28 0,71 0,187 4,8 65 4,5 55 170 1,00 0,2 5,1

0,375 9,5 9-8208 143 40 11 0,28 0,187 4,8 65 4,5 55 170 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Plasma Gas

Press

Flow (CFH) Pierce Pierce Height

300X5397 OPERATION

4T-13

ESAB CUTMASTER 100

Type Torch: SL100 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,060 1,5 9-8210 124 60 250 6,35 0,19 4,8 70 4,8 90 245 0,00 0,2 5,1

0,075 1,9 9-8210 126 60 237 6,02 0,19 4,8 70 4,8 90 245 0,10 0,2 5,1

0,120 3,0 9-8210 126 60 230 5,84 0,19 4,8 70 4,8 90 245 0,10 0,2 5,1

0,135 3,4 9-8210 128 60 142 3,61 0,19 4,8 70 4,8 90 245 0,10 0,2 5,1

0,188 4,8 9-8210 128 60 125 3,18 0,19 4,8 70 4,8 90 245 0,20 0,2 5,1

0,250 6,4 9-8210 123 60 80 2,03 0,19 4,8 70 4,8 90 245 0,30 0,2 5,1

0,375 9,5 9-8210 132 60 34 0,86 0,19 4,8 70 4,8 90 245 0,50 0,2 5,1

0,500 12,7 9-8210 137 60 23 0,58 0,19 4,8 70 4,8 90 245 0,75 0,2 5,1

0,625 15,9 9-8210 139 60 14 0,36 0,19 4,8 70 4,8 90 245 NR NR NR

0,750 19,1 9-8210 145 60 14 0,36 0,19 4,8 70 4,8 90 245 NR NR NR

1,000 25,4 9-8210 156 60 4 0,10 0,19 4,8 70 4,8 90 245 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,06 1,5 9-8210 110 60 165 4,19 0,13 3,2 70 4,8 90 245 0,00 0,20 5,1

0,075 1,9 9-8210 116 60 155 3,94 0,13 3,2 70 4,8 90 245 0,10 0,20 5,1

0,120 3,0 9-8210 115 60 125 3,18 0,13 3,2 70 4,8 90 245 0,10 0,20 5,1

0,135 3,4 9-8210 118 60 80 2,03 0,13 3,2 70 4,8 90 245 0,10 0,20 5,1

0,188 4,8 9-8210 120 60 75 1,91 0,13 3,2 70 4,8 90 245 0,20 0,20 5,1

0,250 6,4 9-8210 121 60 60 1,52 0,13 3,2 70 4,8 90 245 0,30 0,20 5,1

0,375 9,5 9-8210 129 60 28 0,71 0,13 3,2 70 4,8 90 245 0,50 0,20 5,1

0,500 12,7 9-8210 135 60 17 0,43 0,19 4,8 70 4,8 90 245 0,75 0,20 5,1

0,625 15,9 9-8210 135 60 14 0,36 0,19 4,8 70 4,8 90 245 NR NR NR

0,750 19,1 9-8210 142 60 10 0,25 0,19 4,8 70 4,8 90 245 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Type Torch: SL100 With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,060 1,5 9-8210 105 60 350 8,89 0,13 3,2 70 4,8 90 245 0,00 0,20 5,1

0,075 1,9 9-8210 110 60 350 8,89 0,13 3,2 70 4,8 90 245 0,10 0,20 5,1

0,120 3,0 9-8210 110 60 275 6,99 0,13 3,2 70 4,8 90 245 0,10 0,20 5,1

0,188 3,4 9-8210 122 60 140 3,56 0,13 3,2 70 4,8 90 245 0,20 0,20 5,1

0,250 6,4 9-8210 134 60 80 2,03 0,19 4,8 70 4,8 90 245 0,30 0,20 5,1

0,375 9,5 9-8210 140 60 45 1,14 0,19 4,8 70 4,8 90 245 0,50 0,20 5,1

0,500 12,7 9-8210 144 60 26 0,66 0,19 4,8 70 4,8 90 245 0,80 0,20 5,1

0,625 15,9 9-8210 145 60 19 0,48 0,19 4,8 70 4,8 90 245 NR NR NR

0,750 19,1 9-8210 150 60 15 0,38 0,19 4,8 70 4,8 90 245 NR NR NR

4T-14

OPERATION 300X5397

ESAB CUTMASTER 100

Type Torch: SL100 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,060 1,5 9-8211 128 80 280 7,11 0,19 4,8 65 4,5 11 5 340 0,00 0,2 5,1

0,120 3,0 9-8211 126 80 203 5,16 0,19 4,8 65 4,5 11 5 340 0,10 0,2 5,1

0,135 3,4 9-8211 128 80 182 4,62 0,19 4,8 65 4,5 11 5 340 0,10 0,2 5,1

0,188 4,8 9-8211 128 80 137 3,48 0,19 4,8 65 4,5 11 5 340 0,20 0,2 5,1

0,250 6,4 9-8211 131 80 100 2,54 0,19 4,8 65 4,5 11 5 340 0,30 0,2 5,1

0,375 9,5 9-8211 134 80 40 1,02 0,19 4,8 65 4,5 115 340 0,50 0,2 5,1

0,500 12,7 9-8211 136 80 36 0,91 0,19 4,8 65 4,5 11 5 340 0,60 0,2 5,1

0,625 15,9 9-8211 145 80 21 0,53 0,19 4,8 65 4,5 11 5 340 0,75 0,2 5,1

0,750 19,1 9-8211 144 80 14 0,36 0,19 4,8 65 4,5 11 5 340 NR NR NR

0,875 22,2 9-8211 149 80 11 0,28 0,19 4,8 65 4,5 11 5 340 NR NR NR

1,000 25,4 9-8211 162 80 8 0,20 0,19 4,8 65 4,5 11 5 340 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,060 1,5 9-8211 11 0 80 340 8,50 0,125 3,2 65 4,5 11 5 340 0,00 0,2 5,1

0,120 3,0 9-8211 11 5 80 260 6,50 0,125 3,2 65 4,5 11 5 340 0,10 0,2 5,1

0,135 3,4 9-8211 11 3 80 250 6,25 0,125 3,2 65 4,5 11 5 340 0,10 0,2 5,1

0,188 4,8 9-8211 11 4 80 170 4,25 0,125 3,2 65 4,5 11 5 340 0,20 0,2 5,1

0,250 6,4 9-8211 11 6 80 85 2,13 0,125 3,2 65 4,5 11 5 340 0,30 0,2 5,1

0,375 9,5 9-8211 123 80 45 1,13 0,125 3,2 65 4,5 115 340 0,40 0,25 6,4

0,500 12,7 9-8211 133 80 18 0,45 0,125 3,2 65 4,5 11 5 340 0,75 0,25 6,4

0,625 15,9 9-8211 135 80 16 0,40 0,125 3,2 65 4,5 11 5 340 1,00 0,25 6,4

0,750 19,1 9-8211 144 80 8 0,20 0,125 3,2 65 4,5 115 340 NR NR NR

0,875 22,2 9-8211 137 80 8 0,20 0,125 3,2 65 4,5 115 340 NR NR NR

1,000 25,4 9-8211 140 80 8 0,20 0,125 3,2 65 4,5 115 340 NR NR NR

Type Torch: SL100 With Shielded Tip

Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0,06 1,5 9-8211 115 80 320 8,13 0,13 3,2 65 4,5 11 5 340 0,00 0,25 6,4

0,12 3,0 9-8211 120 80 240 6,10 0,13 3,2 65 4,5 11 5 340 0,10 0,25 6,4

0,188 4,8 9-8211 120 80 165 4,19 0,13 3,2 65 4,5 115 340 0,20 0,25 6,4

0,250 6,4 9-8211 124 80 100 2,54 0,13 3,2 65 4,5 115 340 0,30 0,25 6,4

0,375 9,5 9-8211 138 80 60 1,52 0,19 4,8 65 4,5 115 340 0,40 0,25 6,4

0,500 12,7 9-8211 141 80 36 0,91 0,19 4,8 65 4,5 11 5 340 0,60 0,25 6,4

0,625 15,9 9-8211 142 80 26 0,66 0,19 4,8 65 4,5 11 5 340 0,75 0,25 6,4

0,750 19,1 9-8211 150 80 18 0,46 0,19 4,8 65 4,5 11 5 340 NR NR NR

0,875 22,2 9-8211 156 80 8 0,20 0,19 4,8 65 4,5 11 5 340 NR NR NR

1,000 25,4 9-8211 164 80 6 0,15 0,19 4,8 65 4,5 11 5 340 NR NR NR

300X5397 OPERATION

4T-15

ESAB CUTMASTER 100

Type Torch: SL100 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff

Inches

0,250 6,4

0,375 9,5 9-8212 127 100 75 1,90 0,180 4,6 75 5,2 130 390 0,5 0,200 5,1

0,500 12,7 9-8212 132 100 50 1,30 0,180 4,6 75 5,2 130 390 0,6 0,200 5,1

0,625 15,9 9-8212 136 100 30 0,75 0,180 4,6 75 5,2 130 390 0,8 0,200 5,1

0,750 19,0 9-8212 140 100 18 0,45 0,190 4,8 75 5,2 130 390 2,0 0,225 5,7

1,000 25,4 9-8212 147 100 10 0,25 0,190 4,8 75 5,2 130 390 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

9-8212

124

100

110

2,80

0,180

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,250 6,4 9-8212 121 100 110 2,80 0,125 3,2 75 5,2 130 390 0,5 0,200 5,1

0,375 9,5 9-8212 125 100 60 1,50 0,150 3,8 75 5,2 130 390 0,8 0,200 5,1

0,500 12,7 9-8212 132 100 35 0,90 0,150 3,8 75 5,2 130 390 1,0 0,200 5,1

0,625 15,9 9-8212 137 100 20 0,50 0,150 3,8 75 5,2 130 390 2,0 0,225 5,7

0,750 19,0 9-8212 144 100 15 0,40 0,190 4,8 75 5,2 130 390 NR NR NR

1,000 25,4 9-8212 154 100 8 0,20 0,190 4,8 75 5,2 130 390 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

Plasma Gas

Press

4,6 75 5,2 130 390

Flow (CFH) Pierce Pierce Height

0,4 0,200

5,1

Type Torch: SL100 With Shielded Tip

Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches

0,250 6,4 9-8212 120 100 120 3,05 0,180 65 4,5 105 360 0,2 0,225 5,7

0,375 9,5 9-8212 128 100 65 1,65 0,180 65 4,5 105 360 0,4 0,225 5,7

0,500 12,7 9-8212 130 100 45 1,15 0,180 65 4,5 105 360 0,5 0,225 5,7

0,625 15,9 9-8212 135 100 30 0,75 0,180 65 4,5 105 360 0,8 0,225 5,7

0,750 19,0 9-8212 140 100 25 0,65 0,180 65 4,5 105 360 1,0 0,225 5,7

1,000 25,4 9-8212 148 100 10 0,25 0,190 65 4,5 105 360 NR NR NR

(Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

NOTE!

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to Section "Set Operating Pressure" on page <?>.

** Total ow rate includes plasma and secondary gas ow.

4T-16

OPERATION 300X5397

This Page Intentionally Blank

ESAB CUTMASTER 100

300X5397 OPERATION

4T-17

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;

6703581; D496842; D511280; D492709; D499620; D504142

Other Pat(s) Pending 9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8241 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8243 Shield Cap US Pat No(s) 6914211; D493183 Other Pat(s) Pending 9-8235 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8236 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633 Other Pat(s) Pending 9-8238 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8239 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8244 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending

4T-18

OPERATION 300X5397

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 9-8239 Shield Cap 9-8244 Shield Cap 9-8245 Shield Cap

300X5397 OPERATION

4T-19

ESAB CUTMASTER 100

This Page Intentionally Blank

4T-20

OPERATION 300X5397

SECTION 5 SYSTEM: SERVICE

Art # A-07938_AB

5.01 General Maintenance

ESAB CUTMASTER 100

Warning! Disconnect input power before maintaining.

Visual check of torch tip and electrode

Visually inspect the torch body tip, electrode, start cartridge and shield cup

Maintain more often if used under severe conditions

Each Use

Weekly

Visually inspect the cables and leads. Replace as needed

Replace all broken parts

3 Months

Clean exterior of power supply

6 Months

Visually check and Carefully clean the interior

300X5397 SERVICE

5-1

ESAB CUTMASTER 100

5.02 Maintenance Schedule

NOTE!

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Cutting

Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Check plasma and secondary supply and pres-

sure/ow.

3. Purge plasma gas line to remove any moisture build-up.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air

ow.

2. Inspect torch for any cracks or exposed wires, replace if necessary.

3. Inspect input power cable for damage or exposed wires, replace if necessary.

5.03 Common Faults

Problem Symptom

Insufcient

Penetration

Main Arc

Extinguishes

Excessive Dross

Formation

1. Cutting speed too fast.

2. Torch tilted too much.

3. Metal too thick.

4. Worn torch parts

5. Cutting current too low.

6. Non - Genuine ESAB parts used

7. Incorrect gas pressure

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Cutting current too high.

4. Work cable disconnected.

5. Worn torch parts.

6. Non - Genuine ESAB parts used

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine ESAB parts used

6. Incorrect gas pressure

Common Cause

Six Months or Every 720 Cutting Hours:

1. Check the in-line air lter(s), clean or replace as

required.

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, replace if necessary.

4. Vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

Short Torch Parts

Life

Difcult Starting 1. Worn torch parts.

1. Oil or moisture in air source.

2. Exceeding system capability (material too thick).

3. Excessive pilot arc time

4. Gas pressure too low.

5. Improperly assembled torch.

6. Non - Genuine ESAB parts used

2. Non - Genuine ESAB parts used.

3. Incorrect gas pressure.

5-2

SERVICE 300X5397

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 rst 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. In the example below the Temp indicator and 75 psi indicators are on indicating the version would be 2.3.

MAX

MIN

PSI BAR

MAXMAX

MINMIN

Art# A-07988

When the "Fault" indicator is ON or blinking it will be accompanied by one of the pressure indicator lights

depending on what the Fault is. The following table explains each of those Faults.

Pressure

Fault

Indicator

Max Over Pressure

90 Internal Error

85 Check Consumables

80 Consumables Missing

75 Start Error

70 Parts in Place

65 Input Power

Min Under Pressure

NOTE!

Fault explanations are covered in the following tables.

300X5397 SERVICE

5-3

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 Recommended Action

ON / OFF Switch is ON but the A/C Indicator does not light

1. Primary power disconnect is in OFF position.

2. Primary fuses / breakers are blown or tripped.

3. Units internal fuse blown.

4. Faulty components in unit.

1. Turn primary power disconnect switch to ON position.

2. a) Have qualied person check primary fuses / breakers. b) Connect unit to known good primary power receptacle

3. a) Replace fuse. b) If fuse blows again, return to authorized service center for repair or replacement.

4. Return to authorized service center for repair or replacement.

Fault indicator

ashing, 65 PSI indicator ashing

TEMPERATURE indicator ON. FAULT

indicator ashing.

GAS LED OFF, FAULT and MIN pressure indicators

ashing.

FAULT and 70 PSI

indicators ashing.

1. Improper Input Voltage.

2. Primary input voltage problem.

3. Faulty components in unit.

1. Air ow through or around the unit

is obstructed.

2. Duty cycle of the unit has been exceeded

3. Failed components in unit

1. Gas supply not connected to unit.

2. Gas supply not turned ON.

3. Gas supply pressure too low.

4. AIR PRESSURE CONTROL regulator set too low.

5. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to power supply.

3. Problem in torch and leads PIP circuit.

4. Failed components in unit.

1. Check for proper primary input voltage.

2. Have qualied person check primary voltage to insure it meets

unit requirements see section 2.05.

3. Return to authorized service center for repair or replacement.

1. Refer to clearance information – section 2.04

2. Allow unit to cool.

3. Return to authorized service center for repair or replacement.

1. Connect gas supply to unit.

2. Turn gas supply ON.

3. Set air supply inlet pressure to unit to 120 psi.

4. Adjust regulator to set air pressure - see section 4.02.

5. Return to authorized service center for repair or replacement.

1. Hand tighten the shield cup until it is snug.

2. Insure torch ATC is securely fastened to unit.

3. Replace torch and leads or return to authorized service center for repair or replacement.

4. Return to authorized service center for repair or replacement.

FAULT and 75 PSI

indicators ashing.

5-4

SERVICE 300X5397

1. Start signal is active when ON/OFF SWITCH is turned to ON position.

2. Problem in the torch and leads switch circuit.

3. Failed components in unit.

1. Start can be active for one of the following:

• Hand torch switch held closed

• Hand pendant switch held closed

• CNC START signal is active low Release the START signal source

2. Replace torch and leads or return to authorized service center for repair or replacement.

3. Return to authorized service center for repair or replacement.

Problem - Symptom Possible Cause Recommended Action

FAULT & 80 PSI

indicators ashing. Gas ow is cycling

ON and OFF.

1. Torch shield cup is loose.

2. Torch tip, electrode or starter cartridge missing.

3. Torch starter cartridge is stuck.

4. Open conductor in torch leads.

5. Problem in the torch and leads switch circuit.

6. Failed components in unit.

1. Tighten shield cup by hand. Do not overtighten.

2. Turn OFF power supply. Remove shield cup. Install missing parts.

3. Turn OFF power supply. Bleed down system pressure. Remove shield cup, tip and starter cartridge. Check starter

cartridge lower end tting for free movement. Replace if tting

does not move freely.

4. Replace torch and leads or return to authorized service center for repair or replacement.

5. Replace torch and leads or return to authorized service center for repair or replacement.

6. Return to authorized service center for repair or replacement.

ESAB CUTMASTER 100

Nothing happens when torch switch or remote switch

is closed (Or CNC

START signal is

active) No gas ow,

DC LED OFF.

FAULT and 85 PSI

indicators ashing.

No Fault lights ON, no arc in torch.

Fault and 90 PSI

indicators ashing

1. Problem in the torch and leads

switch circuit (Remote pendant switch

circuit).

2. CNC Controller device not providing Start signal.

3. Failed components in unit.

1. Upper O-Ring on torch head is in wrong position.

2. Torch starter cartridge is stuck.

3. Worn or faulty torch parts.

4. Shorted Torch.

5. Temporary Short indicated by 5 blinks per second.

6. Power Supply Failure (Standard

rate of blinking)

1. Failed components in unit. 1. Return to an authorized service center for repair.

1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that

1. Take Torch and Leads (Remote Pendant) to Authorized

Repair Facility.

2. Contact Controller manufacturer.

3. Return to authorized service center for repair or replacement.

1. Remove shield cup from torch; check upper O-Ring position; correct if necessary.

2. Turn OFF power supply. Bleed down system pressure. Remove shield cup, tip and starter cartridge. Check starter

cartridge lower end tting for free movement. Replace if tting

does not move freely.

3. Inspect torch consumable parts. Replace if necessary.

4. Replace torch and leads or return to an authorized service center for repair.

5. Release torch switch and reactivate.

6. Return to authorized service center for repair or replacement.

does not clear the fault, return to an authorized service center for repair.

Pilot arc is ON but cutting arc will not establish

Torch cutting is diminished

1. Work cable not connected to work piece.

2. Work cable/connector broken.

3. Failed components in unit.

1. Incorrect current setting.

2. Worn torch consumables.

3. Poor work cable connection to work piece.

4. Torch being moved too fast.

5. Excessive oil or water in torch.

6. Failed components in unit.

1. Connect work cable.

2. Replace work cable.

3. Return to an authorized service center for repair.

1. Check and adjust to proper setting.

2. Check torch consumables and replace as needed.

3. Check the connection of the Work Lead to the work piece.

4. Reduce cutting speed.

5. Refer to "Check air quality" in section 3 Torch.

6. Return to an authorized service center for repair.

300X5397 SERVICE

5-5

ESAB CUTMASTER 100

Screws

5.06 Power Supply Basic Parts Replacement

WARNING

This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual.

A. Cover Removal

1. Remove the NOTE screws which secure the

Disconnect primary power to the system before disassembling the torch, leads, or power supply.

cover to the main assembly. Do not loosen the lower screws inside the cut out slots in the bottom of the cover.

Upper Screws

Lower

C. Filter Element Assembly Replacement

The Filter Element Assembly is in the rear panel. For

better system performance, the lter element should be checked per the Maintenance Schedule (Subsection

5.02), and either cleaned or replaced.

1. Remove power from the power supply; turn OFF the gas supply and bleed down the system.

2. Remove the system cover. See "A Cover Removal" in this section.

3. Locate the internal air line and the tting from the lter assembly. Number 1 in the following

illustration.

4. Hold a wrench or similar tool against the locking

ring on the lter assembly tting, then pull on the hose to release it. (Numbers 2 and 3 in the

following illustration).

Slots

Lower Screws

Art # A-08429

2. Carefully pull the Cover up and away from the unit.

B. Cover Installation

1. Reconnect the ground wire, if necessary.

2. Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws.

Art # A-07989

6mm

3. Tighten lower screws.

4. Reinstall and tighten the upper screws.

5-6

SERVICE 300X5397

ESAB CUTMASTER 100

Art # A-07990

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

5. Remove the tting from the lter element assembly by inserting a 6 mm hex wrench into the

internal hex tting and turning it counter clockwise (left). Numbers 4 and 5 in the previous

illustration.

6. Disconnect the input line from the lter element

assembly.

7. Remove the lter element assembly through the

rear opening.

NOTE!

If replacing or cleaning just the lter

element refer to the following illustration for disassembly.

Filter Element

4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located inside the Housing.

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and set Element aside to dry.

8. Install the new or cleaned assembly by reversing these procedures.

9. Turn ON the air supply and check for leaks before reinstalling the cover.

Optional Single-Stage Filter Element

Replacement

These instructions apply to power supplies where the optional Single-Stage Filter has been installed.

The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer

to Section 6, Parts List, for replacement lter element

catalog number.

6. Wipe inside of housing clean, then insert the

replacement Filter Element open side rst.

7. Replace Housing on Cover.

8. Reattach gas supply.

NOTE!

If unit leaks between housing and cover, inspect the O-ring for cuts or other damage.

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

lter element catalog number.

1. Shut OFF primary input power.

2. Shut OFF air supply and bleed down system.

1. Remove power from power supply.

2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter Element.

3. Disconnect gas supply hose.

300X5397 SERVICE

5-7

ESAB CUTMASTER 100

First & Second

WARNING

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

4. Note the location and orientation of the old Filter Elements.

5. Slide out the old Filter Elements.

Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could result.

Stage Cartridges (as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above.

7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque

may damage the gasket.

8. Slowly apply air pressure to the assembly, checking for leaks.

NOTE!

A small amount of air leakage from the bottom tting is normal.

This completes the parts replacement procedures.

5-8

SERVICE 300X5397

SECTION 5 TORCH:

Must Remain Open

Lower O-Ring

Art # A-03725

ATC Male Connector

Art #A-03791_AB

Gas Fitting

O-Ring #8-0525

SERVICE

ESAB CUTMASTER 100

5T.01 General Maintenance

NOTE!

Refer to Previous "Section 5: System" for common and fault indicator descriptions.

Cleaning Torch

Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.

WARNING

Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

Upper Groove with Vent Holes

Upper O-Ring in Correct Groove

Threads

Torch Head O-Ring

The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.

CAUTION

Dry the torch thoroughly before reinstalling.

O-Ring Lubrication

An o-ring on the Torch Head and ATC Male Connector requires lubrication on a scheduled basis. This will allow the o-rings to remain pliable and provide a proper seal. The o-rings will dry out, becoming hard and cracked if the lubricant is not used on a regular basis. This can lead to potential performance problems.

It is recommended to apply a very light lm of oring lubricant (Catalog # 8-4025) to the o-rings on

a weekly basis.

ATC O-Ring

NOTE!

DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.

300X5397 SERVICE

5T-9

ESAB CUTMASTER 100

Art # A-08067

Drag Shield Cap

Good Tip

Worn Tip

A-03406

Art # A-08064_AC

Spring-Loaded

Spring-Loaded Lower End Fitting at Reset

Worn Electrode

New Electrode

Art # A-03284

5T.02 Inspection and Replacement

of Consumable Torch Parts

WARNING

Disconnect primary power to the

Remove the consumable torch parts as follows:

1. Unscrew and remove the shield cup from the

system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

NOTE!

The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed.

torch.

4. Remove the tip. Check for excessive wear

(indicated by an elongated or oversized orice).

Clean or replace the tip if necessary.

Example of Tip Wear

5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end tting for free motion. Replace if necessary.

Lower End Fitting Full Compression

Full Extension

NOTE!

Slag built up on the shield cup that cannot be removed may effect the performance of the system.

2. Inspect the cup for damage. Wipe it clean or replace if damaged.

Shield Cups

3. On torches with a shield cup body and a shield

cap or deector, ensure that the cap or deector

is threaded snugly against the shield cup body.

In shielded drag cutting operations (only), there

may be an O-ring between the shield cup body and drag shield cap. Do not lubricate the O-ring.

Shield

Cup Body

6. Pull the Electrode straight out of the Torch Head. Check the face of the electrode for excessive

wear. Refer to the following gure.

Electrode Wear

7. Reinstall the Electrode by pushing it straight into

the torch head until it clicks.

8. Reinstall the desired starter cartridge and tip into

the torch head.

9. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.

O-Ring No. 8-3488

Art # A-03878

5T-10

SERVICE 300X5397

This completes the parts replacement procedures.

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:

Section "6.03 Power Supply Replacement"

Section "6.04 Replacement Power Supply Parts"

Section "6.05 Options and Accessories"

Section "6.06 Replacement Parts for Hand Torch"

Section "6.07 Replacement Parts - for Machine Torches with Unshielded Leads"

Section "6.08 Torch Consumable Parts (SL100)"

NOTE!

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns

If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for each type item. Also include the model and serial number of the power supply. Address all inquiries to your authorized distributor.

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas

pressure regulator / lter, and operating manual.

Qty Description Catalog #

1 ESAB Cutmaster 100 CE Power Supply with 400VAC, 3 phase 50/60 Hz, with input power cable 0559317304

6.04 Replacement Power Supply Parts

Qty Description Catalog #

1 Regulator 9-0115 1 Filter Assembly Replacement Element 9-0116 1 Input Power Cord for 380/400 V Power Supply 9-0216

300X5397 PARTS LIST

6-1

ESAB CUTMASTER 100

led Filter

(Cat.

First & Second

6.05 Options and Accessories

Qty Description Catalog #

1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507

1 Replacement Filter Body 9-7740

1 Replacement Filter Hose (not shown) 9-7742

2 Replacement Filter Element 9-7741 1 Two - Stage Filter Kit (includes Hose & Mounting Screws) 9-9387 1 Two - Stage Air Filter Assembly 9-7527 1 First Stage Cartridge 9-1021 1 Second Stage Cartridge 9-1022 1 Extended Work Cable (50 ft / 15.2 m) with Clamp 9-8529 1 Automation Interface Kit for Start/Stop, OK to move and Divided Arc Voltage) 9-8311 1 Automation Harness for Start/Stop and OK to move 9-9385 1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008 1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010 1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011 1 Remote pendant 7-3460 1 Simple Automation Interface 9-9385

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

No. 9-7743)

Cover

Barbed

Fitting

Assemb

Art # A-02476

Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

Stage Cartridges (as marked)

Art # A-02942

6-2

PARTS LIST 300X5397

ESAB CUTMASTER 100

6.06 Replacement Parts for Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030

2 1 Trigger Assembly Replacement Kit 9-7034

3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219

5 1 Large O-Ring 8-3487 6 1 Small O-Ring 8-3486

7 Leads Assemblies with ATC connectors (includes switch assemblies)

1 SL100, 20 - foot Leads Assembly with ATC connector 4-7836 1 SL100, 50 - foot Leads Assembly with ATC connector 4-7837 8 1 Switch Kit 9-7031

10 1 Torch Control Cable Adapter (includes item # 11) 7-3447

11 1 Through - Hole Protector 9-8103

300X5397 PARTS LIST

Art # A-07993_AB

6-3

ESAB CUTMASTER 100

6.07 Replacement Parts - for Machine Torches with Unshielded Leads

Item No. Qty Description Catalog #

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220

2 1 Large O-Ring 8-3487 3 1 Small O-Ring 8-3486 4 1 PIP Switch Kit 9-7036 5 Unshielded Automated Leads Assemblies with ATC connectors 1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850 1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851 1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852 1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853 6 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842 1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843 1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844 1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845 7 1 11” / 279 mm Rack 9-7041 8 1 11” / 279 mm Mounting Tube 9-7043 9 1 End Cap Assembly 9-7044 10 2 Body, Mounting, Pinch Block 9-4513 11 1 Pin, Mounting, Pinch Block 9-4521 12 1 Torch Holder Sleeve 7-2896 13 1 PIP Plunger and Return Spring Kit 9-7045

1 Pinion Assembly (Not shown) 7-2827 1 5” / 126 mm Positioning Tube (Not shown) 9-7042

NOTE!

*Does not include Control Cable Adapter or Through - Hole Protector.

6-4

PARTS LIST 300X5397

ESAB CUTMASTER 100

5 & 6

A-07994_AB

300X5397 PARTS LIST

6-5

ESAB CUTMASTER 100

, Deflector

6.08 Torch Consumable Parts (SL100)

Ohmic Clip

Manual Torch

9-8259

Ohmic Clip

Automation To rch

9-8224

Electrode

Auto 9-8232

Manual 9-8215

Starter

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Starter Cartridge

Non HF Only 9-8277

70-120A

STANDOFF

CUTTING

Tip:

20A 9-8205 30A 9-8206 40A 9-8208

Tips:

50-55A 9-8209

60A 9-8210

Tips:

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine 40A 9-8245

Shield Cap 9-8243

Drag Shield Cup 9-8235

Shield Cap, Machine 50-60A 9-8238

Shield Cap 9-8243

Drag Shield Cup 70-100A 9-8236

Drag Shield Cup 120A 9-8258

Shield Cap, Machine 70-100A 9-8239

Shield Cap, Machine 120A 9-8256

Shield Cap 9-8243

40-120A

GOUGING

Tips:

Tip A 9-8225 (40 Amps Max.)

Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Art # A-08066_AG

6-6

PARTS LIST 300X5397

Tip E 9-8254 (60 - 120 Amps)

Shield

Cup Body,

9-8237

Shield Cup, Gouging

9-8241

ESAB CUTMASTER 100

This Page Intentionally Blank

300X5397 PARTS LIST

6-7

ESAB CUTMASTER 100

This Page Intentionally Blank

6-8

PARTS LIST 300X5397

ESAB CUTMASTER 100

APPENDIX 1: SEQUENCE OF OPERATION (BLOCK

DIAGRAM)

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

Connect work cable to workpiece.

Set output amperage.

System is ready

for operation.

ON / OFF switch to ON

AC indicator ON.

GAS indicator ON

pressure is adequate

for power supply operation.

ACTION:

RESULT:

ACTION:

RESULT:

when input

Power circuit ready.

ACTION:

RUN / Rapid Auto Restart / SET / LATCH switch

to SET

RESULT:

Gas flows to set

pressure.

Torch moved away from work (while

ACTION:

RUN / Rapid Auto Restart /

SET / LATCH

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

or to

LATCH

is used for specific applications

(torch switch can be released

after main arc transfer).

RESULT: Gas flow stops.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate

Torch switch (START)

RESULT:

Fans turn on. Gas flows briefly,

then stops.Gas restarts.

DC indicator ON

Pilot arc established.

ACTION:

Release Torch switch.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

(Fans will continue to run for

10 minutes after the Torch switch

[START] is removed)

PILOT ARC

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fans shut off.

Main arc stops.

Pilot arc automatically

restarts.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

Art #A-08793

300X5397 APPENDIX

A-1

ESAB CUTMASTER 100

1/ 3

Mo de l:

1max 1eff

3Ø

3Ø1Ø

1Ø

S/N

Standard Symbols

Phase

NOTES:

1. Symbol shown indicates single- or three-phase AC input, static frequency converter-transformer-rectifier, DC output.

2. Indicates input voltages for this power supply. Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built.

3. Top row: Duty cycle values. IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission. Duty cycle value is determined under the power supply manufacturer's test procedures. Second row: Rated cutting current values. Third row: Conventional load voltage values.

4. Sections of the Data Tag may be applied to separate areas of the power supply.

Art # A-12765_AB

Da te of Mf r:

Output Range (Amperage/ Voltage)

Type of Power Supply (Note 1)

Output Current Type

Rated NoLoad Voltage

Plasma Cutting Symbol

Manufacturer's Name and/or Logo, Location, Model and Serial Number and Production Code

Conventional Load Voltage

Regulatory Standard Covering This Type of Power Supply

Duty Cycle Data (Note 3)

Duty Cycle Factor

Input Power Specifications (Phase, AC or DC Hertz Rating)

Input Power Symbol

Rated Supply Voltage (Note 2)

Rated Maximum Supply Current

Maximum Effective Supply Current

Degree of Protection

APPENDIX 2: DATA TAG INFORMATION

A-2

APPENDIX 300X5397

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

ATC Female Receptacle

Front View

Pilot

6 - Open

7 - Open

8 - Open

5 - Open

Negative / Plasma

6 - Open

7 - Open

5 - Open

2 - PIP

3 - Switch

4 - Switch

1 - PIP

4 - Green / Switch

2- Orange / PIP

3 - White / Switch

1 - Black / PIP

Negative / Plasma

8 - Open

ATC Male Connector

Front View

A-03701_AB

ATC Female Receptacle

Front View

ATC Male Connector

Front View

Negative / Plasma

3 - White Pendant Connector

4- Black Pendant Connector

2 - Orange / PIP

1 - Black / PIP

Pilot

2 - PIP

1 - PIP

6 - Open

7 - Open

5 - Open

8 - Ground

8 - Green Pendant Connector Ground

5 - White / Not Used

7 - Green / Not Used

6 - Open

UNSHIELDED MACHINE TORCH

3 - Switch

4 - Switch

Art # A-03799

Negative / Plasma

Pilot

A. Hand Torch Pin - Out Diagram

B. Mechanized (Machine) Torch Pin - Out Diagram

ESAB CUTMASTER 100

300X5397 APPENDIX

A-3

ESAB CUTMASTER 100

Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle

Pilot

Negative / Plasma

Power Supply

PIP

Switch

Male

ATC Leads

Connector

ATC Female

Receptacle

Pilot

Negative / Plasma

Black

Orange

Torch Leads

Torch

Head

To Power Supply

Circuitry

Art # A-03797_AB

Torch

Switch

Green

White

To Power Supply

Circuitry

To rch: Unshielded Mechanized SL100 Machine To rch Leads: Leads with ATC Connector and Remote Pendant Connector Power Supply: with ATC Female Receptacle

Pilot

Negative / Plasma

Power Supply

To Remote Control

Remote

Pendant

Connector

PIP

Switch

Not

Used

Male

AT C Leads

Connector

AT C Female

Receptacle

Pilot Lead

Negative / Plasma Lead

Torch Leads

Torch

Head

Art # A-03798

To Power Supply

Circuitry

Green

To Power Supply

Circuitry

Black

White

Green

Black

Orange

White

APPENDIX 4: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

B. Mechanized Torch Connection Diagram

A-4

APPENDIX 300X5397

ESAB CUTMASTER 100

This Page Intentionally Blank

300X5397 APPENDIX

A-5

ESAB CUTMASTER 100

APPENDIX 5: SYSTEM SCHEMATIC, 400V UNITS

J1J1

SW1SW1

1 3

1 2

2 3

3 4

2 4

MOT1MOT1

FAN

+ -

SOL 1SOL 1

W1W1

SERIAL PORT

+12VDC

K1K1

/INRUSH

W1W1

+12VDC

J7J7

1 2

J5J5

1 2

2 3

J6J6

1 2

1 2 3 4 5

/FAN

/SOLENOID

24VAC

24VAC RET

J4J4

3.3VDC

TXD

RXD

1 /OVERTEMP

2 /FAN_ON

3 /CSR

4 CUR_SET

5 MAIN_PCB_ID

6 COMMON

J13J13

12345

GND

380/400/415V

380/400/415V OR 600V

OR 600V 3 PH AC INPUT

3 PH AC INPUT

PRIMARY POWER CONNECTIONS:

PRIMARY POWER CONNECTIONS: USE L1, L2, L3 & GND

USE L1, L2, L3 & GND

CE UNITS

CE UNITS ONLY

ONLY

EMI

CHOKE

EMI

EMI FILTER

FILTER

INRUSH

RESISTORS

SYNC

BIAS

BIAS SUPPLY

SUPPLY

T1T1

PRI 4 PRI 4

PRI 3PRI 3

PRI 2PRI 2

PRI 1PRI 1

C3,C4,C7,C8*+C3,C4,C7,C8*

C5,C6,C9,C10*+C5,C6,C9,C10*

MTH2MTH2

TP1TP1

MTH2MTH2

TP1TP1

MTH4MTH4

TP5TP5

MTH4MTH4

TP5TP5

MTH8MTH8

TP4TP4

MTH8MTH8

TP4TP4

TP3TP3

MTH6MTH6

PCB1

TP2TP2

MTH1MTH1

TP2TP2

J14J14

MTH1MTH1

+12VDC

+12VDC BIAS

BIAS SUPPLY

SUPPLY

MTH7MTH7

TP8TP8

MTH7MTH7

TP8TP8

AC1AC1

80A_AC180A_AC1

80A_AC280A_AC2

AC2AC2

80A_AC280A_AC2

AC2AC2

AC3AC3

80A_AC380A_AC3

AC3AC3

80A_AC380A_AC3

MAIN PCB ASSY

T2T2

FERRITE

FERRITE FILTER

MOT2MOT2

FAN

MOT3MOT3

FAN

A-12770_AA

FILTER

J4J4

123456789

J4J4

123456789

+12VDC

SYNC

40/50 AMP PCB

+12VDC

J9J9

+12VDC

J1J1

/FAN

J2J2

1 2

PCB5

+12VDC

J2J2

1 2

J3J3

AC1AC1

40A_AC140A_AC1

AC1AC1

40A_AC140A_AC1

AC2AC2

40A_AC240A_AC2

AC2AC2

40A_AC240A_AC2

AC3AC3

40A_AC340A_AC3

AC3AC3

40A_AC340A_AC3

PMTH1PMTH1

PMTH4PMTH4

PCB2

INPUT CAPACITOR PCB

C7 & C10 may not be installed

C16-17+C16-17

C12-13+C12-13

PMTH2PMTH2

PMTH3PMTH3

PMTH2PMTH2

PMTH3PMTH3

PRI 1 PRI 1

PRI 3PRI 3

PRI 4PRI 4

PRI 3PRI 3

PRI 2 PRI 2

PRI 4PRI 4

A-6

APPENDIX 300X5397

ESAB CUTMASTER 100

1TORCH

1 2

2 3

3 4

4 5

5 6

6 7

7 8

P2P2

1 2

2 3

3 4

4 5

5 6

6 7

7 8

J2J2

14 13

13 12

12 11

11 10

10 9

9 8

8 7

7 6

6 5

5 4

4 3

3 2

2 1

P1P1

E1E1

+12VDC

K1K1

PCB4

AUTOMATION

AUTOMATION INTERFACE PCB

INTERFACE PCB

1TORCH

TORCH SWITCHTORCH SWITCH

AUTOMATION

TORCH SOLENOID

OK TO MOVE

}

/START / STOP

}

123

PIP SWITCHPIP SWITCH

WORKWORK

CNC PINOUT

811

1214

To configure DIVIDED ARC VOLTS signal output

To configure DIVIDED ARC VOLTS signal output No jumper installed for ARC VOLTS / 16.67

No jumper installed for ARC VOLTS / 16.67 Jumper pins 1 & 2 for ARC VOLTS / 30

Jumper pins 1 & 2 for ARC VOLTS / 30 Jumper pins 2 & 3 for ARC VOLTS / 50

Jumper pins 2 & 3 for ARC VOLTS / 50

J1J1

1 2

2 3

/START / STOP

}

(-)

DIVIDED ARC VOLTS

}

(+)

(-)

ARC VOLTS

}

(W/ 100K IN SERIES (2))

(+)

9 10

10 11

11 12

OK-TO-MOVE

}

TS1TS1

L1L1

/START

/PIP

+12VDC

PILOT IGBTQ5PILOT IGBT

L1L1

ELECTRODE1ELECTRODE1

L2L2

-V OUT 1-V OUT 1

WORK1WORK1

ATC CONNECTOR

J1J1

1 2

2 3

3 4

4 5

5 6

6 7

7 8

E64

E35

TIP1TIP1

J9J9

5 6

J10J10

P10P10

J10J10

P10P10

1 2

2 3

5 6

6 7

40 PIN RIBBON CABLE SIGNALS

-V_OUT_SIGNAL

FERRITE

FERRITE FILTER

FILTER

-V_OUT_SIGNAL

/TIP_VOLTS

/TIP_SENSE

/460V_IN

/230V_IN

CUR_SET

/RAR (RAPID AUTO RESTART)

/INRUSH

/W1_ON

SHDN

/TORCH_SOLENOID

/SOLENOID_ON

/OK_TO_MOVE

/FAN_ON

/LATCH_ACTIVE

/TORCH_SWITCH

/PIP

AC_ON

CSR

/TORCH_SOLENOID_DETECT

/OVERTEMP

V_IN

+12VDC

COMMON

MAIN_PCB_ID

460_IN

+3.3VDC

TXD

RXD

COMMON

M-L

L-M

M-L

L-M

M-L

L-M

M-L

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

To -V OUT 1

To -V OUT 1 on PCB1

on PCB1

P10P10

3 4

4 5

J11J11

D59 PCRD59 PCR

D78 CSRD78 CSR

+12VDC

TEMP

/OVERTEMP

CIRCUIT

NTCNTC

TEST POINTS

GND1

COMMON

GND2

COMMON

+12V1

+12 VDC SUPPLY

48V1

+48 VDC SUPPLY

I_DMD_1

CURRENT DEMAND

TIP_SEN

TIP DRAG SENSE

SEC1SEC1

SEC2SEC2

CHOKE1CHOKE1

24VAC RETURN

24VAC SUPPLY

OK-TO-MOVE

(5A @ 250VAC / 30VDC)

Current ControlCurrent Control

LATCH

SET

RUN

RAR

ACAC

OVERTEMPOVERTEMP

GASGAS

DCDC

ERRORERROR

FAULT

ERROR IND

MAX

MIN

TEST POINTS

TP1

TP2

TP3

TP4

TP5

TP6

TP7

+12VDC

OVER PRESSURE

INTERNAL ERROR

SHORTED TORCH

CONSUMABLES MISSING

START ERROR

PARTS IN PLACE

INPUT POWER

UNDER PRESSURE

GND

+12 VDC

+5 VDC

3.3 VDC

0.v - 5.0 VDC / 0-100PSI

1.8 VDC

CURRENT DEMAND

D1D1

LOGIC PCB

PCB3

SEE A-09130

INTRO ECO B1357

ECO B1399RWH

ECO B1611 RWH

Last Modified:

Friday, December 11, 2009

0-100PSI / 0-4.5VDC

+5VDC

RWH

MAXMAX

9090

8585

8080

7575

7070

6565

AIR

INLET

MINMIN

J3J3

3 2

2 1

DateByRevisionsRev

03/31/09

05/05/09

NOTE:

TITLE:

09:02:19

GAS CONTROL

REGULATOR

FILTER

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Capacitors are in Microfarads (UF)

SCHEMATIC, ESAB Cutmaster 100/120 20'/50' SL100 400V/208-460V

3ph CE/Non-CE CCC/ 1/3ph CSA (Configured for 460V 3ph)

SOLENOID

VALVE

PRESSURE

TRANSDUCER

123

ATC

A-12770_AA

PCB No:

Assy No:

SupersedesScale

Date:

MARCH 30, 2009

Drawn: References

RWH

Chk: App:

DWG No:

Size

DWG No:

Size

DWG No:

Size

DWG No:

Size

DWG No:

Size

DWG No:

Size

42X1330

Sheet

SEC1SEC1

SEC2SEC2

SEC1SEC1

NTCNTC

CHOKE1CHOKE1

SEC2SEC2

CHOKE1CHOKE1

TEMP

/OVERTEMP

CIRCUIT

+OUT_1+OUT_1

300X5397 APPENDIX

A-7

ESAB CUTMASTER 100

Revision History

Date Rev Description

01/15/2015 AA Manual release

08/14/2015 AB

11/14/2015 AC Revised DoC, removed Printed in text

01/07/2019 AD

Updated art on cover, Updated DoC, added duty cycle values, removed Shielded Machine Torch Leads Assemblies

A-8

APPENDIX 300X5397

ESAB CUTMASTER 100

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300X5397 APPENDIX

A-9

ESAB CUTMASTER 100

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A-10

APPENDIX 300X5397

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ESAB subsidiaries and representative ofﬁces

Europe

AUSTRIA

ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V. Heist-op-den-Berg Tel: +32 70 233 075 Fax: +32 15 257 944

BULGARIA

ESAB Kft Representative Ofﬁce Soﬁa Tel/Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLAND

ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCE

ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03 ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A. Bareggio (Mi) Tel: +39 02 97 96 8.1 Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

NORWAY

AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL Bucharest Tel: +40 316 900 600 Fax: +40 316 900 601

RUSSIA

LLC ESAB Moscow Tel: +7 (495) 663 20 08 Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22 ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC Kiev Tel: +38 (044) 501 23 24 Fax: +38 (044) 575 21 88

North and South America

ARGENTINA

CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A. Contagem-MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48

Asia/Paciﬁc

AUSTRALIA

ESAB South Paciﬁc Archerﬁeld BC QLD 4108 Tel: +61 1300 372 228 Fax: +61 7 3711 2328

CHINA

Shanghai ESAB A/P Shanghai Tel: +86 21 2326 3000 Fax: +86 21 6566 6622

INDIA

ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929

JAPAN

ESAB Japan Tokyo Tel: +81 45 670 7073 Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Paciﬁc Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd Durbanvill 7570 - Cape Town Tel: +27 (0)21 975 8924

Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page www.esab.eu

www.esab.eu

ESAB Cutmaster 100 Plasma Cutting System Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.0 Safety Precautions

2.01 How To Use This Manual

2.03 Receipt Of Equipment

2.06 Power Supply Features

2T.01 Scope of Manual

2T.02 General Description

2T.05 Introduction to Plasma

2T.04 Options And Accessories

3.01 Unpacking

3.02 Lifting Options

3.03 Primary Input Power Connections

3.04 Gas Connections

3T.01 Torch Connections

3T.02 Setting Up Mechanical Torch

4.01 Front Panel Controls / Features

4.02 Preparations for Operation

4T.01 Torch Parts Selection

4T.02 Cut Quality

4T.03 General Cutting Information

4T.04 Hand Torch Operation

4T.05 Gouging

4T.06 Mechanized Torch Operation

4T.07 Parts Selection for SL100 Torch Cutting

4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip

4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip

PATENT INFORMATION

SECTION 5 SYSTEM: SERVICE

5.01 General Maintenance

5.02 Maintenance Schedule

5.03 Common Faults

5.04 Fault Indicator

5.05 Basic Troubleshooting Guide

5.06 Power Supply Basic Parts Replacement

5T.01 General Maintenance

SECTION 6: PARTS LISTS

6.01 Introduction

6.02 Ordering Information

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 Torch Consumable Parts (SL100)

APPENDIX 2: DATA TAG INFORMATION

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

APPENDIX 4: TORCH CONNECTION DIAGRAMS

APPENDIX 5: SYSTEM SCHEMATIC, 400V UNITS

Revision History