ESAB Cutmaster® 100
PLASMA CUTTING SYSTEM
SL100 1Torch™
Operating
Manual
Art # A-12772_AB
100
Revision: AB Issue Date: April 15, 2015 Manual No.: 0-5379
208/230V
400V
460V
esab.com.br
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.com.br.
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 0-5379
Published by:
ESAB
2800 Airport Rd.
Denton, TX 76208
www.esab.com.br
Copyright 2015 by ESAB
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the 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: April 15, 2015
Record the following information for Warranty purposes:
Where Purchased:_______________________________ ________________
Purchase Date:__________________________________ ________________
Power Supply Serial #:___________________________ ________________
Torch Serial #:___________________________________ ________________
i
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar
with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be
sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with
the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained
equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be
replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends
that a telephone or written request for service advice be made to the Authorized Distributor from whom it
was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from
improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!
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 Opening the Contactor Cover ....................................................................3-1
3.04 Primary Input Power Connections ..............................................................3-1
3.05 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-5
4T.06 Mechanized Torch Operation ...................................................................4T-6
4T.07 Parts Selection for SL100 Torch Cutting ..................................................4T-9
4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip .....4T-10
4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip .....4T-14
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-1
5T.01 General Maintenance ................................................................................5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts .......................5T-2
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 ..............................................................6-2
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 Replacement Shielded Machine Torch Leads Assemblies .......................6-6
6.09 Torch Consumable Parts (SL100) ...............................................................6-7
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, 208/460V 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.
Manual 0-5379 GENERAL INFORMATION
1-1
ESAB CUTMASTER 100
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.
Arc welding and cutting can be injurious to yourself and others. Take
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
CAUTION
CAUTION
CAUTION
Class A equipment is not intended for use in residential locations
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.
!
GENERAL INFORMATION Manual 0-5379
1-2
ESAB CUTMASTER 100
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specication or
part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, DANGER, 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 efficient operation
of the system.
CAUTION
!
!
A procedure which, if not properly followed,
may cause damage to the equipment.
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.
2.02 Equipment Identification
The unit’s identication number (specication or part
number), model, and serial number usually appear
on a data tag attached to the rear panel. Equipment
which does not have a data tag such as torch and cable assemblies are identied only by the specication
or part number printed on loosely attached card or
the shipping container. Record these numbers on the
bottom of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against
the invoice to make sure it is complete and inspect
the equipment for possible damage due to shipping.
If there is any damage, notify the carrier immediately
to le a claim. Furnish complete information concerning damage claims or shipping errors to the location
in your area listed in the inside back cover of this
manual.
Include all equipment identication numbers as
described above along with a full description of the
parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to uncrate the unit.
WARNING
Gives information regarding possible electrical shock injury. Warnings will be enclosed
in a box such as this.
DANGER
Means immediate hazards which, if not
!
Additional copies of this manual may be purchased by
contacting ESAB at the address and phone number in
your area listed on back cover of this manual. Include
the Owner’s Manual number and equipment identication numbers.
Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going
to the ESAB web site listed below
http://www.esab.com.br
avoided, will result in immediate, serious
personal injury or loss of life.
Manual 0-5379 INTRODUCTION
2-1
ESAB CUTMASTER 100
2.04 Power Supply Specifications
ESAB Cutmaster® 100 Power Supply Specifications
Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 50/60 Hz
230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
460 VAC (414 - 506 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 Temperature Duty Cycle Ratings @ 40° C (104° F)
All Units Duty Cycle 60% 80% 100%
* 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
Operating Range 0° - 50° C
Current 100 80 70
DC Voltage 120 112 108
IEC IEC IEC
NOTE!
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications 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
10.75"
273 mm
Art # A-08358_AB
16.375"
416 mm
63 lb / 28.6 kg
30.5"
774.7 mm
24"
610 mm
6"
150 mm
Art # A-07925_AB
6"
150 mm
6"
150 mm
INTRODUCTION Manual 0-5379
2-2
2.05 Input Wiring Specifications
ESAB Cutmaster® 100 Power Supply Input Cable Wiring Requirements
Input voltage
Volts Hz kVA I max I1eff Fuse
1 Phase 208 50/60 20.6 99 76 100 4 Type W
230 50/60 21.9 95 74 100 4 Type W
3 Phase 208 50/60 17.7 49 38 60 6
230 50/60 17.9 45 36 60 6
400 50/60 18.7 27 22 32 10
460 50/60 23.1 29 22 30 10
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 flexible 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.
I1eff is taken at TDC 100% rated duty cycle.
Freq Power Input Suggested Sizes
ESAB CUTMASTER 100
Flexible Cord
(amps)
(Min. AWG)
Manual 0-5379 INTRODUCTION
2-3
ESAB CUTMASTER 100
Handle and Leads Wrap
and Clamp
2.06 Power Supply Features
Art # A-08359
Control Panel
To rch Leads Receptacle
Input Power Selection
Filter Assembly
Gas Inlet Port
Input Power Cord
Work Cable
Port for Optional Automation
Interface Cable
Art # A-08360
INTRODUCTION Manual 0-5379
2-4
ESAB CUTMASTER 100
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 properly trained personnel; unqualified
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 flows through the small orifice in the torch tip, which
is focused on the metal to be cut.
A single torch lead provides gas from a single source to be used as
both the plasma and secondary gas. The air flow is divided inside
the torch head. Single - gas operation provides a smaller sized
torch and inexpensive operation.
2T.03 Specifications
A. Torch Configurations
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.
10.125" (257 mm)
3.75"
(95 mm)
1.17" (29 mm)
2. Mechanized Torch, Model
The standard machine torch has a positioning tube with rack
& pinch block assembly.
15.875" / 403 mm
9.285" / 236 mm
1.375" / 35 mm
1.75" /
44.5 mm
0.625" /
16 mm
4.95" / 126 mm
B. Torch Leads Lengths
Art # A-03322_AB
1.175" / 30 mm
Art # A-02998
NOTE!
Refer to Section "2T.05 Introduction to
Plasma", for a more detailed description of
plasma torch operation.
Refer to the Appendix Pages for additional
specifications as related to the Power Supply used.
Hand Torches are available as follows:
• 20ft/6.1m,withATCconnectors
• 50ft/15.2m,withATCconnectors
Machine Torches are available as follows:
• 5foot/1.5m,withATCconnectors
• 10foot/3.05m,withATCconnectors
• 25foot/7.6m,withATCconnectors
• 50foot/15.2m,withATCconnectors
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.
Manual 0-5379 INTRODUCTION
2T-1
ESAB CUTMASTER 100
F. Torch Ratings
Manual Torch Ratings
Ambient
Temperature
Duty Cycle
Maximum Current
Voltage (V
Arc Striking Voltage
Ambient
Temperature
Duty Cycle
Maximum Current
Voltage (V
Arc Striking Voltage
)
peak
Mechanized Torch Ratings
)
peak
G. Gas Requirements
Manual and Mechanized Torch Gas
Specifications
104° F
40° C
100% @ 100 Amps @ 400 scfh
100 Amps
500V
7kV
104° F
40° C
100% @ 100 Amps @ 400 scfh
120 Amps
500V
7kV
2T.04 Options And Accessories
For options and accessories, see section 6.
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)
Operating Pressure
Refer to NOTE
Maximum Input Pressure
Gas Flow (Cutting and
Gouging)
Compressed Air
60 - 95 psi
4.1 - 6.5 bar
125 psi / 8.6 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.
_
Power
Supply
A
+
B
Workpiece
C
Typical Torch Head Detail
By forcing the plasma gas and electric arc through a small
orifice, 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
INTRODUCTION Manual 0-5379
2T-2
ESAB CUTMASTER 100
B. Gas Distribution
The single gas used is internally split into plasma and secondary gases.
The plasma gas flows into the torch through the negative lead,
through the starter cartridge, around the electrode, and out
through the tip orifice.
The secondary gas flows 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.
To Control
Torch Switch
Cable Wiring
PIP Switch
A-02997
Torch Trigger
Shield Cup
Parts - In - Place Circuit Diagram for Hand Torch
Remote Pendant
To AT C
PIP Sw itch
CNC Start
Sh ield Cup
To AT C
To AT C
PIP Sw itch
Automation Torch
PIP Sw itch
Sh ield Cup
Art # A-08168
Sh ield Cup
Parts - In - Place Circuit Diagram for Machine Torch
Manual 0-5379 INTRODUCTION
2T-3
ESAB CUTMASTER 100
This Page Intentionally Blank
INTRODUCTION Manual 0-5379
2T-4
SECTION 3 SYSTEM:
ESAB CUTMASTER 100
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.
!
• Onlypersonsofadequatephysicalstrengthshouldliftthe
unit.
• Liftunitbythehandles,usingtwohands.Donotuse
straps for lifting.
• Useoptionalcartorsimilardeviceofadequatecapacityto
move unit.
• Placeunitonaproperskidandsecureinplacebefore
transporting with a fork lift or other vehicle.
3.03 Opening the Contactor Cover
The input power cord is connected to the main contactor, the
contactor is located inside a box with a snap on cover. The cover
is held in place with two or more snap lock tabs. To remove the
cover release the front latch and tilt the cover up about ½ inch.
Then squeeze both sides of the cover and lift it straight up. See
the Primary Input Power Connections section for the necessary
changes to the Contactor. Remember to replace the Contactor
Cover when the changes are complete.
Disconnect input power cord before moving
unit.
WARNING
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.
1
2
1
2
Art# A-11478
Contactor cover
3.04 Primary Input Power Connections
CAUTION
!
The following illustration and directions are for changing phase of
the power supply.
Single-Phase (1ø) and Jumper Settings
Store copper jumpers on base plate
L1
L2
L3
L4
A. Connections to Single Phase Input Power
These instructions are for changing the input power and or cable
on the 208/230, 400, 460 VAC Power Supply to Single - Phase
input power.
Check your power source for correct voltage before plugging in or connecting the
unit. Check the Voltage Selector at the rear
of the unit for correct setting 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 specified in
Section 2.
Input Power Cable Connections
Three-Phase (3ø)
L1
L2
L3
L4
GND
GND
Single and Three Phase Input Power Wiring
NOTE!
There are two jumpers used for the single
phase 230V setting and none for three
phase.
WARNING
Disconnect input power from the power
supply and input cable before attempting
this procedure.
Art # A-08493
Manual 0-5379 INSTALLATION
3-1
ESAB CUTMASTER 100
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. If the power cable being used is not the factory - supplied cable, use a three - conductor input power cable
for the voltage desired and strip back the insulation on
the individual wires.
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 opening
in the back panel of the power supply. Refer to Section
2 for power cable specifications.
5. Pass the cable being used through the access opening
in the back panel of the power supply. Refer to Section
2 for power cable specifications.
CAUTION
!
The primary power source and power cable
must conform to local electrical code and
the recommended circuit protection and
wiring requirements (refer to table in Section 2).
6. Connect the wires as follows.
• ConnectBusBarJumpersonthecontactoras
shown in prior illustration and on label in the power
supply.
• Green/YellowwiretoGround.
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.
CAUTION
!
The primary power source and power cable
must conform to local electrical code and
the recommended circuit protection and
wiring requirements (refer to table in Section 2).
6. Connect the wires as follows:
• WirestoL1,L2andL3input.Itdoesnotmatter
what order these wires are attached. See previous
illustration and on label in the power supply.
• Green/YellowwiretoGround.
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 dis-
connect switch) to supply power.
10. Connect the input power cable (or close the main disconnect switch) to supply power.
B. 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 changing the input power and or cable
on the 208/230, 400, 460 VAC Power Supply to Three - Phase
input power.
1. Remove the Power Supply cover per instructions found
in section 5.
INSTALLATION Manual 0-5379
3-2
3.05 Gas Connections
Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure
cylinders. Refer to the following two subsections if an optional
air line filter is to be installed.
1. Connect the air line to the inlet port. The illustration
shows typical fittings as an example.
ESAB CUTMASTER 100
Regulator/Filter
Regulator/Filter
NOTE!
For a secure seal, apply thread sealant to
the fitting threads, according to manufacturer's instructions. Do not use Teflon tape
as a thread sealer, as small particles of the
tape may break off and block the small air
passages in the torch.
Assembly
Inlet Port
Hose Clamp
1/4 NPT or ISO-R
Gas Supply
Hose
Art # A-07943
to 1/4” (6mm) Fitting
Air Connection to Inlet Port
Installing Optional Single - Stage Air Filter
An optional filter kit is recommended for improved filtering with
compressed air, to keep moisture and debris out of the torch.
1. Attach the Single - Stage Filter Hose to the Inlet Port.
2. Attach the Filter Assembly to the filter hose.
3. Connect the air line to the Filter. The illustration shows
typical fittings as an example.
NOTE!
For a secure seal, apply thread sealant to
the fitting threads, according to the maker's
instructions. Do Not use Teflon tape as a
thread sealer, as small particles of the tape
may break off and block the small air passages in the torch. Connect as follows:
Assembly
Inlet Port
Art # A-07944
Hose Clamp
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 filter is also for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns.
Connect the air supply as follows:
Manual 0-5379 INSTALLATION
1. Attach the Two Stage Filter bracket to the back of the
power supply per instructions supplied with the filter
assembly.
3-3
ESAB CUTMASTER 100
Regulator/Filter
NOTE!
For a secure seal, apply thread sealant to the fitting threads according to manufacturer's instructions. Do
Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air
passages in the torch.
2. Connect the two stage filter outlet hose to the inlet port of the Regulator / Filter Assembly.
3. Use customer - supplied fittings to connect the air line to the Filter. A 1/4 NPT to 1/4" hose barbed fitting is shown as an
example.
Assembly
Regulator
Input
Hose Clamp
Gas Supply
Hose
1/4 NPT to 1/4”
(6mm) Fitting
2-Stage Filter
Inlet Port (IN)
Outlet Port
(OUT)
Two Stage
Filter
Assembly
Art # A-07945_AC
Optional Two - Stage Filter Installation
Using High Pressure Air Cylinders
When using high pressure air cylinders as the air supply:
1. Refer to the manufacturer’s specifications 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. Briefly 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 flows 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 fitting threads, according to manufacturer's instructions. Do
Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air
passages in the torch.
INSTALLATION Manual 0-5379
3-4
SECTION 3 TORCH:
ESAB CUTMASTER 100
3T.02 Setting Up Mechanical Torch
INSTALLATION
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 source
1. Align the ATC male connector (on the torch lead) with
2. Secure the connection by turning the locking nut clock-
before connecting the torch.
the female receptacle. Push the male connector into
the female receptacle. The connectors should push
together with a small amount of pressure.
wise until it clicks. DO NOT use the locking nut to pull
the connection together. Do not use tools to secure the
connection.
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 source before disassembling the torch or torch leads
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 align the
torch perpendicular to the surface of the workpiece.
Pinch Block
Assembly
Art # A-07885
1
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 position.
Square
2
Workpiece
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.
3. Place a welding filter 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.
Manual 0-5379 INSTALLATION
3T-1
ESAB CUTMASTER 100
This Page Intentionally Blank
INSTALLATION Manual 0-5379
3T-2
ESAB CUTMASTER 100
12
3
!
SECTION 4 SYSTEM:
OPERATION
4.01 Front Panel Controls / Features
See Illustration for numbering Identification
1. Output Current Control
Sets the desired output current. Output settings up to 60 Amps
may be used for drag cutting (with the torch tip contacting the
workpiece) or higher for standoff cutting.
2. Function Control
Function Control Knob, Used to select between the different
operating modes.
SET Used to purge the air through the unit and torch
and leads and to adjust gas pressure.
RUN Used for general cutting operations
RAPID AUTO RESTART Allows for faster restarting
of the Pilot Arc for uninterrupted cutting.
4
MAX
MIN
A
PSI BAR
MAXMAX
MINMIN
!
5
8
7
6
10
9
+
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.
LATCH Used for longer hand held cuts. 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
The Pressure
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 disconnect input power, correct
the fault, and restart the unit. Refer to Section 5 for details.
+
Control is used in the "SET" mode
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 sufficient for torch operation.
8. DC Indicator
Indicator is ON when DC output circuit is active.
9.
Fault Error Indicator
Indicator is ON when Fault circuit is active. See section 5 for
explanations of fault lights.
10. Pressure Indicators
PSI BAR
MAX MAX
90 6.3
85 5.9
80
75
70
65
MINMIN
The Indicators will illuminate according to the pressure set by
the Pressure Control Knob (number 4).
5.5
5.2
4.8
4.5
Art # A-08170
Manual 0-5379 OPERATION
4-1
ESAB CUTMASTER 100
Art # A-04509
1
2
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.
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, Specifications.
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 sufficient 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.
Set Operating Pressure
1. Place the Power Supply Function Control knob to the
SET position. Gas will flow.
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.
Connect Work Cable
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.
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
A
PSI BAR
MAXMAX
MINMIN
!
+
Art# A-07946
OPERATION Manual 0-5379
4-2
ESAB CUTMASTER 100
STANDOFF
ESAB Cutmaster® 100 Gas Pressure Settings
Leads
Length
Up to 25'
(7.6 m)
Each additional
25' (7.6 m)
3. For Drag cutting (60 Amps and below), 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.
SL100
(Hand Torch)
80 psi
5.2 bar
Add 5 psi
0.4 bar
DRAG
SL100
(Mechanized Torch)
80 psi
5.2 bar
Add 5 psi
0.4 bar
ESAB Cutmaster® 100 Gas Pressure Settings
Leads
Length
Up to 25'
(7.6 m)
Each additional
25' (7.6 m)
SL100
(Mechanized Torch)
80 psi
5.5 bar
Add 5 psi
0.4 bar
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.
Postflow
Release the trigger to stop the cutting arc. Gas continues to
flow for approximately 20 seconds. During post - flow, 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 ,
RAPID AUTO RESTART
or LATCH . Gas flow stops.
2. Set the output current to desired amperage with the
Output Current Control Knob.
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.
Manual 0-5379 OPERATION
4-3
ESAB CUTMASTER 100
This Page Intentionally Blank
OPERATION Manual 0-5379
4-4
SECTION 4 TORCH:
Kerf Width
OPERATION
ESAB CUTMASTER 100
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 opera-
tion into the torch head.
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.
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.
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 finish cut quality is desired to avoid a secondary
cleaning operation. The following cut quality characteristics are
illustrated in the following figure:
Cut Surface
Bevel Angle
Top
Spatter
Top Edge
Rounding
Dross
Cut Surface
Build-Up
Cut Surface
Drag Lines
Cut Quality Characteristics
A-00007
Torch Head
Electrode
Start Cartridge
Tip
Shield Cup
A-03510_AB
Torch Parts (Drag Shield Cap & Shield Cup Body Shown)
Manual 0-5379 OPERATION
The desired or specified 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 difficulties if the material is to be welded after the
cutting process.
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.
4T-1
ESAB CUTMASTER 100
Left Side
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
resolidifies 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)
Top spatter or dross on the top of the cut caused by slow travel
speed, excess cutting height, or cutting tip whose orifice has
become elongated.
4T.03 General Cutting Information
WARNING
!
!
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.
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.
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.
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.
Cut Angle
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.
Right Side
Cut Angle
A-00512
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 normally caused by too great a torch
to plate distance. "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 difficult 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.
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 significantly affect the bevel angle.
Reducing standoff will generally result in a more square cut.
OPERATION Manual 0-5379
4T-2
4T.04 Hand Torch Operation
Tr igger
Standoff Cutting With Hand Torch
NOTE!
For best performance and parts 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.
b) For standoff cutting, hold the torch 1/8 - 3/8 in
(3-9 mm) from the workpiece as shown below.
ESAB CUTMASTER 100
Trigger
Trigger Release
A-02986
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 preflow and postflow are a characteristic of the power supply and not a
function of the torch.
1
2
Tr igger Release
Torch
Shield Cup
Standoff Distance
1/8" - 3/8" (3 - 9mm)
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.
3
4
Art # A-03383
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.
Manual 0-5379 OPERATION
4T-3
ESAB CUTMASTER 100
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
Art # A-04034
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 non-conductive.
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.
Trigger
Trigger Release
A-02986
Non-Conductive
Straight Edge
Cutting Guide
A-03539
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.
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 preflow and postflow are a characteristic of the power supply and not a
function of the torch.
Tr igger
1
2
Tr igger Release
3
4
Art # A-03383
7. Cut as usual. Simply release the trigger assembly to
stop cutting.
OPERATION Manual 0-5379
4T-4
8. 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.
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.
NOTE!
The tip should never come in contact with
the workpiece except during drag cutting
operations.
2. Angle the torch slightly to direct blowback particles
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.
ESAB CUTMASTER 100
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 preflow and postflow 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.
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:
• Torchpartswear
• Airquality
• Linevoltageuctuations
• Torchstandoffheight
• Properworkcableconnection
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.
Trigger
Trigger Release
A-02986
Manual 0-5379 OPERATION
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.
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.
4T-5
ESAB CUTMASTER 100
A-00941_AB
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 distance between the torch tip
and workpiece (standoff).
CAUTION
!
Touching the torch tip or shield cup to the
work surface will cause excessive parts
wear.
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 specified 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.
Torch Head
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.
Slag Buildup
Slag generated by gouging on materials such as carbon and
stainless steels, nickels, and alloyed steels, can be removed
easily in most cases. Slag does not obstruct the gouging process if it accumulates to the side of the gouge path. 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.
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 five degree leading arc is generally recommended
for air plasma on mild steel.
3. Trailing Arc
35°
Standoff Height
Workpiece
Gouging Angle and Standoff Distance
OPERATION Manual 0-5379
4T-6
The trailing arc is directed in the opposite direction as torch
travel.
Direction of Torch Travel
Straight Arc
A-02586
Mechanized Torch Operation
ESAB CUTMASTER 100
Standoff Distance
Trailing Arc
Leading Arc
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.
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.
Manual 0-5379 OPERATION
4T-7
ESAB CUTMASTER 100
This Page Intentionally Blank
OPERATION Manual 0-5379
4T-8
4T.07 Parts Selection for SL100 Torch Cutting
Ohmic Clip
Manual Torch
9-8259
ESAB CUTMASTER 100
Ohmic Clip
Automation Torch
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, Deflector
9-8243
Drag Shield Cup
9-8235
Shield Cap, Machine
50-60A 9-8238
Shield Cap, Deflector
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, Deflector
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
Manual 0-5379 OPERATION
Tip E 9-8254 (60 - 120 Amps)
Shield
Cup Body,
9-8237
Shield Cup, Gouging
9-8241
4T-9
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 mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
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
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
0.036 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
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
0.032 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
OPERATION Manual 0-5379
4T-10
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 110 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 119 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 119 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 mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
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
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 110 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 110 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 116 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 116 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
Manual 0-5379 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 mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8211 113 80 320 8.13 0.19 4.8 65 4.5 115 340 0.00 0.19 4.8
0.120 3.0 9-8211 113 80 230 5.84 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8
0.135 3.4 9-8211 115 80 180 4.57 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8
0.188 4.8 9-8211 114 80 140 3.56 0.19 4.8 65 4.5 115 340 0.20 0.19 4.8
0.250 6.4 9-8211 114 80 100 2.54 0.19 4.8 65 4.5 115 340 0.30 0.19 4.8
0.375 9.5 9-8211 117 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 4.5 115 340 0.00 0.25 6.4
0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4
0.188 4.8 9-8211 124 80 180 4.57 0.25 6.4 65 4.5 115 340 0.20 0.25 6.4
0.250 6.4 9-8211 128 80 110 2.79 0.25 6.4 65 4.5 115 340 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 4.5 115 340 0.60 0.25 6.4
0.625 15.9 9-8211 142 80 26 0.66 0.25 6.4 65 4.5 115 340 0.75 0.25 6.4
0.750 19.1 9-8211 145 80 24 0.61 0.25 6.4 65 4.5 115 340 NR NR NR
0.875 22.2 9-8211 153 80 10 0.25 0.25 6.4 65 4.5 115 340 NR NR NR
1.000 25.4 9-8211 162 80 6 0.15 0.25 6.4 65 4.5 115 340 NR NR NR
OPERATION Manual 0-5379
4T-12
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
0.250 6.4
0.375 9.5
0.500 12.7
0.625 15.9
0.750 19.0
1.000 25.4
9-8212 110 100 105 2.65 0.190 4.8 75 5.2 130 390
9-8212 117 100 70 1.75 0.190 4.8 75 5.2 130 390
9-8212 120 100 50 1.25 0.190 4.8 75 5.2 130 390
9-8212 125 100 35 0.90 0.190 4.8 75 5.2 130 390
9-8212 131 100 18 0.45 0.190 4.8 75 5.2 130 390
9-8212
135
100
10
0.25
0.190
4.8 75 5.2 130 390
NR NR NR
0.200 5.1
0.4
0.200 5.1
0.5
0.200 5.1
0.6
1.0 0.200
2.0 0.250
5.1
6.4
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
0.250
0.375
0.500
0.625
0.750
1.000
6.4 9-8212
9.5 9-8212
12.7 9-8212
15.9 9-8212
19.0 9-8212
25.4 9-8212
118
122
126
133
138
139
100
100
100
100
100
100
90
55
30
20
15
10
2.30
1.40
0.75
0.50
0.40
0.25
4.8 75 5.2 130 390
0.190
4.8 75 5.2 130 390
0.190
4.8 75 5.2 130 390
0.190
4.8 75 5.2 130 390
0.190
4.8 75 5.2 130 390
0.190
4.8 75 5.2 130 390
0.190
0.5 0.250
0.8 0.250
1.0 0.250
1.5 0.250
NR NR
NR NR
6.4
6.4
6.4
6.4
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
0.250 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
NOTE!
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-5379 OPERATION
4T-13
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 mm (Cat. No.) Volts (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.036 0.9 9-8208 114 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
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
0.036 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
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
0.032 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
OPERATION Manual 0-5379
4T-14
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 mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
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
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
Manual 0-5379 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 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 4.5 115 340 0.00 0.2 5.1
0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1
0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1
0.188 4.8 9-8211 128 80 137 3.48 0.19 4.8 65 4.5 115 340 0.20 0.2 5.1
0.250 6.4 9-8211 131 80 100 2.54 0.19 4.8 65 4.5 115 340 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 4.5 115 340 0.60 0.2 5.1
0.625 15.9 9-8211 145 80 21 0.53 0.19 4.8 65 4.5 115 340 0.75 0.2 5.1
0.750 19.1 9-8211 144 80 14 0.36 0.19 4.8 65 4.5 115 340 NR NR NR
0.875 22.2 9-8211 149 80 11 0.28 0.19 4.8 65 4.5 115 340 NR NR NR
1.000 25.4 9-8211 162 80 8 0.20 0.19 4.8 65 4.5 115 340 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 110 80 340 8.50 0.125 3.2 65 4.5 115 340 0.00 0.2 5.1
0.120 3.0 9-8211 115 80 260 6.50 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1
0.135 3.4 9-8211 113 80 250 6.25 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1
0.188 4.8 9-8211 114 80 170 4.25 0.125 3.2 65 4.5 115 340 0.20 0.2 5.1
0.250 6.4 9-8211 116 80 85 2.13 0.125 3.2 65 4.5 115 340 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 4.5 115 340 0.75 0.25 6.4
0.625 15.9 9-8211 135 80 16 0.40 0.125 3.2 65 4.5 115 340 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 4.5 115 340 0.00 0.25 6.4
0.12 3.0 9-8211 120 80 240 6.10 0.13 3.2 65 4.5 115 340 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 4.5 115 340 0.60 0.25 6.4
0.625 15.9 9-8211 142 80 26 0.66 0.19 4.8 65 4.5 115 340 0.75 0.25 6.4
0.750 19.1 9-8211 150 80 18 0.46 0.19 4.8 65 4.5 115 340 NR NR NR
0.875 22.2 9-8211 156 80 8 0.20 0.19 4.8 65 4.5 115 340 NR NR NR
1.000 25.4 9-8211 164 80 6 0.15 0.19 4.8 65 4.5 115 340 NR NR NR
OPERATION Manual 0-5379
4T-16
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
0.250 6.4
0.375 9.5
0.500 12.7
0.625 15.9
0.750 19.0
1.000 25.4
9-8212
9-8212
9-8212
9-8212
9-8212
9-8212
124
127
132
136
140
147
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
6.4 9-8212
0.250
0.375
0.500
0.625
0.750
1.000
9.5 9-8212
12.7 9-8212
15.9 9-8212
19.0 9-8212
25.4 9-8212
121 100 110
125 100 60
132 100 35
137 100 20
144 100 15
154 100 8
100
100
100
100
100
100
110
75
50
30
18
10
2.80
1.90
1.30
0.75
0.45
0.25
2.80
1.50
0.90
0.50
0.40
0.20
0.180
0.180
0.180
0.180
0.190
0.190
0.125
0.150
0.150
0.150
0.190
0.190
4.6 75 5.2 130 390
4.6 75 5.2 130 390
4.6 75 5.2 130 390
4.6 75 5.2 130 390
4.8 75 5.2 130 390
4.8 75 5.2
3.2 75 5.2 130 390
3.8 75 5.2 130 390
3.8 75 5.2 130 390
3.8 75 5.2 130 390
4.8 75 5.2 130 390
4.8 75 5.2 130 390
130
390
0.4 0.200
0.5 0.200
0.6 0.200
0.8 0.200
2.0 0.225
NR NR
0.5 0.200
0.8 0.200
1.0 0.200
2.0 0.225
NR NR
NR NR
5.1
5.1
5.1
5.1
5.7
NR
5.1
5.1
5.1
5.7
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
0.250
0.375
0.500
0.625
0.750
1.000
6.4 9-8212
9.5 9-8212
12.7 9-8212
15.9 9-8212
19.0 9-8212
25.4 9-8212
120
128
130
135
140
148
100
100
100
100
100
100
120
65
45
30
25
10
3.05
1.65
1.15
0.75
0.65
0.25
0.180
0.180
0.180
0.180
0.180
0.190
65 4.5 105 360
65 4.5 105 360
65 4.5 105 360
65 4.5 105 360
65 4.5 105 360
65 4.5
105 360 NR NR
0.2 0.225
0.4 0.225
0.5 0.225
0.8 0.225
1.0 0.225
5.7
5.7
5.7
5.7
5.7
NR
NOTE!
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.
Manual 0-5379 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
OPERATION Manual 0-5379
4T-18
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
Manual 0-5379 OPERATION
4T-19
ESAB CUTMASTER 100
This Page Intentionally Blank
OPERATION Manual 0-5379
4T-20
5.01 General Maintenance
ESAB CUTMASTER 100
SECTION 5 SYSTEM:
SERVICE
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
Art # A-07938_AB
Manual 0-5379 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 pressure/
flow.
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
flow.
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.
Six Months or Every 720 Cutting Hours:
5.03 Common Faults
Problem - Symptom Common Cause
Insufficient Penetration 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
Main Arc Extinguishes 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
Excessive Dross
Formation
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
1. Check the in-line air filter(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 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
Difficult Starting 1. Worn torch parts.
2. Non - Genuine ESAB parts used.
3. Incorrect gas pressure.
SERVICE Manual 0-5379
5-2
ESAB CUTMASTER 100
5.04 Fault Indicator
At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used.
To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators,
reading from bottom to top, 0 through 7. In the example below the Temp indicator and 75 psi indicators are ON indicating the version would be 2.3.
7
6
5
4
3
2
1
0
MAX
MIN
A
PSI BAR
MAXMAX
MINMIN
!
+
5
3
1
4
2
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.
Manual 0-5379 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
Fault indicator flashing,
65 PSI indicator
flashing
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. INPUT VOLTAGE SELECTION
SWITCH set for incorrect voltage.
2. Primary input voltage problem.
3. Faulty components in unit.
1. Turn primary power disconnect switch to ON position.
2. a) Have qualified 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.
1. Set INPUT VOLTAGE SELECTION SWITCH to match primary input
voltage.
2. Have qualified person check primary voltage to insure it meets
unit requirements see section 2.05.
3. Return to authorized service center for repair or replacement.
TEMPERATURE
indicator ON. FAULT
indicator flashing.
GAS LED OFF, FAULT
and MIN pressure
indicators flashing.
FAULT and 70 PSI
indicators flashing.
FAULT and 75 PSI
indicators flashing.
1. Air flow 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. 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. 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.
1. Start can be active for one of the following:
•Handtorchswitchheldclosed
•Handpendantswitchheldclosed
•CNCSTARTsignalisactivelow
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.
SERVICE Manual 0-5379
5-4
Problem - Symptom Possible Cause Recommended Action
FAULT & 80 PSI
indicators flashing.
Gas flow is cycling ON
and OFF.
Nothing happens when
torch switch or remote
switch is closed (Or
CNC START signal is
active) No gas flow,
DC LED 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. Problem in the torch and leads
switch circuit (Remote pendant
switch circuit).
2. CNC Contoller device not providing
Start signal.
3. 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 fitting for free movement. Replace if fitting 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.
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.
ESAB CUTMASTER 100
FAULT and 85 PSI
indicators flashing.
No Fault lights ON, no
arc in torch.
Fault and 90 PSI
indicators flashing
Pilot arc is ON but
cutting arc will not
establish
Torch cutting is
diminished
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 does not
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. 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 fitting for free movement. Replace if fitting 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.
clear the fault, return to an authorized service center for repair.
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.
Manual 0-5379 SERVICE
5-5
ESAB CUTMASTER 100
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 upper and lower screws which secure
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
the 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
Screws
C. Filter Element Assembly Replacement
The Filter Element Assembly is in the rear panel. For better system
performance, the filter element should be checked per the Maintenance Schedule (Subsection 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 fitting from the
filter assembly. Number 1 in the following illustration.
4. Hold a wrench or similar tool against the locking
ring on the filter assembly fitting, then pull on the
hose to release it. (Numbers 2 and 3 in the following illustration).
1
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.
3. Tighten lower screws.
Art # A-07989
2
3
4
5
6mm
4. Reinstall and tighten the upper screws.
SERVICE Manual 0-5379
5-6
ESAB CUTMASTER 100
5. Remove the fitting from the filter element assembly
by inserting a 6 mm hex wrench into the internal
hex fitting and turning it counter clock-wise (left).
Numbers 4 and 5 in the previous illustration.
6. Disconnect the input line from the filter element
assembly.
7. Remove the filter element assembly through the
rear opening.
NOTE!
If replacing or cleaning just the filter element refer to
the following illustration for disassembly.
Filter Element
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 filter
element catalog number.
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.
4. Turn the Filter Housing Cover counter-clockwise
and remove it. The Filter Element is located inside
the Housing.
Housing
Art # A-07990
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.
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Cover
Barbed
Fitting
Assembled Filter
Art # A-02476
Optional Single-Stage Filter Element Replacement
5. Remove the Filter Element from the Housing and
set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element open side first.
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.
Manual 0-5379 SERVICE
5-7
ESAB CUTMASTER 100
Optional Two-Stage Filter Element Replacement
The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but
cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.
1. Shut OFF primary input power.
2. Shut OFF air supply and bleed down system.
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.
First & Second
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 fitting is normal.
This completes the parts replacement procedures.
SERVICE Manual 0-5379
5-8
SECTION 5 TORCH:
SERVICE
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.
ESAB CUTMASTER 100
Threads
Lower O-Ring
Torch Head O-Ring
Upper Groove
with Vent Holes
Must Remain Open
Upper O-Ring
in Correct Groove
Art # A-03725
ATC Male Connector
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
!
O-Ring Lubrication
Dry the torch thoroughly before reinstalling.
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 film of o-ring lubricant (Catalog # 8-4025) to the o-rings on a weekly basis.
Art #A-03791
Gas Fitting
O-Ring
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.
Manual 0-5379 SERVICE
5T-1
ESAB CUTMASTER 100
Drag Shield Cap
Spring-Loaded
5T.02 Inspection and Replacement of
Consumable Torch Parts
WARNING
Disconnect primary power to the system
Remove the consumable torch parts as follows:
1. Unscrew and remove the shield cup from the torch.
2. Inspect the cup for damage. Wipe it clean or
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.
NOTE!
Slag built up on the shield cup that cannot
be removed may effect the performance of
the system.
replace if damaged.
4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean
or replace the tip if necessary.
Good Tip
Worn Tip
A-03406
Example of Tip Wear
5. Remove the starter cartridge. Check for excessive
wear, plugged gas holes, or discoloration. Check
the lower end fitting for free motion. Replace if
necessary.
Lower End Fitting
Full Compression
Spring-Loaded
Lower End Fitting at Reset /
Full Extension
Art # A-08064_AC
6. Pull the Electrode straight out of the Torch Head.
Check the face of the electrode for excessive wear.
Refer to the following figure.
3. On torches with a shield cup body and a shield
Art # A-08067
Shield Cups
cap or deflector, ensure that the cap or deflector
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
O-Ring No. 8-3488
Art # A-03878
New Electrode
Art # A-03284
Worn Electrode
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.
This completes the parts replacement procedures.
SERVICE Manual 0-5379
5T-2
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 Replacement Shielded Machine Torch Leads Assemblies"
Section "6.09 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 /
filter, and operating manual.
Qty Description Catalog #
1 ESAB CutMaster® 100 Power Supply 208/230 - 460VAC, Single or 3 Phase, 60Hz,
with 460V single phase input power cable 0559313302
Manual 0-5379 PARTS LIST
6-1
ESAB CUTMASTER 100
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 208 / 230 V Power Supply 9-0191
1 460/600V Power Supply 9-0209
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)
1 Bracket, Filter Mounting (not shown)
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 9-8311
1 Automation Harness 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
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Cover
Barbed
Fitting
Assembled Filter
Art # A-02476
Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit
First & Second
Stage
Cartridges
(as marked)
Art # A-02942
PARTS LIST Manual 0-5379
6-2
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
1
8
2
4
5
6
3
7
Manual 0-5379 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 No.
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.
Refer to Section 6.09 for Replacement Shielded Leads Assemblies.
PARTS LIST Manual 0-5379
6-4
ESAB CUTMASTER 100
9
7
10
8
10
1
2
11
13
3
4
12
5 & 6
A-07994_AB
Manual 0-5379 PARTS LIST
6-5
ESAB CUTMASTER 100
6.08 Replacement Shielded Machine Torch Leads Assemblies
Item No. Qty Description Catalog No.
1 Mechanized Shielded Leads Assemblies with ATC Connectors
1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846
1 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847
1 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848
1 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849
1
Remote Pendant Adapter is
present on Mechanized leads only.
Torch Continuity
('PIP') Switch
A-03684
PARTS LIST Manual 0-5379
6-6
6.09 Torch Consumable Parts (SL100)
Ohmic Clip
Manual Torch
9-8259
ESAB CUTMASTER 100
Ohmic Clip
Automation Torch
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, Deflector
9-8243
Drag Shield Cup
9-8235
Shield Cap, Machine
50-60A 9-8238
Shield Cap, Deflector
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, Deflector
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
Manual 0-5379 PARTS LIST
Tip E 9-8254 (60 - 120 Amps)
Shield
Cup Body,
9-8237
Shield Cup, Gouging
9-8241
6-7
ESAB CUTMASTER 100
This Page Intentionally Blank
PARTS LIST Manual 0-5379
6-8
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-07979_AB
Manual 0-5379 APPENDIX
A-1
ESAB CUTMASTER 100
APPENDIX 2: DATA TAG INFORMATION
Mo de l:
Da te of Mf r:
Type of Power
Supply (Note 1)
1/ 3
f
1
f
Manufacturer's Name and/or
Logo, Location, Model and
S/N
2
Revision Level, Serial Number
and Production Code
Regulatory Standard Covering
This Type of Power Supply
Output Current Type
Plasma Cutting
Symbol
U
0
Rated NoLoad Voltage
Input Power
Symbol
Input Power
Specifications
(Phase, AC or DC
Hertz Rating)
Degree of Protection
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.
X
I
=
U
2
Conventional
Load Voltage
U1
Rated Supply
Voltage (Note 2)
Duty Cycle Factor
I
1
1Ø
Rated Maximum
Supply Current
1max 1eff
3Ø
I
1
Output Range (Amperage/
Voltage)
Duty Cycle Data (Note 3)
3Ø1Ø
Standard Symbols
Maximum Effective
Supply Current
Manufacturer's Electrical
Schematic File Number
and Revision Level
AC
DC
Phase
Ø
Art # A-12765_AA
APPENDIX Manual 0-5379
A-2
APPENDIX 3: TORCH PIN - OUT DIAGRAMS
A. Hand Torch Pin - Out Diagram
ESAB CUTMASTER 100
ATC Male Connector
Negative /
Plasma
4 - Green /
Switch
3 - White /
Switch
2- Orange /
PIP
1 - Black /
PIP
4
3
2
1
Pilot
Front View
8
7
6
5
B. Mechanized (Machine) Torch Pin - Out Diagram
ATC Male Connector
4- Black Pendant
Connector
3 - White Pendant
Connector
2 - Orange /
PIP
Front View
4
3
2
1
UNSHIELDED MACHINE TORCH
Negative / Plasma
8
7
6
5
8 - Open
7 - Open
6 - Open
5 - Open
8 - Green Pendant
Connector
Ground
7 - Green /
Not Used
6 - Open
8 - Ground
7 - Open
6 - Open
5 - Open
8 - Ground
7 - Open
6 - Open
ATC Female Receptacle
Front View
8
7
6
5
Pilot
ATC Female Receptacle
8
7
6
5
2
1
Front View
4
3
2
1
Negative /
Plasma
4 - Switch
3 - Switch
4
3
2 - PIP
1 - PIP
A-03701
Negative / Plasma
4 - Switch
3 - Switch
2 - PIP
1 - Black /
PIP
Art # A-03799
Pilot
5 - White /
Not Used
5 - Open
1 - PIP
Pilot
Manual 0-5379 APPENDIX
A-3
ESAB CUTMASTER 100
APPENDIX 4: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram
To rch: SL60 / SL100 Hand Torch
Leads: To rch Leads with ATC Connector
Power Supply: with ATC Receptacle
Torch
Head
PIP
Switch
Torch
Switch
Torch
Leads
Black
Orange
Green
White
Negative / Plasma
Pilot
Male
ATC Leads
Connector
AT C Female
Receptacle
1
2
5
6
4
3
8
7
Power
Supply
1
2
5
6
4
3
8
7
To Power Supply
Circuitry
To Power Supply
Circuitry
Negative / Plasma
Pilot
Art # A-03797
B. Mechanized Torch Connection Diagram
To rch: Unshielded Mechanized SL100 Machine Torch
Leads: Leads with ATC Connector and
Remote Pendant Connector
Power Supply: with ATC Female Receptacle
Male
AT C Leads
Connector
Torch
Head
PIP
Switch
Not
Used
Pilot Lead
Torch
Leads
Black
Orange
White
Green
Negative / Plasma Lead
To Remote Control
Remote
Pendant
Connector
Black
White
Green
AT C Female
Receptacle
Power
Supply
1
2
5
6
4
3
8
7
1
2
5
6
4
3
8
7
To Power Supply
Circuitry
To Power Supply
Circuitry
Negative / Plasma
Pilot
Art # A-03798
APPENDIX Manual 0-5379
A-4
ESAB CUTMASTER 100
This Page Intentionally Blank
Manual 0-5379 APPENDIX
A-5
ESAB CUTMASTER 100
APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS
D
L1
L2
L3
GND
380/400/415V
OR 600V
3 PH AC INPUT
PRIMARY POWER CONNECTIONS:
USE L1, L2, L3 & GND
C
*
CE UNITS
ONLY
*
1
2
3
4
EMI
FILTER
*
EMI
CHOKE
5
J1J1
SW1SW1
1 3
1
2
3
4
2 4
5
+12VDC
K1K1
/INRUSH
W1W1
MOT1MOT1
FAN
5
W1W1
6
SERIAL PORT
7
L1
T1
8
L2
T2
9
L3
T3
7A
L4
T4
+12VDC
J7J7
1
2
J5J5
1
2
3
24VAC
J6J6
1
24VAC RET
2
J4J4
3.3VDC
1
TXD
2
RXD
3
4
D
5
J13J13
1
2
3
4
+ -
SOL 1SOL 1
/FAN
/SOLENOID
1 /OVERTEMP
2 /FAN_ON
3 /CSR
4 CUR_SET
5 MAIN_PCB_ID
6 COMMON
12345
INRUSH
RESISTORS
6
BIAS
SUPPLY
TP2TP2
+
D1
_
J14J14
SYNC
MTH1MTH1
+12VDC
BIAS
SUPPLY
MTH7MTH7
TP8TP8
AC1AC1
80A_AC180A_AC1
80A_AC280A_AC2
AC2AC2
AC3AC3
80A_AC380A_AC3
4
PRI 3PRI 3
B
PRI 2PRI 2
PRI 2PRI 2
A
PRI 1PRI 1
C3,C4,C7,C8*+C3,C4,C7,C8*
+
C5,C6,C9,C10*+C5,C6,C9,C10*
+
PRI 1PRI 1
MTH2MTH2
TP1TP1
MTH4MTH4
TP5TP5
MTH8MTH8
TP4TP4
TP3TP3
MTH6MTH6
+
Q1
Q2
T1T1
PRI 4 PRI 4
C
D
_
MAIN PCB ASSY
PCB1
T2T2
FERRITE
B
MOT2MOT2
FAN
MOT3MOT3
FAN
FILTER
J4J4
123456789
10
+-
+-
+12VDC
J1J1
1
/FAN
2
J2J2
1
2
+12VDC
J9J9
SYNC
+
D1
A
_
40/50 AMP PCB
PCB5
A-09130_AD
5
+12VDC
J2J2
1
2
J3J3
1
2
PRI 1 PRI 1
A
PRI 3PRI 3
PRI 2 PRI 2
B
PRI 4PRI 4
C
D
+
AC1AC1
AC2AC2
AC3AC3
PMTH1PMTH1
PMTH4PMTH4
40A_AC140A_AC1
40A_AC240A_AC2
40A_AC340A_AC3
PMTH1PMTH1
PMTH4PMTH4
PCB2
C16-17+C16-17
INPUT CAPACITOR PCB
+
C12-13+C12-13
PMTH2PMTH2
PMTH3PMTH3
+
PMTH2PMTH2
PMTH3PMTH3
Q1
Q2
_
4
APPENDIX Manual 0-5379
A-6
ESAB CUTMASTER 100
3
TS1TS1
/START
/PIP
PILOT IGBTQ5PILOT IGBT
+12VDC
L1L1
ELECTRODE1ELECTRODE1
L2L2
-V OUT 1-V OUT 1
WORK1WORK1
TIP1TIP1
J10J10
1
2
3
4
5
6
7
8
J2
J11J11
1
D59 PCRD59 PCR
D78 CSRD78 CSR
+12VDC
2
TEMP
/OVERTEMP
CIRCUIT
NTCNTC
D3
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
Q5
24VAC RETURN
24VAC SUPPLY
OK-TO-MOVE
(5A @ 250VAC / 30VDC)
2
ATC CONNECTOR
J1J1
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
E64
E35
J9J9
78
1
79
2
80
3
81
4
82
5
6
83
7
P10P10
1
2
3
4
5
6
7
8
40 PIN RIBBON CABLE SIGNALS
1
FERRITE
FILTER
-V_OUT_SIGNAL
2
/TIP_VOLTS
3
/TIP_SENSE
4
/460V_IN
5
/230V_IN
6
CUR_SET
7
/RAR (RAPID AUTO RESTART)
8
/INRUSH
9
/W1_ON
10
SHDN
11
/TORCH_SOLENOID
12
/SOLENOID_ON
13
/OK_TO_MOVE
14
/FAN_ON
15
/LATCH_ACTIVE
16
/TORCH_SWITCH
17
/PIP
18
AC_ON
19
CSR
20
/TORCH_SOLENOID_DETECT
21
/OVERTEMP
22
V_IN
23
+12VDC
24
+12VDC
25
COMMON
26
COMMON
29
MAIN_PCB_ID
34
460_IN
35
+3.3VDC
36
TXD
37
RXD
38
COMMON
39
D
M-L
M-L
M-L
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
L-M
M-L
M-L
L-M
M-L
-
+
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
To -V OUT 1
on PCB1
E1E1
P2P2
P10P10
1
2
3
4
5
6
7
8
+12VDC
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
AUTOMATION
INTERFACE PCB
1
1TORCH
PIP SWITCHPIP SWITCH
TORCH SWITCHTORCH SWITCH
AUTOMATION
TORCH SOLENOID
WORKWORK
J2J2
14
OK TO MOVE
13
}
12
11
10
9
8
7
6
5
4
/START / STOP
}
3
2
1
*
123
P1P1
K1K1
PCB4
CNC PINOUT
*
To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS / 16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
J1J1
1
2
3
/START / STOP
}
4
(-)
*
5
DIVIDED ARC VOLTS
}
(+)
6
(-)
7
ARC VOLTS
8
}
(W/ 100K IN SERIES (2))
(+)
9
10
11
12
OK-TO-MOVE
K1
13
}
14
13
47
811
1214
D
C
B
Current ControlCurrent Control
LATCH
SET
RUN
RAR
ACAC
OVERTEMPOVERTEMP
GASGAS
DCDC
ERRORERROR
J1
FAULT
ERROR IND
MAX
90
85
80
75
70
65
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
AA
ECO B1399RWH
AB
ECO B1611 RWH
AB
Last Modified:
Last Modified:
Last Modified:
Friday, December 11, 20091109:02:19
0-100PSI / 0-4.5VDC
MAXMAX
9090
8585
8080
7575
7070
6565
MINMIN
+5VDC
RWH
FILTER
AIR
INLET
J3J3
3
2
1
DateByRevisionsRev
DateByRevisionsRev
DateByRevisionsRev
03/31/09
05/05/09
05/05/09
Information Proprietary to ESAB
Not For Release, Reproduction, or Distribution without Written Consent.
Not For Release, Reproduction, or Distribution without Written Consent.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE:
NOTE:
NOTE:
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)
Capacitors are in Microfarads (UF)
Capacitors are in Microfarads (UF)
TITLE:
TITLE:
TITLE:
09:02:19
09:02:19
CM102/152/35mm/40mm/A80/A120 380/400/415/600V
GAS CONTROL
REGULATOR
PRESSURE
TRANSDUCER
SCHEMATIC,
SCHEMATIC,
SCHEMATIC,
1
SOLENOID
VALVE
123
ATC
A-12771_AB
PCB No:
PCB No:
PCB No:
Assy No:
Assy No:
Assy No:
SupersedesScale
SupersedesScale
SupersedesScale
Date:
Date:
Date:
MARCH 30, 2009
Drawn: References
Drawn: References
Drawn: References
RWH
Chk: App:
Chk: App:
Chk: App:
11
11
DWG No:
Size
DWG No:
Size
DWG No:
Size
D
D
D
42X1330
42X1330
42X1330
A
Sheet
Sheet
Sheet
of
of
of
SEC1SEC1
SEC2SEC2
CHOKE1CHOKE1
D2
NTCNTC
3
TEMP
CIRCUIT
/OVERTEMP
+OUT_1+OUT_1
2
Manual 0-5379 APPENDIX
A-7
ESAB CUTMASTER 100
Revision History
Date Rev Description
01/15/2015 AA Manual release
05/22/2015 AB Miscellaneous corrections and updates
APPENDIX Manual 0-5379
A-8
ESAB CUTMASTER 100
This Page Intentionally Blank
Manual 0-5379 APPENDIX
A-9
ESAB CUTMASTER 100
This Page Intentionally Blank
APPENDIX Manual 0-5379
A-10
This Page Intentionally Blank
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