ESAB Cutmaster® 120
PLASMA CUTTING SYSTEM
SL100 1Torch™
Operating
Manual
Art # A-12769_AB
120
Revision: AB Issue Date: April 15, 2015 Manual No.: 0-5380
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® 120 with SL100 1Torch™
Operating Manual Number 0-5380
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: April 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 AN D 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 ........................................................................................3-3
SECTION 3 TORCH: INSTALLATION .................................................................................3T-1
3T.01 Torch Connections ....................................................................................3T-1
3T.02 Setting Up Mechanical Torch ....................................................................3T-1
SECTION 4 SYSTEM: OPERATION .......................................................................................4-1
4.01 Front Panel Controls / Features .................................................................. 4-1
4.02 Preparations for Operation .........................................................................4-2
SECTION 4 TORCH: OPERATION .......................................................................................4T-1
4T.01 Torch Parts Selection ...............................................................................4T-1
4T.02 Cut Quality ................................................................................................4T-1
4T.03 General Cutting Information ......................................................................4T-2
4T.04 Hand Torch Operation ..............................................................................4T-3
4T.05 Gouging ....................................................................................................4T-6
4T.06 Mechanized Torch Operation ...................................................................4T-7
4T.07 Parts Selection for SL100 Torch Cutting ..................................................4T-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-20
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 120
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 0-5380 GENERAL INFORMATION
1-1
ESAB CUTMASTER 120
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 0-5380
1-2
ESAB CUTMASTER 120
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification 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, 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 identification number (specification 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 identified only by the specification 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 file 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 identification numbers as described above along with a full description of the parts
in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
WARNING
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 identification 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 0-5380 INTRODUCTION
2-1
ESAB CUTMASTER 120
2.04 Power Supply Specifications
ESAB Cutmaster® 120 Power Supply Specifications
Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz
230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50 Hz
460 VAC (414 - 506 VAC), Single Phase, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (540 - 630), Three Phase, 60 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 120 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability
ESAB Cutmaster® 120 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.
**60% at 208/230V 1 Phase input ONLY
Particulates to 5 Microns
Operating Range 0° - 50° C
Current 120 120 100
DC Voltage 128 128 120
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
150 mm
6"
150 mm
6"
INTRODUCTION Manual 0-5380
2-2
2.05 Input Wiring Specifications
ESAB Cutmaster® 120 Power Supply Input Cable Wiring Requirements
Input
voltage
Volts Hz kVA I max I eff Fuse
1 Phase 208 60 26.2 126 98 150 4 Type W
230 60 27.6 118 95 125 4 Type W
460 60 35 76 68 100 4
3 Phase 208 60 21.6 60 55 60 4
230 60 22.3 56 50 60 4
380 50 23 35 32 40 8
400 50 23.6 34 31 40 8
460 60 29.5 37 33 40 8
600 60 29.0 28 25 30 10
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
Freq Power
Input
ESAB CUTMASTER 120
Suggested Sizes
Flexible Cord
(amps)
(Min. AWG)
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.
Manual 0-5380 INTRODUCTION
2-3
ESAB CUTMASTER 120
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 0-5380
2-4
ESAB CUTMASTER 120
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.
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.
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
B. Torch Leads Lengths
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
0.625" /
16 mm
4.95" / 126 mm
1.175" / 30 mm
Art # A-03322_AB
Art # A-02998
C. Torch Parts
D. Parts - In - Place (PIP)
E. Type Cooling
Manual 0-5380 INTRODUCTION
Starter Cartridge, Electrode, Tip, Shield Cup
Torch Head has built - in switch
12 VDC circuit rating
Combination of ambient air and gas stream through
torch.
2T-1
ESAB CUTMASTER 120
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
G. Gas Requirements
Manual and Mechanized Torch Gas
)
peak
Mechanized Torch Ratings
)
peak
Specifications
104° F
40° C
100% @ 100 Amps @ 400 scfh
120 Amps
500V
7kV
104° F
40° C
100% @ 100 Amps @ 400 scfh
120 Amps
500V
7kV
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
60-95psi
4.1-6.5bar
125psi/8.6bar
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
Forstandofftiptherecommendedstandoffis3/16
inches / 4.7 mm.
2T.04 Options And Accessories
Foroptionsandaccessories,seesection6.
_
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 0-5380
2T-2
ESAB CUTMASTER 120
Remote Pendant
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
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 0-5380 INTRODUCTION
2T-3
ESAB CUTMASTER 120
This Page Intentionally Blank
INTRODUCTION Manual 0-5380
2T-4
ESAB CUTMASTER 120
SECTION 3 SYSTEM:
INSTALLATION
3.01 Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping
company before proceeding with the installation.
3. Record Power Supply and Torch model and serial numbers,
purchase date and vendor name, in the information block
at the front of this manual.
3.02 Lifting Options
The Power Supply includes a handle for hand lifting only. Be
sure unit is lifted and transported safely and securely.
WARNING
Do not touch live electrical parts.
Disconnect input power cord before moving
unit.
3.03 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.
1
2
1
2
Art# A-11478
Contactor cover
WARNING
!
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.
• Onlypersons of adequatephysicalstrengthshouldliftthe
unit.
• Liftunitbythehandles,usingtwohands.Donotusestraps
for lifting.
• Useoptionalcartorsimilardeviceofadequatecapacityto
move unit.
• Placeunitonaproperskidandsecureinplacebeforetransporting with a fork lift or other vehicle.
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
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
Art # A-08493
Manual 0-5380 INSTALLATION
NOTE!
There are two jumpers used for the single
phase 230V setting and none for three phase.
3-1
ESAB CUTMASTER 120
A. Connections to Single 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 Single - Phase
input power.
1. Remove the Power Supply cover per instructions found in
section 5.
2. Disconnect the original input power cable from the main
input contactor and the chassis ground connection.
3. Loosen the through - hole protector on the back panel of
the power supply. Pull the original power cable out of the
power supply.
4. 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.
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.
• ConnectBusBarJumpersonthecontactorasshown
in prior illustration and on label in the power supply.
• Green/YellowwiretoGround.
7. Reinstall the Power Supply cover per instructions found in
section 5.
8. Connect the opposite end of individual wires to a customer
supplied plug or main disconnect.
9. 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.
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.
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.Itdoesnotmatterwhat
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 discon-
nect switch) to supply power.
INSTALLATION Manual 0-5380
3-2
ESAB CUTMASTER 120
Regulator/Filter
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.
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.
Regulator/Filter
Assembly
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
Hose Clamp
Gas Supply
Hose
Art # A-07943
Air Connection to Inlet Port
1/4 NPT or ISO-R
to 1/4” (6mm) Fitting
Hose Clamp
Gas Supply
Hose
Art # A-07944
1/4 NPT to 1/4"
(6mm) Fitting
Optional Single - Stage Filter Installation
Manual 0-5380 INSTALLATION
3-3
ESAB CUTMASTER 120
Regulator/Filter
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:
1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the filter assembly.
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 0-5380
3-4
ESAB CUTMASTER 120
SECTION 3 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)
2. Secure the connection by turning the locking nut
before connecting the torch.
with the female receptacle. Push the male connector into the female receptacle. The connectors should push together with a small amount
of pressure.
clockwise until it clicks. DO NOT use the locking
nut to pull the connection together. Do not use
tools to secure the connection.
3T.02 Setting Up Mechanical Torch
NOTE!
An adapter is required to be installed in the
power supply if converting a hand torch system to operate a machine torch.
WARNING
Disconnect primary power at the 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
2
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
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 0-5380 INSTALLATION
3T-1
ESAB CUTMASTER 120
This Page Intentionally Blank
INSTALLATION Manual 0-5380
3T-2
ESAB CUTMASTER 120
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
upto60Ampsmaybeusedfordragcutting(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.
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
4
MAX
MIN
A
PSI BAR
MAXMAX
MINMIN
!
5
8
7
6
10
9
6. Temp Indicator
Indicator is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Let the
unit cool before continuing operation.
7. Gas Indicator
Indicator is ON when minimum input gas pressure
for power supply operation is present. Minimum
pressure for power supply operation is not sufficient
for torch operation.
8. DC Indicator
Indicator is ON when DC output circuit is active.
+
Art# A-07886
ON / OFF Switch controls input power to the
power supply. Up is ON, down is OFF.
4. Air/Gas Pressure Control
The Pressure Control is used in the "SET" mode
to adjust the air/gas pressure. Pull the knob out to
adjust and push in to lock.
5. AC Indicator
Steady light indicates power supply is ready for
operation. Blinking light indicates unit is in protective interlock mode. Shut unit OFF, shut OFF or
disconnect input power, correct the fault, and restart
the unit. Refer to Section 5 for details.
Manual 0-5380 OPERATION
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
5.5
75
5.2
70
4.8
65
4.5
MINMIN
Art # A-08170
The Indicators will illuminate according to the pressure set by the Pressure Control Knob (number 4).
4-1
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