ESAB Cutmaster 40 SL60 1Torch Operating Manual
ESAB Cutmaster® 40
PLASMA CUTTING SYSTEM
SL60 1Torch™
Operating
Manual
Art # A-12777_AA
Révision : AA Issue Date: January 15, 2015 Manual No.: 0-5376
40
120V
230V
esab.eu
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to
provide you with the best service and reliability in the industry. This product is backed by our extensive
warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on
the web at www.esab.eu.
This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB
product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that have stood
the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working
environment within the welding industry.
WARNING
!
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
ESAB Cutmaster® 40 with SL60 1Torch™
Operating Manual Number 0-5376
Published by:
ESAB
2800 Airport Rd.
Denton, TX 76208
(940) 566-2000
www.esab.eu
Copyright 2015 by ESAB
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for
any loss or damage caused by any error or omission in this Manual, whether such
error results from negligence, accident, or any other cause.
Original Publication Date: January 15, 2015
Revision Date:
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 Working Principle ............................................................................................................2-2
2.05 Power Supply Specifications ...........................................................................................2-2
2.06 Input Wiring Specifications .............................................................................................. 2-3
2.07 Power Supply Features .................................................................................................... 2-4
SECTION 2 TORCH: INTRODUCTION ............................................................................................................... 2T-1
2T.01 Scope of Manual ........................................................................................................... 2T-1
2T.02 Specifications .............................................................................................................. 2T-1
2T.03 Introduction to Plasma .................................................................................................. 2T-2
SECTION 3: INSTALLATION ............................................................................................................................... 3-1
3.01 Unpacking .......................................................................................................................3-1
3.02 Lifting Options .................................................................................................................3-1
3.03 Primary Input Power Connections ....................................................................................3-1
3.04 Air Supply Connections ...................................................................................................3-1
SECTION 4 SYSTEM: OPERATION ....................................................................................................................4-1
4.01 Control Panel ...................................................................................................................4-1
4.02 Preparations For Operating ..............................................................................................4-2
4.03 Sequence of Operation ....................................................................................................4-5
4.04 Cut Quality ......................................................................................................................4-7
4.05 General Cutting Information .............................................................................................4-7
SECTION 5 SYSTEM: SERVICE .........................................................................................................................5-1
5.01 General Maintenance ......................................................................................................5-1
5.02 Basic Troubleshooting Guide ............................................................................................5-2
SECTION 5 TORCH: SERVICE .......................................................................................................................... 5T-1
5T.01 General Maintenance .................................................................................................... 5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts ............................................... 5T-1
SECTION 6: PARTS LISTS .................................................................................................................................6-1
6.01 Introduction .....................................................................................................................6-1
6.02 Power Supply Replacement Parts ....................................................................................6-2
6.03 SL60 Torch Consumable Parts ......................................................................................... 6-3
6.04 Optional Accessories .......................................................................................................6-4
APPENDIX 1: ESAB CUTMASTER® 40 CIRCUIT DIAGRAM .............................................................................. A-1
APPENDIX 2: SL60 TORCH PIN-OUT DIAGRAM ............................................................................................... A-2
Revision History .............................................................................................................................................. A-3
TABLE OF CONTENTS
This Page Intentionally Blank
TABLE OF CONTENTS
ESAB CUTMASTER 40
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 0-5376 GENERAL INFORMATION
1-1
ESAB CUTMASTER 40
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.
!
1-2
GENERAL INFORMATION Manual 0-5376
ESAB CUTMASTER 40
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, 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.
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
!
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.eu
A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.
WARNING
Gives information regarding possible electrical shock injury. Warnings will be enclosed
in a box such as this.
DANGER
Means immediate hazards which, if not
avoided, will result in immediate, serious
personal injury or loss of life.
Manual 0-5376 2-1 INTRODUCTION
ESAB CUTMASTER 40
2.04 Working Principle
Transformer
Gas valve Cutting torch
Rectifier
Compressed air
Rectifier
Inverter
Reduce pressure, filter
2.05 Power Supply Specifications
ESAB Cutmaster® 40 Power Supply Specifications
Input Power 120 VAC (+-10%), 1Phase, 50/60Hz
208-230 VAC (+-10%), 1Phase, 50/60Hz
Output Current 20 Amps @ 120VAC, 15A
20-27 Amps @ 120VAC, 20A
20-40 Amps @ 230VAC, 20A
ESAB Cutmaster® 40 Power Supply Duty Cycle (Note 1)
Ambient Temperature 104° F (40° C)
Duty Cycle 30% @ 120VAC, 40% @ 230VAC
Rated Current 27 Amps @ 120VAC, 40 Amps @ 230V
SL60 1Torch Gas Requirements (see section 2T.03)
Notes
1. Duty Cycle is the percentage of time the system can be operated without overheating. Duty cycle is reduced if
primary input voltage (AC) is low or the DC voltage is higher than shown in this chart.
2. Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may cause doublearcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting performance and rapid
electrode wear. Optional filters provide increased filtering capabilities.
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.
Workpiece
Art # A-09204_AB
INTRODUCTION 2-2 Manual 0-5376
120V 15A
120V 20A
230V 20A
30
24
20
27
20
40
A
26lb / 11.8kg
7" (177mm)
Figure 2-1: Power Supply Dimensions & Weight
ESAB CUTMASTER 40
9" (228.6mm)
18.5" (469.9mm)
Art# A-12781_AA
NOTE!
Weight includes torch & leads, input power cord, and work cable with clamp.
CAUTION
!
Provide clearance for proper air flow through the power supply. Operation without proper air flow will
inhibit proper cooling and reduce duty cycle.
2.06 Input Wiring Specifications
ESAB Cutmaster® 40 Input Power Requirements
Input Power Input Current Input Current Input Suggested Sizes (See Note)
Voltage Freq. (kVA) Max (Amps) Ieff (Amps) Fuse (Amps)
(Volts-AC) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph
120 50/60 3.3 27.5 15 25
208 50/60 5.0 24 15.4 23
230 50/60 5.0 21.4 13.5 20
240 50/60 5.0 20.8 13 20
Line Voltages with Suggested Circuit Protection
Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation in this
regard.
NOTE!
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations.
Cable conductor temperature used is
Manual 0-5376 2-3 INTRODUCTION
167° F (75° C).
ESAB CUTMASTER 40
2.07 Power Supply Features
Torch Lead
120/230 VAC Power Source
Air Inlet
Control Panel
120V 15A
120V 20A
230V 20A
30
24
20
27
20
40
A
Art # A-12779_AA
Work Cable and Clamp
Power Cord
On/Off
Switch
Air Inlet
Art# A-09335
INTRODUCTION 2-4 Manual 0-5376
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