ESAB Cutmaster® 80
PLASMA CUTTING SYSTEM
SL60 1Torch™
Operating
Manual
Art # A-12768_AB
80
Revision: AB Issue Date: April 15, 2015 Manual No.: 0-5378
400V
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® 80 with SL60 1Torch™
Operating Manual Number 0-5378
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 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-6
4T.06 Mechanized Torch Operation ................................................................................4T-6
4T.07 Parts Selection for Manual and Mechanized Torch Cutting ....................................4T-8
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip ...............4T-9
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip .............4T-12
PATENT INFORMATION ....................................................................................................................4T-16
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 (SL60) ............................................................................ 6-7
6.10 Torch Consumable Parts (SL100) .......................................................................... 6-8
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
APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS ..............................................................................A-8
REVISION HISTORY ........................................................................................................................... A-10
ESAB CUTMASTER 80
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 0-5378 SAFETY
1-1
ESAB CUTMASTER 80
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.
!
SAFETY Manual 0-5378
1-2
ESAB CUTMASTER 80
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
avoided, will result in immediate, serious
personal injury or loss of life.
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
Manual 0-5378 INTRODUCTION
2-1
ESAB CUTMASTER 80
2.04 Power Supply Specifications
ESAB Cutmaster® 80 Power Supply Specifications
Input Power 460 VAC (414 - 506 VAC), Three Phase, 60 Hz
Input Power Cable
Output Current 30 - 80 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability
ESAB Cutmaster® 80 Power Supply Duty Cycle *
Cable for 208/230V input power includes molded plug.
Power Supply includes input cable.
Particulates to 5 Microns
Ambient Temperature
Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
IEC
Rating
IEC
Rating
IEC
Rating
Duty Cycle 40% 60% 100%
All Units
Current
DC Voltage
80 Amps 65 Amps 50 Amps
112 106 100
* 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.
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-07941
Art # A-07925_AB
16.375"
416 mm
6"
150 mm
24"
22.5"
43 lb / 19.5 kg
0.57 m
INTRODUCTION Manual 0-5378
2-2
610 mm
6"
150 mm
6"
150 mm
2.05 Input Wiring Specifications
ESAB Cutmaster® 80 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I max I1eff Fuse (amps)
3 Phase 400 50/60 11.8 18 12 20 12
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.
Cable size is de-rated based on the Duty Cycle of the equipment.
ESAB CUTMASTER 80
Flexible Cord
(Min. AWG)
Manual 0-5378 INTRODUCTION
2-3
ESAB CUTMASTER 80
and Clamp
2.06 Power Supply Features
Art # A-07942
Handle and Leads Wrap
Control Panel
To rch Leads Receptacle
Work Cable
Port for Optional Automation
Interface Cable
Input Power Selection
Filter Assembly
Gas Inlet Port
Input Power Cord
Art # A-07981
INTRODUCTION Manual 0-5378
2-4
ESAB CUTMASTER 80
SECTION 2 TORCH:
INTRODUCTION
2T.01 Scope of Manual
This manual contains descriptions, operating
instructions and maintenance procedures for the
1Torch Models SL60/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
0.625" /
4.95" / 126 mm
16 mm
1.175" / 30 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
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch Head has built - in switch
12 VDC circuit rating
Art # A-03322_AB
Art # A-02998
E. Type Cooling
Combination of ambient air and gas stream through torch.
Manual 0-5378 INTRODUCTION
2T-1
ESAB CUTMASTER 80
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
100% @ 60 Amps @ 400 scfh
)
100% @ 100 Amps @ 400 scfh
)
G. Gas Requirements
Manual and Mechanized Torch Gas
Specifications
Gas (Plasma and Secondary)
Operating Pressure
Refer to NOTE
Maximum Input Pressure
104° F
40° C
80 Amps
500V
7kV
104° F
40° C
120 Amps
500V
7kV
Compressed Air
60 - 95 psi
4.1 - 6.5 bar
125 psi / 8.6 bar
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.
_
Power
Supply
+
A
Gas Flow (Cutting and
Gouging)
300 - 500 scfh
142 - 235 lpm
WARNING
!
This torch is not to be used with oxygen
(O2).
NOTE!
Operating pressure varies with torch
model, operating amperage, and torch
leads length. Refer to gas pressure settings
charts for each model.
H. Direct Contact Hazard
For standoff tip the recommended standoff is 3/16 inches /
4.7 mm.
2T.04 Options And Accessories
For options and accessories, see section 6.
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.
B. Gas Distribution
The single gas used is internally split into plasma and secondary gases.
B
A-00002
INTRODUCTION Manual 0-5378
2T-2
The plasma gas flows into the torch through the negative lead,
Remote Pendant
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
ESAB CUTMASTER 80
To AT C
To AT C
To AT C
PIP Sw itch
CNC Start
PIP Sw itch
Automation Torch
PIP Sw itch
Parts - In - Place Circuit Diagram for
Machine Torch
Sh ield Cup
Sh ield Cup
Art # A-08168
Sh ield Cup
Manual 0-5378 INTRODUCTION
2T-3
ESAB CUTMASTER 80
This Page Intentionally Blank
INTRODUCTION Manual 0-5378
2T-4
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.
!
• Onlypersonsofadequatephysicalstrength
should lift the unit.
• Liftunitbythehandles,usingtwohands.Donot
use straps for lifting.
• Useoptionalcartorsimilardeviceofadequate
capacity to move unit.
• Placeunitonaproperskidandsecureinplace
before transporting with a fork lift or other vehicle.
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.
ESAB CUTMASTER 80
1
2
1
2
Art# A-11478
Contactor cover
3.04 Primary Input Power Connections
CAUTION
!
The following illustration and directions are for wiring
three phase input power.
Check your power source for correct voltage before plugging in or connecting the
unit. 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.
Three-Phase (3ø) and Jumper Settings
Store copper jumper in spare parts box
L1
L2
L3
L4
GND
L1
L2
L3
L4
Jumper L1 -L4
Three Phase Input Power Wiring
Art # A-07983_AB
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.
Manual 0-5378 INSTALLATION
3-1
ESAB CUTMASTER 80
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.
• SetJumperwiresonthecontactor.See
illustration.
• Green/YellowwiretoGround.
• RemainingwirestoL1,L2andL3input.It
does not matter what order these wires are
attached. See the previous illustrations.
7. With a little slack in the wires, tighten the
through - hole protector to secure the power
cable.
8. Reinstall the Power Supply cover per instructions found in section 5.
9. Connect the opposite end of individual wires to
a customer supplied plug or main disconnect.
10. Connect the input power cable (or close the
main disconnect switch) to supply power.
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
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:
INSTALLATION Manual 0-5378
3-2
ESAB CUTMASTER 80
Regulator/Filter
Regulator/Filter
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:
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)
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.
Outlet Port
(OUT)
Two Stage
Filter
Assembly
Manual 0-5378 INSTALLATION
3-3
ESAB CUTMASTER 80
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INSTALLATION Manual 0-5378
3-4
SECTION 3 TORCH:
INSTALLATION
3T.01 Torch Connections
If necessary, connect the torch to the Power
Supply. Connect only the ESAB model SL60 / 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
2. Secure the connection by turning the locking
before connecting the torch.
lead) with the female receptacle. Push the
male connector into the female receptacle.
The connectors should push together with a
small amount of pressure.
nut clockwise until it clicks. DO NOT use the
locking nut to pull the connection together. Do
not use tools to secure the connection.
ESAB CUTMASTER 80
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
Art # A-07885
Connecting the Torch to the Power
Supply
3. The system is ready for operation.
Check Air Quality
To test the quality of air:
1. Put the ON / OFF switch in the ON
(up) position.
2. Put the Function Control switch in the SET
Square
Workpiece
A-02585
2
1
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.
position.
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 0-5378 INSTALLATION
3T-1
ESAB CUTMASTER 80
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INSTALLATION Manual 0-5378
3T-2
ESAB CUTMASTER 80
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 opera-
tions 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
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 to
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 0-5378 OPERATON
4-1
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