ESAB | ESAB Cutmaster 100 PLASMA CUTTING SYSTEM | Instruction manual | ESAB ESAB Cutmaster 100 PLASMA CUTTING SYSTEM User manual

ESAB ESAB Cutmaster 100 PLASMA CUTTING SYSTEM User manual
ESAB Cutmaster 100
®
PLASMA CUTTING SYSTEM
SL100 1Torch™
Operating
Manual
Art # A-12775_AB
OUTPUT
MAX OUTPUT
100
INPUT POWER
PHASE
VOLTAGE
400V
AMPS
Revision: AD
Issue Date: July 1, 2019
Manual No.: 300X5397
esab.eu
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer
and will strive to provide you with the best service and reliability in the industry. This
product is backed by our extensive warranty and world-wide service network. To locate
your nearest distributor or service agency, visit us on the web at www.esab.eu.
This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB product. Your satisfaction with this product and its safe operation is
our ultimate concern. Therefore please take the time to read the entire manual, especially
the Safety Precautions. They will help you to avoid potential hazards that may exist when
working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable
products that have stood the test of time. We pride ourselves on technical innovation,
competitive prices, excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve
a safer working environment within the welding industry.
!
WARNING
Read and understand this entire Manual and your employer’s safety
practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
ESAB Cutmaster® 100
SL100 1Torch™
Operating Manual Number 300X5397
Published by:
ESAB Group Inc.
2800 Airport Rd.
Denton, TX 76208
(940) 566-2000
www.esab.eu
Copyright 2015, 2019 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: July 1, 2019
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!
DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016
The EMC Directive 2014/30/EU, entering into force 20 April 2016
The RoHS Directive 2011/65/EC, entering into force 2 January 2013
Type of equipment
PLASMA CUTTING SYSTEM
Type designation etc.
ESAB Cutmaster® 100, from serial number MX1518xxxxxx
Brand name or trade mark
ESAB
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No:
ESAB Group Inc.
2800 Airport Rd
Denton TX 76207
Phone: +01 800 426 1888, FAX +01 603 298 7402
The following harmonised standard in force within the EEA has been used in the design:
IEC/EN 60974-1:2017 / AMD1:2019 Arc Welding Equipment - Part 1: Welding power sources.
IEC/EN 60974-10:2014 / AMD1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10: Electromagnetic
compatibility (EMC) requirements
Additional Information: Restrictive use, Class A equipment, intended for use in location other than residential.
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety requirements stated above.
Date
Signature
1 March 2019
Flavio Santos
2019
Position
General Manager
Accessories and Adjacencies
TABLE OF CONTENTS
SECTION 1: SAFETY................................................................................................................1-1
1.0
Safety Precautions.....................................................................................1-1
SECTION 2 SYSTEM: INTRODUCTION .................................................................................2-1
2.01
2.02
2.03
2.04
2.05
2.06
How To Use This Manual...........................................................................2-1
Equipment Identification............................................................................2-1
Receipt Of Equipment................................................................................2-1
Power Supply Specifications.....................................................................2-2
Input Wiring Specifications........................................................................2-3
Power Supply Features..............................................................................2-4
SECTION 2 TORCH: INTRODUCTION ............................................................................... 2T-1
2T.01
2T.02
2T.03
2T.04
2T.05
Scope of Manual...................................................................................... 2T-1
General Description................................................................................. 2T-1
Specifications ......................................................................................... 2T-1
Options And Accessories........................................................................ 2T-2
Introduction to Plasma............................................................................ 2T-2
SECTION 3 SYSTEM: INSTALLATION ..................................................................................3-1
3.01
3.02
3.03
3.04
Unpacking...................................................................................................3-1
Lifting Options............................................................................................3-1
Primary Input Power Connections.............................................................3-1
Gas Connections........................................................................................3-2
SECTION 3 TORCH: INSTALLATION.................................................................................. 3T-1
3T.01
3T.02
Torch Connections.................................................................................. 3T-1
Setting Up Mechanical Torch.................................................................. 3T-1
SECTION 4 SYSTEM: OPERATION........................................................................................4-1
4.01
4.02
Front Panel Controls / Features.................................................................4-1
Preparations for Operation.........................................................................4-2
SECTION 4 TORCH: OPERATION....................................................................................... 4T-1
4T.01
4T.02
4T.03
4T.04
4T.05
4T.06
4T.07
4T.08
4T.09
Torch Parts Selection.............................................................................. 4T-1
Cut Quality............................................................................................... 4T-1
General Cutting Information.................................................................... 4T-2
Hand Torch Operation............................................................................. 4T-3
Gouging.................................................................................................... 4T-6
Mechanized Torch Operation.................................................................. 4T-7
Parts Selection for SL100 Torch Cutting................................................ 4T-8
Recommended Cutting Speeds for SL100 Torch With Exposed Tip.... 4T-9
Recommended Cutting Speeds for SL100 Torch With Shielded Tip.. 4T-13
PATENT INFORMATION..................................................................................................... 4T-18
TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE..............................................................................................5-1
5.01
5.02
5.03
5.04
5.05
5.06
General Maintenance.................................................................................5-1
Maintenance Schedule...............................................................................5-2
Common Faults..........................................................................................5-2
Fault Indicator.............................................................................................5-3
Basic Troubleshooting Guide.....................................................................5-4
Power Supply Basic Parts Replacement...................................................5-6
SECTION 5 TORCH: SERVICE............................................................................................. 5T-9
5T.01
5T.02
General Maintenance.............................................................................. 5T-9
Inspection and Replacement of Consumable Torch Parts.................. 5T-10
SECTION 6: PARTS LISTS......................................................................................................6-1
6.01
6.02
6.03
6.04
6.05
6.06
6.07
6.08
Introduction.................................................................................................6-1
Ordering Information..................................................................................6-1
Power Supply Replacement.......................................................................6-1
Replacement Power Supply Parts.............................................................6-1
Options and Accessories...........................................................................6-2
Replacement Parts for Hand Torch ..........................................................6-3
Replacement Parts - for Machine Torches with Unshielded Leads.........6-4
Torch Consumable Parts (SL100)..............................................................6-6
APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM)....................................... A-1
APPENDIX 2: DATA TAG INFORMATION............................................................................ A-2
APPENDIX 3: TORCH PIN - OUT DIAGRAMS..................................................................... A-3
APPENDIX 4: TORCH CONNECTION DIAGRAMS.............................................................. A-4
APPENDIX 5: SYSTEM SCHEMATIC, 400V UNITS............................................................. A-6
Revision History...................................................................................................................... A-8
ESAB CUTMASTER 100
SECTION 1: SAFETY
1.0
Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works
on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that
apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition
to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator
and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, flame proof
clothing, safety gloves.
- Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualified electrician.
- Appropriate fire extinguishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its
implementation in accordance with national law, electrical and/or electronic equipment that has reached the
end of its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary cutting protection and accessories.
300X5397
GENERAL INFORMATION
1-1
ESAB CUTMASTER 100
WARNING
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.
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 RAYS - 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.
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!
WARNING
Do not use the power source for thawing frozen pipes.
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.
CAUTION
This product is solely intended for metal removal. Any other use
may result in personal injury and / or equipment damage.
CAUTION
Read and understand the instruction manual before
installing or operating.
1-2
GENERAL INFORMATION
!
300X5397
ESAB CUTMASTER 100
SECTION 2 SYSTEM:
INTRODUCTION
2.02 Equipment Identification
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 DANGER, WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these
headings. These special annotations are easily recognized as follows:
NOTE!
An operation, procedure, or background information which requires
additional emphasis or is helpful in
efficient operation of the system.
!
!
CAUTION
A procedure which, if not properly
followed, may cause damage to the
equipment.
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
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.
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
300X5397
INTRODUCTION
2-1
ESAB CUTMASTER 100
2.04 Power Supply Specifications
ESAB Cutmaster 100 Power Supply Specifications
Input Power
400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power Cable Power Supply includes input cable.
Output Current
30 - 100 Amps, Continuously Adjustable
Power Supply Gas Particulates to 5 Microns
Filtering Ability
ESAB Cutmaster 100 Power Supply Duty Cycle *
Ambient Tempera- Duty Cycle Ratings @ 40° C (104° F)
ture
Operating Range 0° - 50° C
Duty Cycle
60%
80%
100%
Ratings
IEC
CE
IEC
CE
IEC
CE
All Units
100A
-80A
80A
70A
70A
Current
120
-112
112
92
108
DC Voltage
* 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
12"
305 mm
Art # A-12887
15"
381 mm
Art # A-07925_AB
6"
150 mm
63 lb / 28.6 kg
2-2
30"
762 mm
24"
610 mm
6"
150 mm
INTRODUCTION
6"
150 mm
300X5397
ESAB CUTMASTER 100
2.05 Input Wiring Specifications
ESAB Cutmaster 100 Power Supply Input Cable Wiring Requirements
Power
Input voltage Freq
Suggested Sizes
Input
Flexible
Flexible
I
Fuse
Volts
Hz
kVA
I eff
Cord (Min.
Cord
max
(amps)
AWG)
(Min. mm2)
3
Phase
400
50
18.7
27
24
32
10
6
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTE!
Refer to Local and National Codes or local authority having jurisdiction for proper wiring
requirements.
The suggested sizes are based on 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.
300X5397
INTRODUCTION
2-3
ESAB CUTMASTER 100
2.06 Power Supply Features
Handle and Leads Wrap
Control Panel
Torch Leads Receptacle
Art # A-08359
Work Cable
and Clamp
Port for Optional Automation
Interface Cable
Filter Assembly
Gas Inlet Port
Art # A-08547
Input Power Cord
2-4
INTRODUCTION
300X5397
ESAB CUTMASTER 100
SECTION 2 TORCH:
INTRODUCTION
10.125" (257 mm)
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.
3.75"
(95 mm)
Art # A-03322_AB
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
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.
1.375" / 35 mm
2T.02 General Description
1.75" /
44.5 mm
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.
0.625" /
16 mm
1.175" / 30 mm
4.95" / 126 mm
Art # A-02998
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20 ft / 6.1 m, with ATC connectors
• 50 ft / 15.2 m, with ATC connectors
Machine Torches are available as follows:
• 5 foot / 1.5 m, with ATC connectors
• 10 foot / 3.05 m, with ATC connectors
• 25 foot / 7.6 m, with ATC connectors
• 50 foot / 15.2 m, with ATC connectors
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch Head has built - in switch
12 VDC circuit rating
2T.03 Specifications
E. Type Cooling
Combination of ambient air and gas stream through
torch.
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.
300X5397
INTRODUCTION
2T-1
ESAB CUTMASTER 100
2T.05 Introduction to Plasma
F. Torch Ratings
Manual Torch Ratings
A. Plasma Gas Flow
Ambient
Temperature
104° F
40° C
Duty Cycle
100% @ 100 Amps @ 400 scfh
Maximum Current
100 Amps
Voltage (Vpeak)
500V
Arc Striking Voltage
7kV
Mechanized Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle
100% @ 100 Amps @ 400 scfh
Maximum Current
120 Amps
Voltage (Vpeak)
500V
Arc Striking Voltage
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.
7kV
G. Gas Requirements
Manual and Mechanized Torch Gas
Specifications
Gas (Plasma and Secondary) Compressed Air
Operating Pressure
Refer to NOTE
60 - 95 psi
4.1 - 6.5 bar
Maximum Input Pressure
125 psi / 8.6 bar
Gas Flow (Cutting and
Gouging)
300 - 500 scfh
142 - 235 lpm
!
_
Power
Supply
+
A
B
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
Workpiece
C
A-00002
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.
For options and accessories, see section 6.
2T-2
INTRODUCTION
300X5397
ESAB CUTMASTER 100
B. Gas Distribution
Remote Pendant
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.
To ATC
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.
PIP Switch
Shield Cup
CNC Start
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.
To ATC
PIP Switch
Shield Cup
Art # A-08168
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.
To ATC
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
Cable Wiring
Torch Switch
PIP Switch
A-02997
Automation Torch
PIP Switch
Shield Cup
Parts - In - Place Circuit Diagram for Machine Torch
Torch Trigger
Shield Cup
Parts - In - Place Circuit Diagram for Hand Torch
300X5397
INTRODUCTION
2T-3
ESAB CUTMASTER 100
This Page Intentionally Blank
2T-4
INTRODUCTION
300X5397
ESAB CUTMASTER 100
SECTION 3 SYSTEM:
INSTALLATION
3.03 Primary Input Power
Connections
!
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.
The following illustration and directions are for wiring
three phase input power.
Input Power Cable Connections
3.02 Lifting Options
Three-Phase (3ø)
The Power Supply includes a handle for hand lifting
only. Be sure unit is lifted and transported safely and
securely.
L1
WARNING
FALLING EQUIPMENT can cause
serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.
• Only persons of adequate physical strength should
lift the unit.
• Lift unit by the handles, using two hands. Do not
use straps for lifting.
Art # A-08548
L2
L3
WARNING
Do not touch live electrical parts.
Disconnect input power cord before
moving unit.
!
CAUTION
Check your power source for correct voltage before plugging in or
connecting the unit. The primary
power source, fuse, and any extension cords used must conform to
local electrical code and the recommended circuit protection and wiring
requirements as specified in Section
2.
L4
GND
Three Phase Input Power Wiring
A. Connections to Three Phase Input Power
WARNING
Disconnect input power from the
power supply and input cable before
attempting this procedure.
These instructions are for replacing the input power and
or cable for 400 VAC Power Supply to Three - Phase
input power.
• Use optional cart or similar device of adequate
capacity to move unit.
1. Remove the Power Supply cover per instructions
found in section 5.
• Place unit on a proper skid and secure in place
before transporting with a fork lift or other vehicle.
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.
300X5397
INSTALLATION
3-1
ESAB CUTMASTER 100
Regulator/Filter
Assembly
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).
!
Inlet Port
Hose Clamp
6. Connect the wires as follows.
•
Wires to L1, L2 and L3 input. It does not
matter what order these wires are attached.
See previous illustration and on label in the
power supply.
•
Green / Yellow wire to Ground.
Gas Supply
Hose
1/4 NPT or ISO-R
to 1/4” (6mm) Fitting
Art # A-07943
7. With a little slack in the wires, tighten the through
- hole protector to secure the power cable.
Air Connection to Inlet Port
8. Reinstall the Power Supply cover per instructions
found in section 5.
Installing Optional Single - Stage Air Filter
9. Connect the opposite end of individual wires to
a customer supplied plug or main disconnect.
An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris
out of the torch.
10. Connect the input power cable (or close the main
disconnect switch) to supply power.
1. Attach the Single - Stage Filter Hose to the Inlet
Port.
2. Attach the Filter Assembly to the filter hose.
3.04 Gas Connections
3. Connect the air line to the Filter. The illustration
shows typical fittings as an example.
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.
3-2
INSTALLATION
300X5397
ESAB CUTMASTER 100
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:
Regulator/Filter
Assembly
Inlet Port
Art # A-07944
Hose Clamp
1/4 NPT to 1/4"
(6mm) Fitting
Gas Supply
Hose
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.
300X5397
INSTALLATION
3-3
ESAB CUTMASTER 100
Regulator/Filter
Assembly
Regulator
Input
2-Stage Filter
Inlet Port (IN)
Outlet Port
(OUT)
Two Stage
Filter
Assembly
Hose Clamp
Gas Supply
Hose
1/4 NPT to 1/4”
(6mm) Fitting
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.
3-4
INSTALLATION
300X5397
ESAB CUTMASTER 100
SECTION 3 TORCH:
INSTALLATION
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.
3T.01 Torch Connections
3T.02 Setting Up Mechanical Torch
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.
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 connecting the torch.
1. Align the ATC male connector (on 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.
2. Secure the connection by turning the locking nut
clockwise until it clicks. DO NOT use the locking
nut to pull the connection together. Do not use
tools to secure the connection.
WARNING
Disconnect primary power at the
source before connecting the torch.
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
Square
1
Art # A-07885
Workpiece
Connecting the Torch to the Power Supply
A-02585
3. The system is ready for operation.
Check Air Quality
To test the quality of air:
1.
/
Mechanical Torch Set - Up
Put the ON / OFF switch in the ON (up)
position.
2. Put the Function Control switch in the SET posi-
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.
tion.
300X5397
INSTALLATION
3T-1
ESAB CUTMASTER 100
This Page Intentionally Blank
3T-2
INSTALLATION
300X5397
ESAB CUTMASTER 100
SECTION 4 SYSTEM:
OPERATION
nect input power, correct the fault, and restart the
unit. Refer to Section 5 for details.
1
2
3
4
4.01 Front Panel Controls /
Features
MIN
See Illustration for numbering Identification
A
MAX
PSI
BAR
MAX
MAX
MIN
MIN
+
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.
5 6 7 8 9 10
6.
Temp Indicator
Indicator is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Let the
unit cool before continuing operation.
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.
Art# A-07886
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.
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
9.
!
Fault Error Indicator
Indicator is ON when Fault circuit is active. See section 5 for explanations of fault lights.
+ The Pressure Control is used in the "SET"
mode to adjust the air/gas pressure. Pull the knob
out to adjust and push in to lock.
5.
AC Indicator
Steady light indicates power supply is ready for operation. Blinking light indicates unit is in protective
interlock mode. Shut unit OFF, shut OFF or discon-
300X5397
OPERATION
4-1
ESAB CUTMASTER 100
10. Pressure Indicators
BAR
MAX
MAX
90
6.3
85
5.9
80
5.5
75
5.2
70
4.8
65
4.5
MIN
MIN
Clamp the work cable to the workpiece or cutting
table. The area must be free from oil, paint and rust.
Connect only to the main part of the workpiece; do
not connect to the part to be cut off.
Art # A-08170
PSI
Connect Work Cable
The Indicators will illuminate according to the pressure set by the Pressure Control Knob (number 4).
Art # A-04509
Power ON
Place the Power Supply ON / OFF switch to the ON
(up) position.
AC indicator turns ON.
4.02 Preparations for Operation
At the start of each operating session:
WARNING
Disconnect primary power at the
source before assembling or disassembling power supply, torch parts,
or torch and leads assemblies.
Gas indicator turns ON if there is sufficient gas
pressure for power supply operation and the cooling
fans turn ON.
NOTE!
Minimum pressure for power supply
operation is lower than minimum for
torch operation.
The cooling fans will turn ON as
soon as the unit is turned ON. After
the unit is idle for ten (10) minutes
the fans will turn OFF. The fans will
come back ON as soon as the torch
switch (Start Signal) is activated or if
the unit is turned off, then turned ON
again. If an over temperature condition occurs, the fans will continue to
run while the condition exists and for
a ten (10) minute period once the
condition is cleared.
Torch Parts Selection
Check the torch for proper assembly and appropriate
torch parts. The torch parts must correspond with
the type of operation, and with the amperage output
of this Power Supply (100 amps maximum). Refer to
Section 4T.07 and following for torch parts selection.
Torch Connection
Check that the torch is properly connected. Only
ESAB model SL100 / Manual or SL100 / Mechanical Torches may be connected to this Power Supply.
See Section 3T of this manual.
Set Operating Pressure
Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets
the power requirements for the unit per Section
2, Specifications.
1. Place the Power Supply Function Control knob
2. Connect the input power cable (or close the main
disconnect switch) to supply power to the system.
2. For Standoff cutting, adjust gas pressure from 70
- 85 psi / 4.8 - 5.9 bar (LED's in center of control
panel). Refer to the Standoff chart for pressure
setting details.
Air Source
to the SET position.
Gas will flow.
Ensure source meets requirements (refer to Section
2). Check connections and turn air supply ON.
4-2
OPERATION
300X5397
ESAB CUTMASTER 100
Cutting Operation
2
1
MIN
A
MAX
PSI
BAR
MAX
MAX
MIN
MIN
When the torch leaves the workpiece during cutting
operations with the Function Control Knob in the
RUN position, there is a brief delay in restarting
the pilot arc. With the knob in the RAPID AUTO
RESTART position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting
arc restarts instantly when the pilot arc contacts the
workpiece. (Use the 'Rapid Auto Restart' position
when cutting expanded metal or gratings, or in gouging or trimming operations when an uninterrupted
restart is desired). And with the knob in the LATCH
position the main cutting arc will be maintained after
the torch switch is released.
+
!
Typical Cutting Speeds
Art# A-07946
STANDOFF
ESAB Cutmaster 100 Gas Pressure Settings
Leads Length
SL100
SL100
(Hand Torch) (Mechanized Torch)
Up to 25' (7.6 m)
80 psi
5.5 bar
80 psi
5.5 bar
Each additional
25' (7.6 m)
Add 5 psi 0.4
bar
Add 5 psi 0.4 bar
3. For Drag cutting, adjust gas pressure from 75 95 psi / 5.2 - 6.5 bar (LED's in center of control
panel). Refer to the Drag Cutting chart for pressure setting details.
Drag (60 Amps or less)
ESAB Cutmaster 100 Gas Pressure
Settings
Leads Length
SL100
(Hand Torch)
Up to 25' (7.6 m)
80 psi
5.5 bar
Each additional
25' (7.6 m)
Add 5 psi
0.4 bar
Cutting speeds vary according to torch output amperage, the type of material being cut, and operator
skill. Refer to Section 4T.08 and following for greater
details.
Output current setting or cutting speeds may be
reduced to allow slower cutting when following a
line, or using a template or cutting guide while still
producing cuts of excellent quality.
Postflow
Release the trigger to stop the cutting arc. Gas continues to flow for approximately 20 seconds. During
post - flow, if the user moves the trigger release to
the rear and presses the trigger, the pilot arc starts.
The main arc transfers to the workpiece if the torch
tip is within transfer distance to the workpiece.
Shutdown
/
Turn the ON / OFF switch to OFF (down).
All Power Supply indicators shut OFF. Unplug
the input power cord or disconnect input power.
Power is removed from the system.
Select Current Output Level
1. Place the Function Control Knob in one of the
three operating positions available:
RUN,
RAPID AUTO RESTART,
or LATCH.
Gas flow stops.
2. Set the output current to desired amperage with
the Output Current Control Knob.
300X5397
OPERATION
4-3
ESAB CUTMASTER 100
This Page Intentionally Blank
4-4
OPERATION
300X5397
ESAB CUTMASTER 100
SECTION 4 TORCH:
OPERATION
Shown)
3. Install the replacement Electrode by pushing it
straight into the torch head until it clicks.
4T.01 Torch Parts Selection
Depending on the type of operation to be done determines the torch parts to be used.
Type of operation:
Drag cutting, standoff cutting or gouging
Torch parts:
Shield Cup, Cutting Tip, Electrode and Starter
Cartridge
4. Install the starter cartridge and desired tip for the
operation into the torch head.
5. Hand tighten the shield cup assembly until it is
seated on the torch head. If resistance is felt
when installing the cup, check the threads before
proceeding.
4T.02 Cut Quality
NOTE!
Refer to Section 4T.07 and following
for additional information on torch
parts.
NOTE!
Cut quality depends heavily on
setup and parameters such as torch
standoff, alignment with the workpiece, cutting speed, gas pressures,
and operator ability.
Change the torch parts for a different operation as follows:
WARNING
Disconnect primary power at the
source before assembling or disassembling power supply, torch parts,
or torch and leads assemblies.
NOTE!
The shield cup holds the tip and
starter cartridge in place. Position
the torch with the shield cup facing
upward to keep these parts from falling out when the cup is removed.
Cut quality requirements differ depending on application. For instance, nitride build - up and bevel angle
may be major factors when the surface will be welded
after cutting. Dross - free cutting is important when finish cut quality is desired to avoid a secondary cleaning
operation. The following cut quality characteristics are
illustrated in the following figure:
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
1. Unscrew and remove the shield cup assembly
from the torch head.
Top Edge
Rounding
2. Remove the Electrode by pulling it straight out
of the Torch Head.
Dross
Build-Up
Large O-Ring
Small O-Ring
Torch Head
Cut Surface
Drag Lines
A-00007
Cut Quality Characteristics
Electrode
Cut Surface
Start Cartridge
The desired or specified condition (smooth or rough)
of the face of the cut.
Tip
Nitride Build - Up
Shield Cup
A-03510_AB
Torch Parts (Drag Shield Cap & Shield Cup Body
300X5397
Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material
is to be welded after the cutting process.
OPERATION
4T-1
ESAB CUTMASTER 100
Bevel Angle
Piloting
The angle between the surface of the cut edge and
a plane perpendicular to the surface of the plate.
A perfectly perpendicular cut would result in a 0°
bevel angle.
Top - Edge Rounding
Rounding on the top edge of a cut due to wearing
from the initial contact of the plasma arc on the
workpiece.
Bottom Dross Buildup
Molten material which is not blown out of the cut area
and resolidifies on the plate. Excessive dross may
require secondary cleanup operations after cutting.
Kerf Width
The width of the cut (or the width of material removed
during the cut).
Top Spatter (Dross)
Top spatter or dross on the top of the cut caused by
slow travel speed, excess cutting height, or cutting
tip whose orifice has become elongated.
4T.03 General Cutting Information
!
!
WARNING
Disconnect primary power at the
source before disassembling the
power supply, torch, or torch leads.
Frequently review the Important
Safety Precautions at the front of
this manual. Be sure the operator is
equipped with proper gloves, clothing, eye and ear protection. Make
sure no part of the operator’s body
comes into contact with the workpiece while the torch is activated.
CAUTION
Sparks from the cutting process can
cause damage to coated, painted,
and other surfaces such as glass,
plastic and metal.
NOTE!
Handle torch leads with care and
protect them from damage.
4T-2
Piloting is harder on parts life than actual cutting
because the pilot arc is directed from the electrode
to the tip rather than to a workpiece. Whenever
possible, avoid excessive pilot arc time to improve
parts life.
Torch Standoff
Improper standoff (the distance between the torch tip
and workpiece) can adversely affect tip life as well as
shield cup life. Standoff may also significantly affect
the bevel angle. Reducing standoff will generally
result in a more square cut.
Edge Starting
For edge starts, hold the torch perpendicular to the
workpiece with the front of the tip near (not touching)
the edge of the workpiece at the point where the cut
is to start. When starting at the edge of the plate, do
not pause at the edge and force the arc to "reach"
for the edge of the metal. Establish the cutting arc
as quickly as possible.
Direction of Cut
In the torches, the plasma gas stream swirls as it
leaves the torch to maintain a smooth column of
gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the
direction of travel, the right side of the cut is more
square than the left.
Left Side
Cut Angle
Right Side
Cut Angle
A-00512
Side Characteristics Of Cut
To make a square - edged cut along an inside
diameter of a circle, the torch should move counterclockwise around the circle. To keep the square
edge along an outside diameter cut, the torch should
travel in a clockwise direction.
Dross
When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed,
or top dross”. Dross present on top of the plate is
OPERATION
300X5397
ESAB CUTMASTER 100
normally caused by too great a torch to plate distance. "Top dross" is normally very easy to remove
and can often be wiped off with a welding glove.
"Slow speed dross" is normally present on the bottom
edge of the plate. It can vary from a light to heavy
bead, but does not adhere tightly to the cut edge,
and can be easily scraped off. "High speed dross"
usually forms a narrow bead along the bottom of
the cut edge and is very difficult to remove. When
cutting a troublesome steel, it is sometimes useful
to reduce the cutting speed to produce "slow speed
dross". Any resultant cleanup can be accomplished
by scraping, not grinding.
Torch
Shield Cup
Standoff Distance
1/8" - 3/8" (3 - 9mm)
4T.04 Hand Torch Operation
A-00024_AB
Standoff Cutting With Hand Torch
NOTE!
For best parts performance and life,
always use the correct parts for the
type of operation.
1. The torch can be comfortably held in one hand
or steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the holding technique that feels most comfortable
and allows good control and movement.
NOTE!
The tip should never come in contact with the workpiece except during drag cutting operations.
2. Depending on the cutting operation, do one of
the following:
Standoff Distance
3. Hold the torch away from your body.
4. Slide the trigger release toward the back of the
torch handle while simultaneously squeezing the
trigger. The pilot arc will start.
Trigger
Trigger Release
A-02986
5. Bring the torch within transfer distance to the
work. The main arc will transfer to the work, and
the pilot arc will shut off.
a. For edge starts, hold the torch perpendicular
to the workpiece with the front of the tip on
the edge of the workpiece at the point where
the cut is to start.
NOTE!
The gas preflow and postflow are a
characteristic of the power supply
and not a function of the torch.
b. For standoff cutting, hold the torch 1/8 - 3/8
in (3-9 mm) from the workpiece as shown
below.
300X5397
OPERATION
4T-3
ESAB CUTMASTER 100
Shield Cup With Straight Edge
Trigger
The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand.
1
2
WARNING
The straight edge must be nonconductive.
Trigger Release
3
Non-Conductive
Straight Edge
Cutting Guide
4
Art # A-03383
6. Cut as usual. Simply release the trigger assembly to stop cutting.
7. Follow normal recommended cutting practices as
provided in the power supply operator's manual.
NOTE!
When the shield cup is properly installed, there is a slight gap between
the shield cup and the torch handle.
Gas vents through this gap as part
of normal operation. Do not attempt
to force the shield cup to close this
gap. Forcing the shield cup against
the torch head or torch handle can
damage components.
8. For a consistent standoff height from the workpiece, install the standoff guide by sliding it
onto the torch shield cup. Install the guide with
the legs at the sides of the shield cup body to
maintain good visibility of the cutting arc. During
operation, position the legs of the standoff guide
against the workpiece.
Shield Cup
Torch Tip
4T-4
Using Drag Shield Cup With Straight Edge
The crown shield cup functions best when cutting
3/16 inch (4.7 mm) solid metal with relatively smooth
surface.
Drag Cutting With a Hand Torch
Drag cutting works best on metal 1/4" (6 mm) thick
or less.
NOTE!
Drag cutting can only be performed
at 60 amps or less.
For best parts performance and life,
always use the correct parts for the
type of operation.
1. Install the drag cutting tip and set the output current.
2. The torch can be comfortably held in one hand
or steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the holding technique that feels most comfortable
and allows good control and movement.
3. Keep the torch in contact with the workpiece
during the cutting cycle.
Standoff Guide
Workpiece
A-03539
Art # A-04034
4. Hold the torch away from your body.
5. Slide the trigger release toward the back of the
torch handle while simultaneously squeezing the
trigger. The pilot arc will start.
OPERATION
300X5397
ESAB CUTMASTER 100
Piercing With Hand Torch
1. The torch can be comfortably held in one hand
or steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the technique that feels most comfortable and
allows good control and movement.
Trigger
Trigger Release
A-02986
NOTE!
The tip should never come in contact with the workpiece except during drag cutting operations.
6. Bring the torch within transfer distance to the
work. The main arc will transfer to the work, and
the pilot arc will shut off.
NOTE!
The gas preflow and postflow are a
characteristic of the power supply
and not a function of the torch.
2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator)
rather than directly back into it until the pierce is
complete.
3. In a portion of the unwanted metal start the
pierce off the cutting line and then continue the
cut onto the line. Hold the torch perpendicular to
the workpiece after the pierce is complete.
Trigger
1
4. Hold the torch away from your body.
2
5. Slide the trigger release toward the back of the
torch handle while simultaneously squeezing the
trigger. The pilot arc will start.
Trigger Release
3
Trigger
4
Trigger Release
Art # A-03383
7. Cut as usual. Simply release the trigger assembly to stop cutting.
8. Follow normal recommended cutting practices as
provided in the power supply operator's manual.
A-02986
6. Bring the torch within transfer distance to the
work. The main arc will transfer to the work, and
the pilot arc will shut off.
NOTE!
When the shield cup is properly installed, there is a slight gap between
the shield cup and the torch handle.
Gas vents through this gap as part
of normal operation. Do not attempt
to force the shield cup to close this
gap. Forcing the shield cup against
the torch head or torch handle can
damage components.
300X5397
OPERATION
NOTE!
The gas preflow and postflow are a
characteristic of the power supply
and not a function of the torch
When the shield cup is properly installed, there is a slight gap between
the shield cup and the torch handle.
Gas vents through this gap as part
of normal operation. Do not attempt
to force the shield cup to close this
gap. Forcing the shield cup against
the torch head or torch handle can
damage components.
4T-5
ESAB CUTMASTER 100
7. Clean spatter and scale from the shield cup and
the tip as soon as possible. Spraying the shield
cup in anti - spatter compound will minimize the
amount of scale which adheres to it.
Cutting speed depends on material, thickness, and the
operator’s ability to accurately follow the desired cut line.
The following factors may have an impact on system
performance:
• Torch parts wear
Torch Travel Speed
NOTE!
Refer to Appendix Pages for additional information as related to the
Power Supply used.
Optimum torch travel speed is dependent on current
setting, lead angle, and mode of operation (hand or
machine torch).
Current Setting
• Air quality
Current settings depend on torch travel speed,
mode of operation (hand or machine torch), and the
amount of material to be removed.
• Line voltage fluctuations
• Torch standoff height
• Proper work cable connection
Pressure Setting
4T.05 Gouging
!
!
WARNING
Be sure the operator is equipped
with proper gloves, clothing, eye and
ear protection and that all safety precautions at the front of this manual
have been followed. Make sure no
part of the operator’s body comes in
contact with the workpiece when the
torch is activated.
Disconnect primary power to the
system before disassembling the
torch, leads, or power supply.
The angle between the torch and workpiece depends
on the output current setting and torch travel speed.
The recommended lead angle is 35°. At a lead angle
greater than 45° the molten metal will not be blown
out of the gouge and may be blown back onto the
torch. If the lead angle is too small (less than 35°),
less material may be removed, requiring more passes. In some applications, such as removing welds
or working with light metal, this may be desirable.
Torch Head
35°
Standoff Height
Workpiece
A-00941_AB
Gouging performance depends on parameters such
as torch travel speed, current level, lead angle (the
angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff).
4T-6
Lead Angle
CAUTION
Sparks from plasma gouging can
cause damage to coated, painted or
other surfaces such as glass, plastic, and metal.
Check torch parts. The torch parts
must correspond with the type of
operation. Refer to Section 4T.07,
Torch Parts Selection.
Gouging Parameters
!
Even though the setting is within the specified range,
if the torch does not pilot well the pressure may need
to be reduced.
CAUTION
Touching the torch tip or shield cup
to the work surface will cause excessive parts wear.
Gouging Angle and Standoff Distance
Standoff Distance
The tip to work distance affects gouge quality and
depth. Standoff distance of 1/8 - 1/4 inch (3 - 6
mm) allows for smooth, consistent metal removal.
Smaller standoff distances may result in a severance
cut rather than a gouge. Standoff distances greater
than 1/4 inch (6 mm) may result in minimal metal
removal or loss of transferred main arc.
OPERATION
300X5397
ESAB CUTMASTER 100
Slag Buildup
Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels,
can be removed easily in most cases. Slag does not
obstruct the gouging process if it accumulates to the
side of the gouge path. However, slag build - up can
cause inconsistencies and irregular metal removal
if large amounts of material build up in front of the
arc. The build - up is most often a result of improper
travel speed, lead angle, or standoff height.
Dir
ect
4T.06 Mechanized Torch Operation
ion
of T
orc
hT
rav
el
Straight Arc
Cutting With Mechanized Torch
Trailing Arc
The mechanized torch can be activated by remote
control pendant or by a remote interface device
such as CNC.
A-02586
Leading Arc
1. To start a cut at the plate edge, position the center
of the torch along the edge of the plate.
Travel Speed
Proper travel speed is indicated by the trail of the
arc which is seen below the plate. The arc can be
one of the following:
1. Straight Arc
A straight arc is perpendicular to the workpiece
surface. This arc is generally recommended
for the best cut using air plasma on stainless or
aluminum.
2. Leading Arc
The leading arc is directed in the same direction
as torch travel. A five degree leading arc is generally recommended for air plasma on mild steel.
3. Trailing Arc
The trailing arc is directed in the opposite direction as torch travel.
Standoff Distance
Mechanized Torch Operation
For optimum smooth surface quality, the travel speed
should be adjusted so that only the leading edge
of the arc column produces the cut. If the travel
speed is too slow, a rough cut will be produced as
the arc moves from side to side in search of metal
for transfer.
Travel speed also affects the bevel angle of a cut.
When cutting in a circle or around a corner, slowing
down the travel speed will result in a squarer cut.
The power source output should be reduced also.
Refer to the appropriate Control Module Operating
Manual for any Corner Slowdown adjustments that
may be required.
Piercing With Machine Torch
To pierce with a machine torch, the arc should be
started with the torch positioned as high as possible
above the plate while allowing the arc to transfer
and pierce. This standoff helps avoid having molten
metal blow back onto the front end of the torch.
When operating with a cutting machine, a pierce or
dwell time is required. Torch travel should not be
enabled until the arc penetrates the bottom of the
plate. As motion begins, torch standoff should be
reduced to the recommended 1/8 - 1/4 inch (3-6 mm)
distance for optimum speed and cut quality. Clean
spatter and scale from the shield cup and the tip as
soon as possible. Spraying or dipping the shield cup
in anti - spatter compound will minimize the amount
of scale which adheres to it.
300X5397
OPERATION
4T-7
ESAB CUTMASTER 100
4T.07 Parts Selection for SL100 Torch Cutting
Ohmic Clip
Automation Torch
9-8224
Ohmic Clip
Manual Torch
9-8259
20-40A
Tip:
STANDOFF
CUTTING
20A
30A
40A
9-8205
9-8206
9-8208
Shield
Cup Body,
9-8237
Shield Cap, Machine
40A 9-8245
Shield Cup
9-8218
Shield Cap, Deflector
9-8243
Drag Shield Cup
9-8235
50-60A
Tips:
STANDOFF
CUTTING
50-55A
60A
Electrode
Auto 9-8232
Manual 9-8215
Starter
Heavy Duty
Cartridge
Starter Cartridge
9-8213 Non HF Only 9-8277
70-120A
STANDOFF
CUTTING
9-8209
9-8210
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield Cap, Machine
50-60A 9-8238
Shield Cap, Deflector
9-8243
Drag Shield Cup
70-100A 9-8236
Tips:
70A 9-8231
80A 9-8211
90/100A 9-8212
120A Auto 9-8233
120A Manual 9-8253
Shield
Cup Body,
9-8237
Drag Shield Cup
120A 9-8258
Shield Cap, Machine
70-100A 9-8239
Shield Cup
9-8218
Shield Cap, Machine
120A 9-8256
Shield Cap, Deflector
9-8243
40-120A
GOUGING
Shield
Cup Body,
9-8237
Tips:
Tip A 9-8225 (40 Amps Max.)
Tip B 9-8226 (50 - 120 Amps)
Shield Cup, Gouging
9-8241
Tip C 9-8227 (60 - 120 Amps)
Tip D 9-8228 (60 - 120 Amps)
Art # A-08066_AG
4T-8
Tip E 9-8254 (60 - 120 Amps)
OPERATION
300X5397
ESAB CUTMASTER 100
4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip
Type Torch: SL100 With Exposed Tip
Type Material: Mild Steel
Type Plasma Gas: Air
Thickness
Tip
Inches
mm
0,036
0,9
9-8208
0,06
1,5
9-8208
0,075
1,9
0,135
3,4
0,188
0,25
0,375
Output
(Cat. No.) Volts(VDC)
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma
Total**
Delay (Sec) Inches
mm
104
40
340
8,64
0,19
4,8
65
4,5
55
170
0,00
0,2
5,1
108
40
250
6,35
0,19
4,8
65
4,5
55
170
0,10
0,2
5,1
9-8208
108
40
190
4,83
0,19
4,8
65
4,5
55
170
0,30
0,2
5,1
9-8208
110
40
105
2,67
0,19
4,8
65
4,5
55
170
0,40
0,2
5,1
4,8
9-8208
113
40
60
1,52
0,19
4,8
65
4,5
55
170
0,60
0,2
5,1
6,4
9-8208
111
40
40
1,02
0,19
4,8
65
4,5
55
170
1,00
0,2
5,1
9,5
9-8208
124
40
21
0,53
0,19
4,8
65
4,5
55
170
NR
NR
NR
0,500 12,7
9-8208
123
40
11
0,28
0,19
4,8
65
4,5
55
170
NR
NR
NR
0,625 15,9
9-8208
137
40
7
0,18
0,19
4,8
65
4,5
55
170
NR
NR
NR
Type Torch: SL100 With Exposed Tip
Type Material: Stainless Steel
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Output
Inches
mm (Cat. No.) Volts(VDC)
0,036
0,9
9-8208
0,05
1,3
0,06
1,5
0,078
0,135
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Plasma Total**
Delay (Sec)
Inches
mm
170
0,00
0,2
5,1
55
170
0,00
0,2
5,1
55
170
0,10
0,2
5,1
4,5
55
170
0,30
0,2
5,1
4,5
55
170
0,40
0,2
5,1
65
4,5
55
170
0,60
0,2
5,1
65
4,5
55
170
1,00
0,2
5,1
65
4,5
55
170
NR
NR
NR
(Amps)
Inches
Meters
Inches
mm
psi*
bar
103
40
355
9,02
0,125
3,2
65
4,5
55
9-8208
98
40
310
7,87
0,125
3,2
65
4,5
9-8208
98
40
240
6,10
0,125
3,2
65
4,5
2,0
9-8208
100
40
125
3,18
0,125
3,2
65
3,4
9-8208
120
40
30
0,76
0,187
4,8
65
0,188
4,8
9-8208
124
40
20
0,51
0,187
4,8
0,25
6,4
9-8208
122
40
15
0,38
0,187
4,8
0,375
9,5
9-8208
126
40
10
0,25
0,187
4,8
Type Torch: SL100 With Exposed Tip
Type Material: Aluminum
Type Plasma Gas: Air
Thickness
Tip
Output
Inches
mm (Cat. No.) Volts(VDC)
0,032
0,8
9-8208
0,051
1,3
9-8208
0,064
1,6
9-8208
0,079
2,0
0,125
3,2
0,188
0,250
0,375
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Plasma Total**
Delay (Sec)
Inches
mm
170
0,00
0,2
5,1
170
0,10
0,2
5,1
55
170
0,10
0,2
5,1
4,5
55
170
0,30
0,2
5,1
4,5
55
170
0,40
0,2
5,1
65
4,5
55
170
0,60
0,2
5,1
65
4,5
55
170
1,00
0,2
5,1
65
4,5
55
170
NR
NR
NR
(Amps)
Inches
Meters
Inches
mm
psi*
bar
110
40
440
11,18
0,187
4,8
65
4,5
55
109
40
350
8,89
0,187
4,8
65
4,5
55
112
40
250
6,35
0,187
4,8
65
4,5
9-8208
112
40
200
5,08
0,19
4,8
65
9-8208
118
40
100
2,54
0,19
4,8
65
4,8
9-8208
120
40
98
2,49
0,187
4,8
6,4
9-8208
123
40
50
1,27
0,187
4,8
9,5
9-8208
134
40
16
0,41
0,187
4,8
300X5397
Pierce Height
OPERATION
Pierce Height
4T-9
ESAB CUTMASTER 100
Type Torch: SL100 With Exposed Tip
Type Material: Mild Steel
Type Plasma Gas: Air
Thickness
Tip
Inches
mm
0,060
1,5
9-8210
0,075
1,9
9-8210
0,120
3,0
9-8210
0,135
3,4
9-8210
0,188
4,8
0,250
6,4
0,375
Output
(Cat. No.) Volts(VDC)
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
(Amps)
Inches
Meters
Inches mm
110
60
290
7,37
0,19
120
60
285
7,24
0,19
120
60
180
4,57
119
60
170
4,32
9-8210
121
60
100
9-8210
119
60
80
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
psi*
bar
Plasma
Total** Delay (Sec) Inches
mm
4,8
70
4,8
90
245
0,00
0,19
4,8
4,8
70
4,8
90
245
0,10
0,19
4,8
0,19
4,8
70
4,8
90
245
0,10
0,19
4,8
0,19
4,8
70
4,8
90
245
0,10
0,19
4,8
2,54
0,19
4,8
70
4,8
90
245
0,20
0,19
4,8
2,03
0,19
4,8
70
4,8
90
245
0,30
0,19
4,8
9,5
9-8210
124
60
50
1,27
0,19
4,8
70
4,8
90
245
0,50
0,19
4,8
0,500 12,7
9-8210
126
60
26
0,66
0,19
4,8
70
4,8
90
245
0,75
0,19
4,8
0,625 15,9
9-8210
127
60
19
0,48
0,19
4,8
70
4,8
90
245
NR
NR
NR
0,750 19,1
9-8210
134
60
14
0,36
0,19
4,8
70
4,8
90
245
NR
NR
NR
1,000 25,4
9-8210
140
60
6
0,15
0,19
4,8
70
4,8
90
245
NR
NR
NR
Type Torch: SL100 With Exposed Tip
Type Material: Stainless Steel
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Inches
mm
0,06
1,5
9-8210
0,075
1,9
0,120
3,0
0,135
3,4
0,188
4,8
0,250
0,375
Output
(Cat. No.) Volts(VDC)
Amperage Speed (Per Minute)
Standoff
(Amps)
Inches
Meters
119
60
350
8,91
0,19
9-8210
116
60
300
7,64
9-8210
123
60
150
3,82
9-8210
118
60
125
9-8210
122
60
90
6,4
9-8210
120
60
9,5
9-8210
130
60
0,500 12,7
9-8210
132
0,625 15,9
9-8210
0,750 19,1
9-8210
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
psi*
bar
Plasma
Total** Delay (Sec) Inches
4,8
70
4,8
90
245
0,00
0,20
5,1
0,19
4,8
70
4,8
90
245
0,10
0,20
5,1
0,19
4,8
70
4,8
90
245
0,10
0,20
5,1
3,18
0,19
4,8
70
4,8
90
245
0,10
0,20
5,1
2,29
0,19
4,8
70
4,8
90
245
0,20
0,20
5,1
65
1,65
0,19
4,8
70
4,8
90
245
0,30
0,20
5,1
30
0,76
0,19
4,8
70
4,8
90
245
0,50
0,20
5,1
60
21
0,53
0,19
4,8
70
4,8
90
245
0,75
0,20
5,1
130
60
15
0,38
0,19
4,8
70
4,8
90
245
NR
NR
NR
142
60
12
0,31
0,25
6,4
70
4,8
90
245
NR
NR
NR
Type Torch: SL100 With Exposed Tip
Type Material: Aluminum
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Inches
mm
0,060
1,5
9-8210
0,075
1,9
0,120
3,0
0,188
3,4
0,250
6,4
0,375
0,500
0,625
0,750
4T-10
Inches mm
Output
(Cat. No.) Volts(VDC)
Amperage Speed (Per Minute)
Standoff
(Amps)
Inches
Meters
Inches mm
110
60
440
11,18
0,25
9-8210
110
60
440
11,18
9-8210
116
60
250
6,35
9-8210
116
60
170
9-8210
132
60
85
9,5
9-8210
140
60
12,7
9-8210
143
60
15,9
9-8210
145
19,1
9-8210
145
Plasma Gas Press
Flow (CFH)
Pierce
mm
Pierce Height
psi*
bar
Plasma
6,4
70
4,8
90
245
0,00
0,25
6,4
0,25
6,4
70
4,8
90
245
0,10
0,25
6,4
0,25
6,4
70
4,8
90
245
0,10
0,25
6,4
4,32
0,25
6,4
70
4,8
90
245
0,20
0,25
6,4
2,16
0,25
6,4
70
4,8
90
245
0,30
0,25
6,4
45
1,14
0,25
6,4
70
4,8
90
245
0,50
0,25
6,4
30
0,76
0,25
6,4
70
4,8
90
245
0,80
0,25
6,4
60
20
0,51
0,25
6,4
70
4,8
90
245
NR
NR
NR
60
18
0,46
0,25
6,4
70
4,8
90
245
NR
NR
NR
OPERATION
Total** Delay (Sec) Inches
mm
300X5397
ESAB CUTMASTER 100
Type Torch: SL100 With Exposed Tip
Type Material: Mild Steel
Type Plasma Gas: Air
Thickness
Tip
Inches
mm
0,060
1,5
9-8211
0,120
3,0
9-8211
0,135
3,4
0,188
4,8
0,250
0,375
Output
(Cat. No.) Volts(VDC)
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma
113
80
320
8,13
0,19
4,8
65
4,5
115
340
0,00
0,19
4,8
113
80
230
5,84
0,19
4,8
65
4,5
115
340
0,10
0,19
4,8
9-8211
115
80
180
4,57
0,19
4,8
65
4,5
115
340
0,10
0,19
4,8
9-8211
114
80
140
3,56
0,19
4,8
65
4,5
115
340
0,20
0,19
4,8
6,4
9-8211
114
80
100
2,54
0,19
4,8
65
4,5
115
340
0,30
0,19
4,8
9,5
9-8211
117
80
42
1,07
0,19
4,8
65
4,5
115
340
0,40
0,19
4,8
0,500 12,7
9-8211
120
80
33
0,84
0,19
4,8
65
4,5
115
340
0,60
0,19
4,8
0,625 15,9
9-8211
133
80
22
0,56
0,19
4,8
65
4,5
115
340
0,75
0,19
4,8
0,750 19,1
9-8211
128
80
18
0,46
0,19
4,8
65
4,5
115
340
NR
NR
NR
0,875 22,2
9-8211
133
80
10
0,25
0,19
4,8
65
4,5
115
340
NR
NR
NR
1,000 25,4
9-8211
132
80
9
0,23
0,19
4,8
65
4,5
115
340
NR
NR
NR
Type Torch: SL100 With Exposed Tip
Tip
Output
(Cat. No.) Volts(VDC)
mm
Type Material: Stainless Steel
Type Plasma Gas: Air
Thickness
Total** Delay (Sec) Inches
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
Inches
mm
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma
Total**
0,060
1,5
9-8211
120
80
340
8,64
0,25
6,4
65
4,5
115
340
0,00
0,25
6,4
0,120
3,0
9-8211
120
80
300
7,62
0,25
6,4
65
4,5
115
340
0,10
0,25
6,4
0,135
3,4
9-8211
120
80
280
7,11
0,25
6,4
65
4,5
115
340
0,10
0,25
6,4
0,188
4,8
9-8211
120
80
140
3,56
0,25
6,4
65
4,5
115
340
0,20
0,25
6,4
0,250
6,4
9-8211
120
80
100
2,54
0,25
6,4
65
4,5
115
340
0,30
0,25
6,4
0,375
9,5
9-8211
126
80
50
1,27
0,25
6,4
65
4,5
115
340
0,40
0,25
6,4
0,500 12,7
9-8211
129
80
28
0,71
0,25
6,4
65
4,5
115
340
0,80
0,25
6,4
0,625 15,9
9-8211
135
80
20
0,51
0,25
6,4
65
4,5
115
340
1,00
0,25
6,4
0,750 19,1
9-8211
143
80
10
0,25
0,25
6,4
65
4,5
115
340
NR
NR
NR
0,875 22,2
9-8211
143
80
9
0,23
0,25
6,4
65
4,5
115
340
NR
NR
NR
1,000 25,4
9-8211
146
80
8
0,20
0,25
6,4
65
4,5
115
340
NR
NR
NR
Type Torch: SL100 with Exposed Tip
Tip
Inches
mm
0,06
1,5
9-8211
0,12
3,0
9-8211
0,188
4,8
0,250
0,375
Output
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma
Total**
120
80
350
8,89
0,25
6,4
65
4,5
115
340
0,00
0,25
6,4
124
80
300
7,62
0,25
6,4
65
4,5
115
340
0,10
0,25
6,4
9-8211
124
80
180
4,57
0,25
6,4
65
4,5
115
340
0,20
0,25
6,4
6,4
9-8211
128
80
110
2,79
0,25
6,4
65
4,5
115
340
0,30
0,25
6,4
9,5
9-8211
136
80
55
1,40
0,25
6,4
65
4,5
115
340
0,40
0,25
6,4
0,500 12,7
9-8211
139
80
38
0,97
0,25
6,4
65
4,5
115
340
0,60
0,25
6,4
0,625 15,9
9-8211
142
80
26
0,66
0,25
6,4
65
4,5
115
340
0,75
0,25
6,4
0,750 19,1
9-8211
145
80
24
0,61
0,25
6,4
65
4,5
115
340
NR
NR
NR
0,875 22,2
9-8211
153
80
10
0,25
0,25
6,4
65
4,5
115
340
NR
NR
NR
1,000 25,4
9-8211
162
80
6
0,15
0,25
6,4
65
4,5
115
340
NR
NR
NR
300X5397
(Cat. No.) Volts(VDC)
mm
Type Material: Aluminum
Type Plasma Gas: Air
Thickness
Delay (Sec) Inches
OPERATION
Delay (Sec) Inches
mm
4T-11
ESAB CUTMASTER 100
Type Torch: SL100 With Exposed Tip
Type Material: Mild Steel
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Inches
mm
0,250
6,4
9-8212
0,375
Output
(Cat. No.) Volts(VDC)
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma
Total** Delay (Sec) Inches
110
100
105
2,65
0,190
4,8
75
5,2
130
390
0,4
0,200
mm
5,1
9,5
9-8212
117
100
70
1,75
0,190
4,8
75
5,2
130
390
0,5
0,200
5,1
0,500 12,7
9-8212
120
100
50
1,25
0,190
4,8
75
5,2
130
390
0,6
0,200
5,1
0,625 15,9
9-8212
125
100
35
0,90
0,190
4,8
75
5,2
130
390
1,0
0,200
5,1
0,750 19,0
9-8212
131
100
18
0,45
0,190
4,8
75
5,2
130
390
2,0
0,250
6,4
1,000 25,4
9-8212
135
100
10
0,25
0,190
4,8
75
5,2
130
390
NR
NR
NR
Type Torch: SL100 With Exposed Tip
Type Material: Stainless Steel
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Inches
mm
0,250
6,4
9-8212
0,375
9,5
9-8212
0,500 12,7
9-8212
0,625 15,9
0,750 19,0
1,000 25,4
Output
(Cat. No.) Volts(VDC)
Amperage Speed (Per Minute)
(Amps)
Inches
Meters
118
100
90
122
100
55
126
100
9-8212
133
9-8212
138
9-8212
139
Standoff
Inches
Plasma Gas Press
Inches
mm
0,250
6,4
9-8212
0,375
9,5
9-8212
0,500 12,7
0,625 15,9
Output
(Cat. No.) Volts(VDC)
Pierce Height
bar
Plasma
Total**
2,30
0,190 4,8
75
5,2
130
390
0,5
0,250
6,4
1,40
0,190 4,8
75
5,2
130
390
0,8
0,250
6,4
30
0,75
0,190 4,8
75
5,2
130
390
1,0
0,250
6,4
100
20
0,50
0,190 4,8
75
5,2
130
390
1,5
0,250
6,4
100
15
0,40
0,190 4,8
75
5,2
130
390
NR
NR
NR
100
10
0,25
0,190 4,8
75
5,2
130
390
NR
NR
NR
Delay (Sec) Inches
mm
Type Material: Aluminum
Type Plasma Gas: Air
Tip
Pierce
psi*
Type Torch: SL100 with Exposed Tip
Thickness
Flow (CFH)
mm
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma
Total**
Delay (Sec) Inches
mm
108
100
120
3,05
0,190
4,8
65
4,5
120
360
0,2
0,225
5,7
117
100
65
1,65
0,190
4,8
65
4,5
120
360
0,4
0,225
5,7
9-8212
120
100
45
1,15
0,190
4,8
65
4,5
120
360
0,5
0,225
5,7
9-8212
125
100
30
0,75
0,190
4,8
65
4,5
120
360
0,8
0,225
5,7
0,750 19,0
9-8212
131
100
25
0,65
0,190
4,8
65
4,5
120
360
1,0
0,225
5,7
1,000 25,4
9-8212
140
100
10
0,25
0,190
4,8
65
4,5
120
360
NR
NR
NR
NOTE!
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m
leads, refer to Section "Set Operating Pressure" on page <?>.
** Total flow rate includes plasma and secondary gas flow.
4T-12
OPERATION
300X5397
ESAB CUTMASTER 100
4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip
Type Torch: SL100 With Shielded Tip
Type Material: Mild Steel
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Output
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
Volts (VDC)
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma
0,036
0,9
9-8208
114
40
170
4,32
0,19
4,8
65
4,5
55
Total** Delay (Sec) Inches
170
0,00
0,2
mm
5,1
0,06
1,5
9-8208
120
40
90
2,29
0,19
4,8
65
4,5
55
170
0,10
0,2
5,1
0,075
1,9
9-8208
121
40
80
2,03
0,19
4,8
65
4,5
55
170
0,30
0,2
5,1
0,135
3,4
9-8208
122
40
75
1,91
0,19
4,8
65
4,5
55
170
0,40
0,2
5,1
0,188
4,8
9-8208
123
40
30
0,76
0,19
4,8
65
4,5
55
170
0,60
0,2
5,1
0,25
6,4
9-8208
125
40
25
0,64
0,19
4,8
65
4,5
55
170
1,00
0,2
5,1
0,375
9,5
9-8208
138
40
11
0,28
0,19
4,8
65
4,5
55
170
NR
NR
NR
0,500 12,7
9-8208
142
40
7
0,18
0,19
4,8
65
4,5
55
170
NR
NR
NR
0,625 15,9
9-8208
152
40
3
0,08
0,19
4,8
65
4,5
55
170
NR
NR
NR
Type Torch: SL100 With Shielded Tip
Type Material: Stainless Steel
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Output
Amperage Speed (Per Minute)
Standoff
Plasma Gas
Press
Flow (CFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
Volts(VDC)
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma Total** Delay (Sec) Inches
mm
0,036
0,9
9-8208
109
40
180
4,57
0,125
3,2
65
4,5
55
170
0,00
0,2
5,1
0,05
1,3
9-8208
105
40
165
4,19
0,125
3,2
65
4,5
55
170
0,00
0,2
5,1
0,06
1,5
9-8208
115
40
120
3,05
0,125
3,2
65
4,5
55
170
0,10
0,2
5,1
0,078
2,0
9-8208
120
40
65
1,65
0,187
4,8
65
4,5
55
170
0,30
0,2
5,1
0,135
3,4
9-8208
125
40
25
0,64
0,187
4,8
65
4,5
55
170
0,40
0,2
5,1
0,188
4,8
9-8208
132
40
20
0,51
0,187
4,8
65
4,5
55
170
0,60
0,2
5,1
0,25
6,4
9-8208
130
40
15
0,38
0,187
4,8
65
4,5
55
170
1,00
0,2
5,1
0,375
9,5
9-8208
130
40
10
0,25
0,187
4,8
65
4,5
55
170
NR
NR
NR
Type Torch: SL100 With Shielded Tip
Type Material: Aluminum
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Output
Amperage Speed (Per Minute)
Standoff
Plasma Gas
Press
Flow (CFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
Volts(VDC)
(Amps)
Inches
Meters
Inches
mm
psi*
bar
0,032
0,8
9-8208
116
40
220
5,59
0,187
4,8
65
4,5
55
170
0,00
0,2
5,1
0,051
1,3
9-8208
116
40
210
5,33
0,187
4,8
65
4,5
55
170
0,00
0,2
5,1
0,064
1,6
9-8208
118
40
180
4,57
0,187
4,8
65
4,5
55
170
0,10
0,2
5,1
0,079
2,0
9-8208
116
40
150
3,81
0,19
4,8
65
4,5
55
170
0,30
0,2
5,1
0,125
3,2
9-8208
130
40
75
1,91
0,19
4,8
65
4,5
55
170
0,40
0,2
5,1
0,188
4,8
9-8208
132
40
60
1,52
0,187
4,8
65
4,5
55
170
0,60
0,2
5,1
0,250
6,4
9-8208
134
40
28
0,71
0,187
4,8
65
4,5
55
170
1,00
0,2
5,1
0,375
9,5
9-8208
143
40
11
0,28
0,187
4,8
65
4,5
55
170
NR
NR
NR
300X5397
OPERATION
Plasma Total** Delay (Sec) Inches
mm
4T-13
ESAB CUTMASTER 100
Type Torch: SL100 With Shielded Tip
Type Material: Mild Steel
Type Plasma Gas: Air
Thickness
Tip
Output
(Cat. No.) Volts(VDC)
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Inches mm
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
Inches
mm
(Amps)
Inches
Meters
psi*
bar
Plasma
Total**
0,060
1,5
9-8210
124
60
250
6,35
0,19
4,8
70
4,8
90
245
Delay (Sec) Inches
0,00
0,2
mm
5,1
0,075
1,9
9-8210
126
60
237
6,02
0,19
4,8
70
4,8
90
245
0,10
0,2
5,1
0,120
3,0
9-8210
126
60
230
5,84
0,19
4,8
70
4,8
90
245
0,10
0,2
5,1
0,135
3,4
9-8210
128
60
142
3,61
0,19
4,8
70
4,8
90
245
0,10
0,2
5,1
0,188
4,8
9-8210
128
60
125
3,18
0,19
4,8
70
4,8
90
245
0,20
0,2
5,1
0,250
6,4
9-8210
123
60
80
2,03
0,19
4,8
70
4,8
90
245
0,30
0,2
5,1
0,375
9,5
9-8210
132
60
34
0,86
0,19
4,8
70
4,8
90
245
0,50
0,2
5,1
0,500 12,7
9-8210
137
60
23
0,58
0,19
4,8
70
4,8
90
245
0,75
0,2
5,1
0,625 15,9
9-8210
139
60
14
0,36
0,19
4,8
70
4,8
90
245
NR
NR
NR
0,750 19,1
9-8210
145
60
14
0,36
0,19
4,8
70
4,8
90
245
NR
NR
NR
1,000 25,4
9-8210
156
60
4
0,10
0,19
4,8
70
4,8
90
245
NR
NR
NR
Type Torch: SL100 With Shielded Tip
Type Material: Stainless Steel
Type Plasma Gas: Air
Thickness
Inches
mm
Tip
Output
(Cat. No.) Volts(VDC)
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
(Amps)
Inches
Meters
Standoff
Inches mm
Plasma Gas Press
Flow (CFH)
psi*
bar
Plasma
Total**
Pierce
Pierce Height
Delay (Sec) Inches
mm
0,06
1,5
9-8210
110
60
165
4,19
0,13
3,2
70
4,8
90
245
0,00
0,20
5,1
0,075
1,9
9-8210
116
60
155
3,94
0,13
3,2
70
4,8
90
245
0,10
0,20
5,1
0,120
3,0
9-8210
115
60
125
3,18
0,13
3,2
70
4,8
90
245
0,10
0,20
5,1
0,135
3,4
9-8210
118
60
80
2,03
0,13
3,2
70
4,8
90
245
0,10
0,20
5,1
0,188
4,8
9-8210
120
60
75
1,91
0,13
3,2
70
4,8
90
245
0,20
0,20
5,1
0,250
6,4
9-8210
121
60
60
1,52
0,13
3,2
70
4,8
90
245
0,30
0,20
5,1
0,375
9,5
9-8210
129
60
28
0,71
0,13
3,2
70
4,8
90
245
0,50
0,20
5,1
0,500 12,7
9-8210
135
60
17
0,43
0,19
4,8
70
4,8
90
245
0,75
0,20
5,1
0,625 15,9
9-8210
135
60
14
0,36
0,19
4,8
70
4,8
90
245
NR
NR
NR
0,750 19,1
9-8210
142
60
10
0,25
0,19
4,8
70
4,8
90
245
NR
NR
NR
Type Torch: SL100 With Shielded Tip
Type Material: Aluminum
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Inches
mm
0,060
1,5
9-8210
0,075
1,9
0,120
3,0
0,188
0,250
0,375
Output
(Cat. No.) Volts(VDC)
Amperage Speed (Per Minute)
Standoff
(Amps)
Inches
Meters
Inches mm
105
60
350
8,89
0,13
9-8210
110
60
350
8,89
9-8210
110
60
275
6,99
3,4
9-8210
122
60
140
6,4
9-8210
134
60
80
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
psi*
bar
Plasma
Total** Delay (Sec) Inches
3,2
70
4,8
90
245
0,00
0,20
mm
5,1
0,13
3,2
70
4,8
90
245
0,10
0,20
5,1
0,13
3,2
70
4,8
90
245
0,10
0,20
5,1
3,56
0,13
3,2
70
4,8
90
245
0,20
0,20
5,1
2,03
0,19
4,8
70
4,8
90
245
0,30
0,20
5,1
9,5
9-8210
140
60
45
1,14
0,19
4,8
70
4,8
90
245
0,50
0,20
5,1
0,500 12,7
9-8210
144
60
26
0,66
0,19
4,8
70
4,8
90
245
0,80
0,20
5,1
0,625 15,9
9-8210
145
60
19
0,48
0,19
4,8
70
4,8
90
245
NR
NR
NR
0,750 19,1
9-8210
150
60
15
0,38
0,19
4,8
70
4,8
90
245
NR
NR
NR
4T-14
OPERATION
300X5397
ESAB CUTMASTER 100
Type Torch: SL100 With Shielded Tip
Type Material: Mild Steel
Type Plasma Gas: Air
Thickness
Tip
Output
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
Volts(VDC)
(Amps)
Inches
Meters
Inches
mm
psi*
bar
0,060
1,5
9-8211
128
80
280
7,11
0,19
4,8
65
4,5
115
340
0,00
0,2
5,1
0,120
3,0
9-8211
126
80
203
5,16
0,19
4,8
65
4,5
115
340
0,10
0,2
5,1
0,135
3,4
9-8211
128
80
182
4,62
0,19
4,8
65
4,5
115
340
0,10
0,2
5,1
0,188
4,8
9-8211
128
80
137
3,48
0,19
4,8
65
4,5
115
340
0,20
0,2
5,1
0,250
6,4
9-8211
131
80
100
2,54
0,19
4,8
65
4,5
115
340
0,30
0,2
5,1
0,375
9,5
9-8211
134
80
40
1,02
0,19
4,8
65
4,5
115
340
0,50
0,2
5,1
0,500 12,7
9-8211
136
80
36
0,91
0,19
4,8
65
4,5
115
340
0,60
0,2
5,1
0,625 15,9
9-8211
145
80
21
0,53
0,19
4,8
65
4,5
115
340
0,75
0,2
5,1
0,750 19,1
9-8211
144
80
14
0,36
0,19
4,8
65
4,5
115
340
NR
NR
NR
0,875 22,2
9-8211
149
80
11
0,28
0,19
4,8
65
4,5
115
340
NR
NR
NR
1,000 25,4
9-8211
162
80
8
0,20
0,19
4,8
65
4,5
115
340
NR
NR
NR
Type Torch: SL100 With Shielded Tip
Tip
Inches
mm
0,060
1,5
9-8211
0,120
3,0
9-8211
0,135
3,4
0,188
0,250
0,375
Output
(Cat. No.) Volts(VDC)
mm
Type Material: Stainless Steel
Type Plasma Gas: Air
Thickness
Plasma Total** Delay (Sec) Inches
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma Total** Delay (Sec) Inches
mm
110
80
340
8,50
0,125
3,2
65
4,5
115
340
0,00
0,2
5,1
115
80
260
6,50
0,125
3,2
65
4,5
115
340
0,10
0,2
5,1
9-8211
113
80
250
6,25
0,125
3,2
65
4,5
115
340
0,10
0,2
5,1
4,8
9-8211
114
80
170
4,25
0,125
3,2
65
4,5
115
340
0,20
0,2
5,1
6,4
9-8211
116
80
85
2,13
0,125
3,2
65
4,5
115
340
0,30
0,2
5,1
9,5
9-8211
123
80
45
1,13
0,125
3,2
65
4,5
115
340
0,40
0,25
6,4
0,500 12,7
9-8211
133
80
18
0,45
0,125
3,2
65
4,5
115
340
0,75
0,25
6,4
0,625 15,9
9-8211
135
80
16
0,40
0,125
3,2
65
4,5
115
340
1,00
0,25
6,4
0,750 19,1
9-8211
144
80
8
0,20
0,125
3,2
65
4,5
115
340
NR
NR
NR
0,875 22,2
9-8211
137
80
8
0,20
0,125
3,2
65
4,5
115
340
NR
NR
NR
1,000 25,4
9-8211
140
80
8
0,20
0,125
3,2
65
4,5
115
340
NR
NR
NR
Type Torch: SL100 With Shielded Tip
Type Material: Aluminum
Type Plasma Gas: Air
Thickness
Tip
Inches
mm
0,06
1,5
9-8211
0,12
3,0
9-8211
0,188
4,8
9-8211
0,250
6,4
9-8211
0,375
9,5
Output
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
(Amps)
Inches
Meters
Inches
mm
psi*
bar
Plasma
Total**
115
80
320
8,13
0,13
3,2
65
4,5
115
340
0,00
0,25
6,4
120
80
240
6,10
0,13
3,2
65
4,5
115
340
0,10
0,25
6,4
120
80
165
4,19
0,13
3,2
65
4,5
115
340
0,20
0,25
6,4
124
80
100
2,54
0,13
3,2
65
4,5
115
340
0,30
0,25
6,4
9-8211
138
80
60
1,52
0,19
4,8
65
4,5
115
340
0,40
0,25
6,4
0,500 12,7
9-8211
141
80
36
0,91
0,19
4,8
65
4,5
115
340
0,60
0,25
6,4
0,625 15,9
9-8211
142
80
26
0,66
0,19
4,8
65
4,5
115
340
0,75
0,25
6,4
0,750 19,1
9-8211
150
80
18
0,46
0,19
4,8
65
4,5
115
340
NR
NR
NR
0,875 22,2
9-8211
156
80
8
0,20
0,19
4,8
65
4,5
115
340
NR
NR
NR
1,000 25,4
9-8211
164
80
6
0,15
0,19
4,8
65
4,5
115
340
NR
NR
NR
300X5397
(Cat. No.) Volts(VDC)
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
OPERATION
Delay (Sec) Inches
mm
4T-15
ESAB CUTMASTER 100
Type Torch: SL100 With Shielded Tip
Type Material: Mild Steel
Type Plasma Gas: Air
Type Secondary Gas: Single Gas Torch
Thickness
Tip
Output
Amperage Speed (Per Minute)
Standoff
Plasma Gas
Press
Flow (CFH)
Pierce
Pierce Height
Inches
mm
(Cat. No.)
Volts(VDC)
(Amps)
Inches
Meters
Inches
mm
psi*
bar
0,250
6,4
9-8212
124
100
110
2,80
0,180
4,6
75
5,2
130
390
0,4
0,200
5,1
0,375
9,5
9-8212
127
100
75
1,90
0,180
4,6
75
5,2
130
390
0,5
0,200
5,1
0,500 12,7
9-8212
132
100
50
1,30
0,180
4,6
75
5,2
130
390
0,6
0,200
5,1
0,625 15,9
9-8212
136
100
30
0,75
0,180
4,6
75
5,2
130
390
0,8
0,200
5,1
0,750 19,0
9-8212
140
100
18
0,45
0,190
4,8
75
5,2
130
390
2,0
0,225
5,7
1,000 25,4
9-8212
147
100
10
0,25
0,190
4,8
75
5,2
130
390
NR
NR
NR
Type Torch: SL100 With Shielded Tip
Tip
Output
(Cat. No.) Volts(VDC)
mm
Type Material: Stainless Steel
Type Plasma Gas: Air
Thickness
Plasma Total** Delay (Sec) Inches
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
Inches
mm
(Amps)
Inches
Meters
Inches
mm
psi*
bar
0,250
6,4
9-8212
121
100
110
2,80
0,125
3,2
75
5,2
Plasma Total** Delay (Sec) Inches
130
390
0,5
0,200
mm
5,1
0,375
9,5
9-8212
125
100
60
1,50
0,150
3,8
75
5,2
130
390
0,8
0,200
5,1
0,500 12,7
9-8212
132
100
35
0,90
0,150
3,8
75
5,2
130
390
1,0
0,200
5,1
0,625 15,9
9-8212
137
100
20
0,50
0,150
3,8
75
5,2
130
390
2,0
0,225
5,7
0,750 19,0
9-8212
144
100
15
0,40
0,190
4,8
75
5,2
130
390
NR
NR
NR
1,000 25,4
9-8212
154
100
8
0,20
0,190
4,8
75
5,2
130
390
NR
NR
NR
Type Torch: SL100 With Shielded Tip
Type Material: Aluminum
Type Plasma Gas: Air
Thickness
Tip
Output
(Cat. No.) Volts(VDC)
Type Secondary Gas: Single Gas Torch
Amperage Speed (Per Minute)
Standoff
mm
Plasma Gas Press
Flow (CFH)
Pierce
Pierce Height
Inches
mm
(Amps)
Inches
Meters
Inches
psi*
bar
Plasma
Total**
0,250
6,4
9-8212
120
100
120
3,05
0,180
65
4,5
105
360
Delay (Sec) Inches
0,2
0,225
mm
5,7
0,375
9,5
9-8212
128
100
65
1,65
0,180
65
4,5
105
360
0,4
0,225
5,7
0,500 12,7
9-8212
130
100
45
1,15
0,180
65
4,5
105
360
0,5
0,225
5,7
0,625 15,9
9-8212
135
100
30
0,75
0,180
65
4,5
105
360
0,8
0,225
5,7
0,750 19,0
9-8212
140
100
25
0,65
0,180
65
4,5
105
360
1,0
0,225
5,7
1,000 25,4
9-8212
148
100
10
0,25
0,190
65
4,5
105
360
NR
NR
NR
NOTE!
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m
leads, refer to Section "Set Operating Pressure" on page <?>.
** Total flow rate includes plasma and secondary gas flow.
4T-16
OPERATION
300X5397
ESAB CUTMASTER 100
This Page Intentionally Blank
300X5397
OPERATION
4T-17
ESAB CUTMASTER 100
PATENT INFORMATION
Plasma Cutting Torch Patents
The following parts are covered under U.S. and Foreign Patents as follows:
Catalog #
Description
Patent(s)
9-8215
Electrode
9-8213
Cartridge
9-8205
Tip
9-8206
Tip
9-8207
Tip
9-8252
Tip
9-8208
Tip
9-8209
Tip
9-8210
Tip
9-8231
Tip
9-8211
Tip
9-8212
Tip
9-8253
Tip
9-8225
Tip
9-8226
Tip
9-8227
Tip
9-8228
Tip
9-8241
Shield Cap
9-8243
Shield Cap
9-8235
Shield Cap
9-8236
Shield Cap
9-8237
Shield Cup
9-8238
Shield Cap
9-8239
Shield Cap
9-8244
Shield Cap
4T-18
US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
US Pat No(s) 6903301; 6717096; 6936786;
6703581; D496842; D511280; D492709;
D499620; D504142 Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6914211; D505309
Other Pat(s) Pending
US Pat No(s) 6914211; D493183
Other Pat(s) Pending
US Pat No(s) 6914211; D505309
Other Pat(s) Pending
US Pat No(s) 6914211; D505309
Other Pat(s) Pending
US Pat No(s) 6914211; D501632; D511633
Other Pat(s) Pending
US Pat No(s) 6914211; D496951
Other Pat(s) Pending
US Pat No(s) 6914211; D496951
Other Pat(s) Pending
US Pat No(s) 6914211; D505309
Other Pat(s) Pending
OPERATION
300X5397
ESAB CUTMASTER 100
Catalog #
Description
Patent(s)
9-8245
Shield Cap
US Pat No(s) 6914211; D496951
Other Pat(s) Pending
The following parts are also licensed under U.S. Patent No. 5, 120, 930 and 5, 132, 512:
Catalog #
Description
9-8235
9-8236
9-8237
9-8238
9-8239
9-8244
9-8245
Shield Cap
Shield Cap
Shield Cup
Shield Cap
Shield Cap
Shield Cap
Shield Cap
300X5397
OPERATION
4T-19
ESAB CUTMASTER 100
This Page Intentionally Blank
4T-20
OPERATION
300X5397
ESAB CUTMASTER 100
SECTION 5 SYSTEM: SERVICE
5.01 General Maintenance
Warning!
Disconnect input power before maintaining.
Maintain more often
if used under severe
conditions
Each Use
Visual check of
torch tip and electrode
Weekly
Visually inspect the torch body tip,
electrode, start cartridge and shield cup
Visually inspect the
cables and leads.
Replace as needed
3 Months
Replace all
broken parts
Clean
exterior
of power supply
6 Months
Visually check and
Carefully clean the
interior
Art # A-07938_AB
300X5397
SERVICE
5-1
ESAB CUTMASTER 100
5.02 Maintenance Schedule
5.03 Common Faults
NOTE!
The actual frequency of maintenance may need to be adjusted
according to the operating environment.
Problem Symptom
Common Cause
Insufficient
Penetration
1. Cutting speed too fast.
2. Torch tilted too much.
3. Metal too thick.
4. Worn torch parts
5. Cutting current too low.
6. Non - Genuine ESAB parts used
7. Incorrect gas pressure
Main Arc
Extinguishes
1. Cutting speed too slow.
2. Torch standoff too high from
workpiece.
3. Cutting current too high.
4. Work cable disconnected.
5. Worn torch parts.
6. Non - Genuine ESAB parts used
Daily Operational Checks or Every Six Cutting
Hours:
1. Check torch consumable parts, replace if damaged or worn.
2. Check plasma and secondary supply and pressure/flow.
3. Purge plasma gas line to remove any moisture
build-up.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air
flow.
2. Inspect torch for any cracks or exposed wires,
replace if necessary.
3. Inspect input power cable for damage or exposed
wires, replace if necessary.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as
required.
2. Check cables and hoses for leaks or cracks,
replace if necessary.
3. Check all contactor points for severe arcing or
pits, replace if necessary.
4. Vacuum dust and dirt out of the entire machine.
!
5-2
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into
the unit can cause metal particles
to interfere with sensitive electrical
components and cause damage to
the unit.
Excessive Dross 1. Cutting speed too slow.
Formation
2. Torch standoff too high from
workpiece.
3. Worn torch parts.
4. Improper cutting current.
5. Non - Genuine ESAB parts used
6. Incorrect gas pressure
Short Torch Parts 1. Oil or moisture in air source.
Life
2. Exceeding system capability
(material too thick).
3. Excessive pilot arc time
4. Gas pressure too low.
5. Improperly assembled torch.
6. Non - Genuine ESAB parts used
Difficult Starting 1. Worn torch parts.
2. Non - Genuine ESAB parts
used.
3. Incorrect gas pressure.
SERVICE
300X5397
ESAB CUTMASTER 100
5.04 Fault Indicator
At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used.
To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit
count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator
and 75 psi indicators are on indicating the version would be 2.3.
7
6
5
4
3
2
1
MIN
0
A
MAX
PSI
BAR
MAX
MAX
MIN
MIN
+
!
1
2 3 4
5
Art# A-07988
!
When the "Fault" indicator is ON or blinking it will be accompanied by one of the pressure indicator lights
depending on what the Fault is. The following table explains each of those Faults.
Pressure Fault
Indicator
Max
Over Pressure
90
Internal Error
85
Check Consumables
80
Consumables Missing
75
Start Error
70
Parts in Place
65
Input Power
Min
Under Pressure
NOTE!
Fault explanations are covered in the following tables.
300X5397
SERVICE
5-3
ESAB CUTMASTER 100
5.05 Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not
attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.
Problem - Symptom Possible Cause
Recommended Action
ON / OFF Switch
is ON but the A/C
Indicator does not
light
1. Primary power disconnect is in
1. Turn primary power disconnect switch to ON position.
OFF position.
2. a) Have qualified person check primary fuses / breakers.
2. Primary fuses / breakers are blown b) Connect unit to known good primary power receptacle
or tripped.
3. a) Replace fuse.
3. Units internal fuse blown.
b) If fuse blows again, return to authorized service center for
4. Faulty components in unit.
repair or replacement.
4. Return to authorized service center for repair or replacement.
Fault indicator
flashing, 65 PSI
indicator flashing
1. Improper Input Voltage.
2. Primary input voltage problem.
3. Faulty components in unit.
1. Check for proper primary input voltage.
2. Have qualified person check primary voltage to insure it meets
unit requirements see section 2.05.
3. Return to authorized service center for repair or replacement.
TEMPERATURE
1. Air flow through or around the unit 1. Refer to clearance information – section 2.04
indicator ON. FAULT is obstructed.
2. Allow unit to cool.
indicator flashing.
2. Duty cycle of the unit has been
3. Return to authorized service center for repair or replacement.
exceeded
3. Failed components in unit
GAS LED OFF,
FAULT and MIN
pressure indicators
flashing.
1. Gas supply not connected to unit.
2. Gas supply not turned ON.
3. Gas supply pressure too low.
4. AIR PRESSURE CONTROL
regulator set too low.
5. Failed components in unit.
1. Connect gas supply to unit.
2. Turn gas supply ON.
3. Set air supply inlet pressure to unit to 120 psi.
4. Adjust regulator to set air pressure - see section 4.02.
5. Return to authorized service center for repair or replacement.
FAULT and 70 PSI
indicators flashing.
1. Shield Cup loose.
2. Torch not properly connected to
power supply.
3. Problem in torch and leads PIP
circuit.
4. Failed components in unit.
1. Hand tighten the shield cup until it is snug.
2. Insure torch ATC is securely fastened to unit.
3. Replace torch and leads or return to authorized service center
for repair or replacement.
4. Return to authorized service center for repair or replacement.
FAULT and 75 PSI
indicators flashing.
1. Start signal is active when ON/OFF 1. Start can be active for one of the following:
SWITCH is turned to ON position.
• Hand torch switch held closed
2. Problem in the torch and leads
• Hand pendant switch held closed
switch circuit.
• CNC START signal is active low
3. Failed components in unit.
Release the START signal source
2. Replace torch and leads or return to authorized service center
for repair or replacement.
3. Return to authorized service center for repair or replacement.
5-4
SERVICE
300X5397
ESAB CUTMASTER 100
Problem - Symptom Possible Cause
Recommended Action
FAULT & 80 PSI
indicators flashing.
Gas flow is cycling
ON and OFF.
1. Tighten shield cup by hand. Do not overtighten.
2. Turn OFF power supply. Remove shield cup. Install missing
parts.
3. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
4. Replace torch and leads or return to authorized service
center for repair or replacement.
5. Replace torch and leads or return to authorized service
center for repair or replacement.
6. Return to authorized service center for repair or replacement.
1. Torch shield cup is loose.
2. Torch tip, electrode or starter
cartridge missing.
3. Torch starter cartridge is stuck.
4. Open conductor in torch leads.
5. Problem in the torch and leads
switch circuit.
6. Failed components in unit.
Nothing happens
when torch switch
or remote switch
is closed (Or CNC
START signal is
active) No gas flow,
DC LED OFF.
1. Problem in the torch and leads
1. Take Torch and Leads (Remote Pendant) to Authorized
switch circuit (Remote pendant switch Repair Facility.
circuit).
2. Contact Controller manufacturer.
2. CNC Controller device not providing 3. Return to authorized service center for repair or replacement.
Start signal.
3. Failed components in unit.
FAULT and 85 PSI
indicators flashing.
1. Upper O-Ring on torch head is in
wrong position.
2. Torch starter cartridge is stuck.
3. Worn or faulty torch parts.
4. Shorted Torch.
5. Temporary Short indicated by 5
blinks per second.
6. Power Supply Failure (Standard
rate of blinking)
1. Remove shield cup from torch; check upper O-Ring position;
correct if necessary.
2. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
3. Inspect torch consumable parts. Replace if necessary.
4. Replace torch and leads or return to an authorized service
center for repair.
5. Release torch switch and reactivate.
6. Return to authorized service center for repair or replacement.
No Fault lights ON,
no arc in torch.
1. Failed components in unit.
1. Return to an authorized service center for repair.
Fault and 90 PSI
indicators flashing
1. Internal Error
1. Turn the ON / OFF switch OFF then back ON again. If that
does not clear the fault, return to an authorized service center
for repair.
Pilot arc is ON but
cutting arc will not
establish
1. Work cable not connected to work
piece.
2. Work cable/connector broken.
3. Failed components in unit.
1. Connect work cable.
2. Replace work cable.
3. Return to an authorized service center for repair.
Torch cutting is
diminished
1. Incorrect current setting.
1. Check and adjust to proper setting.
2. Worn torch consumables.
2. Check torch consumables and replace as needed.
3. Poor work cable connection to work 3. Check the connection of the Work Lead to the work piece.
piece.
4. Reduce cutting speed.
4. Torch being moved too fast.
5. Refer to "Check air quality" in section 3 Torch.
5. Excessive oil or water in torch.
6. Return to an authorized service center for repair.
6. Failed components in unit.
300X5397
SERVICE
5-5
ESAB CUTMASTER 100
5.06 Power Supply Basic Parts
Replacement
!
C. Filter Element Assembly Replacement
The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should be
checked per the Maintenance Schedule (Subsection
5.02), and either cleaned or replaced.
WARNING
Disconnect primary power to the
system before disassembling the
torch, leads, or power supply.
1. Remove power from the power supply; turn OFF
the gas supply and bleed down the system.
This section describes procedures for basic parts
replacement. For more detailed parts replacement
procedures, refer to the Power Supply Service Manual.
A. Cover Removal
1. Remove the NOTE screws which secure the
cover to the main assembly. Do not loosen the
lower screws inside the cut out slots in the bottom
of the cover.
2. Remove the system cover. See "A Cover Removal" in this section.
3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
illustration.
4. Hold a wrench or similar tool against the locking
ring on the filter assembly fitting, then pull on
the hose to release it. (Numbers 2 and 3 in the
following illustration).
Upper
Screws
1
Lower
Screws
Slots
Lower
Screws
Art # A-07989
2
Art # A-08429
2. Carefully pull the Cover up and away from the
unit.
3
B. Cover Installation
4
5
1. Reconnect the ground wire, if necessary.
2. Place the cover onto the power supply so that
slots in the bottom edges of the cover engage
the lower screws.
6mm
3. Tighten lower screws.
4. Reinstall and tighten the upper screws.
5-6
SERVICE
300X5397
ESAB CUTMASTER 100
5. Remove the fitting from the filter element assembly by inserting a 6 mm hex wrench into the
internal hex fitting and turning it counter clockwise (left). Numbers 4 and 5 in the previous
illustration.
4. Turn the Filter Housing Cover counter-clockwise
and remove it. The Filter Element is located
inside the Housing.
Housing
6. Disconnect the input line from the filter element
assembly.
7. Remove the filter element assembly through the
rear opening.
Filter
Element
(Cat. No. 9-7741)
NOTE!
If replacing or cleaning just the filter
element refer to the following illustration for disassembly.
Spring
O-ring
(Cat. No. 9-7743)
Assembled Filter
Cover
Barbed
Fitting
Art # A-02476
Optional Single-Stage Filter Element Replacement
Filter Element
5. Remove the Filter Element from the Housing and
set Element aside to dry.
6. Wipe inside of housing clean, then insert the
replacement Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply.
Art # A-07990
NOTE!
If unit leaks between housing and
cover, inspect the O-ring for cuts or
other damage.
8. Install the new or cleaned assembly by reversing
these procedures.
9. Turn ON the air supply and check for leaks before
reinstalling the cover.
Optional Two-Stage Filter Element
Replacement
Optional Single-Stage Filter Element
Replacement
These instructions apply to power supplies where the
optional Single-Stage Filter has been installed.
The Power Supply shuts down automatically when the
Filter Element becomes completely saturated. The
Filter Element can be removed from its housing, dried,
and reused. Allow 24 hours for Element to dry. Refer
to Section 6, Parts List, for replacement filter element
catalog number.
The Two-Stage Air Filter has two Filter Elements. When
the Filter Elements become dirty the Power Supply will
continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement
filter element catalog number.
1. Shut OFF primary input power.
2. Shut OFF air supply and bleed down system.
1. Remove power from power supply.
2. Shut OFF air supply and bleed down system
before disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.
300X5397
SERVICE
5-7
ESAB CUTMASTER 100
!
WARNING
Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could result.
3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.
4. Note the location and orientation of the old Filter Elements.
5. Slide out the old Filter Elements.
First & Second
Stage
Cartridges
(as marked)
Art # A-02942
Optional Two-Stage Filter Replacement
6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4
above.
7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque
may damage the gasket.
8. Slowly apply air pressure to the assembly, checking for leaks.
NOTE!
A small amount of air leakage from the bottom fitting is normal.
This completes the parts replacement procedures.
5-8
SERVICE
300X5397
ESAB CUTMASTER 100
SECTION 5 TORCH:
SERVICE
Upper Groove
with Vent Holes
Must Remain Open
5T.01 General Maintenance
NOTE!
Refer to Previous "Section 5: System" for common and fault indicator
descriptions.
Upper O-Ring
in Correct Groove
Threads
Lower O-Ring
Cleaning Torch
Art # A-03725
Torch Head O-Ring
Even if precautions are taken to use only clean air
with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect
the pilot arc initiation and the overall cut quality of
the torch.
ATC Male Connector
WARNING
Disconnect primary power to the
system before disassembling the
torch or torch leads.
DO NOT touch any internal torch
parts while the AC indicator light of
the Power Supply is ON.
The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet
rag. In severe cases, the torch can be removed from
the leads and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and blowing
it through with compressed air.
!
CAUTION
Dry the torch thoroughly before
reinstalling.
O-Ring
#8-0525
Art #A-03791_AB
ATC O-Ring
O-Ring Lubrication
An o-ring on the Torch Head and ATC Male Connector requires lubrication on a scheduled basis. This
will allow the o-rings to remain pliable and provide
a proper seal. The o-rings will dry out, becoming
hard and cracked if the lubricant is not used on a
regular basis. This can lead to potential performance
problems.
It is recommended to apply a very light film of oring lubricant (Catalog # 8-4025) to the o-rings on
a weekly basis.
300X5397
Gas Fitting
SERVICE
NOTE!
DO NOT use other lubricants or
grease, they may not be designed
to operate within high temperatures
or may contain “unknown elements”
that may react with the atmosphere.
This reaction can leave contaminants
inside the torch. Either of these
conditions can lead to inconsistent
performance or poor parts life.
5T-9
ESAB CUTMASTER 100
5T.02 Inspection and Replacement
of Consumable Torch Parts
4. Remove the tip. Check for excessive wear
(indicated by an elongated or oversized orifice).
Clean or replace the tip if necessary.
Good Tip
WARNING
Disconnect primary power to the
system before disassembling the
torch or torch leads.
DO NOT touch any internal torch
parts while the AC indicator light of
the Power Supply is ON.
Worn Tip
A-03406
Example of Tip Wear
5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration.
Check the lower end fitting for free motion. Replace if necessary.
Remove the consumable torch parts as follows:
NOTE!
The shield cup holds the tip and
starter cartridge in place. Position
the torch with the shield cup facing
upward to prevent these parts from
falling out when the cup is removed.
Spring-Loaded
Lower End Fitting
Full Compression
Spring-Loaded
Lower End Fitting at Reset /
Full Extension
1. Unscrew and remove the shield cup from the
torch.
NOTE!
Slag built up on the shield cup that
cannot be removed may effect the
performance of the system.
Art # A-08064_AC
6. Pull the Electrode straight out of the Torch Head.
Check the face of the electrode for excessive
wear. Refer to the following figure.
2. Inspect the cup for damage. Wipe it clean or
replace if damaged.
New Electrode
Art # A-08067
Shield Cups
Art # A-03284
3. On torches with a shield cup body and a shield
cap or deflector, ensure that the cap or deflector
is threaded snugly against the shield cup body.
In shielded drag cutting operations (only), there
may be an O-ring between the shield cup body
and drag shield cap. Do not lubricate the O-ring.
Worn Electrode
Electrode Wear
7. Reinstall the Electrode by pushing it straight into
the torch head until it clicks.
8. Reinstall the desired starter cartridge and tip into
the torch head.
Drag Shield Cap
9. Hand tighten the shield cup until it is seated on
the torch head. If resistance is felt when installing
the cup, check the threads before proceeding.
Shield
Cup Body
O-Ring No. 8-3488
This completes the parts replacement procedures.
Art # A-03878
5T-10
SERVICE
300X5397
ESAB CUTMASTER 100
SECTION 6: PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:
Section "6.03 Power Supply Replacement"
Section "6.04 Replacement Power Supply Parts"
Section "6.05 Options and Accessories"
Section "6.06 Replacement Parts for Hand Torch"
Section "6.07 Replacement Parts - for Machine Torches with Unshielded Leads"
Section "6.08 Torch Consumable Parts (SL100)"
NOTE!
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization
will not be accepted.
6.02 Ordering Information
Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial number of the power supply. Address all inquiries to your
authorized distributor.
6.03 Power Supply Replacement
The following items are included with the replacement power supply: work cable & clamp, input power cable, gas
pressure regulator / filter, and operating manual.
Qty Description Catalog #
1
ESAB Cutmaster 100 CE Power Supply with 400VAC, 3 phase 50/60 Hz, with input power cable
0559317304
6.04 Replacement Power Supply Parts
Qty Description Catalog #
1 Regulator 1
Filter Assembly Replacement Element
1
Input Power Cord for 380/400 V Power Supply
300X5397
PARTS LIST
9-0115
9-0116
9-0216
6-1
ESAB CUTMASTER 100
6.05 Options and Accessories
Qty Description Catalog #
1
Single - Stage Filter Kit (includes Filter & Hose) 1
Replacement Filter Body 1
Replacement Filter Hose (not shown)
2
Replacement Filter Element 1
Two - Stage Filter Kit (includes Hose & Mounting Screws)
1
Two - Stage Air Filter Assembly
1
First Stage Cartridge
1
Second Stage Cartridge
1
Extended Work Cable (50 ft / 15.2 m) with Clamp
1
Automation Interface Kit
for Start/Stop, OK to move and Divided Arc Voltage)
1
Automation Harness for Start/Stop and OK to move
1
25' / 7.6 m CNC Cable for Automation Interface Kit
1
35' / 10.7 m CNC Cable for Automation Interface Kit
1
50' /15.2 m CNC Cable for Automation Interface Kit
1 Remote pendant
1 Simple Automation Interface
7-7507
9-7740
9-7742
9-7741
9-9387
9-7527
9-1021
9-1022
9-8529
9-8311
9-9385
9-1008
9-1010
9-1011
7-3460
9-9385
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Assembled Filter
Cover
Barbed
Fitting
Art # A-02476
Optional Single - Stage Filter Kit
6-2
PARTS LIST
First & Second
Stage
Cartridges
(as marked)
Art # A-02942
Optional Two - Stage Filter Kit
300X5397
ESAB CUTMASTER 100
6.06 Replacement Parts for Hand Torch
Item #
Qty
Description
1
1
Torch Handle Replacement Kit (includes items No. 2 & 3)
2
1
Trigger Assembly Replacement Kit 3
1
Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench)
4
1
Torch Head Assembly Replacement Kit (includes items No. 5 & 6)
5
1
Large O-Ring
6
1
Small O-Ring
7
Leads Assemblies with ATC connectors (includes switch assemblies)
1
SL100, 20 - foot Leads Assembly with ATC connector
1
SL100, 50 - foot Leads Assembly with ATC connector
8
1
Switch Kit
10
1
Torch Control Cable Adapter (includes item # 11)
11
1
Through - Hole Protector
Catalog #
9-7030
9-7034
9-8062
9-8219
8-3487
8-3486
4-7836
4-7837
9-7031
7-3447
9-8103
1
8
2
4
5
6
3
7
Art # A-07993_AB
300X5397
PARTS LIST
6-3
ESAB CUTMASTER 100
6.07 Replacement Parts - for Machine Torches with Unshielded Leads
Item No. Qty
Description
1
1
Torch Head Assembly without leads (includes items 2, 3, and 14)
2
1
Large O-Ring
3
1
Small O-Ring
4
1
PIP Switch Kit
5
Unshielded Automated Leads Assemblies with ATC connectors
1
5 - foot / 1.5 m Leads Assembly with ATC connector
1
10 - foot / 3.05 m Leads Assembly with ATC connector
1
25 - foot / 7.6 m Leads Assembly with ATC connector
1
50 - foot / 15.2 m Leads Assembly with ATC connector
6
Unshielded Mechanized Leads Assemblies with ATC connectors
1
5 - foot / 1.5 m Leads Assembly with ATC connector
1
10 - foot / 3.05 m Leads Assembly with ATC connector
1
25 - foot / 7.6 m Leads Assembly with ATC connector
1
50 - foot / 15.2 m Leads Assembly with ATC connector
7
1
11” / 279 mm Rack
8
1
11” / 279 mm Mounting Tube
9
1
End Cap Assembly
10
2
Body, Mounting, Pinch Block 11
1
Pin, Mounting, Pinch Block
12
1
Torch Holder Sleeve
13
1
PIP Plunger and Return Spring Kit
1
Pinion Assembly (Not shown)
1
5” / 126 mm Positioning Tube (Not shown)
Catalog #
9-8220
8-3487
8-3486
9-7036
4-7850
4-7851
4-7852
4-7853
4-7842
4-7843
4-7844
4-7845
9-7041
9-7043
9-7044
9-4513
9-4521
7-2896
9-7045
7-2827
9-7042
NOTE!
*Does not include Control Cable Adapter or Through - Hole Protector.
6-4
PARTS LIST
300X5397
ESAB CUTMASTER 100
9
7
10
8
10
1
2
11
3
4
12
13
5&6
A-07994_AB
300X5397
PARTS LIST
6-5
ESAB CUTMASTER 100
6.08 Torch Consumable Parts (SL100)
Ohmic Clip
Automation Torch
9-8224
Ohmic Clip
Manual Torch
9-8259
20-40A
Tip:
STANDOFF
CUTTING
20A
30A
40A
9-8205
9-8206
9-8208
Shield
Cup Body,
9-8237
Shield Cap, Machine
40A 9-8245
Shield Cup
9-8218
Shield Cap, Deflector
9-8243
Drag Shield Cup
9-8235
50-60A
Tips:
STANDOFF
CUTTING
50-55A
60A
Electrode
Auto 9-8232
Manual 9-8215
Starter
Heavy Duty
Cartridge
Starter Cartridge
9-8213 Non HF Only 9-8277
70-120A
STANDOFF
CUTTING
9-8209
9-8210
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield Cap, Machine
50-60A 9-8238
Shield Cap, Deflector
9-8243
Drag Shield Cup
70-100A 9-8236
Tips:
70A 9-8231
80A 9-8211
90/100A 9-8212
120A Auto 9-8233
120A Manual 9-8253
Shield
Cup Body,
9-8237
Drag Shield Cup
120A 9-8258
Shield Cap, Machine
70-100A 9-8239
Shield Cup
9-8218
Shield Cap, Machine
120A 9-8256
Shield Cap, Deflector
9-8243
40-120A
GOUGING
Shield
Cup Body,
9-8237
Tips:
Tip A 9-8225 (40 Amps Max.)
Tip B 9-8226 (50 - 120 Amps)
Shield Cup, Gouging
9-8241
Tip C 9-8227 (60 - 120 Amps)
Tip D 9-8228 (60 - 120 Amps)
Art # A-08066_AG
6-6
Tip E 9-8254 (60 - 120 Amps)
PARTS LIST
300X5397
ESAB CUTMASTER 100
This Page Intentionally Blank
300X5397
PARTS LIST
6-7
ESAB CUTMASTER 100
This Page Intentionally Blank
6-8
PARTS LIST
300X5397
ESAB CUTMASTER 100
APPENDIX 1: SEQUENCE OF OPERATION (BLOCK
DIAGRAM)
ACTION:
ACTION:
Close external
disconnect switch.
RESULT:
Power to system.
ACTION:
ON / OFF switch to ON
RESULT:
AC indicator
ON.
GAS indicator
ON
when input
pressure is adequate
for power supply operation.
Power circuit ready.
RUN /
Rapid Auto Restart /
SET / LATCH switch
to SET
RESULT:
Gas flows to set
pressure.
ACTION:
RUN / Rapid Auto Restart /
SET / LATCH
switch to RUN
(for most applications)
or to
Rapid Auto Restart
(for gouging, trimming,
or expanded metal
applications)
or to
LATCH
is used for specific applications
(torch switch can be released
after main arc transfer).
RESULT:
ACTION:
Connect work cable to workpiece.
Set output amperage.
ACTION:
RESULT:
Torch moved away from work (while
still activated).
System is ready
for operation.
RESULT:
Main arc stops.
Pilot arc automatically
restarts.
ACTION:
Protect eyes and activate
Torch switch (START)
Gas flow stops.
PILOT ARC
RESULT:
Fans turn on. Gas flows briefly,
then stops.Gas restarts.
ACTION:
Torch moved within
transfer distance of workpiece.
DC indicator
ON
Pilot arc established.
RESULT:
Main arc transfers.
Pilot arc off.
ACTION:
Release Torch switch.
RESULT:
Main arc stops.
Gas flow stops after post - flow.
ACTION:
ON / OFF switch
to OFF
(Fans will continue to run for
10 minutes after the Torch switch
[START] is removed)
RESULT:
All indicators off.
Power supply fans shut off.
ACTION:
Unplug input
power cord or
open external
disconnect.
RESULT:
No power to system.
Art #A-08793
300X5397
APPENDIX
A-1
ESAB CUTMASTER 100
APPENDIX 2: DATA TAG INFORMATION
Model :
Dat e of Mf r :
Type of Power
Supply (Note 1)
1/ 3
f1
Manufacturer's Name and/or
Logo, Location, Model and
Serial Number
and Production Code
S/N
Regulatory Standard Covering
This Type of Power Supply
f2
Output Current Type
Duty Cycle Factor
Output Range (Amperage/
Voltage)
Plasma Cutting
Symbol
X
U0
=
Rated NoLoad Voltage
Duty Cycle Data (Note 3)
I
U2
Conventional
Load Voltage
Rated Maximum
Supply Current
Input Power
Symbol
U1
I 1max 3Ø
1
1Ø
1
1Ø
I 1eff
3Ø
Maximum Effective
Supply Current
Input Power
Specifications
(Phase, AC or DC
Hertz Rating)
Degree of Protection
Rated Supply
Voltage (Note 2)
NOTES:
1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission.
Duty cycle value is determined under the power supply
manufacturer's test procedures.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.
4. Sections of the Data Tag may be applied to separate areas
of the power supply.
A-2
APPENDIX
Standard Symbols
AC
DC
Ø
Phase
Art # A-12765_AB
300X5397
ESAB CUTMASTER 100
APPENDIX 3: TORCH PIN - OUT DIAGRAMS
A. Hand Torch Pin - Out Diagram
Negative /
Plasma
8 - Open
4 - Green /
Switch
3 - White /
Switch
Negative /
Plasma
8 - Open
4 - Switch
4
3
2- Orange /
PIP
1 - Black /
PIP
ATC Female Receptacle
Front View
ATC Male Connector
Front View
6
5
2
1
8
7
7 - Open
7 - Open
6 - Open
6 - Open
5 - Open
8
7
6
5
2
1
3 - Switch
4
3
2 - PIP
5 - Open
1 - PIP
Pilot
Pilot
A-03701_AB
B. Mechanized (Machine) Torch Pin - Out Diagram
Negative / Plasma
2 - Orange /
PIP
Negative / Plasma
8 - Green Pendant
Connector
Ground
4- Black Pendant
Connector
3 - White Pendant
Connector
4
3
2
1
ATC Female Receptacle
Front View
UNSHIELDED MACHINE TORCH
ATC Male Connector
Front View
6
5
8
7
7 - Green /
Not Used
7 - Open
6 - Open
6 - Open
5 - White /
Not Used
1 - Black /
PIP
4 - Switch
8 - Ground
8
7
6
5
2
1
3 - Switch
2 - PIP
1 - PIP
5 - Open
Pilot
4
3
Pilot
Art # A-03799
300X5397
APPENDIX
A-3
ESAB CUTMASTER 100
APPENDIX 4: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram
Torch: SL60 / SL100 Hand Torch
Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle
Torch
Head
Male
ATC Leads
Connector
ATC Female
Receptacle
Power
Supply
Torch
Leads
PIP
Switch
Torch
Switch
Black
1
1
Orange
2
2
5
5
6
6
Green
4
4
White
3
3
8
8
7
7
Negative / Plasma
To Power Supply
Circuitry
To Power Supply
Circuitry
Negative / Plasma
Pilot
Pilot
Art # A-03797_AB
B. Mechanized Torch Connection Diagram
Torch: Unshielded Mechanized SL100 Machine Torch
Leads: Leads with ATC Connector and
Remote Pendant Connector
Power Supply: with ATC Female Receptacle
Male
ATC Leads
Connector
Torch
Head
To Remote Control
Remote
Pendant
Connector
ATC Female
Receptacle
Power
Supply
Torch
Leads
PIP
Switch
Black
1
1
Orange
2
2
White
5
5
6
6
Black 4
White 3
Green 8
4
7
7
Not
Used
Green
Negative / Plasma Lead
Pilot Lead
3
To Power Supply
Circuitry
To Power Supply
Circuitry
8
Negative / Plasma
Pilot
Art # A-03798
A-4
APPENDIX
300X5397
ESAB CUTMASTER 100
This Page Intentionally Blank
300X5397
APPENDIX
A-5
ESAB CUTMASTER 100
APPENDIX 5: SYSTEM SCHEMATIC, 400V UNITS
5
4
T1
3
2
C
1
2
3
4
5
4
PRI 4
PRI 3
J1
SW1
1
BIAS
SUPPLY
PRI 2
D
INRUSH
RESISTORS
+12VDC
PRI 1
+
TP2
MTH1
B
A
D
PRI 2
PRI 1
+
MTH2 TP1
K1
Q1
EMI
*CHOKE
/INRUSH
+12VDC
BIAS
SUPPLY
D1
+ C3,C4,C7,C8*
UNITS
* CEONLY
TP8
EMI
*FILTER
L1
1
1
L2
2
2
L3
3
3
GND
4
4
_
W1
MTH7
AC1
80A_AC1
AC2
80A_AC2
AC3
80A_AC3
MTH4 TP5
7
L1
T1
8
L2
T2
L3
T3
L4
T4
9
7A
380/400/415V
OR 600V
3 PH AC INPUT
PRIMARY POWER CONNECTIONS:
USE L1, L2, L3 & GND
MTH8 TP4
MOT1
C
+
+12VDC
J7
FAN
MTH6
1
2
-
Q2
+
J5
SOL 1
1
2
3
5
C5,C6,C9,C10*
/SOLENOID
24VAC
J6
1
2
W1
TP3
/FAN
24VAC RET
_
6
J14
J4
1
2
3
4
5
6
D
J13
/OVERTEMP
/FAN_ON
/CSR
CUR_SET
MAIN_PCB_ID
COMMON
PCB1
MAIN PCB ASSY
1
2
3
4
5
6
1
2
3
4
5
SERIAL PORT
SYNC
3.3VDC
TXD
RXD
T2
FERRITE
FILTER
J2
B
+12VDC
+
1
2
+
MOT3
J2
FAN
1
2
PRI 1
+12VDC
+12VDC
PRI 3
PRI 2
A
B
J9
/FAN
C
PRI 4
D
+
SYNC
-
J1
FAN
J3
1
2
3
4
5
6
7
8
9
10
J4
MOT2
1
2
1
2
AC1
40A_AC1
AC2
40A_AC2
-
AC3
PMTH1
+
Q1
40A_AC3
PMTH1
C16-17
+
D1
PCB2
PMTH2
PMTH2
PMTH3
PMTH3
INPUT CAPACITOR PCB
Q2
C7 & C10 may not be installed
C12-13
+
A
PMTH4
PMTH4
_
PCB5
40/50 AMP PCB
_
A-12770_AA
5
A-6
4
APPENDIX
300X5397
ESAB CUTMASTER 100
3
2
1
1TORCH
TS1
PIP SWITCH
L1
TORCH SWITCH
1
2
J11
SEC1
SEC2
+12VDC
CHOKE1
ATC CONNECTOR
J1
TEMP
CIRCUIT
1
2
3
4
5
6
7
8
/OVERTEMP
NTC
-V OUT 1
1
2
3
4
5
6
7
8
E64
-
E35
+
AUTOMATION
TORCH SOLENOID
D
ELECTRODE1
D3
TIP1
Q5
PILOT IGBT
WORK1
WORK
J9
/PIP
1
2
3
4
5
6
7
/START
24VAC RETURN
24VAC SUPPLY
78
79
80
81
82
83
J2
J10
1
2
3
4
5
6
7
8
OK-TO-MOVE
(5A @ 250VAC / 30VDC)
+12VDC
P10
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
} OK TO MOVE
CNC PINOUT
3
1
7
4
11
14
8
12
} /START / STOP
J2
C
40 PIN RIBBON CABLE SIGNALS
D78 CSR
GND1
GND2
+12V1
48V1
I_DMD_1
TIP_SEN
COMMON
COMMON
+12 VDC SUPPLY
+48 VDC SUPPLY
CURRENT DEMAND
TIP DRAG SENSE
FERRITE
FILTER
-V_OUT_SIGNAL
/TIP_VOLTS
/TIP_SENSE
/460V_IN
/230V_IN
CUR_SET
/RAR (RAPID AUTO RESTART)
/INRUSH
/W1_ON
SHDN
/TORCH_SOLENOID
/SOLENOID_ON
/OK_TO_MOVE
/FAN_ON
/LATCH_ACTIVE
/TORCH_SWITCH
/PIP
AC_ON
CSR
/TORCH_SOLENOID_DETECT
/OVERTEMP
V_IN
+12VDC
+12VDC
COMMON
COMMON
MAIN_PCB_ID
460_IN
+3.3VDC
TXD
RXD
COMMON
D
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
M-L
M-L
M-L
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
L-M
M-L
M-L
L-M
M-L
*
To -V OUT 1
on PCB1
P1
*
1
2
3
D59 PCR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
29
34
35
36
37
38
39
TEST POINTS
J1
E1
P10
P2
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS / 16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
1
2
3
4
5
6
7
8
9
10
11
12
13
14
+12VDC
K1
PCB4
AUTOMATION
INTERFACE PCB
K1
} /START / STOP
} (+) *DIVIDED
(-)
(-)
} (+)
ARC VOLTS
ARC VOLTS
(W/ 100K IN SERIES (2))
} OK-TO-MOVE
L2
B
J1
SEC1
SEC2
CHOKE1
AC
OVERTEMP
GAS
ERROR
NTC
TEMP
CIRCUIT
Current Control
/OVERTEMP
LATCH
FAULT
MAX
90
85
80
75
70
65
MIN
OVER PRESSURE
INTERNAL ERROR
SHORTED TORCH
CONSUMABLES MISSING
START ERROR
PARTS IN PLACE
INPUT POWER
UNDER PRESSURE
MAX
90
85
TEST POINTS
DC
D2
ERROR IND
TP1
TP2
TP3
TP4
TP5
TP6
TP7
80
GND
+12 VDC
+5 VDC
3.3 VDC
0.v - 5.0 VDC / 0-100PSI
1.8 VDC
CURRENT DEMAND
GAS CONTROL
75
REGULATOR
70
+12VDC
D1
SOLENOID
VALVE
FILTER
65
MIN
PRESSURE
TRANSDUCER
SET
+5VDC
RAR
3
2
1
0-100PSI / 0-4.5VDC
PCB3
J3
1
2
3
RUN
+OUT_1
ATC
AIR
INLET
LOGIC PCB
A
A-12770_AA
SEE
A-09130
3
AA
AB
AB
Date
PCB No:
RWH
03/31/09
ECO B1399
RWH
05/05/09
Assy No:
Scale
ECO B1611
RWH
05/05/09
Revisions
Last Modified:
Friday, December 11, 2009
09:02:19
Supersedes
Date:
MARCH 30, 2009
NOTE:
2
300X5397
By
INTRO ECO B1357
Rev
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)
TITLE: SCHEMATIC, ESAB Cutmaster 100/120
20'/50' SL100 400V/208-460V
3ph CE/Non-CE CCC/ 1/3ph CSA (Configured for 460V 3ph)
Drawn:
RWH
References
Chk:
App:
Size
DWG No:
D
1
Sheet
of 1
42X1330
1
APPENDIX
A-7
ESAB CUTMASTER 100
Revision History
Date
Rev
Description
01/15/2015
AA
Manual release
08/14/2015
AB
Updated art on cover, Updated DoC, added duty cycle values, removed Shielded
Machine Torch Leads Assemblies
11/14/2015
AC
Revised DoC, removed Printed in text
01/07/2019
AD
A-8
APPENDIX
300X5397
ESAB CUTMASTER 100
This Page Intentionally Blank
300X5397
APPENDIX
A-9
ESAB CUTMASTER 100
This Page Intentionally Blank
A-10
APPENDIX
300X5397
This Page Intentionally Blank
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 70 233 075
Fax: +32 15 257 944
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
www.esab.eu
©2015 ESAB Welding and Cutting Products
Distributors
For addresses and phone numbers to our distributors in other
countries, please visit our home
page
www.esab.eu
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