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100

400V

Art # A-12775_AB

INPUT POWER

VOLTAGE

OUTPUT

MAX OUTPUT

PHASE

AMPS

Revision:

Issue Date:

July 1, 2019

Manual No.:

300X5397

ESAB Cutmaster

100

PLASMA CUTTING SYSTEM
SL100 1Torch™

Operating

Manual

esab.eu

Содержание Cutmaster 100

Страница 1: ...400V Art A 12775_AB INPUT POWER VOLTAGE OUTPUT MAX OUTPUT PHASE AMPS Revision AD Issue Date July 1 2019 Manual No 300X5397 ESAB Cutmaster 100 PLASMA CUTTING SYSTEM SL100 1Torch Operating Manual esab...

Страница 2: ...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...

Страница 3: ...eproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or da...

Страница 4: ...reof 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 periodi...

Страница 5: ...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...

Страница 6: ...3 1 3 02 Lifting Options 3 1 3 03 Primary Input Power Connections 3 1 3 04 Gas Connections 3 2 SECTION 3 TORCH INSTALLATION 3T 1 3T 01 Torch Connections 3T 1 3T 02 Setting Up Mechanical Torch 3T 1 SEC...

Страница 7: ...ECTION 6 PARTS LISTS 6 1 6 01 Introduction 6 1 6 02 Ordering Information 6 1 6 03 Power Supply Replacement 6 1 6 04 Replacement Power Supply Parts 6 1 6 05 Options and Accessories 6 2 6 06 Replacement...

Страница 8: ...o 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 s...

Страница 9: ...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 Exc...

Страница 10: ...mber in your area listed on back cover of this manual Include the Owner s Manual number and equipment identifica tion numbers Electronic copies of this manual can also be downloaded at no charge inAcr...

Страница 11: ...gs IEC CE IEC CE IEC CE Current 100A 80A 80A 70A 70A DC Voltage 120 112 112 92 108 NOTE The duty cycle will be reduced if the primary input power AC is low or the output voltage DC is higher than show...

Страница 12: ...8 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 ha...

Страница 13: ...0X5397 2 4 2 06 Power Supply Features Handle and Leads Wrap Torch Leads Receptacle Control Panel Art A 08359 Work Cable and Clamp Art A 08547 Input Power Cord Port for Optional Automation Interface Ca...

Страница 14: ...rom 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 Ref...

Страница 15: ...s Flow Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive The plasma arc cutting and gouging processes use this plasma to tra...

Страница 16: ...to transfer to the work D Main Cutting Arc DC power is also used for the main cutting arc The negative output is connected to the torch electrode through the torch lead The positive output is con nec...

Страница 17: ...ESAB CUTMASTER 100 INTRODUCTION 300X5397 2T 4 This Page Intentionally Blank...

Страница 18: ...Power Connections CAUTION Check your power source for cor rect voltage before plugging in or connecting the unit The primary power source fuse and any exten sion cords used must conform to local elect...

Страница 19: ...to Unit The connection is the same for compressed air or high pressure cylinders Refer to the following two subsec tions if an optional air line filter is to be installed 1 Connect the air line to the...

Страница 20: ...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 th...

Страница 21: ...hey 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...

Страница 22: ...y for operation Check Air Quality To test the quality of air 1 Put the ON OFF switch in the ON up position 2 Put the Function Control switch in the SET posi tion 3 Place a welding filter lens in front...

Страница 23: ...ESAB CUTMASTER 100 INSTALLATION 300X5397 3T 2 This Page Intentionally Blank...

Страница 24: ...e of the system interlocks is activated 3 ON OFF Power Switch ON OFF Switch controls input power to the power supply Up is ON down is OFF 4 Air Gas Pressure Control The Pressure Control is used in the...

Страница 25: ...disconnect switch to supply power to the system Air Source Ensure source meets requirements refer to Section 2 Check connections and turn air supply ON Connect Work Cable Clamp the work cable to the...

Страница 26: ...position when the torch leaves the work piece 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...

Страница 27: ...ESAB CUTMASTER 100 OPERATION 300X5397 4 4 This Page Intentionally Blank...

Страница 28: ...pushing it straight into the torch head until it clicks 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...

Страница 29: ...g 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 im...

Страница 30: ...h 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 al...

Страница 31: ...onduc tive straight edge to make straight cuts by hand WARNING The straight edge must be non conductive A 03539 Non Conductive Straight Edge Cutting Guide Using Drag Shield Cup With Straight Edge The...

Страница 32: ...r maximum heat protection Choose the technique that feels most comfortable and allows good control and movement NOTE The tip should never come in con tact with the workpiece except dur ing drag cuttin...

Страница 33: ...and workpiece standoff CAUTION Touching the torch tip or shield cup to the work surface will cause exces sive parts wear Torch Travel Speed NOTE Refer to Appendix Pages for addi tional information as...

Страница 34: ...pposite direc tion as torch travel Standoff Distance Straight Arc Trailing Arc Leading Arc Direction of Torch Travel A 02586 Mechanized Torch Operation For optimum smooth surface quality the travel sp...

Страница 35: ...ield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Machine 50 60A 9 8238 Drag Shield Cup 9 8235 Drag Shield Cup 70 100A 9 8236 Drag...

Страница 36: ...s Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 036 0 9 9 8208 103 40 355 9 02 0 125 3 2 65 4 5 55 170 0 00 0 2 5 1 0 05 1 3 9 8208 98 40 310 7 87 0 125 3 2 65 4 5 55 170 0 00 0 2...

Страница 37: ...es mm 0 06 1 5 9 8210 119 60 350 8 91 0 19 4 8 70 4 8 90 245 0 00 0 20 5 1 0 075 1 9 9 8210 116 60 300 7 64 0 19 4 8 70 4 8 90 245 0 10 0 20 5 1 0 120 3 0 9 8210 123 60 150 3 82 0 19 4 8 70 4 8 90 245...

Страница 38: ...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...

Страница 39: ...0 2 30 0 190 4 8 75 5 2 130 390 0 5 0 250 6 4 0 375 9 5 9 8212 122 100 55 1 40 0 190 4 8 75 5 2 130 390 0 8 0 250 6 4 0 500 12 7 9 8212 126 100 30 0 75 0 190 4 8 75 5 2 130 390 1 0 0 250 6 4 0 625 15...

Страница 40: ...s 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...

Страница 41: ...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...

Страница 42: ...5 1 0 120 3 0 9 8211 115 80 260 6 50 0 125 3 2 65 4 5 115 340 0 10 0 2 5 1 0 135 3 4 9 8211 113 80 250 6 25 0 125 3 2 65 4 5 115 340 0 10 0 2 5 1 0 188 4 8 9 8211 114 80 170 4 25 0 125 3 2 65 4 5 115...

Страница 43: ...12 121 100 110 2 80 0 125 3 2 75 5 2 130 390 0 5 0 200 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...

Страница 44: ...ESAB CUTMASTER 100 300X5397 OPERATION 4T 17 This Page Intentionally Blank...

Страница 45: ...US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8211 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8212 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8253 Tip...

Страница 46: ...eld Cap US Pat No s 6914211 D496951 Other Pat s Pending The following parts are also licensed under U S Patent No 5 120 930 and 5 132 512 Catalog Description 9 8235 Shield Cap 9 8236 Shield Cap 9 8237...

Страница 47: ...ESAB CUTMASTER 100 OPERATION 300X5397 4T 20 This Page Intentionally Blank...

Страница 48: ...ck 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 Clean exterior of pow...

Страница 49: ...UTION Do not blow air into the power sup ply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit 5 03 Com...

Страница 50: ...w the Temp indicator and 75 psi indicators are on indicating the version would be 2 3 A PSI BAR MAX MAX MIN MIN 1 2 3 4 Art A 07988 MIN MAX 0 1 2 3 4 5 6 7 5 When the Fault indicator is ON or blinking...

Страница 51: ...been exceeded 3 Failed components in unit 1 Refer to clearance information section 2 04 2 Allow unit to cool 3 Return to authorized service center for repair or replacement GAS LED OFF FAULT and MIN...

Страница 52: ...uck 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 p...

Страница 53: ...sary 2 Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws 3 Tighten lower screws 4 Reinstall and tighten the upper screws C Filter Element Ass...

Страница 54: ...ry Refer to Section 6 Parts List for replacement filter element catalog number 1 Remove power from power supply 2 Shut OFF air supply and bleed down system before disassembling Filter to change Filter...

Страница 55: ...ide 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...

Страница 56: ...d blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling O Ring Lubrication An o ring on the Torch Head and ATC Male Connec tor requires lubrication on a scheduled...

Страница 57: ...may be an O ring between the shield cup body and drag shield cap Do not lubricate the O ring Drag Shield Cap Shield Cup Body O Ring No 8 3488 Art A 03878 4 Remove the tip Check for excessive wear ind...

Страница 58: ...our 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 assembl...

Страница 59: ...able 50 ft 15 2 m with Clamp 9 8529 1 Automation Interface Kit for Start Stop OK to move and Divided Arc Voltage 9 8311 1 Automation Harness for Start Stop and OK to move 9 9385 1 25 7 6 m CNC Cable f...

Страница 60: ...ew and wrench 9 8062 4 1 Torch Head Assembly Replacement Kit includes items No 5 6 9 8219 5 1 Large O Ring 8 3487 6 1 Small O Ring 8 3486 7 Leads Assemblies with ATC connectors includes switch assembl...

Страница 61: ...2 m Leads Assembly with ATC connector 4 7853 6 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 foot 1 5 m Leads Assembly with ATC connector 4 7842 1 10 foot 3 05 m Leads Assembly with...

Страница 62: ...ESAB CUTMASTER 100 300X5397 PARTS LIST 6 5 A 07994_AB 1 4 2 3 5 6 7 8 9 10 12 11 10 13...

Страница 63: ...Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Machine 50 60A 9 8238 Drag Shield Cup 9 8235 Drag Shield Cup 70 100A 9 8236 Drag Shiel...

Страница 64: ...ESAB CUTMASTER 100 300X5397 PARTS LIST 6 7 This Page Intentionally Blank...

Страница 65: ...ESAB CUTMASTER 100 PARTS LIST 300X5397 6 8 This Page Intentionally Blank...

Страница 66: ...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 i...

Страница 67: ...e 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 powe...

Страница 68: ...Switch 1 Black PIP Negative Plasma 8 Open ATC Male Connector Front View A 03701_AB B Mechanized Machine Torch Pin Out Diagram ATC Female Receptacle Front View ATC Male Connector Front View Negative Pl...

Страница 69: ...5 6 4 3 8 7 1 2 5 6 4 3 8 7 Torch Switch Green White To Power Supply Circuitry B Mechanized Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and...

Страница 70: ...ESAB CUTMASTER 100 300X5397 APPENDIX A 5 This Page Intentionally Blank...

Страница 71: ...T2 PMTH4 PMTH4 MTH1 MTH1 PRI 2 PRI 2 TP1 TP1 C5 C6 C9 C10 C5 C6 C9 C10 TP8 TP8 40A_AC1 40A_AC1 J3 J3 1 2 PMTH3 PMTH3 PMTH2 PMTH2 J2 J2 1 2 A 12770_AA 5 5 4 4 D C B A 12VDC 12VDC 12VDC 12VDC 12VDC 24V...

Страница 72: ...7 WORK WORK P10 P10 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 AB ECO B1611 RWH 05 05 09 AA AB Friday December 11 2009 SEE A 09130 A 12770_AA 3 3 2 2 1 1 D C B A 12VDC 12VDC 12VDC 5VDC 12VDC DWG No Sheet of Sup...

Страница 73: ...sion 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 Revi...

Страница 74: ...ESAB CUTMASTER 100 300X5397 APPENDIX A 9 This Page Intentionally Blank...

Страница 75: ...ESAB CUTMASTER 100 APPENDIX 300X5397 A 10 This Page Intentionally Blank...

Страница 76: ...This Page Intentionally Blank...

Страница 77: ...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...

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