ESAB CUTMASTER 80 PLASMA CUTTING SYSTEM SERVICE MANUAL User manual

ESAB CUTMASTER

®

80

PLASMA CUTTING SYSTEM

SL60 1Torch™

Revision: AA Issue Date: July 30, 2015 Manual No.: 0-5410

Service

Manual

esab.eu

80

400V

Art # A-12774_AA

PHASE

INPUT POWER

VOLTAGE

OUTPUT

MAX OUTPUT

CAUTION

This Service Manual is for experienced technicians. 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 equip-

ment 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 ap-

proval 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.

!

WARNING

Read and understand this entire Manual and your employer’s safety practices before install-

ing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement,

the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply

ESAB CutMaster 80

SL60 1Torch™

Service Manual Number 0-5410

Published by:

ESAB Group Inc.

2800 Airport Rd.

Denton TX 76207 USA

http://www.esab.eu

Reproduction 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 damage caused by any error or omission in this Manual, whether such error

results from negligence, accident, or any other cause.

Original Publication Date: July 30, 2015

Revision Date:

i

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1: SAFETY PRECAUTIONS ....................................................................................... 1

SECTION 2 SYSTEM: INTRODUCTION ................................................................................2-1

2.01 How To Use This Manual ...........................................................................2-1

2.02 Equipment Identiﬁcation .............................................................................2-1

2.03 Receipt Of Equipment .................................................................................2-1

2.04 Power Supply Speciﬁcations ......................................................................2-2

2.05 Input Wiring Speciﬁcations .........................................................................2-3

2.06 Power Supply Features ..............................................................................2-4

SECTION 2 TORCH: INTRODUCTION ................................................................................2T-1

2T.01 Scope of Manual .......................................................................................2T-1

2T.02 General Description ..................................................................................2T-1

2T.03 Speciﬁcations ...........................................................................................2T-1

2T.04 Options And Accessories ..........................................................................2T-2

2T.05 Introduction to Plasma ..............................................................................2T-2

SECTION 3 SYSTEM: INSTALLATION ..................................................................................3-1

3.01 Unpacking ................................................................................................... 3-1

3.02 Lifting Options ............................................................................................. 3-1

3.03 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

SECTION 4 SYSTEM: OPERATION ........................................................................................4-1

4.01 Front Panel Controls / Features ..................................................................4-1

4.02 Preparations for Operation .........................................................................4-2

SECTION 4 TORCH: OPERATION ........................................................................................4T-1

4T.01 Torch Parts Selection ...............................................................................4T-1

4T.02 Cut Quality ................................................................................................4T-1

4T.03 General Cutting Information ......................................................................4T-2

4T.04 Hand Torch Operation ..............................................................................4T-3

4T.05 Gouging ....................................................................................................4T-6

4T.06 Mechanized Torch Operation ...................................................................4T-7

4T.07 Parts Selection for Manual and Mechanized Torch Cutting ......................4T-9

4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip 4T-10

4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip 4T-14

PATENT INFORMATION .....................................................................................................4T-18

TABLE OF CONTENTS

SECTION 5 SYSTEM: SERVICE .............................................................................................5-1

5.01 General Maintenance .................................................................................5-1

5.02 Maintenance Schedule ...............................................................................5-2

5.03 Common Faults ..........................................................................................5-2

5.04 Fault Indicator .............................................................................................5-3

5.05 Basic Troubleshooting Guide ......................................................................5-4

5.06 Power Supply Basic Parts Replacement ....................................................5-6

5.07 Circuit Fault Isolation ..................................................................................5-8

5.08 Main Input and Internal Power Problems ..................................................5-11

5.09 Pilot Arc Problems ....................................................................................5-15

5.10 Main Arc and Controls Problems ..............................................................5-17

5.11 CNC Interface Problems ........................................................................... 5-17

5.12 Test Procedures .......................................................................................5-17

5.13 Capacitor PCB Layout & Signals ..............................................................5-20

5.14 Logic PCB Layout & Signals ..................................................................... 5-22

5.15 MAIN PCB Layout & Signals ....................................................................5-26

5.16 Main PCB Wiring Diagram ........................................................................ 5-28

SECTION 5 TORCH: SERVICE .............................................................................................5T-1

5T.01 General Maintenance ...............................................................................5T-1

5T.02 Inspection and Replacement of Consumable Torch Parts .......................5T-2

SECTION 6: PARTS LISTS......................................................................................................6-1

6.01 Introduction .................................................................................................6-1

6.02 Ordering Information ................................................................................... 6-1

6.03 Power Supply Replacement .......................................................................6-1

6.04 Major External Replacement Parts .............................................................6-2

6.05 Front Panel Replacement Parts ..................................................................6-3

6.06 Left Side Replacement Parts .....................................................................6-4

6.07 Right Side Replacement Parts ...................................................................6-5

6.08 Options and Accessories ............................................................................6-6

6.09 Replacement Parts for Hand Torch ...........................................................6-7

6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads ......6-8

6.11 Torch Consumable Parts (SL60) ..............................................................6-10

6.12 Torch Consumable Parts (SL100) ............................................................6-11

SECTION 7: REPLACEMENT PROCEDURES ......................................................................7-1

7.01 Scope ..........................................................................................................7-1

7.02 Anti-Static Handling Procedures ................................................................. 7-1

7.03 Parts Replacement - General Information ..................................................7-1

7.04 Major External Parts ...................................................................................7-1

7.05 Front Panel Parts Replacement ..................................................................7-2

7.06 Left Side Internal Parts Replacement .........................................................7-4

7.07 Rear Panel Parts Replacement ..................................................................7-5

7.08 Right Side Internal Parts Replacement .......................................................7-6

TABLE OF CONTENTS

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

Publication History ................................................................................................................... A-8

This Page Intentionally Blank

ESAB CUTMASTER 80

Manual 0-5410 1 SAFETY PRECAUTIONS

SECTION 1:

SAFETY PRECAUTIONS

!

WARNING

These Safety Precautions are for your

protection. They summarize precau-

tionary information from the references

listed in Additional Safety Information

section. Before performing any installa-

tion or operating procedures, be sure to

read and follow the safety precautions

listed below as well as all other manu-

als, material safety data sheets, labels,

etc. Failure to observe Safety Precau-

tions can result in injury or death

PROTECT YOURSELF AND OTHERS -

Some welding, cutting, and gouging pro-

cesses are noisy and require ear protection.

The arc, like the sun, emits ultraviolet (UV)

and other radiation and can injure skin and eyes. Hot

metal can cause burns. Training in the proper use of the

processes and equipment is essential to prevent acci-

dents. Therefore:

1. Always wear safety glasses with side shields

in any work area, even if welding helmets, face

shields, and goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when operat-

ing or observing operations. Warn bystanders not

to watch the arc and not to expose themselves

to the rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy

long-sleeve shirt, cuff-less trousers, high-topped

shoes, and a welding helmet or cap for hair

protection, to protect against arc rays and hot

sparks or hot metal. A ameproof apron may also

be desirable as protection against radiated heat

and sparks.

4. Hot sparks or metal can lodge in rolled up

sleeves, trouser cuffs, or pockets. Sleeves and

collars should be kept buttoned, and open pock-

ets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition

or curtains.

6. Use goggles over safety glasses when chipping

slag or grinding. Chipped slag may be hot and

can y far. Bystanders should also wear goggles

over safety glasses.

FIRES AND EXPLOSIONS - Heat from ames

and arcs can start res. Hot slag or sparks

can also cause res and explosions. There-

fore:

1. Remove all combustible materials well away

from the work area or cover the materials with a

protective non-ammable covering. Combustible

materials include wood, cloth, sawdust, liquid and

gas fuels, solvents, paints and coatings, paper,

etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in oors or wall openings and cause a

hidden smoldering re or res on the oor below.

Make certain that such openings are protected

from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until

the workpiece has been completely cleaned so

that there are no substances on the workpiece

which might produce ammable or toxic vapors.

Do not do hot work on closed containers. They

may explode.

4. Have re extinguishing equipment handy for

instant use, such as a garden hose, water pail,

sand bucket, or portable re extinguisher. Be

sure you are trained in its use.

5. Do not use equipment beyond its ratings. For

example, overloaded welding cable can overheat

and create a re hazard.

6. After completing operations, inspect the work

area to make certain there are no hot sparks or

hot metal which could cause a later re. Use re

watchers when necessary.

7. For additional information, refer to NFPA Stan-

dard 51B, “Fire Prevention in Use of Cutting and

Welding Processes”, available from the National

Fire Protection Association, Batterymarch Park,

Quincy, MA 02269.

ELECTRICAL SHOCK - Contact with live

electrical parts and ground can cause se-

vere injury or death. DO NOT use AC weld-

ing current in damp areas, if movement is

conned, or if there is danger of falling.

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

3. Connect the work cable to the workpiece. A poor

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn

or damaged cables.

ESAB CUTMASTER 80

SAFETY PRECAUTIONS 2 Manual 0-5410

5. Keep everything dry, including clothing, work

area, cables, torch/Piston, and power source.

6. Make sure that all parts of your body are insu-

lated from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on

the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS - May

be dangerous. Electric current flowing

through any conductor causes localized

Electric and Magnetic Fields (EMF). Welding

and cutting current creates EMF around

welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health effects

which are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables to-

gether. Secure them with tape when possible.

B. Never coil the torch or work cable around

your body.

C. Do not place your body between the torch

and work cables. Route cables on the same

side of your body.

D. Connect the work cable to the workpiece as

close as possible to the area being welded.

E. Keep welding power source and cables as

far away from your body as possible.

FUMES AND GASES - Fumes and gases,

can cause discomfort or harm, particularly

in conned spaces. Do not breathe fumes

and gases. Shielding gases can cause as-

phyxiation. Therefore:

1. Always provide adequate ventilation in the work

area by natural or mechanical means. Do not

weld, cut, or gouge on materials such as galva-

nized steel, stainless steel, copper, zinc, lead,

beryllium, or cadmium unless positive mechani-

cal ventilation is provided. Do not breathe fumes

from these materials.

2. Do not operate near degreasing and spraying

operations. The heat or arc rays can react with

chlorinated hydrocarbon vapors to form phos-

gene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat

irritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the

work area. Do not continue to operate if physical

discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing

below) for specic ventilation recommendations.

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases which con-

tain chemicals known to the State of California to

cause birth defects and, in some cases, cancer.

(California Health & Safety Code §25249.5 et

seq.)

CYLINDER HANDLING - Cylinders, if mis-

handled, can rupture and violently release

gas. Sudden rupture of cylinder, valve, or

relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed

to operate from the compressed gas cylinder.

Do not use adaptors. Maintain hoses and t-

tings in good condition. Follow manufacturer’s

operating instructions for mounting regulator to

a compressed gas cylinder.

2. Always secure cylinders in an upright position

by chain or strap to suitable hand trucks, under-

carriages, benches, walls, post, or racks. Never

secure cylinders to work tables or xtures where

they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed.

Have valve protection cap in place if regulator

is not connected. Secure and move cylinders by

using suitable hand trucks. Avoid rough handling

of cylinders.

4. Locate cylinders away from heat, sparks, and

ames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard

P-1, “Precautions for Safe Handling of Com-

pressed Gases in Cylinders”, which is available

from Compressed Gas Association, 1235 Jef-

ferson Davis Highway, Arlington, VA 22202.

EQUIPMENT MAINTENANCE - Faulty or im-

properly maintained equipment can cause in-

jury or death. Therefore:

ESAB CUTMASTER 80

Manual 0-5410 3 SAFETY PRECAUTIONS

1. Always have qualied personnel perform the

installation, troubleshooting, and maintenance

work. Do not perform any electrical work unless

you are qualied to perform such work.

2. Before performing any maintenance work inside

a power source, disconnect the power source

from the incoming electrical power.

3. Maintain cables, grounding wire, connections,

power cord, and power supply in safe working

order. Do not operate any equipment in faulty

condition.

4. Do not abuse any equipment or accessories.

Keep equipment away from heat sources such as

furnaces, wet conditions such as water puddles,

oil or grease, corrosive atmospheres and inclem-

ent weather.

5. Keep all safety devices and cabinet covers in

position and in good repair. 6. Use equipment

only for its intended purpose. Do not modify it in

any manner.

ADDITIONAL SAFETY INFORMATION - For

more information on safe practices for electric

arc welding and cutting equipment, ask your

supplier for a copy of “Precautions and Safe

Practices for Arc Welding, Cutting and Gouging”, Form

52-529.

The following publications, which are available from the

American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”

2. AWS C5.1 - “Recommended Practices for Plasma

Arc Welding”

3. AWS C5.2 - “Recommended Practices for Plasma

Arc Cutting”

4. AWS C5.3 - “Recommended Practices for Air Carbon

Arc Gouging and Cutting”

5. AWS C5.5 - “Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - “Recommended Practices for Gas Metal

Arc Welding”“

7. AWS SP - “Safe Practices” - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, “Recommended Safe Practices

for Welding and Cutting of Containers That Have Held

Hazardous Substances.”

MEANING OF SYMBOLS - As used throughout this

manual:

NOTE!

An operation, procedure, or back-

ground information which requires

additional emphasis or is helpful in

efcient operation of the system.

!

CAUTION

A procedure which, if not properly

followed, may cause damage to the

equipment.

!

WARNING

A procedure which, if not properly

followed, may cause injury to the

operator or others in the operating

area.

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.

ESAB CUTMASTER 80

SAFETY PRECAUTIONS 4 Manual 0-5410

Engineering control must be used to reduce exposures to safe levels (in compliance

with the new PEL). The specic details of the standard are complex and may require

the assistance of an occupational health professional to reach full compliance

For additional information about Hexavalent Chromium contact your occupational health professional

and read the OSHA web page at http://www.osha.gov/SLTC/hexavalentchromium/

When plasma cutting stainless steel,

you must comply with the OSHA

standard to protect your employees

from Hexavalent Chromium

exposure.

ESAB CUTMASTER 80

Manual 0-5410 5 SAFETY PRECAUTIONS

CANCER HAZARD; CAN DAMAGE

SKIN, EYES, NASAL PASSAGES, AND

LUNGS; AUTHORIZED PERSONNEL

ONLY; RESPIRATORS MAY BE

REQUIRED.

For additional information about Hexavalent Chromium contact your occupational health professional

and read the OSHA web page at http://www.osha.gov/SLTC/hexavalentchromium/

CHROMIUM (VI)

Cr(VI)

HEXAVALENT CHROMIUM)

Hexavalent Chromium Cr(VI) is a toxic

chemical component within fume and

dust particles created in a variety of

processes, including plasma cutting

of stainless steel.

On February 28, 2006, the Occupational

Safety and Health Agency (OSHA) pub-

lished a revised

standard to protect workers from the potential

hazards of hexavalent chromium.

• Occupational exposure to hexavalent

chromium (Cr(VI)) must be below the

Permissible Exposure Limit (PEL) of 5 μg/m3

for an eight hour time weighted average.

• Workplace or job-speciﬁc monitoring must

be done to establish areas of potential

exposure and to quantify the potential

exposure.

• Employees who may be exposed to levels

of Cr(VI) at or above the new PEL must

be informed and c

orrective measures

implemented.

• Protective clothing and respiratory

protection must be given to employees who

have potential exposure.

• Medical surveillance of employees with

potential exposure to Cr(VI) must be

conducted.

• Areas of potential exposure to Cr(VI) must

be

indicated with warning signs containing the

text shown at left.

• Engineering control must be used to reduce

exposures to safe levels (in compliance

with the new PEL). The speciﬁc details of

the standard are complex and may require

the assistance of an occupation

al health

professional to reach full compliance

ESAB CUTMASTER 80

SAFETY PRECAUTIONS 6 Manual 0-5410

This Page Intentionally Blank

ESAB CUTMASTER 80

Manual 0-5410 2-1 INTRODUCTION

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specication or

part numbers listed on page i.

To ensure safe operation, read the entire manual,

including the chapter on safety instructions and warn-

ings.

Throughout this manual, the words WARNING,

CAUTION, DANGER, and NOTE may appear. Pay

particular attention to the information provided under

these headings. These special annotations are easily

recognized as follows:

NOTE!

An operation, procedure, or background

information which requires additional

emphasis or is helpful in efcient opera-

tion of the system.

!

CAUTION

A procedure which, if not properly

followed, may cause damage to the

equipment.

!

WARNING

A procedure which, if not properly

followed, may cause injury to the

operator or others in the operating

area.

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 identica-

tion numbers.

Electronic copies of this manual can also be down-

loaded at no charge in Acrobat PDF format by going

to the ESAB web site listed below

http://www.esab.eu

2.02 EquipmentIdentication

The unit’s identication number (specication 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 ca-

ble assemblies are identied only by the specication

or part number printed on loosely attached card or the

shipping container. Record these numbers on the bot-

tom 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 le a claim. Furnish complete information concern-

ing damage claims or shipping errors to the location

in your area listed in the inside back cover of this

manual.

Include all equipment identication numbers as de-

scribed 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.

ESAB CUTMASTER 80

INTRODUCTION 2-2 Manual 0-5410

2.04 Power Supply Speciﬁcations

ESAB Cutmaster 80 Power Supply Speciﬁcations

Input Power 400/415 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

Input Power Cable Power Supply includes input power cable.

Output Current 20 - 80 Amps, Continuously Adjustable

Power Supply Gas

Filtering Ability

Particulates to 5 Microns

ESAB Cutmaster 80 Power Supply Duty Cycle *

Ambient Temperature

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

IEC Rating IEC Rating IEC Rating

All Units

Duty Cycle 40% 60% 100%

Current 80 Amps 65 Amps 50 Amps

DC Voltage 112 106 102

* 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 specied by the International Electro-Technical Commission. These

specications include calculating an output voltage based upon power supply rated current. To fa-

cilitate comparison between power supplies, all manufacturers use this output voltage to determine

duty cycle.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

22,5"

571,5 mm

43 lb / 19,5 kg

10,75"

273 mm

16,375"

416 mm

Art # A-07941_AB

6"

150 mm

24"

610 mm

6"

150 mm

6"

150 mm

Art # A-07925_AB

ESAB CUTMASTER 80

Manual 0-5410 2-3 INTRODUCTION

2.05 Input Wiring Speciﬁcations

ESAB Cutmaster 80 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Volts Hz kVA I max I eff

Fuse

(amps)

Flexible Cord

(Min. AWG)

3 Phase 400 50/60 11.8 17 11 20 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTE!

Refer to Local and National Codes or local authority having jurisdiction for proper wiring require-

ments.

Cable size is de-rated based on the Duty Cycle of the equipment.

ESAB CUTMASTER 80

INTRODUCTION 2-4 Manual 0-5410

2.06 Power Supply Features

Handle and Leads Wrap

To rch Leads Receptacle

Control Panel

Art # A-07942

Work Cable

and Clamp

Art # A-08544

Input Power Cord

Port for Optional Automation

Interface Cable

Gas Inlet Port

Filter Assembly

ESAB CUTMASTER 80

Manual 0-5410 2T-1 INTRODUCTION

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operating instruc-

tions and maintenance procedures for the 1Torch

Models SL60/Manual and SL100/Mechanized Plasma

Cutting Torches. Service of this equipment is restrict-

ed to properly trained personnel; unqualied person-

nel are strictly cautioned against attempting repairs or

adjustments not covered in this manual, at the risk of

voiding the Warranty.

Read this manual thoroughly. A complete understand-

ing of the characteristics and capabilities of this equip-

ment will assure the dependable operation for which it

was designed.

2T.02 General Description

Plasma torches are similar in design to the automo-

tive 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 nega-

tively charged electrode and the positively charged

tip. Once the pilot arc has ionized the plasma gas, the

superheated column of gas ows through the small

orice 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 ow 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" on page 2T-2, for a more

detailed description of plasma torch

operation.

Refer to the Appendix Pages for ad-

ditional specications as related to the

Power Supply used.

2T.03 Speciﬁcations

A. Torch Conﬁgurations

1. Hand/Manual Torch, Models

The hand torch head is at 75° to the torch handle.

The hand torches include a torch handle and torch

trigger assembly.

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

Art # A-03322_AB

2. Mechanized Torch, Model

The standard machine torch has a positioning

tube with rack & pinch block assembly.

Art # A-02998

1.75" /

44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" /

16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm

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

E. Type Cooling

Combination of ambient air and gas stream through

torch.

ESAB CUTMASTER 80

INTRODUCTION 2T-2 Manual 0-5410

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

104° F

40° C

Duty Cycle

100% @ 60 Amps @ 400 scfh

Maximum Current

80 Amps

Voltage (V

peak

)

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 (V

peak

)

500V

Arc Striking Voltage

7kV

G. Gas Requirements

Manual and Mechanized Torch Gas

Specications

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

!

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 set-

tings charts for each model.

H. Direct Contact Hazard

For standoff tip the recommended standoff is 3/16

inches / 4.7 mm.

2T.04 Options And Accessories

For options and accessories, see section 6.

2T.05 Introduction to Plasma

A. Plasma Gas Flow

Plasma is a gas which has been heated to an

extremely high temperature and ionized so that it

becomes electrically conductive. The plasma arc

cutting and gouging processes use this plasma to

transfer an electrical arc to the workpiece. The metal

to be cut or removed is melted by the heat of the arc

and then blown away.

While the goal of plasma arc cutting is separation of

the material, plasma arc gouging is used to remove

metals to a controlled depth and width.

In a Plasma Cutting Torch a cool gas enters Zone B,

where a pilot arc between the electrode and the torch

tip heats and ionizes the gas. The main cutting arc

then transfers to the workpiece through the column

of plasma gas in Zone C.

A-00002

Workpiece

Power

Supply

+

_

C

B

A

Typical Torch Head Detail

By forcing the plasma gas and electric arc through a

small orice, 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 allow-

ing for a fast, slag - free cut.

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ESAB CUTMASTER 80 PLASMA CUTTING SYSTEM SERVICE MANUAL User manual

ESAB CUTMASTER 80 PLASMA CUTTING SYSTEM SERVICE MANUAL User manual

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