ESAB ESAB CUTMASTER® 120 SL100 1Torch User manual

ESAB CUTMASTER

®

120

PLASMA CUTTING SYSTEM

SL100 1Torch™

esab.eu

Revision: AB Issue Date: April 20, 2016 Manual No.: 0-5412

120

400V

Art # A-12776_AB

OUTPUT

MAX OUTPUT

INPUT POWER

VOLTAGE

PHASE

AMPS

Service

Manual

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 120

SL100 1Torch™

Service Manual Number 0-5412

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.

For Printing Material Specication refer to document 47x1909

Publication Date: July 30, 2015

Revision Date: April 20, 2016

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-2

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 SL100 Torch Cutting ..................................................4T-9

4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip ......4T-10

4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip ......4T-15

TABLE OF CONTENTS

PATENT INFORMATION .....................................................................................................4T-21

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 ......................................................................5-6

5.06 Circuit Fault Isolation ..................................................................................5-8

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

5.08 Pilot Arc Problems ....................................................................................5-16

5.09 Main Arc and Controls Problems ..............................................................5-19

5.10 CNC Interface Problems ........................................................................... 5-19

5.11 Test Procedures .......................................................................................5-20

5.12 Main PCB Layout & Signals ......................................................................5-24

5.13 Capacitor PCB Layout & Signals ..............................................................5-27

5.14 Logic PCB Layout & Signals ..................................................................... 5-28

5.15 40AMP Logic PCB Layout & Signals ........................................................5-30

5.16 Right Side Wiring Diagram .......................................................................5-32

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 Machine Torches with Unshielded Leads ............6-8

6.11 Replacement Shielded Machine Torch Leads Assemblies ......................6-10

6.12 Torch Consumable Parts (SL100 SV) ......................................................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 ..................................................................7-6

7.08 Right Side Internal Parts Replacement .......................................................7-8

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 120

Manual 0-5412 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 120

SAFETY PRECAUTIONS 2 Manual 0-5412

5. Keep everything dry, including clothing, work

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

6. Make sure that all parts of your body are insulated

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 together.

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 ttings in

good condition. Follow manufacturer’s operating

instructions for mounting regulator to a com-

pressed 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 120

Manual 0-5412 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 sup-

plier for a copy of “Precautions and Safe Prac-

tices 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 Haz-

ardous 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 120

SAFETY PRECAUTIONS 4 Manual 0-5412

When plasma cutting stainless steel,

you must comply with the OSHA

standard to protect your employees

from Hexavalent Chromium

exposure.

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 mayb requires the as-

sistance 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/hexavalentchro-

mium.

!

DANGER

ESAB CUTMASTER 120

Manual 0-5412 5 SAFETY PRECAUTIONS

CANCER HAZARD; CAN DAMAGE

SKIN; EYES, NASAL PASSAGES, AND

LUNGS; AUTHORIZED PERESONNEL

ONLY; RESPIRATORS MAY BE

REQUIRED.

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.

For additional information about Hexavalent Chromium contact your occupational health

professional and read the OSHA web page at http://www.osha.gov/SLTC/hexavalentchro-

mium.

!

DANGER

On February 28, 2006, the Occupational Safety

and Health Agency (OSHA) published 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 pg/m3 for an eight hour time

weighted average.

• Workplace or job-speciﬁc monitoring must be

done to establish areas of potential exposure and

the quantify the potential exposure.

• Employees who may be exposed to levels of Cr

(VI) at or above the new PEL must be informed

and corrective measures implemented.

• Protective clothing and respiratory protection

must be given to employees who have potential

exposure.

• Medical surveillance of employees with poten-

tial 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 occupational health professional to reach full

compliance.

ESAB CUTMASTER 120

SAFETY PRECAUTIONS 6 Manual 0-5412

This Page Intentionally Blank

ESAB CUTMASTER 120

Manual 0-5412 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 in-

structions and warnings.

Throughout this manual, the words

WARNING, CAUTION, DANGER, and NOTE

may appear. Pay particular attention to the

information provided under these headings.

These special annotations are easily recog-

nized 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 ad-

dress and phone number in your area listed

on back cover of this manual. Include the

Owner’s Manual number and equipment

identication 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

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 at-

tached to the rear panel. Equipment which

does not have a data tag such as torch

and cable 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 com-

plete and inspect the equipment for possible

damage due to shipping. If there is any dam-

age, 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 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.

ESAB CUTMASTER 120

INTRODUCTION 2-2 Manual 0-5412

2.04 PowerSupplySpecications

ESABCutmaster120PowerSupplySpecications

Input Power

380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

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

Input Power Cable Power Supply includes input cable.

Output Current 30 - 120 Amps, Continuously Adjustable

Power Supply Gas Filtering

Ability

Particulates to 5 Microns

ESAB Cutmaster 120 Power Supply Duty Cycle *

Ambient Temperature

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

All Units

Duty Cycle N/A 80% 100%

Current 120 110

IEC IEC IEC

DC Voltage 128 124

* 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 facilitate comparison between power sup-

plies, all manufacturers use this output voltage to determine duty cycle.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

30.5"

774.7 mm

63 lb / 28.6 kg

10.75"

273 mm

16.375"

416 mm

Art # A-08358_AB

6"

150 mm

24"

610 mm

6"

150 mm

6"

150 mm

Art # A-07925_AB

ESAB CUTMASTER 120

Manual 0-5412 2-3 INTRODUCTION

2.05 InputWiringSpecications

ESAB Cutmaster 120 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)

Flexible Cord

(Min. mm

2

)

3

Phase

380 50 23 35 32 40 8 10

400 50 23.6 34 31 40 8 10

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 exible power cable with power plug in-

stallations. For hard-wired installations refer to local or national codes.

I

1

max is taken at TDC rated minimum duty cycle.

I

1

eff is taken at TDC 100% rated duty cycle.

ESAB CUTMASTER 120

INTRODUCTION 2-4 Manual 0-5412

2.06 Power Supply Features

Handle and Leads Wrap

To rch Leads Receptacl

e

Control Panel

Ar

t # A-08359

Work Cable

and Clamp

Art # A-08547

Input Power Cord

Port for Optional Automation

Interface Cable

Gas Inlet

Port

Filter Assembly

ESAB CUTMASTER 120

Manual 0-5412 2T-1 INTRODUCTION

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operat-

ing 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; unqualied personnel are strictly cau-

tioned against attempting repairs or adjustments

not covered in this manual, at the risk of voiding

the Warranty.

Read this manual thoroughly. A complete

understanding of the characteristics and capabili-

ties of this equipment will assure the dependable

operation for which it was designed.

2T.02 General Description

Plasma torches are similar in design to the

automotive spark plug. They consist of negative

and positive sections separated by a center insu-

lator. 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 col-

umn 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 Intro-

duction 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Specications

A. TorchCongurations

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.

Ar

t # 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 120

INTRODUCTION 2T-2 Manual 0-5412

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

104° F

40° C

Duty Cycle 100% @ 120 Amps @ 400 scfh

Maximum Current 120 Amps

Voltage (V

peak

) 500V

Arc Striking Voltage 7kV

Mechanized Torch Ratings

Ambient

Temperature

104° F

40° C

Duty Cycle 100% @ 120 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 settings charts for each

model.

H. Direct Contact Hazard

For standoff tip the recommended standoff is

3/16 inches / 4.7 mm.

2T.04 Options And Accessories

For options and accessories, see section 6.

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 sepa-

ration 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

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ESAB ESAB CUTMASTER® 120 SL100 1Torch User manual

ESAB ESAB CUTMASTER® 120 SL100 1Torch User manual

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