ESAB CUTMASTER 60 PLASMA CUTTING SYSTEM SERVICE MANUAL User manual

Category
Welding System
Type
User manual
ESAB CUTMASTER
®
60
PLASMA CUTTING SYSTEM
SL60 1Torch™
Revision: AA Issue Date: July 30, 2015 Manual No.: 0-5409
Service
Manual
esab.eu
Art #A-12773_AA
60
400V
PHASE
INPUT POWER
VOLTAGE
MAX OUTPUT
OUTPUT
AMPS
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 60
SL60 1Torch™
Service Manual Number 0-5409
Published by:
ESAB Group Inc.
2800 Airport Rd.
Denton TX 76207 USA
http://www.esab.eu
Copyright 2015 by ESAB
All rights reserved.
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 SL60 Torch Cutting ....................................................4T-9
4T.08 Recommended Cutting Speeds for SL60 Torch With Exposed Tip ........4T-10
4T.09 Recommended Cutting Speeds for SL60 Torch With Shielded Tip ........4T-13
PATENT INFORMATION .....................................................................................................4T-16
TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE .............................................................................................5-1
5.01 General Maintenance .................................................................................5-1
5.02 Maintenance Schedule ...............................................................................5-2
5.03 Common Faults ..........................................................................................5-2
5.04 Fault Indicator .............................................................................................5-3
5.05 Basic Troubleshooting Guide ......................................................................5-4
5.06 Power Supply Basic Parts Replacement ....................................................5-6
5.07 Circuit Fault Isolation ..................................................................................5-8
5.08 Main Input and Internal Power Problems ..................................................5-11
5.09 Pilot Arc Problems ....................................................................................5-16
5.10 Main Arc and Controls Problems ..............................................................5-17
5.11 CNC Interface Problems ........................................................................... 5-18
5.12 Test Procedures .......................................................................................5-18
5.13 Capacitor PCB Layout & Signals ..............................................................5-22
5.14 Logic PCB Layout & Signals ..................................................................... 5-24
5.15 Main PCB Layout & Signals ......................................................................5-28
5.16 Main PCB Wiring Diagram ........................................................................ 5-30
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 (SL60) ..............................................................6-11
6.13 Torch Consumable Parts (SL100) ............................................................6-12
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, 380/400/415V UNITS ................................................ A-6
Publication History ................................................................................................................... A-8
This Page Intentionally Blank
ESAB CUTMASTER 60
Manual 0-5409 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 60
SAFETY PRECAUTIONS 2 Manual 0-5409
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 manufacturers 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 60
Manual 0-5409 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 60
SAFETY PRECAUTIONS 4 Manual 0-5409
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 60
Manual 0-5409 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-specic 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 specic details of
the standard are complex and may require
the assistance of an occupation
al health
professional to reach full compliance
ESAB CUTMASTER 60
SAFETY PRECAUTIONS 6 Manual 0-5409
This Page Intentionally Blank
ESAB CUTMASTER 60
Manual 0-5409 2-1 INTRODUCTION
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owners 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 Owners 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 60
INTRODUCTION 2-2 Manual 0-5409
2.04 Power Supply Specifications
ESABCutmaster60PowerSupplySpecications
Input Power 400/415 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power Cable Power Supply includes input cable.
Cable for 400V 3 Phase.
Output Current 20 - 60 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability
Particulates to 5 Microns
ESAB Cutmaster 60 Power Supply Duty Cycle *
Ambient Tempera-
ture
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 60 Amps 50 Amps 30 Amps
DC Voltage 104 100 92
* 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 60
Manual 0-5409 2-3 INTRODUCTION
2.05 Input Wiring Specifications
ESAB Cutmaster 60 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 16 11 20 14
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 60
INTRODUCTION 2-4 Manual 0-5409
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 60
Manual 0-5409 2T-1 INTRODUCTION
SECTION 2 TORCH:
INTRODUCTION
2T.01 Scope of Manual
This manual contains descriptions, operating instructions
and maintenance procedures for the 1Torch Models
SL60/Manual and SL100/Mechanized Plasma Cutting
Torches. Service of this equipment is restricted to prop-
erly trained personnel; unqualied personnel are strictly
cautioned against attempting repairs or adjustments not
covered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding
of the characteristics and capabilities of this equipment
will assure the dependable operation for which it was
designed.
2T.02 General Description
Plasma torches are similar in design to the automotive
spark plug. They consist of negative and positive sec-
tions 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 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 2"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 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
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 60
INTRODUCTION 2T-2 Manual 0-5409
F. Torch Ratings
Manual Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle
100% @ 60 Amps @ 400 scfh
Maximum Current
60 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 60 PLASMA CUTTING SYSTEM SERVICE MANUAL User manual

Category
Welding System
Type
User manual

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