ESAB Cutmaster 100 Bedienungsanleitung

100

400V

Art # A-12775_AB

INPUT POWER VOLTAGE

OUTPUT MAX OUTPUT

PHASE

AMPS

Revision: AD Issue Date: July 1, 2019 Manual No.: 300X5397

ESAB Cutmaster®100

PLASMA CUTTING SYSTEM

SL100 1Torch™

Operating

Manual

esab.eu

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new ESAB product. We are proud to have you as our customer

and will strive to provide you with the best service and reliability in the industry. This

product is backed by our extensive warranty and world-wide service network. To locate

your nearest distributor or service agency, visit us on the web at www.esab.eu.

This Operating Manual has been designed to instruct you on the correct use and opera-

tion of your ESAB product. Your satisfaction with this product and its safe operation is

our ultimate concern. Therefore please take the time to read the entire manual, especially

the Safety Precautions. They will help you to avoid potential hazards that may exist when

working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

ESAB is a Global Brand of manual and automation Plasma Cutting Products.

We distinguish ourselves from our competition through market-leading, dependable

products that have stood the test of time. We pride ourselves on technical innovation,

competitive prices, excellent delivery, superior customer service and technical support,

together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve

a safer working environment within the welding industry.

WARNING

Read and understand this entire Manual and your employer’s safety

practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufac-

turer's best judgement, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply

ESAB Cutmaster® 100

SL100 1Torch™

Operating Manual Number 300X5397

Published by:

ESAB Group Inc.

2800 Airport Rd.

Denton, TX 76208

(940) 566-2000

www.esab.eu

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: January 15, 2015

Revision Date: July 1, 2019

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ________________

Purchase Date:__________________________________ ________________

Power Supply Serial #:___________________________ ________________

Torch Serial #:___________________________________________________

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar

with the principles of operation and safe practices for arc welding and cutting equip-

ment, we urge you to read our booklet, “Precautions and Safe Practices for Arc

Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to

install, operate, or maintain this equipment. Do NOT attempt to install or operate this

equipment until you have read and fully understand these instructions. If you do not

fully understand these instructions, contact your supplier for further information. Be

sure to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and

accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with

the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained

equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be

replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends

that a telephone or written request for service advice be made to the Authorized Distributor from whom it

was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manu-

facturer. 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 manufac-

turer or a service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

OPERATING.

PROTECT YOURSELF AND OTHERS!

DECLARATION OF CONFORMITY

According to

The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016

The EMC Directive 2014/30/EU, entering into force 20 April 2016

The RoHS Directive 2011/65/EC, entering into force 2 January 2013

Type of equipment

PLASMA CUTTING SYSTEM

Type designation etc.

ESAB Cutmaster® 100, from serial number MX1518xxxxxx

Brand name or trade mark

ESAB

Manufacturer or his authorised representative established within the EEA

Name, address, telephone No:

ESAB Group Inc.

2800 Airport Rd

Denton TX 76207

Phone: +01 800 426 1888, FAX +01 603 298 7402

The following harmonised standard in force within the EEA has been used in the design:

IEC/EN 60974-1:2017 / AMD1:2019 Arc Welding Equipment - Part 1: Welding power sources.

IEC/EN 60974-10:2014 / AMD1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10: Electromagnetic

compatibility (EMC) requirements

Additional Information: Restrictive use, Class A equipment, intended for use in location other than residential.

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised

representative established within the EEA, that the equipment in question complies with the safety re-

quirements stated above.

Date Signature Position

1 March 2019

Flavio Santos General Manager

Accessories and Adjacencies

2019

TABLE OF CONTENTS

SECTION 1: SAFETY...............................................................................................................1-1

1.0 Safety Precautions ....................................................................................1-1

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 SL100 Torch Cutting ............................................... 4T-8

4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip... 4T-9

4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip. 4T-13

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

TABLE OF CONTENTS

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

5.01 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

SECTION 5 TORCH: SERVICE............................................................................................ 5T-9

5T.01 General Maintenance ............................................................................. 5T-9

5T.02 Inspection and Replacement of Consumable Torch Parts................. 5T-10

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 Replacement Power Supply Parts ............................................................6-1

6.05 Options and Accessories ..........................................................................6-2

6.06 Replacement Parts for Hand Torch .........................................................6-3

6.07 Replacement Parts - for Machine Torches with Unshielded Leads........6-4

6.08 Torch Consumable Parts (SL100) .............................................................6-6

APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM)...................................... A-1

APPENDIX 2: DATA TAG INFORMATION ........................................................................... A-2

APPENDIX 3: TORCH PIN - OUT DIAGRAMS .................................................................... A-3

APPENDIX 4: TORCH CONNECTION DIAGRAMS ............................................................. A-4

APPENDIX 5: SYSTEM SCHEMATIC, 400V UNITS ............................................................ A-6

Revision History..................................................................................................................... A-8

ESAB CUTMASTER 100

300X5397 GENERAL INFORMATION 1-1

1.0 Safety Precautions

Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works

on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that

apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition

to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting

equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator

and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

- Always wear recommended personal safety equipment, such as safety glasses, ﬂame proof

clothing, safety gloves.

- Do not wear loose ﬁtting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualiﬁed electrician.

- Appropriate ﬁre extinguishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its

implementation in accordance with national law, electrical and/or electronic equipment that has reached the

end of its life must be disposed of at a recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain information on approved col-

lection stations.

For further information contact the nearest ESAB dealer.

ESAB can provide you with all necessary cutting protection and accessories.

SECTION 1: SAFETY

ESAB CUTMASTER 100

GENERAL INFORMATION 300X5397

1-2

WARNING Arc welding and cutting can be injurious to yourself and others. Take

precautions when welding and cutting. Ask for your employer's safety

practices which should be based on manufacturers' hazard data.

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with

applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your

breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and ﬁlter

lens and wear protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause ﬁre. Make sure therefore that there are no inﬂammable

materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmuffs or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING Do not use the power source for thawing frozen pipes.

CAUTION Class A equipment is not intended for use in residential locations

where the electrical power is provided by the public low-voltage

supply system. There may be potential difﬁculties in ensuring

electromagnetic compatibility of class A equipment in those lo-

cations, due to conducted as well as radiated disturbances.

CAUTION This product is solely intended for metal removal. Any other use

may result in personal injury and / or equipment damage.

CAUTION Read and understand the instruction manual before

installing or operating.

ESAB CUTMASTER 100

300X5397 INTRODUCTION 2-1

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, in-

cluding the chapter on safety instructions and warnings.

Throughout this manual, the words DANGER, WARN-

ING, CAUTION, and NOTE may appear. Pay par-

ticular attention to the information provided under these

headings. These special annotations are easily recog-

nized as follows:

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.

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 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 attached to the rear panel. Equipment which

does not have a data tag such as torch and cable as-

semblies 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 bottom of page

i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the

invoice to make sure it is complete and inspect the

equipment for possible damage due to shipping. If there

is any damage, notify the carrier immediately to le a

claim. Furnish complete information concerning damage

claims or shipping errors to the location in your area listed

in the inside back cover of this manual.

Include all equipment 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.

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