ESAB Cutmaster 40 SL60 1Torch Bedienungsanleitung

Art # A-12777_AA

Révision : AA Issue Date: January 15, 2015 Manual No.: 0-5376

40 230V

120V

Operating

Manual

ESAB Cutmaster®40

PLASMA CUTTING SYSTEM

SL60 1Torch™

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 operation 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 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® 40 with SL60 1Torch™

Operating Manual Number 0-5376

Published by:

ESAB

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

publisher 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:

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 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 desig-

nated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

OPERATING.

PROTECT YOURSELF AND OTHERS!

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 Working Principle ............................................................................................................2-2

2.05 Power Supply Speciﬁcations ...........................................................................................2-2

2.06 Input Wiring Speciﬁcations ..............................................................................................2-3

2.07 Power Supply Features....................................................................................................2-4

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

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

2T.02 Speciﬁcations .............................................................................................................. 2T-1

2T.03 Introduction to Plasma .................................................................................................. 2T-2

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

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

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

3.03 Primary Input Power Connections....................................................................................3-1

3.04 Air Supply Connections ...................................................................................................3-1

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

4.01 Control Panel...................................................................................................................4-1

4.02 Preparations For Operating..............................................................................................4-2

4.03 Sequence of Operation....................................................................................................4-5

4.04 Cut Quality ......................................................................................................................4-7

4.05 General Cutting Information.............................................................................................4-7

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

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

5.02 Basic Troubleshooting Guide............................................................................................5-2

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

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

5T.02 Inspection and Replacement of Consumable Torch Parts ............................................... 5T-1

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

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

6.02 Power Supply Replacement Parts....................................................................................6-2

6.03 SL60 Torch Consumable Parts.........................................................................................6-3

6.04 Optional Accessories .......................................................................................................6-4

APPENDIX 1: ESAB CUTMASTER®40 CIRCUIT DIAGRAM .............................................................................. A-1

APPENDIX 2: SL60 TORCH PIN-OUT DIAGRAM............................................................................................... A-2

Revision History.............................................................................................................................................. A-3

TABLE OF CONTENTS

This Page Intentionally Blank

ESAB CUTMASTER 40

Manual 0-5376 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 40

GENERAL INFORMATION Manual 0-5376

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 loca-

tions, 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 40

Manual 0-5376 2-1 INTRODUCTION

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just speciﬁcation or part numbers

listed on page i.

To ensure safe operation, read the entire manual, including the

chapter on safety instructions 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 recognized as follows:

NOTE!

An operation, procedure, or background

information which requires additional

emphasis or is helpful in efﬁcient 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 electri-

cal 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 identiﬁcation 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 Identiﬁcation

The unit’s identiﬁcation number (speciﬁcation 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 assemblies are identiﬁed only by the

speciﬁcation 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 pos-

sible damage due to shipping. If there is any damage, notify the

carrier immediately to ﬁle 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 identiﬁcation 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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