ESAB Cutmaster 100 SL100 1Torch User manual

100
380/400V
Art # A-12775
esab.com.cn
ESAB Cutmaster®100
Plasma Cutting System
SL100 1TorchTM
Operating
Manual
Revision: AB Issue Date: April 8, 2015 Manual No.: 0-5404

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 lo-
cate your nearest distributor or service agency, visit us on the web at www.esab.com.cn.
This Operating Manual has been designed to instruct you on the correct use and op-
eration of your ESAB product. Your satisfaction with this product and its safe opera-
tion 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 judge-
ment, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
ESAB Cutmaster®100 with SL100 1Torch™
Operating Manual Number 0-5404
Published by:
ESAB
2800 Airport Rd.
Denton, Texas 76207
www.esab.com.cn
Copyright © 2015 by
ESAB
All rights reserved.
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: April 8, 2015
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________
Purchase Date:__________________________________ __________
Power Supply Serial #:___________________________ __________
Torch Serial #:___________________________________ __________
i

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 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 equip-
ment. 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 designated 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 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-3
4T.04 Hand Torch Operation....................................................................................4T-4
4T.05 Gouging .........................................................................................................4T-7
4T.06 Mechanized Torch Operation..........................................................................4T-8
4T.07 Parts Selection for SL100 Torch Cutting........................................................4T-9
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip ....4T-10
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip ....4T-14
PATENT INFORMATION ....................................................................................................................4T-18

TABLE OF CONTENTS
SECTION 5 SYSTEM:
SERVICE..................................................................................................................................... 5-1
5.01 General Maintenance ...................................................................................... 5-1
5.02 Maintenance Schedule.................................................................................... 5-2
5.03 Common Faults............................................................................................... 5-2
5.04 Fault Indicator................................................................................................. 5-3
5.05 Basic Troubleshooting Guide .......................................................................... 5-4
5.06 Power Supply Basic Parts Replacement ......................................................... 5-6
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 Replacement Power Supply Parts................................................................... 6-2
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 Replacement Shielded Machine Torch Leads Assemblies .............................. 6-5
6.09 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, 380/400V UNITS.......................................................................A-6
APPENDIX 6: PUBLICATION HISTORY................................................................................................ A-8

ESAB CUTMASTER 100
Manual 0-5404 SAFETY 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, ame proof
clothing, safety gloves.
- Do not wear loose tting 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 qualied electrician.
- Appropriate re 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 collection 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
SAFETY Manual 0-5404
1-2
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 lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus 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
This product is solely intended for plasma cutting. Any other use may
result in personal injury and / or equipment damage.
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 poten-
tial diculties in ensuring electromagnetic compat-
ibility of class A equipment in those locations, due to
conducted as well as radiated disturbances.
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
Do not use the power source for thawing frozen pipes.
WARNING
!

ESAB CUTMASTER 100
Manual 0-5404 INTRODUCTION 2-1
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, CAU-
TION, 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 informa-
tion which requires additional emphasis or is help-
ful in e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 operat-
ing area.
WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a box
such as this.
Additional copies of this manual may be purchased
by contacting ESAB at the address and phone num-
ber 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 down-
loaded at no charge in Acrobat PDF format by going
to the ESAB web site listed below
http://www.esab.com.cn
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 specifica-
tion 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
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.

ESAB CUTMASTER 100
INTRODUCTION Manual 0-5404
2-2
2.04 Power Supply Specifications
ESAB Cutmaster®100 Power Supply Specifications
Input Power 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 100 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability Particulates to 5 Microns
ESAB Cutmaster®100 Power Supply Duty Cycle *
Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
All Units
Duty Cycle 40% 60% 100%
Rating IEC CE IEC CE IEC CE
Current 100A 80A 70A
DC Voltage 120 112 108
* 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 supplies, 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