ESAB Cutmaster 120 ®
PLASMA CUTTING SYSTEM
SL100 1Torch™
Operating
Manual
Art # A-12776_AB
OUTPUT MAX OUTPUT INPUT POWER VOLTAGE
120 PHASE 400V
AMPS
Revision: AC Issue Date: August 14, 2015 Manual No.: 0-5398
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® 120
SL100 1Torch™
Operating Manual Number 0-5398
Published by:
ESAB Group Inc.
2800 Airport Rd.
Denton, TX 76208
(940) 566-2000
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: January 15, 2015
Revision Date: August 14, 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 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
We ESAB Group Inc.
of 2800 Airport Road
Denton, TX 76207 U.S.A.
in accordance with the following Directive(s):
• 2006/95/EC The Low Voltage Directive, entering into force 16 January 2007
• 2004/108/EC The Electromagnetic Compatibility (EMC) Directive, entering into force 20 July 2007
• RoHS Directive 2001/EC, entering into force 2 January 2013
hereby declare that:
Equipment: PLASMA CUTTING SYSTEM
Model Name/Number: ESAB Cutmaster® 120
Market Release Date: May 30, 2015
is in conformity with the applicable requirements of the following harmonized standards:
• EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.
• EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC)
requirements
Classification: The equipment described in this document is Class A and intended for industrial use.
Manufacturer’s Authorized Representative
Steve Ward V.P. Europe and General Manager
(Signature)
Address: ESAB
Steve Ward
Europa Building
(Full Name)
Chorley N Industrial Park
Chorley, Lancashire, V.P. Europe and General Manager
England PR6 7BX (Position)
Date: May 30, 2015
WARNING
! This Class A equipment is not intended for use in residential locations where the electrical power is provid-
ed by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic
compatibility in those locations, due to conducted as well as radiated disturbances.
TABLE OF CONTENTS
SECTION 1: SAFETY...............................................................................................................1-1
1.0 Safety Precautions.......................................................................................1-1
РАЗДЕЛ 1: БЕЗОПАСНОСТ...................................................................................................1-1
ČÁST 1: Bezpečnostní............................................................................................................1-1
SEKTION 1: SIKKERHEDSFORANSTALTNINGER................................................................1-1
KAPITEL 1: SICHERHEIT........................................................................................................1-1
SECCIÓN 1: SEGURIDAD.......................................................................................................1-1
PEAÜKK 1: Ohutus.................................................................................................................1-1
KAPPALE 1: Turvallisuus.......................................................................................................1-1
CHAPITRE 1 : SÉCURITÉ........................................................................................................1-1
SECTION 1: Važne sigurnosne..............................................................................................1-1
1. FEJEZET: Biztonsági...........................................................................................................1-1
SEZIONE 1: SICUREZZA.........................................................................................................1-1
1 SKYRIUS. Saugos................................................................................................................1-1
1 NODAĻA : Drošības..............................................................................................................1-1
HOOFDSTUK 1: VEILIGHEID..................................................................................................1-1
AVSNITT 1: Sikkerhet..............................................................................................................1-1
ROZDZIAŁ 1: BEZPIECZEŃSTWO.........................................................................................1-1
SECÇÃO 1: Segurança...........................................................................................................1-1
SECŢIUNEA 1: Securitate.......................................................................................................1-1
РАЗДЕЛ 1, Правила техники................................................................................................1-1
ČASŤ 1: Bezpečnostné pokyny.............................................................................................1-1
RAZDELEK 1 - VARNOST.......................................................................................................1-1
TABLE OF CONTENTS
AVSNITT 1: SÄKERHET..........................................................................................................1-1
1.0 Säkerhetsåtgärder..................................................................................... 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-14
PATENT INFORMATION......................................................................................................4T-20
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...............................................................6-1
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
This Page Intentionally Blank
ESAB CUTMASTER 120
SECTION 1: SAFETY
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.
Manual 0-5398 GENERAL INFORMATION 1-1
