CUTMASTER® 60i
PLASMA CUTTING SYSTEM
OPERATING
MANUAL
Art # A-14032
SL60QD
OUTPUT MAX OUTPUT
60
Revision: AA Issue Date: 15 February, 2019
VOLTAGE
400V
esab.com
INPUT POWER
3
Manual No.: 0-5562
EU 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/EU, entering into force 2 January 2013
Type of equipment
PLASMA CUTTING SYSTEM
Type designation etc.
CutMaster 60i, from serial number MX1723XXXXXX
Brand name or trade mark
ESAB
Manufacturer or his authorised representative
Name, address, telephone No:
ESAB Group Inc.
2800 Airport Rd
Denton TX 76207 USA
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 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.
IEC/EN 60974-10:2014 + AMD 1:2015 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 , that the equipment in question complies with the safety requirements stated above.
Date Signature Position
9 June, 2017
Flavio Santos General Manager
Accessories and
Adjacencies
2017
TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION..................................................... 11
1.01 Notes, Cautions and Warnings...............................................................................11
SECTION 1 : INFORMATIONS GÉNÉRALES ..............................................13
1.01 Remarques, avertissements et mises en garde......................................................13
SECTION 2 SYSTEM: INTRODUCTION ....................................................15
2.01 How To Use This Manual ........................................................................................ 15
2.02 Equipment Identication ...................................................................................... 15
2.03 Receipt Of Equipment ...........................................................................................15
2.04 Power Supply Specications .................................................................................16
2.05 Input Wiring Specications ................................................................................... 18
2.06 Power Supply Features .......................................................................................... 19
SECTION 2 TORCH: INTRODUCTION ...................................................... 21
2T.01 Scope of Manual .................................................................................................. 21
2T.02 General Description ............................................................................................. 21
2T.03 Specications .....................................................................................................21
2T.04 Quick Connection Torch .......................................................................................22
SECTION 3 SYSTEM: INSTALLATION ...................................................... 23
3.01 Unpacking ............................................................................................................23
3.02 Lifting Options ...................................................................................................... 23
3.03 Opening the Main Switch Cover ............................................................................23
3.04 Primary Input Power Connections, 3 Phase ...........................................................24
3.05 Gas Connections ....................................................................................................24
3.06 Work Lead Connections .........................................................................................27
SECTION 3 TORCH:
INSTALLATION .................................................................................... 29
3T.01 Torch Connections ...............................................................................................29
3T.02 Setting Up Mechanical Torch ............................................................................... 29
SECTION 4 SYSTEM: OPERATION ..........................................................31
4.01 Front Panel Controls / Features .............................................................................31
4.02 Preparations for Operation ....................................................................................34
SECTION 4 TORCH: OPERATION .............................................................39
4T.01 Torch Parts Selection ........................................................................................... 39
4T.02 Hand Torch Operation .......................................................................................... 39
4T.03 Gouging ..............................................................................................................42
4T.04 Mechanized Torch Operation ...............................................................................43
4T.05 Recommended Cutting Speeds With Exposed Tip ................................................45
4T.06 Recommended Cutting Speeds With Shielded Tip ...............................................48
TABLE OF CONTENTS
PATENT INFORMATION ........................................................................51
SECTION 5 SYSTEM: SERVICE ................................................................53
5.01 General Maintenance ............................................................................................ 53
5.02 Maintenance Schedule .......................................................................................... 53
5.03 Common Faults ..................................................................................................... 54
5.04 Fault Indicator .......................................................................................................55
5.05 Basic Troubleshooting Guide ................................................................................. 56
5.06 Power Supply Basic Parts Replacement .................................................................59
SECTION 5 TORCH: SERVICE .................................................................63
5T.01 General Maintenance ..........................................................................................63
5T.02 Inspection and Replacement of Consumable Torch Parts ..................................... 64
SECTION 6: PARTS LISTS ...................................................................... 65
6.01 Introduction .......................................................................................................... 65
6.02 Ordering Information ............................................................................................ 65
6.03 Power Supply Replacement ..................................................................................65
6.04 Replacement Power Supply Parts .........................................................................66
6.05 Options and Accessories ........................................................................................66
6.06 External Replacement Parts (Plastic) ...................................................................67
6.07 Replacement Parts for Hand Torch ........................................................................68
6.08 Torch Consumable Parts (SL60) .............................................................................69
6.09 Torch Consumable Parts (SL100) ...........................................................................70
APPENDIX 1: DATA TAG INFORMATION .................................................71
APPENDIX 2: TORCH PIN OUT DIAGRAMS ........................................... 72
APPENDIX 3: TORCH CONNECTION DIAGRAMS ......................................73
APPENDIX 4: PUBLICATION HISTORY ................................................... 74
CUTMASTER 60i
SECTION 2 SYSTEM: INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just product(s) listed on page i.
To ensure safe operation, read the entire manual, including the chapter on safety instructions and
warnings.
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 Operating Manual number and
equipment identication 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 and clicking on "Product Support" / "ESAB Documentation": /
"Download Library", then navigate to "Plasma Equipment" and then "Manual".
http://www.esab.com
2.02 Equipment Identication
The unit’s identication number (specication or part number), model, and serial number usually appear
on a data tag attached to the bottom. Equipment which does not have a data tag such as torch and
cable assemblies are identied only by the specication 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 on the back cover of this manual.
Include all equipment identication numbers as described above, along with a full description of the
parts in error.
0-5562 INTRODUCTION
Included items:
• 60i Power Supply
• SL60QD™ Torch and Leads
• Work Lead with Work Clamp
• Spare Parts Kit ( 2 Elec trodes, 2 Tips, 1 Shield
cup)
• Operating Manual
• Filter Wrench
Move the equipment to the installation site before
un-boxing the unit. Use care to avoid damaging
the equipment when opening the box.
15
CUTMASTER 60i
2.04 Power Supply Specications
2.04.01 3 Phase
60i 208 - 480 VAC 3 Phase Power Supply Specifications
Input Power 208 - 480 VAC(187 - 528 VAC), 3 Phase, 50/60 Hz
3 Phase Input Power Cable
Output Current 10 - 60 Amps, Continuously Adjustable
Power Supply Gas Filtering
Ability
Maximum Inlet Pressure 125 PSI (8.6 bar)
60i 400 VAC 3 Phase CE Power Supply Specifications
Input Power 400 VAC, 3 Phase, 50/60 Hz
3 Phase Input Power Cable
Output Current 10 - 60 Amps, Continuously Adjustable
Power Supply Gas Filtering
Ability
Maximum Inlet Pressure 125 PSI (8.6 bar)
Power Supply includes 9' three phase 12AWG 4/C input
cable without plug.
Particulates to 5 Microns
Power Supply includes 9' three phase 12AWG 4/C input
cable with plug.
Particulates to 5 Microns
2.04.02 Additional Power Supply Specications
60i Power Supply Duty Cycle *
Ambient Air Temperature
All Units
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output
Recommended Pierce Maximum
3/4" (19.05mm) 5/8" (15.86mm) 1 1/2" (38mm)
INTRODUCTION 0-5562
16
voltage (DC) is higher than shown in this chart.
Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
Rating
Duty Cycle 50% 60% 100%
Current
DC Voltage
60i Cut Capacity
60 Amps 50 Amps 40 Amps
126 122 119
Generator Recommendations
CUTMASTER 60i
When using generators to power the 60i Plasma Cutting System, the following ratings are a minimum
and are to be used along with the ratings listed above.
A60i Generator Specifications
Generator Output Rating 60i Output Current Arc Characteristic
15 kW 60A Full
12 kW
10 kW
NOTE!
Due to circuitry, age and condition two generators with the same ratings may produce dierent results. Adjust the
amperage accordingly.
60A Limited
45A Full
45A Limited
30A Full
Power Supply Dimensions & Weight Ventilation Clearance Requirements
0-5562 INTRODUCTION
17
CUTMASTER 60i
2.05 Input Wiring Specications
WARNING
Each CutMaster 60i system is a dedicated 1 Phase OR 3 Phase system and cannot be recongured to the other.
Personal injury could occur if changing the phase is attempted.
3 Phase
3 Phase CutMaster 60i Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I max I1eff
208 50/60 9.1 26 18.5 40 12 AWG (2.5mm2)
230 50/60 9.1 23.3 16.5 30 12 AWG (2.5mm2)
380 50/60 8.9 13.8 9.8 20 14 AWG (2.5mm2)
3 Phase
400 50/60 8.9 13.2 9.4 20 14 AWG (2.5mm2)
415 50/60 9.1 12.8 9.1 20 16 AWG (1.5mm2)
480 50/60 9.2 11.3 8.0 15 16 AWG (1.5mm2)
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
Fuse
(amps)
Flexible Cord (Min.
AWG)
Three Phase
NOTE!
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
INTRODUCTION 0-5562
18
2.06 Power Supply Features
CUTMASTER 60i
0-5562 INTRODUCTION
19
SECTION 2 TORCH: INTRODUCTION
2T.01 Scope of Manual
This manual contains descriptions, operating
instructions and maintenance procedures for
the 1Torch Models SL60, SL60QD™ and SL100/
Mechanized Plasma Cutting Torches. Service of
this equipment is restricted to properly trained
personnel; unqualied 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
CAUTION
Torch Leads are exible but internal wires can
be broken. Do not exceed a 2" radius bend and
avoid repeated tight bends when possible.
NOTE!
Refer to Section "4Torch", for a more detailed
description of plasma torch operation.
Refer to the Appendix Pages for
additional specications as related
to the Power Supply used.
2T.03 Specications
A. Torch Congurations
1. Hand/Manual Torch, Model
SL60QD™
The hand torch head is at 75° to the torch
handle. The hand torches include a torch
handle and torch trigger assembly.
CUTMASTER 60i
2. Mechanized Torch, Model
The standard machine torch has a positioning tube with rack & pinch block
assembly.
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20 ft / 6.1 m, with ATC connectors
• 50 ft / 15.2 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
15 VDC circuit rating
E. Type Cooling
Combination of ambient air and gas stream
through torch.
F. Torch Ratings
Manual Torch Ratings
Ambient
Temperature
Duty Cycle
Maximum
Current
Voltage (V
Arc Striking
Voltage
) 500V
peak
104° F
40° C
100% @ 60 Amps @ 400
scfh
60 Amps
500V
0-5562 INTRODUCTION
21
CUTMASTER 60i
Mechanized Torch Ratings
Ambient
Temperature
Duty Cycle
Maximum
Current
Voltage (V
Arc Striking
Voltage
G. Gas Requirements
Manual and Mechanized Torch Gas
Gas (Plasma and Secondary) Compressed Air
Operating Pressure
Refer to NOTE
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow (Cutting and
100% @ 100 Amps @ 400
) 500V
peak
Specifications
Gouging)
104° F
40° C
scfh
120 Amps
500V
90 - 120 psi
6.2 - 8.3 bar
5 - 8.3 SCFM
300 - 500 scfh
142 - 235 lpm
2T.04 Quick Connection Torch
The new SL60QD™ (Quick Disconnect) torch allows
for a quick change of the torch handle assembly
from the leads. To change the torch handle assembly do the following.
1. Remove the torch handle assembly by
grasping the torch handle in one hand
and the coupler nut and leads in the
other.
2. Rotate the nut a minimum of one full
turn to the left (counter clockwise) and
pull the torch handle assembly out from
the leads in a straight line.
3. To reattach, grasp both as before and
carefully align the internal connecting
parts.
4. Carefully press the two together in a
straight line.
5. Align the mark on the coupler nut with
that on the top of the torch handle and
rotate to the right (clockwise) drawing
the two together and seating the
connections inside. Do not use tools to
tighten.
WARNING
This Torch is not to be used with oxygen (O2).
The SL60QD torch should not be used on an HF
system.
NOTE!
Operating pressure varies with torch model,
operating amperage, and torch leads length. Refer
to gas pressure settings charts for each model.
H. Direc t Contact Hazard
For stando tip the recommended stando
is 3/16 inches / 4.7 mm.
INTRODUCTION 0-5562
22
CUTMASTER 60i
SECTION 3 SYSTEM: INSTALLATION
3.01 Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor
and / or shipping company before proceeding with the installation.
3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name,
in the information block at the front of this manual.
3.02 Lifting Options
The Power Supply includes handles for hand lifting only. Be sure unit is lifted and transported safely
and securely.
WARNING
Do not touch live electrical parts.
Disconnect input power cord before moving unit.
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLES are not for mechanical lifting.
• Only persons of adequate physical strength should lift the unit.
• Lift unit by the handles, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other
vehicle.
3.03 Opening the Main Switch Cover
Systems are congured for and come with power cord connected for single phase or three phase
conguration depending on system purchased. The input power switch is located on the rear panel
along the top. To access the input locations, remove the screw at the top of the cover and ip down.
WARNING
Disconnect power before removing the cover.
Main Switch Cover
0-5562 INSTALLATION
23
CUTMASTER 60i
3.04 Primary Input Power Connections, 3 Phase
3 Phase
WARNING
Each CutMaster 60i system is a dedicated 1 Phase OR 3 Phase system and cannot be recongured to
the other. Personal injury could occur if changing the phase is attempted.
CAUTION
The primary power source, fuse, and any extension cords used must conform to local electrical code
and the recommended circuit protection and wiring requirements as specied in Section 2.
Three Phase Input Power Wiring
NOTE!
As long as the power supply is connected to input power ranging from 208 VAC to 480 VAC, the
system will automatically detect this and run accordingly.
3.05 Gas Connections
Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure cylinders. Refer to the following two
subsections if an optional air line lter is to be installed.
1. Connect the air line to the inlet port. The illustration shows typical ttings as an example.
NOTE!
For a secure seal, apply thread sealant to the tting threads, according to manufacturer’s instructions.
Do not use Teon tape as a thread sealer, as small particles of the tape may break o and block the small
air passages in the torch.
Air Connection to Inlet Port
INSTALLATION 0-5562
24
CUTMASTER 60i
NOTE!
Filter replacement part numbers can be found in Section 6 of this manual.
Installing Optional Single - Stage Air Filter
An optional lter kit (7-7507) is recommended for improved ltering with compressed air, to keep
moisture and debris out of the torch.
1. Attach the Single - Stage Filter Hose to the Inlet Port 1/4" NPT of the system lter.
2. Attach the Filter Assembly to the lter hose.
3. Connect the air line to the Filter using the 1/4" NPT. The illustration shows typical ttings as
an example.
NOTE!
For a secure seal, apply thread sealant to the tting threads, according to manufacturer’s instructions.
Do not use Teon tape as a thread sealer, as small particles of the tape may break o and block the
small air passages in the torch.
Optional Single - Stage Filter Installation
NOTE!
Filter replacement part numbers can be found in Section 6 of this manual
0-5562 INSTALLATION
25
CUTMASTER 60i
Installing Optional Two - Stage Air Filter Kit
This optional two - stage air line lter (9-9387) is also for use on compressed air shop systems. Filter
removes moisture and contaminants to at least 5 microns.
Connect the air supply as follows:
1. Attach the Two Stage Filter bracket to the back of the power supply with the screws supplied.
NOTE!
For a secure seal, apply thread sealant to the tting threads, according to manufacturer’s instructions.
Do not use Teon tape as a thread sealer, as small particles of the tape may break o and block the
small air passages in the torch.
2. Connect the two stage lter outlet hose to the inlet port of the Regulator / Filter Assembly.
3. Use customer - supplied ttings to connect the air line to the Filter. A 5/16" (8mm) O.D.
smooth tubing should be used with the press in tting.
Optional Two - Stage Filter Installation
NOTE!
Filter replacement part numbers can be found in Section 6 of this manual
Using High Pressure Air Cylinders
When using high pressure air cylinders as the air supply:
1. Refer to the manufacturer’s specications for installation and maintenance procedures for
high pressure regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign
material. Briey open each cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet
pressures up to 120 psi (8.3 bar) maximum and ows of least 300-500 scfh / 5 - 8.3 CFM (142235 lpm).
4. Connect supply hose to the cylinder.
NOTE!
Pressure should be set at 120 psi (8.3 bar) at the high pressure cylinder regulator.
INSTALLATION 0-5562
26
CUTMASTER 60i
3.06 Work Lead Connections
Connect the Work Lead to the power supply and the work piece.
1. Attach the Dinse type connection of the work lead to the power supply front panel as shown
below. Push in and turn clockwise to the right until tight.
2. Connect the work clamp to the workpiece or cutting table. The area must be free from oil,
paint and rust. Connect only to the main part of the work piece; do not connect to the part
to be cut o.
0-5562 INSTALLATION
27
SECTION 3 TORCH:
INSTALLATION
3T.01 Torch Connections
If necessary, connect the torch to the Power Supply. Connect only the ESAB model SL60, SL60QD™
or SL100 / Mechanical Torch to this power supply.
Maximum torch leads length is 100 feet / 30.5 m,
including extensions.
CUTMASTER 60i
2. Select SET mode.
3. Place a welding lter lens in front of the
torch and turn ON the air. Do not start
an arc! Any oil or moisture in the air will
be visible on the lens.
3T.02 Setting Up Mechanical Torch
WARNING
Disconnect primary power at the source before
connecting the torch.
1. Align the ATC male connector (on the
torch lead) with the female receptacle.
Push the male connector into the female
receptacle. The connectors should
push together with a small amount of
pressure.
2. Secure the connection by turning the
locking nut clockwise until it clicks.
DO NOT use the locking nut to pull the
connection together. Do not use tools
to secure the connection.
1
2
WARNING
Disconnect primary power at the source before
disassembling the torch or torch leads.
The mechanical torch includes a positioning tube
with rack and pinch block assembly.
1. Mount the torch assembly on the cutting table.
2. To obtain a clean vertical cut, use a
square to align the torch perpendicular
to the surface of the workpiece.
Art # A-13286_AB
Connecting the Torch to the Power Supply
3. The system is ready for operation.
Check Air Quality
To test the quality of air:
1. Put the ON / OFF switch in the ON (Left)
position.
0-5562 INSTALLATION
Mechanical Torch Set - Up
3. The proper torch parts (shield cup, tip,
start cartridge, and electrode) must be
installed for the type of operation. Refer
to Section "4T.01 Torch Parts Selection".
29
SECTION 4 SYSTEM: OPERATION
4.01 Front Panel Controls / Features
See Illustration for numbering Identication
CUTMASTER 60i
1. Numeric Display
• Displays software revision at start up
• Displays amperage values (Factory default)
• Displays error codes
• Displays pre-set (preview) maintenance functions
2. AC Indicator
Steady light indicates power supply is ready for operation. Blinking light indicates the input
voltage is outside of operating range or internal fault.
3. DC Indicator
Indicator is ON when DC output circuit is active.
4. Latch/Lock
Indicator is ON when unit is in "Latch" mode.
0-5562 OPERATION
31
CUTMASTER 60i
5. Set Mode Indicator
Indicator is ON when unit is owing gas and pressure can be set.
6. Shield Cup In Place Indicator
Indicator is Blinking when any of the following are not in place or connected: Shield Cup, ATC
leads or Quick Disconnect.
7. Gouge Mode Indicator
Indicator is ON when unit is in "Gouge" mode and all Cutting Indicators (#8) are illuminated.
8. Type of Cutting Indicator
Dierent segments will be illuminated to indicate dierent types of cutting.
• Gouging - All illuminated
• Normal Cutting and Latch Mode - Center indicator will be OFF.
• RAR (Rapid Auto Restart) Cutting - Every other indicator will be OFF.
• Set Mode - All indicators will be OFF.
9. Fault Indicator
Indicator is ON when unit is in fault condition. See error codes appendix for fault light explanations. Flashing when active.
Factory default: OFF
10. EOL (End Of Life) Indicator
Indicator is normally OFF. It is also OFF during Drag Cutting.
When on it is to inform user that consumable failure is imminent
Active and/or operable in all cutting modes except Drag.
11. Over Temp Indicator
Indicator is normally OFF. Indicator is ON/FLASHING when internal temperature exceeds normal
limits. Let the unit cool before continuing operation.
12. Gas Pressure Indicator
Indicator used to show low, optimal and high gas pressure. Torch type, lead length, cutting mode
and amperage should all be set prior to setting the gas pressure. (90 - 125 PSI / 6.2 - 8.6 bar)
OPERATION 0-5562
32
CUTMASTER 60i
One of 7 segments will always be on when unit is on. The gas bottle will be illuminated and ash
during a gas pressure fault. Bottle will ash when pressure is below a minimum threshold. Bottle
will be on continuously when acceptable.
Factory default: One, or two segments and gas bottle will be illuminated depending on the gas
pressure level. The green indicator in the middle indicates the recommended pressure for the
process (Amps, torch type, lead length). Dierent processes have dierent optimum pressures.
Yellow indicates above or below optimum pressure and red indicates unacceptable pressure for
good cutting. Each LED represents 5 psi. Two adjacent LEDs will represent a value in between
the two or 2.5 lb. pressure change.
13. Gas Pressure Selector
Rotate the lower knob to set the gas pressure.
14. Torch Type Indicator
Used for selecting one of the three torch options and torch length for each. SLV will be automatically detected.
Factory default: On, SL60 which includes SL60QD™ (Quick Disconnect)
Press and release the lower knob without rotating it to step through selection of torch type.
NOTE!
If you have gone past the desired setting, you will need to continue to step through all the other torch types and lengths
to get back to return to it.
15. Lead Length Indicator
Used for selecting torch lead length for each torch type ranging between 20’ and 100’ leads.
Factory default: On, 20’
Press and release the lower knob without rotating it to step through selection of torch type
followed by lead length.
Up to 35’ Lead (10.7 m)
Above 35' to 50’ Lead (15.2 m)
Above 50' to 75’ Lead (22.9 m)
Above 75' to 100’ Lead (30.5 m)
NOTE!
If you have gone past the desired setting, you will need to continue to step through all the other torch types and lengths
to get back to return to it.
0-5562 OPERATION
33
CUTMASTER 60i
16. Upper Knob - Amp and Mode Selector
Rotate knob to increase or decrease amperage. Indicator is ON when numeric display is
showing amperage output.
Press and release knob without turning to step through the dierent Modes.
Factory default: On
Numeric display
17. Torch Quick Disconnect Receptacle
Torch Leads are connected here by aligning the connectors, pressing in and turning locking ring
clockwise-to-the-right to secure. Connection should only be snug with no tools used.
18. Work Lead Dinse type receptacle
Align Dinse type connector on work lead with receptacle, press in and turn clockwise to the
right until tight.
4.02 Preparations for Operation
At the start of each operating session:
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and
leads assemblies.
Torch Parts Selection
Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type of operation, and with the amperage output of this Power Supply (60 amps
maximum). Refer to Section 4T.07 and following for torch parts selection.
Torch Connection
Check that the torch is properly connected. Only ESAB models SL60, SL60QD™ / Manual or SL100
/ Mechanical Torches may be connected to this Power Supply. See Section 3T of this manual.
Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets
the power requirements for the unit per Section 2, Specications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the
system.
Air Source
Ensure source meets requirements (refer to Section 2). Check connections and turn air supply ON.
OPERATION 0-5562
34
CUTMASTER 60i
Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and
rust. Connect only to the main part of the workpiece; do not connect to the part to be cut o.
Power ON
Place the Power Supply ON / OFF switch to the ON (right) position. AC indicator turns ON.
The Control Board performs several tests to determine the system is ready to operate. During the
self-tests the digital display rst shows (revision) followed by the rmware revision
number which includes decimals. 1.1.0 is an example of a production released code revision
that may be displayed.
Next displayed is the “checksum” a combination of letters and numbers that are unique to the rmware revision. These are used by service personal to determine if the rmware has been corrupted.
If there are no issues detected the output current setting will be displayed with the letter "A" to
the right, showing the output current setting. Should a problem be detected the fault code in
the format Exxx will display and the “A” will not be illuminated. Refer to Section 5.04 for fault
code explanations.
and the cooling fan turns ON. (90 - 125 PSI / 6.2 - 8.6 bar)
The cooling fan will turn ON as soon as the unit is turned ON. After a short amount of time the fan
switches to low speed. The fan will return to high speed as soon as the torch switch (Start Signal)
is activated or if the unit is turned OFF, then turned ON again. If an over temperature condition
occurs, the fan will continue to run at high speed while the condition exists and for a ve (5)
minute period once the condition is cleared.
0-5562 OPERATION
Gas indicator turns ON if there is sucient gas pressure for power supply operation
NOTE!
Minimum pressure for power supply operation is lower than minimum for torch operation.
35
CUTMASTER 60i
Select Cutting Mode
1. Press and release the upper knob without turning to enter the mode selection menu. Place
the system in one of the four cutting modes available by pressing and releasing the knob
until you reach the desired mode.:
RUN
LATCH .
RAPID AUTO RESTART
GOUGE
SET/PURGE (gas ow only)
2. After selecting the cutting mode, set the output current by turning the knob.
Set Torch Parameters
1. Press and release the bottom knob without rotating to enter the torch type and leads length
selections.
Set Operating Pressure
NOTE!
Before the gas pressure is set, the torch type, leads length, type of cutting and amperage should all be set as they
will aect the pressures required. If any of those are changed, the pressure should be checked again to make sure it is
optimized.
1. Gas pressure must be set in the cutting mode to be used, not in the SET/PURGE mode. Each
mode may require a dierent pressure for optimal cutting. (90 - 125 PSI / 6.2 - 8.6 bar)
OPERATION 0-5562
36
CUTMASTER 60i
2. Set the gas pressure/ow using the lower knob, 2. Changes will show on the Gas Pressure
Interlock. The green indicator in the center is the ideal setting. Each indicator
when lit separately is equal to 5 lbs. from the segment next to it. Each will show 5, 10, or 15
lbs or more below or above the ideal. When two segments are illuminated together then
the change is half as much or 2.5 lbs. The pressure settings will all be aected by the other
settings for torch, torch length and type of cutting and will require adjustments to the pressure
setting.
Cutting Operation
When the torch leaves the workpiece during cutting operations in the RUN mode, there is a brief
delay in restarting the pilot arc. With the system in the RAPID AUTO RESTART mode, when the
torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly
when the pilot arc contacts the workpiece. (Use the 'Rapid Auto Restart' mode when cutting
expanded metal or gratings, or trimming operations when an uninterrupted restart is desired).
With the system in the LATCH mode the main cutting arc will be maintained after the torch switch
is released. To exit or cancel the LATCH mode, press and release the trigger again or lift the torch
from the cutting surface so the arc goes out.
Typical Cutting Speeds
Cutting speeds vary according to torch output amperage, the type of material being cut, and
operator skill. Refer to Section "4T.08 Recommended Cutting Speeds With Exposed Tip" and
following for greater details.
Output current setting or cutting speeds may be reduced to allow slower cutting when following
a line, or using a template or cutting guide while still producing cuts of excellent quality.
Postow
Release the trigger to stop the cutting arc. Gas continues to ow for approximately 20 seconds.
During post - ow, if the user moves the trigger release to the rear and presses the trigger, the
pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance
to the workpiece.
Shutdown
Turn the ON / OFF switch to OFF, to the left as you face the unit from the rear. After a short delay
all Power Supply indicators and fan shut OFF. Unplug the input power cord or disconnect input
power. Power is removed from the system.
NOTE!
To maximize the longevity of the internal electronics, allow the power supply to continue running (without cutting)
until the cooling fan speed changes to slow. This may take a few minutes.
0-5562 OPERATION
37
A-03510_AB
SECTION 4 TORCH: OPERATION
CUTMASTER 60i
4T.01 Torch Parts Selection
Depending on the type of operation to be done
determines the torch parts to be used.
Type of operation:
Drag cutting, stando cutting or gouging
Torch parts:
Shield Cup, Cutting Tip, Electrode and
Start Cartridge
NOTE!
Refer to Section 4T.07 and following for additional
information on torch parts.
Change the torch parts for a dierent operation
as follows:
WARNING
Disconnect primary power at the source before
assembling or disassembling torch parts, or
torch and leads assemblies.
NOTE!
The shield cup holds the tip and start cartridge
in place. Position the torch with the shield cup
facing upward to keep these parts from falling out
when the cup is removed.
1. Unscrew and remove the shield cup
assembly from the torch head.
2. Remove the Electrode by pulling it
straight out of the Torch Head.
Large O-Ring
Torch Head
Electrode
Start Cartridge
Small O-Ring
Tip
3. Install the replacement Electrode by
pushing it straight into the torch head
until it clicks.
4. Install the start cartridge and desired tip
for the operation into the torch head.
5. Hand tighten the shield cup assembly
until it is seated on the torch head. If
resistance is felt when installing the cup,
check the threads before proceeding.
4T.02 Hand Torch Operation
Stando Cutting With Hand Torch
NOTE!
For best performance and parts life, always use
the correct parts for the type of operation.
1. The torch can be comfortably held in
one hand or steadied with two hands.
Position the hand to press the Trigger on
the torch handle. With the hand torch,
the hand may be positioned close to the
torch head for maximum control or near
the back end for maximum heat protection. Choose the holding technique that
feels most comfortable and allows good
control and movement.
NOTE!
The tip should never come in contact with the
workpiece except during drag cutting operations.
2. Depending on the cutting operation, do
one of the following:
a. For edge starts, hold the torch per-
pendicular to the workpiece with
the front of the tip on the edge of
the workpiece at the point where
the cut is to start.
b. For stando cutting, hold the torch
1/8 - 3/8 in (3-9 mm) from the workpiece as shown below.
Shield Cup
Torch Parts
0-5562 OPERATION
39
CUTMASTER 60i
1/8" - 3/8" (3 - 9mm)
Art # A-13150
t # A-03383
Tr igger
Art # A-04034
Torch
Shield Cup
Stando Distance
3. Hold the torch away from your body.
4. Slide the trigger release toward the back
of the torch handle while simultaneously squeezing the trigger. The pilot arc
will start.
Standoff Distance
Trigger
6. Cut as usual. Simply release the trigger
assembly to stop cutting.
7. Follow normal recommended cutting
practices as provided in the power
supply operator's manual.
NOTE!
When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
cup against the torch head or torch handle can
damage components.
8. For a consistent stando height from the
workpiece, install the stando guide by
sliding it onto the torch shield cup. Install the guide with the legs at the sides
of the shield cup body to maintain good
visibility of the cutting arc. During operation, position the legs of the stando
guide against the workpiece.
Trigger Release
Shield Cup
5. Bring the torch within transfer distance
to the work. The main arc will transfer to
the work, and the pilot arc will shut OFF.
NOTE!
The gas preow and postow are a characteristic
of the power supply and not a function of the
torch.
Shield Cup With Straight Edge
The drag shield cup can be used with a non
conductive straight edge to make straight cuts
Standoff Guide
Torch Tip
Workpiece
by hand.
1
Tr igger Release
3
OPERATION 0-5562
40
2
4
Ar
WARNING
The straight edge must be non - conductive.
Non-Conductive
Straight Edge
Cutting Guide
Using Drag Shield Cup With Straight Edge
The crown shield cup functions best when
Art # A-13150
t # A-03383
Tr igger
cutting 3/16 inch (4.7 mm) solid metal with
relatively smooth surface.
Drag Cutting With a Hand Torch
Drag cutting works best on metal 1/4" (6
mm) thick or less.
NOTE!
For best parts performance and life, always use
the correct parts for the type of operation.
1. Install the drag cutting tip and set the
output current.
2. The torch can be comfortably held in
one hand or steadied with two hands.
Position the hand to press the Trigger on
the torch handle. With the hand torch,
the hand may be positioned close to the
torch head for maximum control or near
the back end for maximum heat protection. Choose the holding technique that
feels most comfortable and allows good
control and movement.
4. Keep the torch in contact with the workpiece during the cutting cycle.
5. Hold the torch away from your body.
6. Slide the trigger release toward the back
of the torch handle while simultaneously squeezing the trigger. The pilot arc
will start.
7. Bring the torch within transfer distance
to the work. The main arc will transfer to
the work, and the pilot arc will shut OFF.
NOTE!
The gas preow and postow are a characteristic
of the power supply and not a function of the
torch.
Trigger Release
Trigger
CUTMASTER 60i
1
2
Tr igger Release
3
4
8. Cut as usual. Simply release the trigger
assembly to stop cutting.
9. Follow normal recommended cutting
practices as provided in the power
supply operator's manual.
NOTE!
When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
cup against the torch head or torch handle can
damage components.
Piercing With Hand Torch
1. Hold the torch away from your body.
2. The torch can be comfortably held in
one hand or steadied with two hands.
Position the hand to press the Trigger on
the torch handle. With the hand torch,
the hand may be positioned close to
the torch head for maximum control or
near the back end for maximum heat
protection. Choose the technique that
feels most comfortable and allows good
control and movement.
NOTE!
The tip should never come in contact with the
workpiece except during drag cutting operations.
Ar
0-5562 OPERATION
41
CUTMASTER 60i
Art # A-13150
!
!
!
3. Angle the torch slightly to direct blowback particles away from the torch tip
(and operator) rather than directly back
into it until the pierce is complete.
4. In a portion of the unwanted metal start
the pierce o the cutting line and then
continue the cut onto the line. Hold the
torch perpendicular to the workpiece
after the pierce is complete.
5. Slide the trigger release toward the back
of the torch handle while simultaneously squeezing the trigger. The pilot arc
will start.
Trigger
Trigger Release
4T.03 Gouging
WARNING
Be sure the operator is equipped with proper
gloves, clothing, eye and ear protection and that
all safety precautions at the front of this manual
have been followed. Make sure no part of the operator’s body comes in contact with the workpiece
when the torch is activated.
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
CAUTION
Sparks from plasma gouging can cause damage
to coated, painted or other surfaces such as glass,
plastic, and metal.
Check torch parts. The torch parts must
correspond with the type of operation. Refer to
Section 4T.07, Torch Parts Selection.
Gouging Parameters
6. Bring the torch within transfer distance
to the work. The main arc will transfer to
the work, and the pilot arc will shut OFF.
NOTE!
The gas preow and postow are a characteristic
of the power supply and not a function of the
torch.
When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
cup against the torch head or torch handle can
damage components.
7. Clean spatter and scale from the shield
cup and the tip as soon as possible.
Spraying the shield cup in anti - spatter
compound will minimize the amount of
scale which adheres to it.
Cutting speed depends on material, thickness,
and the operator’s ability to accurately follow the
desired cut line. The following factors may have
an impact on system performance:
• Torch parts wear
• Air quality
• Line voltage uctuations
• Torch stando height
• Proper work cable connection
OPERATION 0-5562
42
Gouging performance depends on parameters such as torch travel speed, current level,
lead angle (the angle between the torch and
workpiece), and the distance between the
torch tip and workpiece (stando).
CAUTION
Touching the torch tip or shield cup to the work
surface will cause excessive parts wear.
Torch Travel Speed
NOTE!
Refer to Appendix Pages for additional information as related to the Power Supply used.
Optimum torch travel speed is dependent
on current setting, lead angle, and mode of
operation (hand or machine torch).
Current Setting
Current settings depend on torch travel
speed, mode of operation (hand or machine
torch), and the amount of material to be
removed.
Lead Angle
35°
Workpiece
Torch Head
Standoff Height
Standoff Distance
Straight Arc
Trailing Arc
Leading Arc
Direction of Torch Travel
A-02586
The angle between the torch and workpiece
depends on the output current setting and
torch travel speed. The recommended lead
angle is 35°. At a lead angle greater than 45°
the molten metal will not be blown out of
the gouge and may be blown back onto the
torch. If the lead angle is too small (less than
35°), less material may be removed, requiring
more passes. In some applications, such as
removing welds or working with light metal,
this may be desirable.
Gouging Angle and Stando Distance
Stando Distance
The tip to work distance aects gouge quality and depth. Stando distance of 1/8 - 1/4
inch (3 - 6 mm) allows for smooth, consistent
metal removal. Smaller stando distances
may result in a severance cut rather than a
gouge. Stando distances greater than 1/4
inch (6 mm) may result in minimal metal
removal or loss of transferred main arc.
Slag Buildup
CUTMASTER 60i
4T.04 Mechanized Torch Operation
Cutting With Mechanized Torch
The mechanized torch can be activated
by remote control pendant or by a remote
interface device such as CNC.
1. To start a cut at the plate edge, position
the center of the torch along the edge
of the plate.
Travel Speed
Proper travel speed is indicated by the trail
of the arc which is seen below the plate. The
arc can be one of the following:
1. Straight Arc
A straight arc is perpendicular to the
workpiece surface. This arc is generally
recommended for the best cut using air
plasma on stainless or aluminum.
2. Leading Arc
The leading arc is directed in the same
direction as torch travel. A ve degree
leading arc is generally recommended
for air plasma on mild steel.
3. Trailing Arc
The trailing arc is directed in the opposite
direction as torch travel.
Slag generated by gouging on materials such
as carbon and stainless steels, nickels, and
alloyed steels, can be removed easily in most
cases. Slag does not obstruct the gouging
process if it accumulates to the side of the
gouge path. However, slag build - up can
cause inconsistencies and irregular metal
removal if large amounts of material build
up in front of the arc. The build - up is most
often a result of improper travel speed, lead
angle, or stando height.
0-5562 OPERATION
Mechanized Torch Operation
43
CUTMASTER 60i
For optimum smooth surface quality, the
travel speed should be adjusted so that
only the leading edge of the arc column
produces the cut. If the travel speed is too
slow, a rough cut will be produced as the arc
moves from side to side in search of metal
for transfer.
Travel speed also aects the bevel angle of
a cut. When cutting in a circle or around a
corner, slowing down the travel speed will
result in a squarer cut. The power source
output should be reduced also. Refer to the
appropriate Control Module Operating Manual for any Corner Slowdown adjustments
that may be required.
Piercing With Machine Torch
To pierce with a machine torch, the arc
should be started with the torch positioned
as high as possible above the plate while
allowing the arc to transfer and pierce. This
stando helps avoid having molten metal
blow back onto the front end of the torch.
When operating with a cutting machine, a
pierce or dwell time is required. Torch travel
should not be enabled until the arc penetrates the bottom of the plate. As motion
begins, torch stando should be reduced to
the recommended 1/8 - 1/4 inch (3-6 mm)
distance for optimum speed and cut quality.
Clean spatter and scale from the shield cup
and the tip as soon as possible. Spraying
or dipping the shield cup in anti - spatter
compound will minimize the amount of scale
which adheres to it.
OPERATION 0-5562
44
4T.05 Recommended Cutting Speeds With Exposed Tip
CutMaster® 60i With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Out-
put
Amper-
age
Speed (Per
Minute)
Stando Plasma Gas
Pressure*
CUTMASTER 60i
Flow (SCFH) Pierce Pierce Height
Inches mm (Cat.
0.036 0.9 9-8208 104 40 340 8.64 0.19 4.8
0.06 1.5 9-8208 108 40 250 6.35 0.19 4.8 55 170 0.10 0.2 5.1
0.075 1.9 9-8208 108 40 190 4.83 0.19 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 110 40 105 2.67 0.19 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 113 40 60 1.52 0.19 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 111 40 40 1.02 0.19 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 124 40 21 0.53 0.19 4.8 55 170 NR NR NR
0.500 12.7 9-8208 123 40 11 0.28 0.19 4.8 55 170 NR NR NR
0.625 15.9 9-8208 137 40 7 0.18 0.19 4.8 55 170 NR NR NR
CutMaster® 60i With Exposed Tip Type Material: Stainless Steel
Thickness Tip Out-
Inches mm (Cat.
0.036 0.9 9-8208 103 40 355 9.02 0.125 3.2
0.05 1.3 9-8208 98 40 310 7.87 0.125 3.2 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 98 40 240 6.10 0.125 3.2 55 170 0.10 0.2 5.1
0.078 2.0 9-8208 100 40 125 3.18 0.125 3.2 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 124 40 20 0.51 0.187 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 122 40 15 0.38 0.187 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 126 40 10 0.25 0.187 4.8 55 170 NR NR NR
Volts
No.)
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
No.)
(Amps) Inches Meters Inch-esmm psi bar Plasma Total** Delay
(VDC)
Amper-
put
Volts
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
(VDC)
age
Speed (Per
Minute)
Stando Plasma G as
when selected.
pressure dial. This is illuminated green
Set to the central region on the
Pressure*
pressure dial. This is illuminated
green when selected.
55 170 0.00 0.2 5.1
Flow (SCFH) Pierce Pierce Height
Set to the central region on the
55 170 0.00 0.2 5.1
(Sec)
Inches mm
Inches mm
(Sec)
0-5562 OPERATION
45
CUTMASTER 60i
CutMaster® 60i With Exposed Tip Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Out-
Inches mm (Cat.
No.)
0.032 0.8 9-8208 110 40 440 11.18 0.187 4.8
0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 55 170 0.10 0.2 5.1
0.064 1.6 9-8208 112 40 250 6.35 0.187 4.8 55 170 0.10 0.2 5.1
0.079 2.0 9-8208 112 40 200 5.08 0.19 4.8 55 170 0.30 0.2 5.1
0.125 3.2 9-8208 118 40 100 2.54 0.19 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 120 40 98 2.49 0.187 4.8 55 170 0.60 0.2 5.1
0.250 6.4 9-8208 123 40 50 1.27 0.187 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 134 40 16 0.41 0.187 4.8 55 170 NR NR NR
CutMaster® 60i With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Out-
Inches mm (Cat.
No.)
0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8
0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 90 245 0.10 0.19 4.8
0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 90 245 0.10 0.19 4.8
0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 90 245 0.10 0.19 4.8
0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 90 245 0.20 0.19 4.8
0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 90 245 0.30 0.19 4.8
0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 90 245 0.50 0.19 4.8
0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 90 245 0.75 0.19 4.8
0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 90 245 Rolling Pierce
0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 90 245 Rolling Pierce
1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 90 245 Rolling Pierce
1.250 31.8 9-8210 NR, manual cutting only 90 245 NR
1.500 38.1 9-8210 NR, manual cutting only 90 245 NR
Amper-
put
Volts
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
(VDC)
put
Volts
(VDC)
Speed (Per
age
Minute)
Amper-
(Amps) Inches Meters Inches mm psi bar Plasma Total** D elay
age
Speed (Per
Minute)
Stando Plasma Gas
Stando Plasma Gas
Pressure*
pressure dial. This is illuminated
green when selected.
Pressure*
illuminated green when selected.
Set to the central region on the
Set to the central region on the pressure dial. This is
Flow (SCFH) Pi erce Pierce Height
55 170 0.00 0.2 5.1
Flow (SCFH) Pierce Pierce Height
90 245 0.00 0.19 4.8
Inches mm
(Sec)
Inches mm
(Sec)
Rolling Pierce
A Rolling Peirce begins cutting with the torch head placed at an angleto the work surface. Splatter/
dross are blown away from the work area as the torch cuts. The torch head rotates towards vertical as
the cut grows deeper and pierces the workpiece.
Art # A-13353
OPERATION 0-5562
46
CUTMASTER 60i
CutMaster® 60i With Exposed Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary G as: Single Gas Torch
Thickness Tip Out-
Inches mm (C at.
No.)
0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8
0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 90 245 0.10 0.20 5.1
0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 90 245 0.10 0.20 5.1
0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 90 245 0.75 0.20 5.1
0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 90 245 Rolling Pierce
0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 90 245 Rolling Pierce
1.000 25.4 9-8210 NR, manual cutting only 90 245 Rolling Pierce
1.250 31.8 9-8210 NR, manual cutting only 90 245 NR
CutMaster® 60i With Exposed Tip Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Out-
Inches mm (Cat.
No.)
0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4
0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 90 245 0.10 0.25 6.4
0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 90 245 0.10 0.25 6.4
0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 90 245 0.20 0.25 6.4
0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 90 245 0.30 0.25 6.4
0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 90 245 0.50 0.25 6.4
0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 90 245 0.80 0.25 6.4
0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 90 245 Rolling Pierce
0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 90 245 Rolling Pierce
1.000 25.4 9-8210 NR, manual cutting only 90 245 Rolling Pierce
1.250 31.8 9-8210 NR, manual cutting only 90 245 NR
Amper-
put
Volts
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
(VDC)
put
Volts
(VDC)
Speed (Per
age
Minute)
Amper-
Speed (Per
age
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
Minute)
Stando Plasma Gas
Stando Plasma Gas
Pressure*
Set to the central region on the pressure dial. This is
illuminated green when selected.
Pressure*
Set to the central region on the pressure dial.
This is illuminated green when selected.
Flow (SCFH) Pierce Pierce Height
90 245 0.00 0.20 5.1
Flow (SCFH) Pierce Pierce
90 245 0.00 0.25 6.4
Inches mm
(Sec)
Height
Inches mm
(Sec)
NOTE!
* If the proper torch and lead length are selected using the 'gas pressure selector' knob and the central region (green)
on the pressure dial is selected, the pressure is optimized for the selected cutting amperage. Refer to Section 4 of the
Operating Manual, "Set Operating Pressure".
** Total ow rate includes plasma and secondary gas ow.
0-5562 OPERATION
47
CUTMASTER 60i
4T.06 Recommended Cutting Speeds With Shielded Tip
CutMaster® 60i With Shielded Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single G as Torch
Thickness Tip Out-
put
Amper-
age
Speed (Per
Minute)
Stando Plasma Gas
Pressure*
Flow (SCFH) Pierce Pierce Height
Inches mm (Cat.
0.036 0.9 9-8208 114 40 170 4.32 0.19 4.8
0.06 1.5 9-8208 120 40 90 2.29 0.19 4.8 55 170 0.10 0.2 5.1
0.075 1.9 9-8208 121 40 80 2.03 0.19 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 122 40 75 1.91 0.19 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 123 40 30 0.76 0.19 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 125 40 25 0.64 0.19 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 138 40 11 0.28 0.19 4.8 55 170 NR NR NR
0.500 12.7 9-8208 142 40 7 0.18 0.19 4.8 55 170 NR NR NR
0.625 15.9 9-8208 152 40 3 0.08 0.19 4.8 55 170 NR NR NR
CutMaster® 60i With Shielded Tip Type Material: Stainless Steel
Thickness Tip Out-
Inches mm (Cat.
0.036 0.9 9-8208 109 40 180 4.57 0.125 3.2
0.05 1.3 9-8208 105 40 165 4.19 0.125 3.2 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 115 40 120 3.05 0.125 3.2 55 170 0.10 0.2 5.1
0.078 2.0 9-8208 120 40 65 1.65 0.187 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 125 40 25 0.64 0.187 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 132 40 20 0.51 0.187 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 130 40 15 0.38 0.187 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 130 40 10 0.25 0.187 4.8 55 170 NR NR NR
Volts
No.)
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
No.)
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
(VDC)
Amper-
put
Volts
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
(VDC)
age
Speed (Per
Minute)
Stando Plasma Gas
pressure dial. This is illuminated green
when selected.
Pressure*
pressure dial. This is illuminated
green when selected.
55 170 0.00 0.2 5.1
Set to the central region on the
Flow (SCFH) Pierce Pierce Height
Set to the central region on the
55 170 0.00 0.2 5.1
(Sec)
(Sec)
Inches mm
Inches mm
OPERATION 0-5562
48
CutMaster® 60i With Shielded Tip Type Material: Aluminum
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Ti p Out-
put
Amper-
age
Speed (Per
Minute)
Stando Plasma Gas
Pressure*
CUTMASTER 60i
Flow (SCFH) Pierce Pierce Height
Inches mm (Cat.
0.032 0.8 9-8208 116 40 220 5.59 0.187 4.8
0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 55 170 0.00 0.2 5.1
0.064 1.6 9-8208 118 40 180 4.57 0.187 4.8 55 170 0.10 0.2 5.1
0.079 2.0 9-8208 116 40 150 3.81 0.19 4.8 55 170 0.30 0.2 5.1
0.125 3.2 9-8208 130 40 75 1.91 0.19 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 132 40 60 1.52 0.187 4.8 55 170 0.60 0.2 5.1
0.250 6.4 9-8208 134 40 28 0.71 0.187 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 143 40 11 0.28 0.187 4.8 55 170 NR NR NR
CutMaster® 60i With Shielded Tip Type Material: Mild Steel
Thickness Tip O ut-
Inches mm (Cat.
0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8
0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 90 245 0.10 0.2 5.1
0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 90 245 0.10 0.2 5.1
0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 90 245 0.10 0.2 5.1
0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 90 245 0.20 0.2 5.1
0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 90 245 0.30 0.2 5.1
0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 90 245 0.50 0.2 5.1
0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 90 245 0.75 0.2 5.1
0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 90 245 NR NR NR
0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 90 245 NR NR NR
1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 90 245 NR NR NR
Volts
No.)
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
No.)
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
(VDC)
Amper-
put
Volts
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
(VDC)
age
Speed (Per
Minute)
Stando Plasma Gas
pressure dial. This is illuminated
green when selected.
Pressure*
Set to the central region on the pressure dial.
This is illuminated green when selected.
Set to the central region on the
55 170 0.00 0.2 5.1
Flow (SCFH) Pierce Pierce Height
90 245 0.00 0.2 5.1
Inches mm
(Sec)
Inches mm
(Sec)
0-5562 OPERATION
49
CUTMASTER 60i
CutMaster® 60i With Shielded Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Out-
put
Amper-
age
Speed (Per
Minute)
Stando Plasma G as
Pressure*
Flow (SCFH) Pi erce Pierce
Height
Inches mm (Ca t.
0.06 1.5 9-8210 110 60 165 4.19 0.13 3.2
0.075 1.9 9-8210 116 60 155 3.94 0.13 3.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 115 60 125 3.18 0.13 3.2 90 245 0.10 0.20 5.1
0.135 3.4 9-8210 118 60 80 2.03 0.13 3.2 90 245 0.10 0.20 5.1
0.188 4.8 9-8210 120 60 75 1.91 0.13 3.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 121 60 60 1.52 0.13 3.2 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 129 60 28 0.71 0.13 3.2 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 135 60 17 0.43 0.19 4.8 90 245 0.75 0.20 5.1
0.625 15.9 9-8210 135 60 14 0.36 0.19 4.8 90 245 NR NR NR
0.750 19.1 9-8210 142 60 10 0.25 0.19 4.8 90 245 NR NR NR
CutMaster® 60i With Shielded Tip Type Material: Aluminum
Thickness Tip Out-
Inches mm (Cat.
0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2
0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 90 245 0.10 0.20 5.1
0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 90 245 0.80 0.20 5.1
0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 90 245 NR NR NR
0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 90 245 NR NR NR
Volts
No.)
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
No.)
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
(VDC)
Amper-
put
Volts
(Amps) Inches Meters Inches mm psi bar Plasma Total** Delay
(VDC)
age
Speed (Per
Minute)
Stando Plasma Gas
dial. This is illuminated green when
selected.
Pressure*
pressure dial. This is illuminated green
when selected.
Set to the central region on the pressure
90 245 0.00 0.20 5.1
Flow (SCFH) Pierce Pierce
90 245 0.00 0.20 5.1
Set to the central region on the
Inches mm
(Sec)
Height
Inches mm
(Sec)
NOTE!
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to Section 4 of the
Operating Manual, "Set Operating Pressure".
** Total ow rate includes plasma and secondary gas ow.
OPERATION 0-5562
50
CUTMASTER 60i
PATENT INFORMATION
Plasma Cutting Torch Patents
The following parts are covered under U.S. and Foreign Patents as follows:
Catalog # Description Patent(s)
9-8215 Electrode US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786; 6703581;
D496842; D511280; D492709; D499620; D504142
Other Pat(s) Pending
9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8241 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8243 Shield Cap US Pat No(s) 6914211; D493183
Other Pat(s) Pending
9-8235 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8236 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633
Other Pat(s) Pending
9-8238 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
9-8239 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
9-8244 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8245 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
0-5562 OPERATION
51
CUTMASTER 60i
The following parts are also licensed under U.S. Patent No. 5,120,930 and
5,132,512:
Catalog # Description
9-8235 Shield Cap
9-8236 Shield Cap
9-8237 Shield Cup
9-8238 Shield Cap
9-8239 Shield Cap
9-8244 Shield Cap
9-8245 Shield Cap
Patents Pending for the following:
Quick Disconnect Torch and Quick Disconnect Torch Leads
OPERATION 0-5562
52
5.01 General Maintenance
CUTMASTER 60i
SECTION 5 SYSTEM: SERVICE
Warning!
Disconnect input power before maintaining.
Visually inspect the torch body,
consumables and Quick Connect
Replace all
broken parts
Art# A-13267
Maintain more often
if used under severe
conditions
Each Use
Visual check of
torch tip and electrode
Weekly
Visually inspect the
cables and leads.
Replace as needed
3 Months
Clean
exterior
of power supply
5.02 Maintenance Schedule
NOTE!
The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged or worn.
2. Check plasma and secondary supply and pressure/ow.
3. Purge plasma gas line to remove any moisture build-up.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air ow.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
3. Inspect input power cable for damage or exposed wires, replace if necessary.
0-5562 SERVICE
53
CUTMASTER 60i
!
Six Months or Every 720 Cutting Hours:
1. Check the in-line air lter(s), clean or replace as required.
2. Check cables and hoses for leaks or cracks, replace if necessary.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere
with sensitive electrical components and cause damage to the unit.
5.03 Common Faults
Problem -
Symptom
Insufficient
Penetration
Main Arc
Extinguishes
Excessive
Dross
Formation
Short Torch
Parts Life
Difficult
Starting
Common Cause
1. Cutting speed too fast.
2. Torch tilted too much.
3. Metal too thick.
4. Worn torch parts
5. Cutting current too low.
6. Non - Genuine Thermal Dynamics parts used
7. Incorrect gas pressure
1. Cutting speed too slow.
2. Torch standoff too high from workpiece.
3. Cutting current too high.
4. Work cable disconnected.
5. Worn torch parts.
6. Non - Genuine Thermal Dynamics parts used
1. Cutting speed too slow.
2. Torch standoff too high from workpiece.
3. Worn torch parts.
4. Improper cutting current.
5. Non - Genuine Thermal Dynamics parts used
6. Incorrect gas pressure
1. Oil or moisture in air source.
2. Exceeding system capability (material too thick).
3. Excessive pilot arc time
4. Gas pressure too low.
5. Improperly assembled torch.
6. Non - Genuine Thermal Dynamics parts used
1. Worn torch parts.
2. Non - Genuine Thermal Dynamics parts used.
3. Incorrect gas pressure.
SERVICE 0-5562
54
CUTMASTER 60i
5.04 Fault Indicator
At initial power up, the system goes through a series of self checks before it is ready for use. If during
those checks it detects something is not within proper operating parameters, a fault will occur. If that
happens the Fault indicator will light followed by the Error Code , and number in the digital display.
Error Code Indicator
Indicates when there is something that needs to be adjusted or repaired.
E001, E002, etc. Light up fault indicator also.
Error Code Description
E001 Over Temp Ambient temperature too high, duty cycle exceeded, fan failure
or other internal fault.
E002 Input Fault Input voltage outside the range of the unit or internal fault
resulting in low bus voltage.
1phase / 3phase jumpers J300 on Bias PCB set wrong.
E004 PIP Fault Parts in Place fault. Shield cup not in place or tight.
E005 PIC Fault Parts in Contact fault. Missing or worn tip/start cartridge or
electrode. Inlet pressure exceeds rating causing continuous gas
ow.
E009 Fan Fault Fan failed or disconnected.
E010 Low Output Current Work Lead current less than output current setting. Shorted
pilot switch or defective current sensor possible.
E012 Output Fault Tip to electrode voltage too low. Consumables fail to separate
when gas ows, start cartridge stuck, failed power supply, no
output or shorted torch body.
E014 Trigger Fault Torch trigger (start signal) active at start up.
E016 Pressure Fault Low Air/Gas pressure. Output pressure too low for selected
parameters.
0-5562 SERVICE
55
CUTMASTER 60i
5.05 Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair
unless you have had training in power electronics measurement and troubleshooting techniques.
Problem Symptom
ON / OFF Switch
is ON but the A/C
Indicator does not
light
Fault indicator
ashing, Error Code
E002
TEMPERATURE
indicator ON.
FAULT indicator
ashing. Error Code
E001
GAS LED OFF,
FAULT and MIN
pressure indicators
ashing. Error Code
E016
FAULT and
indicators ashing.
Error Code E004
FAULT and
indicators ashing.
Error Code E014
FAULT indicators
ashing. Error code
E005
SERVICE 0-5562
56
Possible Cause Recommended Action
1. Primary power disconnect is in OFF
position.
2. Primary fuses / breakers are blown
or tripped.
3. Faulty components in unit.
1. Primary input voltage problem.
2. Faulty components in unit.
1. Air ow through or around the unit is
obstructed.
2. Duty cycle of the unit has been
exceeded.
3. Failed components in unit.
1. Gas supply not connected to unit.
2. Gas supply not turned ON.
3. Gas supply pressure too low.
4. Failed components in unit.
1. Shield Cup loose.
2. Torch not properly connected to power
supply.
3. Problem in torch and leads PIP circuit.
4. Failed components in unit.
1. Start signal is active when ON/OFF
SWITCH is turned to ON position.
2. Problem in the torch and leads switch
circuit.
3. Failed components in unit.
1. Torch shield cup is loose.
2. Torch tip, electrode or starter cartridge
missing.
3. Torch start cartridge is stuck.
4. Unit inlet gas pressure is too high
causing continuous gas ow.
5. Open conductor in torch leads.
6. Problem in the torch and leads switch
circuit.
7. Failed components in unit.
1. Turn primary power disconnect switch to ON position.
2. a) Have qualied person check primary fuses / breakers.
b) Connect unit to known good primary power receptacle
3. Return to authorized service center for repair or replacement.
1. Have qualied person check primary voltage to insure it meets unit
requirements see Section "2.05 Input Wiring Specications" on page
19.
2. Return to authorized service center for repair or replacement.
1. Refer to clearance information – see Section "2.04 Power Supply
Specications" on page 18
2. Allow unit to cool.
3. Return to authorized service center for repair or replacement.
1. Connect gas supply to unit.
2. Turn gas supply ON.
3. Set air supply inlet pressure to unit to 120 psi. Set leads length to
match the actual length being used.
4. Return to authorized service center for repair or replacement.
1. Hand tighten the shield cup until it is snug.
2. Insure torch ATC is securely fastened to unit.
3. Replace torch and leads or return to authorized service center for
repair or replacement.
4. Return to authorized service center for repair or replacement.
1. Start can be active for one of the following:
• Hand torch switch held closed
• Hand pendant switch held closed
• CNC START signal is active low
Release the START signal source
2. Replace torch and leads or return to authorized service center for
repair or replacement.
3. Return to authorized service center for repair or replacement.
1. Tighten shield cup by hand. Do not over tighten.
2. Turn OFF power supply. Remove shield cup. Install missing parts.
3. Turn OFF power supply. Bleed down system pressure. Remove shield
cup, tip and start cartridge. Check start cartridge lower end tting for
free movement. Replace if tting does not move freely.
4. Decrease gas supply pressure to 125 PSI or less.
5. Replace torch and leads or return to authorized service center for
repair or replacement.
6. Replace torch and leads or return to authorized service center for
repair or replacement.
7. Return to authorized service center for repair or replacement
Problem -
Symptom
Nothing happens
when torch switch
or remote switch
is closed (Or CNC
START signal is
active) No gas
ow, DC LED OFF.
FAULT indicators
ashing. Error code
E012
No Fault lights ON,
no arc in torch.
FAULT indicators
ashing Error code
E024 or E031
Pilot arc is ON but
cutting arc will not
establish
FAULT indicator.
Work Lead Current
is less than output
current setting.
Error code E010
Low Output
Current.
Torch cutting is
diminished
CUTMASTER 60i
Possible Cause Recommended Action
1. Problem in the torch and leads switch
circuit (Remote pendant switch circuit).
2. CNC Controller device not providing
Start signal.
3. Failed components in unit.
1. Upper O-ring on torch head is in
wrong position.
2. Torch starter cartridge is stuck.
3. Worn or faulty torch parts.
4. Shorted Torch.
1. Failed components in unit. 1. Return to an authorized service center for repair.
1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that does not
1. Work cable not connected to work
piece.
2. Work cable/connector broken.
3. Failed components in unit.
1. Inverter board pilot IGBT may be
shorted
2. HCT1 Current Sensor or harness is bad.
1. Incorrect current setting.
2. Worn torch consumables.
3. Poor work cable connection to work
piece.
4. Torch being moved too fast.
5. Excessive oil or water in torch.
6. Failed components in unit.
1. Take Torch and Leads (Remote Pendant) to Authorized Repair Facility.
2. Contact Controller manufacturer.
3. Return to authorized service center for repair or replacement.
1. Remove shield cup from torch; check upper O-ring position; correct
if necessary.
2. Turn OFF power supply. Bleed down system pressure. Remove shield
cup, tip and starter cartridge. Check starter cartridge lower end tting
for free movement. Replace if tting does not move freely.
3. Inspect torch consumable parts. Replace if necessary.
4. Replace torch and leads or return to an authorized service center for
repair.
clear the fault, return to an authorized service center for repair.
1. Connect work cable.
2. Replace work cable.
3. Return to an authorized service center for repair.
1. Return to an authorized service center for repair
2. Return to an authorized service center for repair
1. Check and adjust to proper setting.
2. Check torch consumables and replace as needed.
3. Check the connection of the Work Lead to the work piece.
4. Reduce cutting speed.
5. Refer to "Check air quality" in Section 3 Torch.
6. Return to an authorized service center for repair.
0-5562 SERVICE
57
CUTMASTER 60i
Sequence of Operation (Block Diagram)
ACTION:
Close external
disconnect switch.
RESULT:
Power to system.
Connect work cable to workpiece.
Protect eyes and activate
Torch switch (START)
Fan goes to high speed. Gas flows
briefly, then stops. Gas restarts.
DC indicator ON
Pilot arc established.
Release Torch switch.
Main/Pilot arc stops.
Gas flow stops after post - flow.
(Fans will continue to run for
5 minutes after the Torch switch
[START] is removed)
ON / OFF switch to ON
AC indicator ON.
for power supply operation.
ACTION:
RESULT:
System is ready
for operation.
ACTION:
RESULT:
ACTION:
RESULT:
ACTION:
RESULT:
GAS indicator
ON when input
pressure is adequate
Power circuit ready.
ACTION:
Set Torch Type and
Lead Length. Select
SET/PURGE mode
to confirm the gas
operation and purge
the torch if needed
PILOT ARC
ACTION:
ON / OFF switch
to OFF
RESULT:
All indicators off.
Power supply fans shut off.
ACTION:
Select desired Operating mode
RUN,
LATCH,
Rapid Auto Restart (RAR),
Set desired Operating Current
Set the Gas pressure to
the green (nominal) indicator.
ACTION:
Torch moved away from work (while
still activated).
RESULT:
Main arc stops.
Pilot arc automatically
restarts.
ACTION:
Torch moved within
transfer distance of workpiece.
RESULT:
Main arc transfers.
Pilot arc off.
No power to system.
Gouge .
Marking
ACTION:
Unplug input
power cord or
open external
disconnect.
RESULT:
Art #A-13266_AB
SERVICE 0-5562
58
CUTMASTER 60i
Art # A-07990
5.06 Power Supply Basic Parts Replacement
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
This section describes procedures for basic parts replacement. For more detailed parts replacement
procedures, refer to the Power Supply Service Manual.
A. Filter Element Assembly Replacement
The Filter Element Assembly (9-0116) is in the rear panel. For better system performance, the lter element should be checked per the Maintenance Schedule (Section 5.02), and either cleaned or replaced.
Regulator/Filter
Assembly
Art # A-13255
1. Remove power from the power supply; turn OFF the gas supply and bleed down the system.
2. Remove the clear lter bowl with wrench provided with the system 9-9675.
NOTE!
Filter replacement part numbers can be found in Section 6 of this manual.
3. Remove the lter element and clean or replace.
NOTE!
If replacing or cleaning just the lter element refer to the following illustration for disassembly.
Filter Element
4. Install the new or cleaned assembly by reversing these procedures.
5. Turn ON the air supply and check for leaks before reinstalling the cover.
0-5562 SERVICE
59
CUTMASTER 60i
Optional Single-Stage Filter Element Replacement
These instructions apply to power supplies where the optional Single-Stage Filter has been installed.
The Power Supply shuts down automatically when the Filter Element becomes completely saturated.
The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to
dry. Refer to Section 6, Parts List, for replacement lter element catalog number.
1. Remove power from power supply.
2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter
Element.
3. Disconnect gas supply hose.
4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located
inside the Housing.
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Cover
Barbed
Fitting
Assembled Filter
Art # A-02476
Optional Single-Stage Filter Element Replacement
5. Remove the Filter Element from the Housing and set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element open side rst.
7. Replace Housing on Cover.
8. Reattach gas supply. Check for leaks.
NOTE!
If unit leaks between housing and cover, inspect the O-ring for cuts or other damage.
Optional Two-Stage Filter Element Replacement
The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power
Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts
List, for replacement lter element catalog number.
1. Shut OFF primary input power.
2. Shut OFF air supply and bleed down system.
SERVICE 0-5562
60
CUTMASTER 60i
!
WARNING
Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could result.
3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements
to move freely.
4. Note the location and orientation of the old Filter Elements.
5. Slide out the old Filter Elements.
First & Second
Stage
Cartridges
(as marked)
Art # A-02942
Optional Two-Stage Filter Replacement
6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as
noted in Step 4 above.
7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).
Improper torque may damage the gasket.
8. Slowly apply air pressure to the assembly, checking for leaks.
NOTE!
A small amount of air leakage from the bottom tting is normal.
NOTE!
Filter replacement part numbers can be found in Section 6 of this manual.
This completes the parts replacement procedures.
0-5562 SERVICE
61
SECTION 5 TORCH: SERVICE
Lower O-Ring
Art # A-03725
CUTMASTER 60i
5T.01 General Maintenance
NOTE!
Refer to Previous “Section 5: System” for common and fault indicator descriptions.
Cleaning Torch
Even if precautions are taken to use only
clean air with a torch, eventually the inside of
the torch becomes coated with residue. This
buildup can aect the pilot arc initiation and
the overall cut quality of the torch.
WARNING
Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.
The inside of the torch should be cleaned
with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases,
the torch can be removed from the leads
and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and
blowing it through with compressed air.
Upper Groove
with Vent Holes
Must Remain Open
Upper O-Ring
in Correct Groove
Threads
Torch Head O-Ring
ATC Male Connector
Gas Fitting
CAUTION
!
Dry the torch thoroughly before reinstalling.
O-Ring Lubrication
An O-Ring on the Torch Head and ATC Male
Connector requires lubrication on a scheduled basis. This will allow the O-Rings to
remain pliable and provide a proper seal.
The O-Rings will dry out, becoming hard
and cracked if the lubricant is not used on
a regular basis. This can lead to potential
performance problems.
It is recommended to apply a very light lm
of O-Ring lubricant (Catalog # 8-4025) to the
O-Rings on a weekly basis.
0-5562 SERVICE
Art #A-03791_AB
ATC O-Ring
NOTE!
DO NOT use other lubricants or grease, they may
not be designed to operate within high temperatures or may contain “unknown elements” that
may react with the atmosphere. This reaction
can leave contaminants inside the torch. Either
of these conditions can lead to inconsistent
performance or poor parts life.
O-Ring
#8-0525
63
CUTMASTER 60i
Art # A-08067
Good Tip
Worn Tip
Spring-Loaded
Spring-Loaded
/
Art # A-03284
5T.02 Inspection and Replacement of
Consumable Torch Parts
WARNING
Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.
Remove the consumable torch parts as follows:
NOTE!
The shield cup holds the tip and starter cartridge
in place. Position the torch with the shield
cup facing upward to prevent these parts from
falling out when the cup is removed.
1. Unscrew and remove the shield cup
from the torch.
NOTE!
Slag built up on the shield cup that cannot be
removed may eect the performance of the
system.
2. Inspect the cup for damage. Wipe it
clean or replace if damaged.
4. Remove the tip. Check for excessive
wear (indicated by an elongated or
oversized orice). Clean or replace the
tip if necessary.
A-03406
Example of Tip Wear
5. Remove the starter cartridge. Check
for excessive wear, plugged gas holes,
or discoloration. Check the lower end
tting for free motion. Replace if necessary.
Lower End Fitting
Full Compression
6. Pull the Electrode straight out of the
Torch Head. Check the face of the electrode for excessive wear. Refer to the
following gure.
Lower End Fitting at Reset
Full Extension
Art # A-08064_AC
New Electrode
Shield Cups
3. On torches with a shield cup body and
a shield cap or deector, ensure that
the cap or deector is threaded snugly
against the shield cup body. In shielded
drag cutting operations (only), there
may be an O-Ring between the shield
cup body and drag shield cap. Do not
lubricate the O-Ring.
Drag Shield Cap
Shield
Cup Body
7. Reinstall the Electrode by pushing it
8. Reinstall the desired starter cartridge
9. Hand tighten the shield cup until it is
Worn Electrode
Electrode Wear
straight into the torch head until it clicks.
and tip into the torch head.
seated on the torch head. If resistance
is felt when installing the cup, check the
threads before proceeding.
This completes the parts replacement procedures.
O-Ring No. 8-3488
SERVICE 0-5562
64
Art # A-03878
CUTMASTER 60i
SECTION 6: PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:
6.03 Power Supply Replacement
6.04 Replacement Power Supply Parts
6.05 Options and Accessories
6.06 External Replacement Parts (Plastic)
6.07 Replacement Parts for SL60QD™ Hand Torch
6.08 Torch Consumable Parts (SL60 / SL60QD™)
6.09 Torch Consumable Parts SL100
NOTE!
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper
authorization will not be accepted.
6.02 Ordering Information
Order replacement parts by catalog number and complete description of the part or assembly, as listed
in the parts list for each type item. Also include the model and serial number of the power supply.
Address all inquiries to your authorized distributor.
6.03 Power Supply Replacement
The following items are included with the replacement power supply: work cable & clamp, input power
cable, gas pressure regulator / lter, and operating manual.
Qty Description Catalog #
1 CutMaster 60i Power Supply
400VAC, THREE Phase, 60Hz, Non CE
with input power cable and plug 0559356303
1 CutMaster 60i Power Supply
400VAC, THREE Phase, 60Hz, CE
with input power cable and plug 0559356304
0-5562 PARTS LIST
65
CUTMASTER 60i
6.04 Replacement Power Supply Parts
Qty Description Catalog #
1 Filter Assembly Replacement Element (Factory lter) 9-0116
1 THREE phase Input Power Cord for 208/480 V Power Supply 9-9706
6.05 Options and Accessories
Qty Description Catalog #
1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two - Stage Filter Kit (includes Hose & Mounting Screws) 9-9387
1 Two - Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Work Cable #8 with 50mm Dinse plug 9-9692
1 Multi - Purpose Cart 7-8888
1 Filter Wrench (Factory Filter) 9-9675
Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit
PARTS LIST 0-5562
66
CUTMASTER 60i
6.06 External Replacement Parts (Plastic)
Item # Qty Description Catalog #
1 1 Handle, Case Top 9-9702
2 1 Bezel, Side Frame RH 9-9703
3 1 Handle, CM60i (3 total) 9-9665
4 1 Foot, Case Front 9-9694
5 1 Bezel, Side Frame LH 9-9704
6 1 Foot, Case Rear 9-9693
Screws and nuts can be obtained at a local hardware store.
a M5x0.8x12mm screw
b M5x0.8x16mm screw
c M5x0.8 nut
0-5562 PARTS LIST
67
CUTMASTER 60i
6.07 Replacement Parts for Hand Torch
Item # Qty Description Catalog #
1 1 SL60QD™ Torch Handle Assembly (PKG) 7-5681
2 Leads Assemblies with ATC connector and Quick Connectors
1 SL60QD™, 20 - foot Leads Assembly with ATC and QD
connectors 4-5620
1 SL60QD™, 50 - foot Leads Assembly with ATC and QD
connectors 4-5650
1&2 1 SL60QD™ Torch and Leads Assembly, 20 - foot 7-5620
1&2 1 SL60QD™ Torch and Leads Assembly, 50 - foot 7-5650
PARTS LIST 0-5562
68
6.08 Torch Consumable Parts (SL60)
CUTMASTER 60i
0-5562 PARTS LIST
69
CUTMASTER 60i
6.09 Torch Consumable Parts (SL100)
PARTS LIST 0-5562
70
APPENDIX 1: DATA TAG INFORMATION
CUTMASTER 60i
0-5562 APPENDIX
71
CUTMASTER 60i
APPENDIX 2: TORCH PIN - OUT DIAGRAMS
A. Hand Torch Pin - Out Diagram
B. Mechanized (Machine) Torch Pin - Out Diagram
C. Automation SL100SV Torch Pin - out Diagram
APPENDIX 0-5562
72
APPENDIX 3: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram
B. Mechanized Torch Connection Diagram
CUTMASTER 60i
0-5562 APPENDIX
73
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