ESAB Cutmaster 60 Plasma Cutting System SL60 1TORCH Instruction manual

ESAB Cutmaster® 60

PLASMA CUTTING SYSTEM
SL60 1Torch™

Operating
Manual

Art # A-12764_AB

60

Revision: AB Issue Date: April 15, 2015 Manual No.: 0-5377

208/460V

460V

esab.com.br

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.com.br.

This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB
product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

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

We distinguish ourselves from our competition through market-leading, dependable products that have stood
the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer working
environment within the welding industry.

WARNING

!

Read and understand this entire Manual and your employer’s safety practices before install­ing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply
ESAB Cutmaster® 60 with SL60 1Torch™
Operating Manual Number 0-5377

Published by:
ESAB
2800 Airport Rd.
Denton, TX 76208

www.esab.com.br

Copyright ©2015 by ESAB, Inc.

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of
the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party
for any loss or damage caused by any error or omission in this Manual, whether
such error results from negligence, accident, or any other cause.

Original Publication Date: January 15, 2015
Revision Date: April 15, 2015

Record the following information for Warranty purposes:

Where Purchased:_______________________________ __________

Purchase Date:__________________________________ __________

Power Supply Serial #:___________________________ __________

Torch Serial #:___________________________________ __________

i

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of
operation and safe practices for arc welding and cutting equipment, we urge you to read our book­let, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT
permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install
or operate this equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be sure to read the
Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompany­ing labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions
provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should
not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately.
Should such repair or replacement become necessary, the manufacturer recommends that a telephone or
written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a
service facility designated by the manufacturer.

!

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

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

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

SECTION 2 SYSTEM: INTRODUCTION ................................................................................................ 2-1

2.01 How To Use This Manual ....................................................................................... 2-1

2.02 Equipment Identification ....................................................................................... 2-1

2.03 Receipt Of Equipment ........................................................................................... 2-1

2.04 Power Supply Specifications ................................................................................. 2-2

2.05 Input Wiring Specifications .................................................................................... 2-3

2.06 Power Supply Features ......................................................................................... 2-4

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

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

2T.02 General Description .............................................................................................2T-1

2T.03 Specifications .....................................................................................................2T-1

2T.04 Options And Accessories ...................................................................................... 2T-2

2T.05 Introduction to Plasma .........................................................................................2T-2

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

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

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

3.03 Opening the Contactor Cover ................................................................................ 3-1

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

3.05 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 Manual and Mechanized Torch Cutting ....................................4T-8

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

4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip .............4T-11

PATENT INFORMATION ....................................................................................................................4T-14

TABLE OF CONTENTS

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

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

5.02 Maintenance Schedule ......................................................................................... 5-2

5.03 Common Faults..................................................................................................... 5-2

5.04 Fault Indicator ....................................................................................................... 5-3

5.05 Basic Troubleshooting Guide ................................................................................. 5-4

5.06 Power Supply Basic Parts Replacement ................................................................ 5-6

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

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

5T.02 Inspection and Replacement of Consumable Torch Parts ......................................5T-2

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

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

6.02 Ordering Information ............................................................................................. 6-1

6.03 Power Supply Replacement .................................................................................. 6-1

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

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

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

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

6.08 Replacement Shielded Machine Torch Leads Assemblies ..................................... 6-6

6.09 Torch Consumable Parts (SL60) ............................................................................ 6-7

6.10 Torch Consumable Parts (SL100) .......................................................................... 6-8

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, 208/460V UNITS .......................................................................A-6

REVISION HISTORY ............................................................................................................................. A-8

This Page Intentionally Blank

This Page Intentionally Blank

ESAB CUTMASTER 60

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 col­lection stations.
For further information contact the nearest ESAB dealer.

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

Manual 0-5377 SAFETY

1-1

ESAB CUTMASTER 60

WARNING

ELECTRIC SHOCK - Can kill.

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

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

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your
breathing zone and the general area.

ARC R AYS - Can injure eyes and burn skin.

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

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

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

Arc welding and cutting can be injurious to yourself and others. Take
precautions when welding and cutting. Ask for your employer's safety
practices which should be based on manufacturers' hazard data.

NOISE - Excessive noise can damage hearing.

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

- Warn bystanders of the risk.

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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

Do not use the power source for thawing frozen pipes.

WARNING

CAUTION

CAUTION

CAUTION

Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those loca­tions, due to conducted as well as radiated disturbances.

This product is solely intended for metal removal. Any other use may
result in personal injury and / or equipment damage.

Read and understand the instruction manual before
installing or operating.

!

SAFETY Manual 0-5377

1-2

ESAB CUTMASTER 60

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part
numbers listed on page i.

To ensure safe operation, read the entire manual, includ­ing the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAU­TION, DANGER, and NOTE may appear. Pay particular
attention to the information provided under these head­ings. These special annotations are easily recognized
as follows:

NOTE!

An operation, procedure, or background
information which requires additional
emphasis or is helpful in efficient operation
of the system.

CAUTION

!

!

A procedure which, if not properly followed,
may cause damage to the equipment.

WARNING

A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.

2.02 Equipment Identification

The unit’s identification number (specification or part
number), model, and serial number usually appear on
a data tag attached to the rear panel. Equipment which
does not have a data tag such as torch and cable as­semblies are identified only by the specification or part
number printed on loosely attached card or the shipping
container. Record these numbers on the bottom of page
i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to file a
claim. Furnish complete information concerning damage
claims or shipping errors to the location in your area
listed in the inside back cover of this manual.

Include all equipment identification numbers as de­scribed above along with a full description of the parts
in error.

Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.

WARNING

Gives information regarding possible
electrical shock injury. Warnings will be
enclosed in a box such as this.

DANGER

Means immediate hazards which, if not
avoided, will result in immediate, serious
personal injury or loss of life.

Additional copies of this manual may be purchased by
contacting ESAB at the address and phone number in
your area listed on back cover of this manual. Include
the Owner’s Manual number and equipment identifica­tion numbers.

Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
ESAB web site listed below

http://www.esab.com.br

Manual 0-5377 INTRODUCTION

2-1

ESAB CUTMASTER 60

2.04 Power Supply Specifications

ESAB Cutmaster 60® Power Supply Specifications

208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz

230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz

Input Power

380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

460 VAC (414 - 506 VAC), Single Phase, 60 Hz

460 VAC (414 - 506 VAC), Three Phase, 60 Hz

Input Power Cable

Cable for 460 V, Three Phase input power includes molded plug.

Power Supply includes input cable.

Output Current 20 - 60 Amps, Continuously Adjustable

Power Supply Gas Filtering

Ability

Particulates to 5 Microns

ESAB Cutmaster 60® Power Supply Duty Cycle *

Ambient Temperature

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

IEC Rating

Duty Cycle 40% 60% 100%

All Units

Current

DC Voltage

60 Amps 50 Amps 30 Amps

104 100 92

* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output

voltage (DC) is higher than shown in this chart.

NOTE!

IEC Rating is determined as specified by the International Electro-Technical Commission. These specifica­tions include calculating an output voltage based upon power supply rated current. To facilitate comparison
between power supplies, all manufacturers use this output voltage to determine duty cycle.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

10.75"

273 mm

Art # A-07941

Art # A-07925_AB

16.375"

416 mm

6"

150 mm

24"

22.5"

0.57 m

43 lb / 19.5 kg

INTRODUCTION Manual 0-5377

2-2

610 mm

6"

150 mm

6"

150 mm

2.05 Input Wiring Specifications

ESAB Cutmaster 60® Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Volts Hz kVA I max I1eff Fuse (amps)

208 60 10.4 47 30 50 10

ESAB CUTMASTER 60

Flexible Cord

(Min. AWG)

1 Phase

3 Phase

230 60 10.8 45 29 50 10

460 60 15.2 31 20 35 12

208 60 5.4 26 17 30 12

230 50/60 5.8 24 16 30 12

380 50/60 6.1 16 11 20 14

400 50/60 6.4 16 11 20 14

460 60 7.4 16 10 20 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

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.

Manual 0-5377 INTRODUCTION

2-3

ESAB CUTMASTER 60

Handle and Leads Wrap

and Clamp

2.06 Power Supply Features

Art # A-07942

Control Panel

To rch Leads Receptacle

Work Cable

Input Power Selection

Filter Assembly

Gas Inlet Port

Input Power Cord

Port for Optional Automation
Interface Cable

Art # A-07981

INTRODUCTION Manual 0-5377

2-4

ESAB CUTMASTER 60

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operating instruc­tions and maintenance procedures for the 1Torch
Models SL60/Manual and SL100/Mechanized Plasma
Cutting Torches. Service of this equipment is restricted
to properly trained personnel; unqualified 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

Plasma torches are similar in design to the automotive
spark plug. They consist of negative and positive sec­tions separated by a center insulator. Inside the torch,
the pilot arc starts in the gap between the negatively
charged electrode and the positively charged tip. Once
the pilot arc has ionized the plasma gas, the superheated
column of gas flows through the small orifice in the torch
tip, which is focused on the metal to be cut.

A single torch lead provides gas from a single source to
be used as both the plasma and secondary gas. The
air flow is divided inside the torch head. Single - gas
operation provides a smaller sized torch and inexpen­sive operation.

NOTE!

Refer to Section "2T.05 Introduction to
Plasma", for a more detailed description of
plasma torch operation.
Refer to the Appendix Pages for additional
specifications as related to the Power Sup­ply used.

2T.03 Specifications

A. Torch Configurations

1. Hand/Manual Torch, Models

The hand torch head is at 75° to the torch handle.
The hand torches include a torch handle and
torch trigger assembly.

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

2. Mechanized Torch, Model

The standard machine torch has a positioning
tube with rack & pinch block assembly.

15.875" / 403 mm

9.285" / 236 mm

1.375" / 35 mm

1.75" /

44.5 mm

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20ft/6.1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

0.625" /
16 mm

4.95" / 126 mm

1.175" / 30 mm

Art # A-03322_AB

Art # A-02998

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

12 VDC circuit rating

E. Type Cooling

Combination of ambient air and gas stream through
torch.

Manual 0-5377 INTRODUCTION

2T-1

ESAB CUTMASTER 60

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

Duty Cycle 100% @ 60 Amps @ 400 scfh

Maximum Current 80 Amps

Voltage (V

Arc Striking Voltage 7kV

Ambient

Temperature

Duty Cycle 100% @ 100 Amps @ 400 scfh

Maximum Current 120 Amps

Voltage (V

Arc Striking Voltage 7kV

G. Gas Requirement

Manual and Mechanized Torch Gas Specifications

Gas (Plasma and Secondary) Compressed Air

) 500V

peak

Mechanized Torch Ratings

) 500V

peak

104° F

40° C

104° F

40° C

2T.05 Introduction to Plasma

A. Plasma Gas Flow

Plasma is a gas which has been heated to an
extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma
to transfer an electrical arc to the workpiece. The
metal to be cut or removed is melted by the heat of
the arc and then blown away.

While the goal of plasma arc cutting is separation of
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.

In a Plasma Cutting Torch a cool gas enters Zone
B, where a pilot arc between the electrode and the
torch tip heats and ionizes the gas. The main cut­ting arc then transfers to the workpiece through the
column of plasma gas in Zone C.

Operating Pressure

Refer to NOTE

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and Gouging)

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh

142 - 235 lpm

WARNING

!

This torch is not to be used with oxygen
(O2).

NOTE!

Operating pressure varies with torch
model, operating amperage, and torch
leads length. Refer to gas pressure settings
charts for each model.

H. Direct Contact Hazard

For standoff tip the recommended standoff is 3/16
inches / 4.7 mm.

2T.04 Options And Accessories

For options and accessories, see Section 6.

_

Power

Supply

A

+

B

Workpiece

C

Typical Torch Head Detail

By forcing the plasma gas and electric arc through
a small orifice, the torch delivers a high concentra­tion of heat to a small area. The stiff, constricted
plasma arc is shown in Zone C. Direct current (DC)
straight polarity is used for plasma cutting, as shown
in the illustration.

Zone A channels a secondary gas that cools the
torch. This gas also assists the high velocity plasma
gas in blowing the molten metal out of the cut al­lowing for a fast, slag - free cut.

A-00002

INTRODUCTION Manual 0-5377

2T-2

ESAB CUTMASTER 60

up

up

up

Art # A-08168

B. Gas Distribution

The single gas used is internally split into plasma
and secondary gases.

The plasma gas flows into the torch through the
negative lead, through the starter cartridge, around
the electrode, and out through the tip orifice.

The secondary gas flows down around the outside
of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc.

C. Pilot Arc

When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot
arc creates a path for the main arc to transfer to
the work.

D. Main Cutting Arc

DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
through the torch lead. The positive output is con­nected to the workpiece via the work cable and to
the torch through a pilot wire.

E. Parts - In - Place (PIP)

The torch includes a 'Parts - In - Place' (PIP) circuit.
When the shield cup is properly installed, it closes
a switch. The torch will not operate if this switch
is open.

To Control

Torch Switch

Cable Wiring

PIP Switch

A-02997

Torch Trigger

Shield Cup

Parts - In - Place Circuit Diagram for Hand Torch

Remote Pendant

To AT C

PIP Sw itch

CNC Start

Sh ield C

To AT C

To AT C

PIP Sw itch

Automation Torch

PIP Sw itch

Sh ield C

Sh ield C

Parts - In - Place Circuit Diagram for Machine Torch

Manual 0-5377 INTRODUCTION

2T-3

ESAB CUTMASTER 60

This Page Intentionally Blank

INTRODUCTION Manual 0-5377

2T-4

SECTION 3 SYSTEM:

ESAB CUTMASTER 60

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 a handle for hand lifting only.
Be sure unit is lifted and transported safely and securely.

WARNING

Do not touch live electrical parts.

!

• 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.

Disconnect input power cord before moving
unit.

WARNING

FALLING EQUIPMENT can cause serious per­sonal injury and can damage equipment.
HANDLE is not for mechanical lifting.

1

2

1

2

Art# A-11478

Contactor cover

3.04 Primary Input Power Connections

CAUTION

!

Most units are shipped from the factory with a 460 Volt
input power cable wired to the input contactor in the
three - phase configuration. The following illustration
and directions are for replacing the input power cable.

Single-Phase (1ø) and Jumper Settings

Store copper jumpers on base plate

L1

L2

L3

L4

Check your power source for correct volt­age before plugging in or connecting the
unit. Check the Voltage Selector at the rear
of the unit for correct setting before plug­ging in or connecting the unit. 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 specified in
Section 2.

Input Power Cable Connections

Three-Phase (3ø)

L1

L2

L3

L4

GND

GND

Three Phase Input Power Wiring

Art # A-08493

3.03 Opening the Contactor Cover

The input power cord is connected to the main contac­tor, the contactor is located inside a box with a snap
on cover. The cover is held in place with two or more
snap lock tabs. To remove the cover release the front
latch and tilt the cover up about ½ inch. Then squeeze
both sides of the cover and lift it straight up. See the
Primary Input Power Connections section for the neces­sary changes to the Contactor. Remember to replace
the Contactor Cover when the changes are complete.

Manual 0-5377 INSTALLATION

Connections to Three Phase Input Power

These instructions are for changing the input power and
or cable on the 208/230, 400, 460 VAC Power Supply
to Three - Phase input power.

WARNING

Disconnect input power from the power
supply and input cable before attempting
this procedure.

1. Remove the Power Supply cover per instructions
found in Section 5.

2. Disconnect the original input power cable from
the main input contactor and the chassis ground
connection.

3-1

ESAB CUTMASTER 60

Regulator/Filter

3. Loosen the through - hole protector on the back
panel of the power supply. Pull the original
power cable out of the power supply.

4. Using a customer supplied four - conductor input
power cable for the voltage desired, strip back
the insulation on the individual wires.

5. Pass the cable being used through the access
opening in the back panel of the power supply.
Refer to Section 2 for power cable specifications.

CAUTION

!

The primary power source and power cable
must conform to local electrical code and
the recommended circuit protection and
wiring requirements (refer to table in Sec­tion 2).

6. Connect the wires as follows.

• SetJumper wireson thecontactor. See

previous illustrations.

• Green/YellowwiretoGround.

• Remainingwires toL1,L2andL3input.It

does not matter what order these wires are
attached.

7. With a little slack in the wires, tighten the through

- hole protector to secure the power cable.

8. Reinstall the Power Supply cover per instructions
found in Section 5.

9. Connect the opposite end of individual wires to
a customer supplied plug or main disconnect.

10. Connect the input power cable (or close the main
disconnect switch) to supply power.

Regulator/Filter
Assembly

Inlet Port

Hose Clamp

1/4 NPT or ISO-R

Gas Supply
Hose

Art # A-07943

to 1/4” (6mm) Fitting

Air Connection to Inlet Port

Installing Optional Single - Stage Air Filter

An optional filter kit is recommended for improved filter­ing with compressed air, to keep moisture and debris
out of the torch.

1. Attach the Single - Stage Filter Hose to the Inlet
Port.

2. Attach the Filter Assembly to the filter hose.

3. Connect the air line to the Filter. The illustration
shows typical fittings as an example.

NOTE!

For a secure seal, apply thread sealant to
the fitting threads, according to the maker's
instructions. Do Not use Teflon tape as a
thread sealer, as small particles of the tape
may break off and block the small air pas­sages in the torch. Connect as follows:

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 filter is to be installed.

1. Connect the air line to the inlet port. The illustra­tion shows typical fittings as an example.

NOTE!

For a secure seal, apply thread sealant to
the fitting threads, according to manufac­turer's instructions. Do not use Teflon tape
as a thread sealer, as small particles of the
tape may break off and block the small air
passages in the torch.

Hose Clamp

Gas Supply
Hose

Optional Single - Stage Filter Installation

INSTALLATION Manual 0-5377

3-2

Assembly

Inlet Port

Art # A-07944

1/4 NPT to 1/4"

(6mm) Fitting

ESAB CUTMASTER 60

Regulator/Filter

Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line filter 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 per instructions supplied
with the filter assembly.

NOTE!

For a secure seal, apply thread sealant to
the fitting threads according to manufac­turer's instructions. Do Not use Teflon tape
as a thread sealer as small particles of the
tape may break off and block the small air
passages in the torch.

2. Connect the two stage filter outlet hose to the
inlet port of the Regulator / Filter Assembly.

3. Use customer - supplied fittings to connect the
air line to the Filter. A 1/4 NPT to 1/4" hose
barbed fitting is shown as an example.

Assembly

Regulator
Input

2-Stage Filter
Inlet Port (IN)

Outlet Port
(OUT)

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s specifications 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. Briefly 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 100 psi (6.9 bar) maximum and
flows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the cylinder.

NOTE!

Pressure should be set at 100 psi (6.9 bar)
at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6
mm) I.D.
For a secure seal, apply thread sealant
to the fitting threads, according to manu­facturer's instructions. Do Not use Teflon
tape as a thread sealer, as small particles
of the tape may break off and block the
small air passages in the torch.

Hose Clamp

Gas Supply
Hose

Two Stage
Filter
Assembly

1/4 NPT to 1/4”
(6mm) Fitting

Art # A-07945_AC

Optional Two - Stage Filter Installation

Manual 0-5377 INSTALLATION

3-3

ESAB CUTMASTER 60

This Page Intentionally Blank.

INSTALLATION Manual 0-5377

3-4

ESAB CUTMASTER 60

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Supply.
Connect only the ESAB model SL60 Manual or SL100
Mechanical Torch to this power supply. Maximum torch
leads length is 100 feet / 30.5 m, including extensions.

WARNING

Disconnect primary power at the source

1. Align the ATC male connector (on the torch lead)

2. Secure the connection by turning the locking nut

before connecting the torch.

with the female receptacle. Push the male con­nector into the female receptacle. The connec­tors should push together with a small amount
of pressure.

clockwise until it clicks. DO NOT use the locking
nut to pull the connection together. Do not use
tools to secure the connection.

3T.02 Setting Up Mechanical Torch

NOTE!

When converting a hand torch or a machine
torch system to operate an Automation
100SLV torch, one of the CNC interface
options will be required if not previously
installed.

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.

Pinch Block
Assembly

2

1

Art # A-07885

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 (up)
position.

2. Put the Function Control switch in the SET
position.

3. Place a welding filter lens in front of the torch
and turn ON the air. Do not start an arc!

Square

Workpiece

A-02585

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" on page 4T-1 for details.

Any oil or moisture in the air will be visible on the

lens.

Manual 0-5377 INSTALLATION

3T-1

ESAB CUTMASTER 60

This Page Intentionally Blank

INSTALLATION Manual 0-5377

3T-2

ESAB CUTMASTER 60

12

3

!

SECTION 4 SYSTEM:

OPERATION

4.01 Front Panel Controls / Features

See Illustration for numbering Identification

1. Output Current Control

Sets the desired output current. Output settings up
to 60 Amps may be used for drag cutting (with the
torch tip contacting the workpiece) or for standoff
cutting.

2. Function Control

Function Control Knob; Used to select between the
different operating modes.

SET Used to purge the air through the unit
and torch and leads and to adjust gas pressure.

RUN Used for general cutting operations

RAPID AUTO RESTART Allows for faster
restarting of the Pilot Arc for uninterrupted cutting.

LATCH Used for longer hand held cuts.
Once a cutting arc is established, the torch switch
can be released. The cutting arc will remain ON until
the torch is lifted away from the work piece, the torch
leaves the edge of the work piece the torch switch
is activated again or if one of the system interlocks
is activated.

3. ON / OFF Power Switch

4

MAX

MIN

A

PSI BAR

MAXMAX

MINMIN

!

5

8

7

6

10

9

6. Temp Indicator

Indicator is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Let the
unit cool before continuing operation.

7. Gas Indicator

Indicator is ON when minimum input gas pressure
for power supply operation is present. Minimum
pressure for power supply operation is not sufficient
for torch operation.

8. DC Indicator

Indicator is ON when DC output circuit is active.

+

Art# A-07886

ON / OFF Switch controls input power to the
power supply. Up is ON, down is OFF.

4. Air/Gas Pressure Control

The Pressure
mode to adjust the air/gas pressure. Pull the knob
OUT to adjust and push IN to lock.

5. AC Indicator

Steady light indicates power supply is ready for
operation. Blinking light indicates unit is in pro­tective interlock mode. Shut unit OFF, shut OFF
or disconnect input power, correct the fault, and
restart the unit.  Refer toSECTION 5SYSTEM:
SERVICE for details.

Manual 0-5377 OPERATION

+

Control is used in the "SET"

9.

Fault Error Indicator

Indicator is ON when Fault circuit is active. See
Section 5 for explanations of fault lights.

10. Pressure Indicators

PSI BAR

MAX MAX

90 6.3

85 5.9

80

75

70

65

MINMIN

5.5

5.2

4.8

4.5

Art # A-08170

The Indicators will illuminate according to the pres­sure set by the Pressure Control Knob (number 4).

4-1

ESAB CUTMASTER 60

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 4T.07 Parts Selection for Manual and
Mechanized Torch Cutting and following for torch
parts selection.

Torch Connection

Check that the torch is properly connected. Only
ESAB model SL60 Manual or SL100 Mechanical
Torches may be connected to this Power Supply.
See Section 3T of this manual.

Power ON

Place the Power Supply ON / OFF switch to the

ON (up) position. AC indicator turns

ON. Gas indicator turns ON if there is sufficient
gas pressure for power supply operation and the
cooling fans turn ON.

NOTE!

Minimum pressure for power supply
operation is lower than minimum for torch
operation.
The cooling fans will turn ON as soon as
the unit is turned ON. After the unit is idle
for ten (10) minutes the fans will turn OFF.
The fans will come back ON 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
fans will continue to run while the condition
exists and for a ten (10) minute period once
the condition is cleared.

Set Operating Pressure

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, Specifications.

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.

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 off.

1. Place the Power Supply Function Control knob

to the SET position. Gas will flow.

2. For Standoff cutting, adjust gas pressure from
70 - 85 psi / 4.8 - 5.9 bar (LED's in center of
control panel). Refer to the Standoff chart for
pressure setting details.

Art # A-04509

OPERATION Manual 0-5377

4-2

ESAB CUTMASTER 60

1

2

Select Current Output Level

1. Place the Function Control Knob in one of the
three operating positions available:

MIN

MAX

A

PSI BAR

MAXMAX

+

RUN ,

RAPID AUTO RESTART

or LATCH . Gas flow stops.

MINMIN

!

2. Set the output current to desired amperage with
the Output Current Control Knob.

Cutting Operation

When the torch leaves the workpiece during cut­ting operations with the Function Control Knob in
the RUN position, there is a brief delay in restarting

Art# A-07946

STANDOFF

ESAB Cutmaster® 60 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

SL60

(Hand Torch)

75 psi

5.2 bar

SL100

(Mechanized Torch)

75 psi

5.2 bar

Each

additional

25'

Add 5 psi

0.4 bar

Add 5 psi

0.4 bar

the pilot arc. With the knob in the RAPID AUTO
RESTART position, 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'
position when cutting expanded metal or gratings,
or in gouging or trimming operations when an un­interrupted restart is desired). And with the knob
in the LATCH position the main cutting arc will be
maintained after the torch switch is released.

Typical Cutting Speeds

(7.6 m)

Cutting speeds vary according to torch output am-

3. For Drag cutting, adjust gas pressure from 75 ­95 psi / 5.2 - 6.5 bar (LED's in center of control
panel). Refer to the Drag Cutting chart for pres­sure setting details.

DRAG

ESAB Cutmaster® 60 Gas Pressure Settings

Leads Length

Up to 25'

(7.6 m)

SL60

(Hand Torch)

80 psi

5.5 bar

perage, the type of material being cut, and operator
skill. Refer to Section 4T.08 Recommended Cutting
Speeds for Mechanized Torch 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.

Postflow

Release the trigger to stop the cutting arc. Gas con­tinues to flow for approximately 20 seconds. During
post - flow, if the user moves the trigger release to

Each additional 25'

(7.6 m)

Add 5 psi

0.4 bar

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

Manual 0-5377 OPERATION

Turn the ON / OFF switch to OFF
(down). All Power Supply indicators shut OFF.
Unplug the input power cord or disconnect input
power. Power is removed from the system.

4-3

ESAB CUTMASTER 60

This Page Intentionally Blank

OPERATION Manual 0-5377

4-4

ESAB CUTMASTER 60

Kerf Width

Cut Surface
Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

SECTION 4 TORCH:

OPERATION

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, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter
Cartridge

NOTE!

Refer to Section 4T.07 and following for ad­ditional information on torch parts.

Change the torch parts for a different operation as fol­lows:

WARNING

Disconnect primary power at the source
before assembling or disassembling power
supply, torch parts, or torch and leads as­semblies.

3. Install the replacement Electrode by pushing it
straight into the torch head until it clicks.

4. Install the starter 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 Cut Quality

NOTE!

Cut quality depends heavily on setup and
parameters such as torch standoff, align­ment with the workpiece, cutting speed,
gas pressures, and operator ability.

Cut quality requirements differ depending on applica­tion. For instance, nitride build - up and bevel angle
may be major factors when the surface will be welded
after cutting. Dross - free cutting is important when fin­ish cut quality is desired to avoid a secondary cleaning
operation. The following cut quality characteristics are
illustrated in the following figure:

Torch Parts (Drag Shield Cap & Shield Cup Body

NOTE!

The shield cup holds the tip and starter
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.

Torch Head

Electrode

Start Cartridge

A-03510_AB

Tip

Shield Cup

Shown)

Cut Quality Characteristics

Cut Surface

The desired or specified condition (smooth or rough)
of the face of the cut.

Nitride Build - Up

Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material
is to be welded after the cutting process.

Bevel Angle

The angle between the surface of the cut edge and
a plane perpendicular to the surface of the plate.
A perfectly perpendicular cut would result in a 0°
bevel angle.

Manual 0-5377 OPERATION

4T-1

ESAB CUTMASTER 60

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

Top - Edge Rounding

Rounding on the top edge of a cut due to wearing
from the initial contact of the plasma arc on the
workpiece.

Bottom Dross Buildup

Molten material which is not blown out of the cut
area and resolidifies on the plate. Excessive dross
may require secondary cleanup operations after
cutting.

Kerf Width

The width of the cut (or the width of material re­moved during the cut).

Top Spatter (Dross)

Top spatter or dross on the top of the cut caused by
slow travel speed, excess cutting height, or cutting
tip whose orifice has become elongated.

4T.03 General Cutting Information

WARNING

!

!

Piloting

Piloting is harder on parts life than actual cutting
because the pilot arc is directed from the electrode
to the tip rather than to a workpiece. Whenever
possible, avoid excessive pilot arc time to improve
parts life.

Torch Standoff

Improper standoff (the distance between the torch
tip and workpiece) can adversely affect tip life as
well as shield cup life. Standoff may also signifi­cantly affect the bevel angle. Reducing standoff will
generally result in a more square cut.

Disconnect primary power at the source be­fore disassembling the power supply, torch,
or torch leads.
Frequently review the Important Safety Pre­cautions at the front of this manual. Be sure
the operator is equipped with proper gloves,
clothing, eye and ear protection. Make sure
no part of the operator’s body comes into
contact with the workpiece while the torch
is activated.

CAUTION

Sparks from the cutting process can cause
damage to coated, painted, and other sur­faces such as glass, plastic and metal.

NOTE!

Handle torch leads with care and protect
them from damage.

Edge Starting

For edge starts, hold the torch perpendicular to the
workpiece with the front of the tip near (not touch­ing) the edge of the workpiece at the point where
the cut is to start. When starting at the edge of the
plate, do not pause at the edge and force the arc
to "reach" for the edge of the metal. Establish the
cutting arc as quickly as possible.

Direction of Cut

In the torches, the plasma gas stream swirls as it
leaves the torch to maintain a smooth column of
gas. This swirl effect results in one side of a cut
being more square than the other. Viewed along the
direction of travel, the right side of the cut is more
square than the left.

Side Characteristics Of Cut

To make a square - edged cut along an inside
diameter of a circle, the torch should move coun­terclockwise around the circle. To keep the square
edge along an outside diameter cut, the torch should
travel in a clockwise direction.

Dross

When dross is present on carbon steel, it is com­monly referred to as either “high speed, slow speed,
or top dross”. Dross present on top of the plate is
normally caused by too great a torch to plate dis­tance. "Top dross" is normally very easy to remove
and can often be wiped off with a welding glove.
"Slow speed dross" is normally present on the bot­tom edge of the plate. It can vary from a light to
heavy bead, but does not adhere tightly to the cut
edge, and can be easily scraped off. "High speed
dross" usually forms a narrow bead along the bot­tom of the cut edge and is very difficult to remove.
When cutting a troublesome steel, it is sometimes
useful to reduce the cutting speed to produce "slow
speed dross". Any resultant cleanup can be ac­complished by scraping, not grinding.

OPERATION Manual 0-5377

4T-2

4T.04 Hand Torch Operation

Shield Cup

Torch

Standoff Distance

1/8" - 3/8" (3 - 9mm)

Standoff 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 perpendicular

to the workpiece with the front of the tip on
the edge of the workpiece at the point where
the cut is to start.

ESAB CUTMASTER 60

Trigger

Trigger Release

A-02986

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 preflow and postflow are a char­acteristic of the power supply and not a
function of the torch.

Tr igger

1

2

Tr igger Release

b. For standoff cutting, hold the torch 1/8 - 3/8

in (3-9 mm) from the workpiece as shown
below.

Standoff 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.

3

4

Art # A-03383

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.

Manual 0-5377 OPERATION

4T-3

ESAB CUTMASTER 60

Art # A-04034

8. For a consistent standoff height from the work­piece, install the standoff 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 standoff guide
against the workpiece.

Shield Cup

Standoff Guide

Torch Tip

Workpiece

Shield Cup With Straight Edge

The drag shield cup can be used with a non conduc­tive straight edge to make straight cuts by hand.

WARNING

The straight edge must be non-conductive.

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.

3. Keep the torch in contact with the workpiece
during the cutting cycle.

4. Hold the torch away from your body.

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

A-02986

Non-Conductive

Straight Edge
Cutting Guide

A-03539

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when 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.

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 preflow and postflow are a char­acteristic of the power supply and not a
function of the torch.

Tr igger

1

2

Tr igger Release

3

4

Art # A-03383

7. Cut as usual. Simply release the trigger assem­bly to stop cutting.

OPERATION Manual 0-5377

4T-4

ESAB CUTMASTER 60

8. 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. 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.

2. 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.

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 preflow and postflow 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standoffheight

• Properworkcableconnection

3. In a portion of the unwanted metal start the
pierce off the cutting line and then continue the
cut onto the line. Hold the torch perpendicular
to the workpiece after the pierce is complete.

4. Hold the torch away from your body.

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

A-02986

Manual 0-5377 OPERATION

4T-5

ESAB CUTMASTER 60

35°

Workpiece

Torch Head

Standoff Height

A-00941_AB

4T.05 Gouging

WARNING

!

!

Gouging Parameters

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
(standoff).

!

Torch Travel Speed

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.

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.

CAUTION

Touching the torch tip or shield cup to the
work surface will cause excessive parts
wear.

NOTE!

Refer to Appendix Pages for additional
information as related to the Power Supply
used.

Lead Angle

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 Standoff Distance

Standoff Distance

The tip to work distance affects gouge quality and
depth. Standoff distance of 1/8 - 1/4 inch (3 - 6
mm) allows for smooth, consistent metal removal.
Smaller standoff distances may result in a severance
cut rather than a gouge. Standoff distances greater
than 1/4 inch (6 mm) may result in minimal metal
removal or loss of transferred main arc.

Slag Buildup

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 standoff height.

OPERATION Manual 0-5377

4T-6

ESAB CUTMASTER 60

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

4T.06 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 five 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.

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 affects 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 standoff 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 standoff 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.

Manual 0-5377 OPERATION

Mechanized Torch Operation

4T-7

ESAB CUTMASTER 60

4T.07 Parts Selection for Manual and Mechanized Torch Cutting

Start

Cartridge

9-8213

DRAG TIP

CUTTING

40A

CUTTING

50-60A

CUTTING

Tips:

20A 9-8205
30A 9-8206
40A 9-8207
60A 9-8252

DRAG SHIELD

CUTTING

Tip:

40A 9-8208

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Tips:

50-55A 9-8209

60A 9-8210

STANDOFF

CUTTING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Deflector

9-8243

Shield Cap, Drag

40A 9-8244

Shield Cap, Deflector

9-8243

Standoff Guide

9-8251

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Deflector

9-8243

Standoff Guide

9-8281

Electrode

9-8215

Art # A-12790_AA

DRAG SHIELD

CUTTING

70-120A

CUTTING

80A 9-8211

90/100A 9-8212

Tips:

70A 9-8231

120A 9-8253

STANDOFF CUTTING

40-120A

GOUGING

Tips:

Tip Gouging A 9-8225 (40 Amps Max.)

Tip Gouging B 9-8226 (50 - 100 Amps)

Tip Gouging C 9-8227 (60 - 120 Amps)

Tip Gouging D 9-8228 (60 - 120 Amps)

Tip Gouging E 9-8254 (60 - 120 Amps)

O-Ring No. 8-3488

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cap, Drag
70-100A 9-8236

Shield Cap, Deflector

9-8243

Standoff Guide

9-8281

Shield Cap, Gouging

9-8241

NOTE
ESAB Cutmaster 60 uses 60A and less
ESAB Cutmaster 80 uses 80A and less
ESAB Cutmaster 100 uses 100A and less
ESAB Cutmaster 120 uses 120A and less

OPERATION Manual 0-5377

4T-8

ESAB CUTMASTER 60

4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip

Type Torch: SL60 With Exposed Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

Inches

0.036 0.9 9-8208 104 40 340 8.64 0.19 4.8 70 4.8 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 108 40 250 6.35 0.19 4.8 70 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 70 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 70 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 70 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 70 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 70 4.8 55 170 NR NR NR

0.500 12.7 9-8208 123 40 11 0.28 0.19 4.8 70 4.8 55 170 NR NR NR

0.625 15.9 9-8208 137 40 7 0.18 0.19 4.8 70 4.8 55 170 NR NR NR

Thickness Tip Output Amperage

Inches

0.036 0.9 9-8208 103 40 355 9.02 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1

0.05 1.3 9-8208 98 40 310 7.87 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 98 40 240 6.10 0.125 3.2 70 4.8 55 170 0.10 0.2 5.1

0.078 2.0 9-8208 100 40 125 3.18 0.125 3.2 70 4.8 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 70 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 70 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 70 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 70 4.8 55 170 NR NR NR

(Cat.

mm

No.)

Type Torch: SL60 With Exposed Tip Type Material: Stainless Steel

(Cat.

mm

No.)

Volts

(VDC)

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Speed (Per

Minute)

Standoff

Standoff

Plasma Gas

Press

Plasma Gas

Press

Flow (CFH) Pierce

Delay
(Sec)

Flow (CFH) Pierce

Delay

(Sec)

Pierce
Height

Inches mm

Pierce
Height

Inches mm

Type Torch: SL60 With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

Inches

0.032 0.8 9-8208 110 40 440 11.18 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1

0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 70 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 70 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 70 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 70 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 70 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 70 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 70 4.8 55 170 NR NR NR

Manual 0-5377 OPERATION

mm

(Cat.

No.)

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Pierce
Height

Inches mm

4T-9

ESAB CUTMASTER 60

Type Torch: SL60 With Exposed Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

Inches

0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8 75 5.2 90 245 0.00 0.19 4.8

0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8

0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8

0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8

0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 75 5.2 90 245 0.20 0.19 4.8

0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.19 4.8

0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 75 5.2 90 245 0.50 0.19 4.8

0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 75 5.2 90 245 0.75 0.19 4.8

0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 75 5.2 90 245 NR NR NR

0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR

1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 75 5.2 90 245 NR NR NR

mm

(Cat.

No.)

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Pierce
Height

Inches mm

Type Torch: SL60 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

Inches

0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8 75 5.2 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1

0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1

0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 75 5.2 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 75 5.2 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 75 5.2 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 75 5.2 90 245 0.75 0.20 5.1

0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 75 5.2 90 245 NR NR NR

0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 75 5.2 90 245 NR NR NR

mm

(Cat.

No.)

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay
(Sec)

Pierce
Height

Inches mm

OPERATION Manual 0-5377

4T-10

ESAB CUTMASTER 60

Type Torch: SL60 With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

mm

(Cat.
No.)

Inches

0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 75 5.2 90 245 0.00 0.25 6.4

0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 75 5.2 90 245 0.10 0.25 6.4

0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 75 5.2 90 245 0.10 0.25 6.4

0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 75 5.2 90 245 0.20 0.25 6.4

0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 75 5.2 90 245 0.30 0.25 6.4

0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 75 5.2 90 245 0.50 0.25 6.4

0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 75 5.2 90 245 0.80 0.25 6.4

0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 75 5.2 90 245 NR NR NR

0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 75 5.2 90 245 NR NR NR

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Standoff

NOTE!

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to "Set
Operating Pressure" on page 4-2 .
** Total flow rate includes plasma and secondary gas flow.

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Pierce
Height

Inches mm

4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip

Type Torch: SL60 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

Inches

0.036 0.9 9-8208 114 40 170 4.32 0.19 4.8 70 4.8 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 120 40 90 2.29 0.19 4.8 70 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 70 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 70 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 70 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 70 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 70 4.8 55 170 NR NR NR

0.500 12.7 9-8208 142 40 7 0.18 0.19 4.8 70 4.8 55 170 NR NR NR

0.625 15.9 9-8208 152 40 3 0.08 0.19 4.8 70 4.8 55 170 NR NR NR

mm

(Cat. No.)

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Pierce
Height

Inches mm

Manual 0-5377 OPERATION

4T-11

ESAB CUTMASTER 60

Type Torch: SL60 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

Inches

0.036 0.9 9-8208 109 40 180 4.57 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1

0.05 1.3 9-8208 105 40 165 4.19 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 115 40 120 3.05 0.125 3.2 70 4.8 55 170 0.10 0.2 5.1

0.078 2.0 9-8208 120 40 65 1.65 0.187 4.8 70 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 70 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 70 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 70 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 70 4.8 55 170 NR NR NR

Thickness Tip Output Amperage

Inches

0.032 0.8 9-8208 116 40 220 5.59 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1

0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 70 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 70 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 70 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 70 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 70 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 70 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 70 4.8 55 170 NR NR NR

(Cat. No.)

mm

Type Torch: SL60 With Shielded Tip Type Material: Aluminum

(Cat. No.)

mm

Volts

(VDC)

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Speed (Per

Minute)

Standoff

Standoff

Plasma Gas

Press

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Flow (CFH) Pierce

Delay

(Sec)

Pierce
Height

Inches mm

Pierce

Height

Inches mm

Type Torch: SL60 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

Inches

0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 75 5.2 90 245 0.00 0.2 5.1

0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1

0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1

0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1

0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 75 5.2 90 245 0.20 0.2 5.1

0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.2 5.1

0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 75 5.2 90 245 0.50 0.2 5.1

0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 75 5.2 90 245 0.75 0.2 5.1

0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR

0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR

1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 75 5.2 90 245 NR NR NR

OPERATION Manual 0-5377

4T-12

mm

(Cat. No.)

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Pierce
Height

Inches mm

ESAB CUTMASTER 60

Type Torch: SL60 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

Inches

0.06 1.5 9-8210 110 60 165 4.19 0.13 3.2 75 5.2 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 116 60 155 3.94 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 115 60 125 3.18 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1

0.135 3.4 9-8210 118 60 80 2.03 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1

0.188 4.8 9-8210 120 60 75 1.91 0.13 3.2 75 5.2 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 121 60 60 1.52 0.13 3.2 75 5.2 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 129 60 28 0.71 0.13 3.2 75 5.2 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 135 60 17 0.43 0.19 4.8 75 5.2 90 245 0.75 0.20 5.1

0.625 15.9 9-8210 135 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR

0.750 19.1 9-8210 142 60 10 0.25 0.19 4.8 75 5.2 90 245 NR NR NR

(Cat. No.)

mm

Type Torch: SL60 With Shielded Tip Type Material: Aluminum

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay
(Sec)

Pierce
Height

Inches mm

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage

Inches

0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 75 5.2 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1

0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 75 5.2 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 75 5.2 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 75 5.2 90 245 0.80 0.20 5.1

0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 75 5.2 90 245 NR NR NR

0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 75 5.2 90 245 NR NR NR

mm

(Cat. No.)

Volts

(VDC)

(Amps) Inches Meters Inches mm psi* bar Plasma Total**

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Pierce
Height

Inches mm

NOTE!

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to "Set
Operating Pressure" on page 4-2
** Total flow rate includes plasma and secondary gas flow.

Manual 0-5377 OPERATION

4T-13

ESAB CUTMASTER 60

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

OPERATION Manual 0-5377

4T-14

ESAB CUTMASTER 60

Catalog # Description Patent(s)

9-8245 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending

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

Manual 0-5377 OPERATION

4T-15

ESAB CUTMASTER 60

This Page Intentionally Blank.

OPERATION Manual 0-5377

4T-16

5.01 General Maintenance

ESAB CUTMASTER 60

SECTION 5 SYSTEM:

SERVICE

Warning!
Disconnect input power before maintaining.

Visual check of
torch tip and electrode

Visually inspect the torch body tip,
electrode, start cartridge and shield cup

Maintain more often
if used under severe
conditions

Each Use

Weekly

Visually inspect the
cables and leads.
Replace as needed

Replace all
broken parts

3 Months

Clean
exterior
of power supply

6 Months

Visually check and
Carefully clean the
interior

Art # A-07938_AB

Manual 0-5377 SERVICE

5-1

ESAB CUTMASTER 60

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/flow.

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
flow.

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.

5.03 Common Faults

Problem - Symptom Common Cause

Insufficient Penetration 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 ESAB parts used

7. Incorrect gas pressure

Main Arc Extinguishes 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 ESAB parts used

Excessive Dross

Formation

1. Cutting speed too slow.

2. Torch standoff too high from
workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine ESAB parts used

6. Incorrect gas pressure

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace as
required.

2. Check cables and hoses for leaks or cracks,
replace if necessary.

3. Check all contactor points for severe arcing or
pits, replace if necessary.

4. Vacuum dust and dirt out of the entire machine.

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.

Short Torch Parts Life 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 ESAB parts used

Difficult Starting 1. Worn torch parts.

2. Non - Genuine ESAB parts used.

3. Incorrect gas pressure.

SERVICE Manual 0-5377

5-2

ESAB CUTMASTER 60

5.04 Fault Indicator

At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used.

To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit
count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator
and 75 psi indicators are ON indicating the version would be 2.3.

7
6

5
4

3
2
1

0

MAX

MIN

A

PSI BAR

MAXMAX

MINMIN

!

+

5

3

1

4

2

Art# A-07988

When the ! "Fault" indicator is ON or blinking it will be accompanied by one of the pressure indicator lights
depending on what the fault is. The following table explains each of those Faults.

Pressure

Fault

Indicator

Max Over Pressure

90 Internal Error

85 Check Consumables

80 Consumables Missing

75 Start Error

70 Parts in Place

65 Input Power

Min Under Pressure

NOTE!

Fault explanations are covered in the following tables.

Manual 0-5377 SERVICE

5-3

ESAB CUTMASTER 60

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 Possible Cause Recommended Action

ON / OFF Switch is ON
but the A/C Indicator
does not light

Fault indicator flashing,
65 PSI indicator
flashing

TEMPERATURE
indicator ON.
FAULT indicator
flashing.

1. Primary power disconnect is in OFF
position.

2. Primary fuses / breakers are blown
or tripped.

3. Units internal fuse blown.

4. Faulty components in unit.

1. INPUT VOLTAGE SELECTION
SWITCH set for incorrect voltage.

2. Primary input voltage problem.

3. Faulty components in unit.

1. Air flow through or around the unit
is obstructed.

2. Duty cycle of the unit has been
exceeded.

3. Failed components in unit.

1. Turn primary power disconnect switch to ON position.

2. a) Have qualified person check primary fuses / breakers.
b) Connect unit to known good primary power receptacle

3. a) Replace fuse.
b) If fuse blows again, return to authorized service center for
repair or replacement.

4. Return to authorized service center for repair or replacement.

1. Set INPUT VOLTAGE SELECTION SWITCH to match primary input
voltage.

2. Have qualified person check primary voltage to insure it meets
unit requirements see Section "2.05 Input Wiring Specifications"
on page 5-4.

3. Return to authorized service center for repair or replacement.

1. Refer to clearance information – see Section "2.04 Power
Supply Specifications" on page 5-4

2. Allow unit to cool.

3. Return to authorized service center for repair or replacement.

GAS LED OFF,
FAULT and MIN
pressure indicators
flashing.

FAULT and 70 PSI
indicators flashing.

FAULT and 75 PSI
indicators flashing.

1. Gas supply not connected to unit.

2. Gas supply not turned ON.

3. Gas supply pressure too low.

4. AIR PRESSURE CONTROL regulator
set too low.

5. 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. Connect gas supply to unit.

2. Turn gas supply ON.

3. Set air supply inlet pressure to unit to 120 psi.

4. Adjust regulator to set air pressure - see Section "4. Air/Gas
Pressure Control" on page 5-4

5. 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.

SERVICE Manual 0-5377

5-4

ESAB CUTMASTER 60

Problem - Symptom Possible Cause Recommended Action

FAULT & 80 PSI
indicators flashing.
Gas flow is cycling ON
and OFF.

1. Torch shield cup is loose.

2. Torch tip, electrode or starter
cartridge missing.

3. Torch start cartridge is stuck.

4. Open conductor in torch leads.

5. Problem in the torch and leads
switch circuit.

6. Failed components in unit.

1. Tighten shield cup by hand. Do not overtighten.

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
fitting for free movement. Replace if fitting does not move freely.

4. Replace torch and leads or return to authorized service center
for repair or replacement.

5. Replace torch and leads or return to authorized service center
for repair or replacement.

6. Return to authorized service center for repair or replacement.

Nothing happens when
torch switch or remote
switch is closed (Or
CNC START signal is
active) No gas flow,
DC LED OFF.

FAULT and 85 PSI
indicators flashing.

No Fault lights ON, no
arc in torch.

FAULT and 85 PSI
indicators flashing

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.

5. Temporary Short indicated by 5
blinks per second.

6. Power Supply Failure (Standard
rate of blinking)

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

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 fitting for free movement. Replace if fitting 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.

5. Release torch switch and reactivate.

6. Return to authorized service center for repair or replacement.

not clear the fault, return to an authorized service center for repair.

Pilot arc is ON but
cutting arc will not
establish

Torch cutting is
diminished

Manual 0-5377 SERVICE

1. Work cable not connected to work
piece.

2. Work cable/connector broken.

3. Failed components in unit.

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. Connect work cable.

2. Replace work cable.

3. 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.

5-5

ESAB CUTMASTER 60

5.06 Power Supply Basic Parts Replacement

WARNING

!

This section describes procedures for basic parts
replacement. For more detailed parts replacement
procedures, refer to the Power Supply Service Manual.

A. Cover Removal

1. Remove the upper and lower screws which

Disconnect primary power to the system
before disassembling the torch, leads, or
power supply.

secure the cover to the main assembly. Do not
loosen the lower screws inside the cut out slots
in the bottom of the cover.

Upper
Screws

Lower
Screws

Slots

C. Filter Element Assembly Replacement

The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should be
checked per the Maintenance Schedule (Section 5.02),
and either cleaned or replaced.

1. Remove power from the power supply; turn OFF
the gas supply and bleed down the system.

2. Remove the system cover. See "A Cover Re­moval" in this section.

3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
illustration.

4. Hold a wrench or similar tool against the locking
ring on the filter assembly fitting, then pull on
the hose to release it. (Numbers 2 and 3 in the
following illustration).

1

Lower
Screws

Art # A-07947

2. Carefully pull the Cover up and away from the
unit.

B. Cover Installation

1. Reconnect the ground wire, if necessary.

2. Place the cover onto the power supply so that
slots in the bottom edges of the cover engage
the lower screws.

3. Tighten lower screws.

Art # A-07989

2

3

4

5

6mm

4. Reinstall and tighten the upper screws.

SERVICE Manual 0-5377

5-6

ESAB CUTMASTER 60

5. Remove the fitting from the filter element as­sembly by inserting a 6 mm hex wrench into
the internal hex fitting and turning it counter
clock-wise (left). Numbers 4 and 5 in the previ­ous illustration.

6. Disconnect the input line from the filter element
assembly.

7. Remove the filter element assembly through the
rear opening.

NOTE!

If replacing or cleaning just the filter ele­ment refer to the following illustration for
disassembly.

Filter Element

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 filter 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

Art # A-07990

8. Install the new or cleaned assembly by reversing
these procedures.

9. Turn ON the air supply and check for leaks before
reinstalling the cover.

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 first.

7. Replace Housing on Cover.

8. Reattach gas supply.

NOTE!

If unit leaks between housing and cover,
inspect the O-ring for cuts or other damage.

Manual 0-5377 SERVICE

5-7

ESAB CUTMASTER 60

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
filter element catalog number.

1. Shut OFF primary input power.

2. Shut OFF air supply and bleed down system.

WARNING

!

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.

Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury
could result.

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 fitting is normal.

This completes the parts replacement procedures.

SERVICE Manual 0-5377

5-8

SECTION 5 TORCH:

SERVICE

ESAB CUTMASTER 60

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 affect
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.

Lower O-Ring

Torch Head O-Ring

Gas Fitting

Upper Groove
with Vent Holes
Must Remain Open

Upper O-Ring
in Correct Groove

Threads

Art # A-03725

ATC Male Connector

CAUTION

!

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 film of O­Ring lubricant (Catalog # 8-4025) to the O-Rings on
a weekly basis.

Dry the torch thoroughly before reinstalling.

Art #A-03791

O-Ring

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.

Manual 0-5377 SERVICE

5T-1

ESAB CUTMASTER 60

Spring-Loaded

5T.02 Inspection and Replacement of

Consumable Torch Parts

WARNING

Disconnect primary power to the system

Remove the consumable torch parts as follows:

1. Unscrew and remove the shield cup from the

2. Inspect the cup for damage. Wipe it clean or

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.

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.

torch.

NOTE!

Slag built up on the shield cup that cannot
be removed may effect the performance of
the system.

replace if damaged.

4. Remove the tip. Check for excessive wear
(indicated by an elongated or oversized orifice).
Clean or replace the tip if necessary.

Good Tip

Worn Tip

A-03406

Example of Tip Wear

5. Remove the starter cartridge. Check for exces­sive wear, plugged gas holes, or discoloration.
Check the lower end fitting for free motion.
Replace if necessary.

Lower End Fitting
Full Compression

Spring-Loaded
Lower End Fitting at Reset /
Full Extension

Art # A-08064_AC

6. Pull the Electrode straight out of the Torch Head.
Check the face of the electrode for excessive
wear. Refer to the following figure.

3. On torches with a shield cup body and a shield

Art # A-08067

Shield Cups

cap or deflector, ensure that the cap or deflector
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 O­Ring.

Drag Shield Cap

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

New Electrode

Art # A-03284

Worn Electrode

Electrode Wear

7. Reinstall the Electrode by pushing it straight into
the torch head until it clicks.

8. Reinstall the desired starter cartridge and tip into
the torch head.

9. Hand tighten the shield cup until it is seated on
the torch head. If resistance is felt when install­ing the cup, check the threads before proceed­ing.

This completes the parts replacement procedures.

SERVICE Manual 0-5377

5T-2

ESAB CUTMASTER 60

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 Replacement Parts for Hand Torch

6.07 Replacement Parts - for Machine Torches with Unshielded Leads

6.08 Replacement Shielded Machine Torch Leads Assemblies

6.09 Torch Consumable Parts (SL60)

6.10 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 / filter, and operating manual.

Qty Description Catalog #

1 ESAB Cutmaster® 60 Power Supply
208/230 - 460VAC, 3 Phase, 50/60Hz, input power cable 0559351302

Manual 0-5377 PARTS LIST

6-1

ESAB CUTMASTER 60

6.04 Replacement Power Supply Parts

Qty Description Catalog #

1 Regulator 9-0115
1 Filter Assembly Replacement Element 9-0116
1 Input Power Cord for 208/230 V Power Supply 8-4384
1 Input Power Cord for 460/600 V Power Supply 9-8593

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 Extended Work Cable (50 ft / 15.2 m) with Clamp 9-8529
1 Multi - Purpose Cart 7-8888
1 Automation Interface Kit 9-8311
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008
1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011
1 Nylon Dust Cover 9-7071

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 Kit Optional Two - Stage Filter Kit

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

PARTS LIST Manual 0-5377

6-2

ESAB CUTMASTER 60

6.06 Replacement Parts for Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
2 1 Trigger Assembly Replacement Kit 9-7034
3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O-Ring 8-3487
6 1 Small O-Ring 8-3486
7 Leads Assemblies with ATC connectors (includes switch assemblies)
1 SL60, 20 ft /6.1m Leads Assembly with ATC connector 4-7834
1 SL100, 20 ft /6.1m Leads Assembly with ATC connector 4-7836
1 SL100, 50 ft /15.2m Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031

1

8

2

4

5

6

3

7

Manual 0-5377 PARTS LIST

Art # A-07993_AB

6-3

ESAB CUTMASTER 60

6.07 Replacement Parts - for Machine Torches with Unshielded Leads

Item No. Qty Description Catalog No.

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O-Ring 8-3487
3 1 Small O-Ring 8-3486
4 1 PIP Switch Kit 9-7036
5 Unshielded Automated Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853
6 Unshielded Mechanized Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Le-ads Assembly with ATC connector 4-7842
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845
7 1 11” / 279 mm Rack 9-7041
8 1 11” / 279 mm Mounting Tube 9-7043
9 1 End Cap Assembly 9-7044
10 2 Body, Mounting, Pinch Block 9-4513
11 1 Pin, Mounting, Pinch Block 9-4521
12 1 Torch Holder Sleeve 7-2896
13 1 PIP Plunger and Return Spring Kit 9-7045
1 Pinion Assembly (Not shown) 7-2827
1 5” / 126 mm Positioning Tube (Not shown) 9-7042

PARTS LIST Manual 0-5377

6-4

10

ESAB CUTMASTER 60

9

7

8

10

1

2

3

4

13

11

12

5 & 6

A-07994_AB

Manual 0-5377 PARTS LIST

6-5

ESAB CUTMASTER 60

6.08 Replacement Shielded Machine Torch Leads Assemblies

Item No. Qty Description Catalog No.

1 Mechanized Shielded Leads Assemblies with ATC Connectors
1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846
1 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847
1 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848
1 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849

1

Remote Pendant Adapter is
present on Mechanized leads only.

Torch Continuity
('PIP') Switch

A-03684

PARTS LIST Manual 0-5377

6-6

6.09 Torch Consumable Parts (SL60)

ESAB CUTMASTER 60

Start

Cartridge

9-8213

DRAG TIP

CUTTING

40A

CUTTING

50-60A

CUTTING

Tips:

20A 9-8205
30A 9-8206
40A 9-8207
60A 9-8252

DRAG SHIELD

CUTTING

Tip:

40A 9-8208

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Tips:

50-55A 9-8209

60A 9-8210

STANDOFF

CUTTING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Deflector

9-8243

Shield Cap, Drag

40A 9-8244

Shield Cap, Deflector

9-8243

Standoff Guide

9-8251

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Deflector

9-8243

Standoff Guide

9-8281

Electrode

9-8215

Art # A-12790_AA

DRAG SHIELD

CUTTING

70-120A

CUTTING

80A 9-8211

90/100A 9-8212

Tips:

70A 9-8231

120A 9-8253

STANDOFF CUTTING

40-120A

GOUGING

Tips:

Tip Gouging A 9-8225 (40 Amps Max.)

Tip Gouging B 9-8226 (50 - 100 Amps)

Tip Gouging C 9-8227 (60 - 120 Amps)

Tip Gouging D 9-8228 (60 - 120 Amps)

Tip Gouging E 9-8254 (60 - 120 Amps)

O-Ring No. 8-3488

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cap, Drag

70-100A 9-8236

Shield Cap, Deflector

9-8243

Standoff Guide

9-8281

Shield Cap, Gouging

9-8241

NOTE
ESAB Cutmaster 60 uses 60A and less
ESAB Cutmaster 80 uses 80A and less
ESAB Cutmaster 100 uses 100A and less
ESAB Cutmaster 120 uses 120A and less

Manual 0-5377 PARTS LIST

6-7

ESAB CUTMASTER 60

6.10 Torch Consumable Parts (SL100)

Ohmic Clip

Manual Torch

9-8259

Ohmic Clip

Automation Torch

9-8224

Electrode

Auto 9-8232

Manual 9-8215

Starter

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Starter Cartridge

Non HF Only 9-8277

70-120A

STANDOFF

CUTTING

Tip:

20A 9-8205
30A 9-8206
40A 9-8208

Tips:

50-55A 9-8209

60A 9-8210

Tips:

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine
40A 9-8245

Shield Cap, Deflector
9-8243

Drag Shield Cup
9-8235

Shield Cap, Machine
50-60A 9-8238

Shield Cap, Deflector
9-8243

Drag Shield Cup
70-100A 9-8236

Drag Shield Cup
120A 9-8258

Shield Cap, Machine
70-100A 9-8239

Shield Cap, Machine
120A 9-8256

Shield Cap, Deflector
9-8243

40-120A

GOUGING

Tips:

Tip A 9-8225 (40 Amps Max.)

Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Art # A-08066_AG

PARTS LIST Manual 0-5377

6-8

Tip E 9-8254 (60 - 120 Amps)

Shield

Cup Body,

9-8237

Shield Cup, Gouging

9-8241

ESAB CUTMASTER 60

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

Connect work cable to workpiece.

Set output amperage.

System is ready

for operation.

ON / OFF switch to ON

AC indicator ON.

GAS indicator ON

pressure is adequate

for power supply operation.

ACTION:

RESULT:

ACTION:

RESULT:

when input

Power circuit ready.

ACTION:

RUN /
Rapid Auto Restart /
SET / LATCH switch

to SET

RESULT:

Gas flows to set

pressure.

Torch moved away from work (while

ACTION:

RUN / Rapid Auto Restart /

SET / LATCH

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

or to

LATCH

is used for specific applications

(torch switch can be released

after main arc transfer).

RESULT: Gas flow stops.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate

Torch switch (START)

RESULT:

Fans turn on. Gas flows briefly,

then stops.Gas restarts.

DC indicator ON

Pilot arc established.

ACTION:

Release Torch switch.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

(Fans will continue to run for

10 minutes after the Torch switch

[START] is removed)

PILOT ARC

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fans shut off.

Main arc stops.

Pilot arc automatically

restarts.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

Art #A-07979_AB

Manual 0-5377 APPENDIX

A-1

ESAB CUTMASTER 60

APPENDIX 2: DATA TAG INFORMATION

Mo de l:

Da te of Mf r:

Type of Power
Supply (Note 1)

1/ 3

Manufacturer's Name and/or
Logo, Location, Model and

S/N

f

1

f

2

Revision Level, Serial Number
and Production Code

Regulatory Standard Covering
This Type of Power Supply

Output Current Type

Plasma Cutting
Symbol

U

0

Rated No­Load Voltage

Input Power
Symbol

Input Power
Specifications
(Phase, AC or DC
Hertz Rating)

Degree of Protection

NOTES:

1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.

2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.

3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission.
TDC duty cycle value is determined under the power supply
manufacturer's test procedures.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.

4. Sections of the Data Tag may be applied to separate areas
of the power supply.

X

I

=

U

2

Conventional
Load Voltage

U1

Rated Supply
Voltage (Note 2)

Duty Cycle Factor

Rated Maximum
Supply Current

1max 1eff

I

1

1Ø

3Ø

Output Range (Amperage/
Voltage)

Duty Cycle Data (Note 3)

I

1

3Ø1Ø

Standard Symbols

Maximum Effective
Supply Current

Manufacturer's Electrical
Schematic File Number
and Revision Level

AC

DC

Phase

Ø

Art # A-12765_AA

APPENDIX Manual 0-5377

A-2

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram

ESAB CUTMASTER 60

ATC Male Connector

Negative /
Plasma

4 - Green /
Switch

3 - White /
Switch

2- Orange /
PIP

1 - Black /
PIP

4

3

2
1

Pilot

Front View

6
5

8
7

5 - Open

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector

4- Black ­Pendant
Connector

3 - White ­Pendant
Connector

2 - Orange /
PIP

Front View

4
3

2
1

UNSHIELDED MACHINE TORCH

Negative / Plasma

8 - Green ­Pendant
Connector
Ground

8
7

6

5

7 - Green /
Not Used

6 - Open

8 - Open

7 - Open

6 - Open

8 - Ground

7 - Open

6 - Open

5 - Open

8 - Ground

7 - Open

6 - Open

ATC Female Receptacle

Front View

8
7

6
5

Pilot

ATC Female Receptacle

8
7

6

5

2
1

Front View

4
3

2
1

Negative /
Plasma

4 - Switch

3 - Switch

4
3

2 - PIP

1 - PIP

A-03701

Negative / Plasma

4 - Switch

3 - Switch

2 - PIP

1 - Black /
PIP

Art # A-03799

Pilot

5 - White /
Not Used

5 - Open

1 - PIP

Pilot

Manual 0-5377 APPENDIX

A-3

ESAB CUTMASTER 60

APPENDIX 4: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

To rch: SL60 / SL100 Hand Torch
Leads: To rch Leads with ATC Connector
Power Supply: with ATC Receptacle

Torch

Head

PIP

Switch

Torch

Switch

Torch
Leads

Black

Orange

Green

White

Negative / Plasma

Pilot

Male

ATC Leads

Connector

AT C Female

Receptacle

1

2

5

6

4

3

8

7

1

2

5

6

4

3

8

7

Power
Supply

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03797

B. Mechanized Torch Connection Diagram

To rch: Unshielded Mechanized SL100 Machine Torch
Leads: Leads with ATC Connector and
Remote Pendant Connector
Power Supply: with ATC Female Receptacle

Male

AT C Leads

Connector

Torch

Head

PIP

Switch

Not

Used

Pilot Lead

Torch
Leads

Black

Orange

White

Green

Negative / Plasma Lead

To Remote Control

Remote
Pendant

Connector

Black

White

Green

AT C Female

Receptacle

Power
Supply

1

1

2

2

5

5

6

6

4

4

3

3

8

8

7

7

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03798

APPENDIX Manual 0-5377

A-4

ESAB CUTMASTER 60

This Page Intentionally Blank

Manual 0-5377 APPENDIX

A-5

ESAB CUTMASTER 60

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

D

*

PRIMARY
AC INPUT

JUMPER

C

*

PRIMARY POWER CONNECTIONS:

3PH USE L1,L2,L3 & GND
REMOVE JUMPER BETWEEN L2 TO L3

1PH USE L1, L2 & GND ­INSTALL JUMPER BETWEEN L2 TO L3

B

A

A-12766_AA

SW1SW1

1 3

2 4

L1

L2

L3

GND

SW2SW2

INPUT VOLTAGE SELECTOR
(Closed for 230VAC input)

5

W1W1

6

SERIAL PORT

40 PIN RIBBON CABLE SIGNALS

1

-V_OUT_SIGNAL
/TIP_VOLTS

2

/TIP_SENSE

3
4

/460V_IN

5

/230V_IN

6

CUR_SET

7

/RAR (RAPID AUTO RESTART)

8

/INRUSH

9

/W1_ON

10

/SHDN

11

/TORCH_SOLENOID

12

/SOLENOID_ON

13

/OK_TO_MOVE

14

/FAN_ON

15

/LATCH_ACTIVE

16

/TORCH_SWITCH

17

/PIP

18

AC_ON

19

CSR

20

/TORCH_SOLENOID_DETECT

21

/OVERTEMP

22

V_IN

23

+12VDC

24

+12VDC

25

COMMON

26

COMMON

29

MAIN_PCB_ID

34

460_IN

35

+3.3VDC

36

TXD

37

RXD

38

COMMON

39

D

5

J3J3

1
2
3

J12J12

123

+12VDC

BIAS
SUPPLY

J1J1

1
2
3
4
5

INRUSH

RESISTORS

W1W1

L1

L2

L3

L4

5

AC1AC1

7

T1

AC2AC2

8

T2

AC3AC3

9

T3

7A

T4

J3J3

460_IN

1
2

J6J6

1

24 VAC RETURN

2

J4J4

3.3VDC

1

TXD

2

RXD

3
4

D

5

M-L

M-L
M-L
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
L-M
M-L
M-L
L-M
M-L

Current ControlCurrent Control

LATCH

SET

RUN

RAR

ACAC

OVERTEMPOVERTEMP

GASGAS

DCDC

ERRORERROR

/INRUSH

D1

24VAC

/460

K1K1

D59 PCRD59 PCR

D78 CSRD78 CSR

J2

J1

ERROR IND FAULT

MAX
90
85
80
75
70
65
MIN

TEST POINTS

TP1
TP2
TP3
TP4
TP5
TP6
TP7

+12VDC

PCB3

/230

K1K1

PCB2

PCB1

40 CIRCUIT

RIBBON CABLE

OVER PRESSURE
INTERNAL ERROR
SHORTED TORCH
CONSUMABLES MISSING
START ERROR
PARTS IN PLACE
INPUT POWER
UNDER PRESSURE

GND
+12 VDC
+5 VDC

3.3 VDC

0.v - 5.0 VDC / 0-100PSI

1.8 VDC
POT. DEMAND

D1D1

LOGIC PCB

MTH3MTH3

K2K2

MTH5MTH5

MAIN PCB ASSY

4

K1-K4K1-K4

K5, K6K5, K6

MTH1MTH1

C1-C4*+C1-C4*

+

MTH4MTH4

K6K6

K5K5

MTH6MTH6

C5-C8*+C5-C8*

+

MTH7MTH7

C3 & C5 not installed

INPUT CAPACITOR PCB

0-100PSI / 0-4.5VDC

4

3

T1T1

COMMON
COMMON
COMMON
+12 VDC SUPPLY
+48 VDC SUPPLY
CURRENT DEMAND
TIP DRAG SENSE

/SOLENOID

GAS CONTROL

REGULATOR

PRI 1 PRI 1

AB

SOLENOID
VALVE

PRESSURE
TRANSDUCER

PRI 4 PRI 4

123

PRI 3PRI 3

DC

ATC

3

PRI 2 PRI 2

MTH2MTH2

Q1

K3K3

K4K4

MTH8MTH8

MAXMAX

9090

8585

8080

7575

7070

6565

MINMIN

+5VDC

Q2

TEST POINTS

GND1
GND2
GND3
+12V1
48V1
I_DMD_1
TIP_SEN

+12VDC

J5J5

123

SOL1SOL1

FILTER
AIR
INLET

J3J3

1
2
3

2

2

APPENDIX Manual 0-5377

A-6

ESAB CUTMASTER 60

1

CM82 / A60 ONLY

TS1TS1

SEC1SEC1

+12VDC

J11J11

NTCNTC

TEMP
CIRCUIT

1TORCH

PIP SWITCHPIP SWITCH

TORCH SWITCHTORCH SWITCH

AUTOMATION
TORCH SOLENOID

WORKWORK

J2 PINOUT

D

C

13

47

811

1214

-V OUT 1-V OUT 1

ELECTRODE1ELECTRODE1

WORK1WORK1

L1L1

ATC CONNECTOR

J1J1

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

J2J2

14
13
12
11
10
9
8
7
6
5
4
3
2
1

-

+

OK TO MOVE

}

(5A @250VAC / 30VDC)

/START / STOP

}

(Sink 50mA @12VDC)

E64

TIP1TIP1

E35

J9J9

78

1

79

2

80

3

81

4

82

5
6

83

7

P10P10

J10J10

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

1

2

/OVERTEMP

D3

SEC2SEC2

Q5

/START

24VAC RETURN

24VAC SUPPLY

OK-TO-MOVE

CHOKE1CHOKE1

PILOT IGBTQ5PILOT IGBT

/PIP

+12VDC

SupersedesScale

SupersedesScale

SupersedesScale

Sheet

Sheet

Sheet

11

11

11

of

of

of

B

A

+12VDC

1

2

J7J7

+ -

MOT1MOT1

1

+12VDC

J8J8

+ -

MOT2MOT2

1

2

NAFNAF

/FAN/FAN

SEE A-09131

INTRO ECO B534

AA
AB

ECO B855

AC
AD

ECO B1357

AE

Last Modified:

Last Modified:

Last Modified:

P10P10

Monday, March 30, 2009

Monday, March 30, 2009

Monday, March 30, 2009

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

**

To -V OUT 1
on PCB1

1
2
3
4
5
6
7
8

J1J1

1
2
3
4
5
6
7
8

J3J3

E1E1

+12VDC

K1K1

PCB4

Date

Date

Date

ByRevisionsRev

ByRevisionsRev

ByRevisionsRev

RWH 07/23/07

MNC 04/23/08ECO B890

MNC 05/09/08

MNC 10/03/08ECO B1159

RWH 03/31/09

13:16:29

13:16:29

13:16:29

123

AUTOMATION
INTERFACE PCB

To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS /16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50

J2J2

1
2
3

/START / STOP

}

4

(-)

5

DIVIDED ARC VOLTS

}

*

(+)

6
7

(-)

ARC VOLTS

8

}

(W/ 100K IN SERIES (2))

(+)

9
10
11
12

OK-TO-MOVE

13

K1

NOTE: UNLESS OTHERWISE SPECIFIED -

NOTE: UNLESS OTHERWISE SPECIFIED -

NOTE: UNLESS OTHERWISE SPECIFIED -

1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.

1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.

1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.

2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).

2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).

2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).

TITLE:

TITLE:

TITLE:

Schematic, ESAB Cutmaster 60 20' SL60
208-460V 1/3ph CSA (Configured for 460V 3ph

}

14

A-12766_AA

PCB No:

PCB No:

PCB No:

Assy No:

Assy No:

Assy No:

Date:

Date:

Date:

Thursday, March 27, 2008

Thursday, March 27, 2008

Thursday, March 27, 2008

Drawn: References

Drawn: References

Drawn: References

RWH

Chk: App:

Chk: App:

Chk: App:

DWG No:

Size

DWG No:

Size

DWG No:

Size

42X1298

42X1298

42X1298

C

C

C

Manual 0-5377 APPENDIX

A-7

ESAB CUTMASTER 60

Revision History

Date Rev Description

01/15/2015 AA Manual release

05/22/2015 AB Miscellaneous corrections and updates

APPENDIX Manual 0-5377

A-8

This Page Intentionally Blank

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna-Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Heist-op-den-Berg
Tel: [phone]
Fax: [phone]

BULGARIA

ESAB Kft Representative Office
Sofia
Tel/Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Herlev
Tel: [phone]
Fax: [phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel: [phone]
Fax: [phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]
ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel: [phone]
Fax: [phone]

ITALY

ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: [phone]
Fax: [phone]

THE NETHERLANDS

ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]

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AS ESAB
Larvik
Tel: [phone]
Fax: [phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

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ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

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ESAB Romania Trading SRL
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Tel: [phone]
Fax: [phone]

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Tel: [phone]
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Tel: [phone]
Fax: [phone]

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Tel: [phone]
Fax: [phone]

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Tel: [phone]
Fax: [phone]
ESAB international AB
Gothenburg
Tel: [phone]
Fax: [phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

UKRAINE

ESAB Ukraine LLC
Kiev
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem-MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Prod­ucts
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

AUSTRALIA

ESAB South Pacific
Archerfield BC QLD 4108
Tel: [phone]
Fax: [phone]

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: [phone]
Fax: [phone]

JAPAN

ESABJapan

Tokyo
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd

USJ

Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Africa

EGYPT

ESAB Egypt
Dokki-Cairo
Tel: [phone]
Fax: [phone]

SOUTH AFRICA

ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: [phone]

Distributors
For addresses and phone num­bers to our distributors in other
countries, please visit our home
page
www.esab.eu

www.esab.eu

©2015 ESAB Welding and Cutting Products

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