ESAB Cutmaster 60, Cutmaster 80 SL60 1Torch, Cutmaster 80 Operating Manual

60

380/400V

Art # A-12773

esab.com.cn

ESAB Cutmaster® 60

Plasma Cutting System
SL60 1Torch

TM

Operating
Manual

Revision: AA Issue Date: January 15, 2015 Manual No.: 0-5402

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.cn

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 0-5402

Published by:
ESAB
2800 Airport Rd.
Denton, Texas 76207

www.esab.com.cn

Copyright © 2015 by
ESAB

All rights reserved.

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

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

Original Publication Date: January 15, 2015
Revision Date:

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

3.04 Gas Connections ............................................................................................. 3-2

SECTION 3 TORCH:

INSTALLATION ..........................................................................................................................3T-1

3T.01 Torch Connections .........................................................................................3T-1

3T.02 Setting Up Mechanical Torch .........................................................................3T-1

SECTION 4 SYSTEM:

OPERATION ............................................................................................................................... 4-1

4.01 Front Panel Controls / Features ....................................................................... 4-1

4.02 Preparations for Operation .............................................................................. 4-2

SECTION 4 TORCH:

OPERATION ...............................................................................................................................4T-1

4T.01 Torch Parts Selection .....................................................................................4T-1

4T.02 Cut Quality .....................................................................................................4T-1

4T.03 General Cutting Information ...........................................................................4T-2

4T.04 Hand Torch Operation ....................................................................................4T-3

4T.05 Gouging .........................................................................................................4T-6

4T.06 Mechanized Torch Operation ..........................................................................4T-7

4T.07 Parts Selection for 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-13

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, 380/400V UNITS ....................................................................... A-6

APPENDIX 6: PUBLICATION HISTORY ................................................................................................ A-8

ESAB CUTMASTER 60

Manual 0-5402 SAFETY

1-1

1.0 Safety Precautions

Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding or plasma cutting equipment. The following
recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well acquainted with the operation of the welding or
plasma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which
can result in injury to the operator and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

-

relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

- Always wear recommended personal safety equipment, such as safety glasses, ame proof
clothing, safety gloves.

- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualied electrician.

- Appropriate re extinguishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in
accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of
at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.
For further information contact the nearest ESAB dealer.

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

SECTION 1: SAFETY

ESAB CUTMASTER 60

SAFETY Manual 0-5402

1-2

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

ELECTRIC SHOCK - Can kill.

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

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

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

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

AR C RAYS - Can injure eyes and burn skin.

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

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus or other hearing protection.

- Warn bystanders of the risk.

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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING

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

CAUTION

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

CAUTION

Read and understand the instruction manual before
installing or operating.

CAUTION

Do not use the power source for thawing frozen pipes.

WARNING

!

ESAB CUTMASTER 60

Manual 0-5402 INTRODUCTION

2-1

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

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

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

Throughout this manual, the words WARNING, CAU­TION, 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 ecient operation of the system.

!

CAUTION

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

!

WARNING

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

WARNING

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

Additional copies of this manual may be purchased
by contacting ESAB at the address and phone 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.cn

2.02 Equipment Identification

The unit’s identification number (specification or part
number), model, and serial number usually appear
on a data tag attached to the rear panel. Equipment
which does not have a data tag such as torch and
cable assemblies are identified only by the 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 un­crate the unit.

ESAB CUTMASTER 60

INTRODUCTION Manual 0-5402

2-2

2.04 Power Supply Specifications

ESAB Cutmaster® 60 Power Supply Specifications

Input Power

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

400 VAC (360 - 440 VAC),

Three Phase, 50/60 Hz

Input Power Cable

Power Supply includes input cable.

Cable for 400V, Three Phase,

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

All Units

Duty Cycle 40% 60% 100%

Rating

IEC CE IEC CE IEC CE

Current

60A 60A 50A 50A 30A 30A

DC Voltage

104 104 100 100 92 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 specied by the International Electro-Technical Commission. These specications include
calculating an output voltage based upon power supply rated current. To facilitate comparison between power supplies, all
manufacturers use this output voltage to determine duty cycle.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

22.5"

0.57 m

43 lb / 19.5 kg

10.75"

273 mm

16.375"

416 mm

Art # A-07941

6"

150 mm

24"

610 mm

6"

150 mm

6"

150 mm

Art # A-07925_AB

ESAB CUTMASTER 60

Manual 0-5402 INTRODUCTION

2-3

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

1max

I

1eff

Fuse (amps)

Flexible Cord (Min.

AWG)

3 phase

380 50/60 11 16 11 20 14# (around

2.5mm2)

400 50/60 11 16 11 20 14# (around 2.5mm

2

)

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on US 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.
I

1max

is taken at rated minimum duty cycle.

I

1e

is taken at 100% rated duty cycle.

ESAB CUTMASTER 60

INTRODUCTION Manual 0-5402

2-4

2.06 Power Supply Features

Handle and Leads Wrap

To rch Leads Receptacle

Control Panel

Art # A-07942

Work Cable

and Clamp

Art # A-08544

Input Power Cord

Port for Optional Automation
Interface Cable

Gas Inlet Port

Filter Assembly

ESAB CUTMASTER 60

Manual 0-5402 INTRODUCTION

2T-1

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!

An operation,Refer to Section "2T.05 Introduction to
Plasma", for a more detailed description of plasma
torch operation.
Refer to the Appendix Pages for additional speci­cations 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)

Art # A-03322_AB

2. Mechanized Torch, Model

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

Art # A-02998

1.75" /

44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" /
16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20ft/6.1m,withATCconnectors

• 50ft/15.2m,withATCconnectors

Machine Torches are available as follows:

• 5foot/1.5m,withATCconnectors

• 10foot/3.05m,withATCconnectors

• 25foot/7.6m,withATCconnectors

• 50foot/15.2m,withATCconnectors

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

12 VDC circuit rating

E. Type Cooling

Combination of ambient air and gas stream
through torch.

ESAB CUTMASTER 60

INTRODUCTION Manual 0-5402

2T-2

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

104° F

40° C

Duty Cycle 100% @ 60 Amps @ 400 scfh

Maximum Current 80 Amps

Voltage (V

peak

) 500V

Arc Striking Voltage 7kV

Mechanized Torch Ratings

Ambient

Temperature

104° F

40° C

Duty Cycle 100% @ 100 Amps @ 400 scfh

Maximum Current 120 Amps

Voltage (V

peak

) 500V

Arc Striking Voltage 7kV

G. Gas Requirements

Manual and Mechanized Torch Gas Specifications

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

60 - 95 psi

4.1 - 6.5 bar

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and Gouging)

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.

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.

A-00002

Workpiece

Power

Supply

+

_

C

B

A

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.

ESAB CUTMASTER 60

Manual 0-5402 INTRODUCTION

2T-3

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.

A-02997

Torch Trigger

PIP Switch

Shield Cup

To Control

Cable Wiring

Torch Switch

Parts - In - Place Circuit Diagram for Hand Torch

PIP Sw itch

Sh ield Cup

To ATC

CNC Start

PIP Sw itch

Sh ield Cup

PIP Sw itch

Sh ield Cup

Remote Pendant

Automation To rch

To ATC

To ATC

Art # A-08168

Parts - In - Place Circuit Diagram for Machine Torch

ESAB CUTMASTER 60

INTRODUCTION Manual 0-5402

2T-4

This Page Intentionally Blank

ESAB CUTMASTER 60

Manual 0-5402 INSTALLATION

3-1

SECTION 3 SYSTEM:

INSTALLATION

3.01 Unpacking

1. Use the packing lists to identify and account
for each item.

2. Inspect each item for possible shipping
damage. If damage is evident, contact your
distributor and / or shipping company before
proceeding with the installation.

3. Record Power Supply and Torch model and
serial numbers, purchase date and vendor
name, in the information block at the front of
this manual.

3.02 Lifting Options

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

WARNING

Do not touch live electrical parts.
Disconnect input power cord before moving unit.

!

WARNING

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

• Only persons of adequate physical strength

should lift the unit.

• Lift unitbythehandles, using twohands.Do

not use straps for lifting.

• Useoptionalcartorsimilardeviceofadequate

capacity to move unit.

• Placeunitonaproperskidandsecureinplace

before transporting with a fork lift or other ve­hicle.

3.03 Primary Input Power Connections

!

CAUTION

Check your power source for correct voltage 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 specied in Section 2..

Most units are shipped from the factory with a
380/400Volt input power cable wired to the input
contactor in the three - phase configuration. The
following illustrations and directions are for replacing
input cable.

Art # A-08548

Input Power Cable Connections

Three-Phase (3ø)

GND

L1

L2

L3

L4

Three Phase Input Power Wiring

WARNING

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

These instructions are for changing the input power
and or cable on the 380/ 400 VAC Power Supply to
Three - Phase input power.

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. 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).

ESAB CUTMASTER 60

INSTALLATION Manual 0-5402

3-2

6. Connect the wires as follows.

• WiringtoL1,L2andL3input.Seetheprevi­ous illustration and power label. It does not
matter what order these wires are attached.

• Green/YellowwiretoGround.

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.

3.04 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 tting
threads, according to manufacturer's instructions.
Do not use Teon tape as a thread sealer, as small
particles of the tape may break o and block the
small air passages in the torch.

Art # A-07943

Hose Clamp

Regulator/Filter

Assembly

Inlet Port

Gas Supply
Hose

1/4 NPT or ISO-R
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 tting
threads, according to manufacturer's instructions.
Do not use Teon tape as a thread sealer, as small
particles of the tape may break o and block the
small air passages in the torch.

Art # A-07944

Hose Clamp

1/4 NPT to 1/4"

(6mm) Fitting

Regulator/Filter
Assembly

Inlet Port

Gas Supply
Hose

Optional Single - Stage Filter Installation

ESAB CUTMASTER 60

Manual 0-5402 INSTALLATION

3-3

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 tting threads, according to manufacturer's instructions. Do not use Teon
tape as a thread sealer, as small particles of the tape may break o and block the small air passages in the torch.

2. Connect the two stage 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.

Regulator
Input

Gas Supply
Hose

1/4 NPT to 1/4”
(6mm) Fitting

Regulator/Filter

Assembly

2-Stage Filter
Inlet Port (IN)

Outlet Port
(OUT)

Two Stage
Filter
Assembly

Art # A-07945_AC

Hose Clamp

Optional Two - Stage Filter Installation

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 tting threads, according to manufacturer's instructions. Do Not use Teon
tape as a thread sealer, as small particles of the tape may break o and block the small air passages in the torch.

ESAB CUTMASTER 60

INSTALLATION Manual 0-5402

3-4

This Page Intentionally Blank

ESAB CUTMASTER 60

Manual 0-5402 INSTALLATION

3T-1

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 before con­necting the torch.

1. Align the ATC male connector (on the torch
lead) with the female receptacle. Push the
male connector into the female receptacle.
The connectors should push together with a
small amount of pressure.

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

1

2

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!

Any oil or moisture in the air will be visible on

the lens.

3T.02 Setting Up Mechanical Torch

NOTE!

When converting a hand torch to a mechanical
torch, one adaptor will be required inside the
power source.

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.

A-02585

Workpiece

Square

Pinch Block
Assembly

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.07
for the selection of torch parts.

ESAB CUTMASTER 60

INSTALLATION Manual 0-5402

3T-2

This Page Intentionally Blank

ESAB CUTMASTER 60

Manual 0-5402 OPERATION

4-1

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 higher
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

ON

/ OFF Switch controls input power to

the power supply. Up is ON, down is OFF.

4. Air/Gas Pressure Control

The Pressure

+

Control is used in the
"SET" 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 for details.

A

+

PSI BAR

MAXMAX

MINMIN

!

12

3

4

5

6

7

8

9

Art# A-07886

MIN

MAX

10

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.

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

MINMIN

80

75

70

65

5.5

85 5.9

90 6.3

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).

ESAB CUTMASTER 60

OPERATION Manual 0-5402

4-2

4.02 Preparations for Operation

At the start of each operating session:

WARNING

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

Torch Parts Selection

Check the torch for proper assembly and ap­propriate torch parts. The torch parts must cor­respond with the type of operation, and with the
amperage output of this Power Supply (60 amps
maximum). Refer to Section 4T.07 and following
for torch parts selection.

Torch Connection

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

Check Primary Input Power Source

1. Check the power source for proper input volt­age. Make sure the input power source meets
the power requirements for the unit per Section
2, 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.

Art # A-04509

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 o, 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

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.

A

+

PSI BAR

MAXMAX

MINMIN

!

1

2

Art# A-07946

MIN

MAX

ESAB CUTMASTER 60

Manual 0-5402 OPERATION

4-3

STANDOFF

ESAB Cutmaster

®

60 Gas Pressure Settings

Leads

Length

SL60

(Hand Torch)

SL100

(Mechanized Torch)

Up to 25'

(7.6 m)

75 psi

5.2 bar

75 psi

5.2 bar

Each

additional

25'

(7.6 m)

Add 5 psi

0.4 bar

Add 5 psi

0.4 bar

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

SL60

(Hand Torch)

Up to 25'

(7.6 m)

80 psi

5.5 bar

Each additional 25'

(7.6 m)

Add 5 psi

0.4 bar

Select Current Output Level

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

RUN

,

RAPID AUTO RESTART

or LATCH

. Gas flow stops.

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
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

Cutting speeds vary according to torch output
amperage, the type of material being cut, and
operator skill. Refer to Section "4T.08
Recommended Cutting Speeds 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 the rear and presses the trigger, the
pilot arc starts. The main arc transfers to the
workpiece if the torch tip is within transfer distance
to the workpiece.

Shutdown

Turn the ON

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

ESAB CUTMASTER 60

OPERATION Manual 0-5402

4-4

This Page Intentionally Blank

ESAB CUTMASTER 60

Manual 0-5402 OPERATION

4T-1

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 torch parts, or torch and
leads assemblies.

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.

A-03510_AB

Electrode

Start Cartridge

Tip

Shield Cup

Torch Head

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

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 stando, 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:

Kerf Width

Cut Surface
Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

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.

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.

ESAB CUTMASTER 60

OPERATION Manual 0-5402

4T-2

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

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.

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.

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.

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

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.

ESAB CUTMASTER 60

Manual 0-5402 OPERATION

4T-3

4T.04 Hand Torch Operation

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 perpendicu-

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

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

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

A-00024_AB

Shield Cup

Torch

Standoff Distance

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

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.

A-02986

Trigger

Trigger Release

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 preow and postow are a characteristic of
the power supply and not a function of the torch.

3

4

Tr igger

2

1

Tr igger Release

Art # A-11504

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

7. Follow normal recommended cutting practices
as provided in the power supply operator's
manual.

NOTE!

When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield cup
against the torch head or torch handle can damage
components.

8. For a consistent 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

Workpiece

Standoff Guide

Art # A-04034

Torch Tip

ESAB CUTMASTER 60

OPERATION Manual 0-5402

4T-4

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.

A-03539

Non-Conductive

Straight Edge
Cutting Guide

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.

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.

A-02986

Trigger

Trigger Release

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 preow and postow are a characteristic of
the power supply and not a function of the torch.

3

4

Art # A-03383

Tr igger

2

1

Tr igger Release

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

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.

ESAB CUTMASTER 60

Manual 0-5402 OPERATION

4T-5

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.

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.

A-02986

Trigger

Trigger Release

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 preow and postow 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

ESAB CUTMASTER 60

OPERATION Manual 0-5402

4T-6

4T.05 Gouging

!

WARNING

Be sure the operator is equipped with proper
gloves, clothing, eye and ear protection and that all
safety precautions at the front of this manual have
been followed. Make sure no part of the operator’s
body comes in contact with the workpiece when
the torch is activated.
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.

!

CAUTION

Sparks from plasma gouging can cause damage
to coated, painted or other surfaces such as glass,
plastic, and metal.
Check torch parts. The torch parts must correspond
with the type of operation. Refer to Section 4T.07,
Torch Parts Selection.

Gouging Parameters

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).

!

CAUTION

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

Torch Travel Speed

NOTE!

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

Optimum torch travel speed is dependent on cur­rent setting, lead angle, and mode of operation
(hand or machine torch).

Current Setting

Current settings depend on torch travel speed,
mode of operation (hand or machine torch), and
the amount of material to be removed.

Lead Angle

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.

35°

Workpiece

Torch Head

Standoff Height

A-00941_AB

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.

ESAB CUTMASTER 60

Manual 0-5402 OPERATION

4T-7

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.

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

Mechanized Torch Operation

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.

ESAB CUTMASTER 60

OPERATION Manual 0-5402

4T-8

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

Start

Cartridge

9-8277

Electrode

9-8215

Tips:

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

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)

Shield Cap, Gouging

9-8241

Shield Cap, Drag

40A 9-8244

40A 9-8208

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

120A 9-8253

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Drag
70-100A 9-8236

Shield

Cup Body,

9-8237

70-120A

50-60A

40A

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Tip:

Tips:

Tips:

Tips:

DRAG TIP

CUTTING

40-120A

GOUGING

CUTTING

CUTTING

CUTTING

Art # A-11505

DRAG SHIELD

CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8281

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Standoff Guide

9-8281

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

STANDOFF CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8251

ESAB CUTMASTER 60

Manual 0-5402 OPERATION

4T-9

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

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce
Height

Inches

mm

(Cat.

No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

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

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce
Height

Inches

mm

(Cat.

No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

Type Torch: SL60 With Exposed Tip Type Material: Aluminum

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce

Height

Inches

mm

(Cat.
No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

ESAB CUTMASTER 60

OPERATION Manual 0-5402

4T-10

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

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce

Height

Inches

mm

(Cat.

No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

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

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce

Height

Inches

mm

(Cat.

No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

Type Torch: SL60 With Exposed Tip Type Material: Aluminum

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce

Height

Inches

mm

(Cat.
No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

NOTE!

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, the gas pressure shall be
set at 4.8 bar.
** Total ow rate includes plasma and secondary gas ow.

ESAB CUTMASTER 60

Manual 0-5402 OPERATION

4T-11

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

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce

Height

Inches

mm

(Cat. No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

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

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce
Height

Inches

mm

(Cat.
No.)

Volts

(VDC)

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

Delay

(Sec)

Inches mm

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

Type Torch: SL60 With Shielded Tip Type Material: Aluminum

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce
Height

Inches

mm

(Cat.

No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

ESAB CUTMASTER 60

OPERATION Manual 0-5402

4T-12

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

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce
Height

Inches

mm

(Cat. No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

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

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce

Height

Inches

mm

(Cat.

No.)

Volts

(VDC)

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

Delay
(Sec)

Inches mm

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

Type Torch: SL60 With Shielded Tip Type Material: Aluminum

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

Thickness Tip Output Amperage

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Pierce
Height

Inches

mm

(Cat.

No.)

Volts

(VDC)

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

Delay

(Sec)

Inches mm

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

NOTE!

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, the gas pressure shall be
set at 4.8 bar.
** Total ow rate includes plasma and secondary gas ow.

ESAB CUTMASTER 60

Manual 0-5402 OPERATION

4T-13

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
9-8277 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

ESAB CUTMASTER 60

OPERATION Manual 0-5402

4T-14

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

ESAB CUTMASTER 60

Manual 0-5402 SERVICE

5-1

SECTION 5 SYSTEM:

SERVICE

5.01 General Maintenance

Warning!
Disconnect input power before maintaining.

Each Use

Visual check of
torch tip and electrode

Weekly

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

Visually inspect the
cables and leads.
Replace as needed

3 Months

Clean
exterior
of power supply

6 Months

Replace all
broken parts

Visually check and
Carefully clean the
interior

Maintain more often
if used under severe
conditions

Art # A-07938_AB

ESAB CUTMASTER 60

SERVICE Manual 0-5402

5-2

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.

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.

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

Short Torch Parts Life1. 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.

ESAB CUTMASTER 60

Manual 0-5402 SERVICE

5-3

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.

A

+

PSI BAR

MAXMAX

MINMIN

!

1

2

3

4

Art# A-07988

MIN

MAX

0

1

2

3

4

5

6

7

5

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
Indicator

Fault

Max Over Pressure
90 Internal Error
85 Shorted Torch
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.

ESAB CUTMASTER 60

SERVICE Manual 0-5402

5-4

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

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. 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.

Fault indicator
flashing, 65 PSI
indicator flashing

1. Primary input voltage problem.

2. Faulty components in unit.

1. Have qualified person check primary voltage to insure it
meets unit requirements see Section "2.05 Input Wiring
Specifications" on page 2-3.

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

TEMPERATURE
indicator ON.
FAULT indicator
flashing.

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. Refer to clearance information – see Section "2.04 Power
Supply Specifications" on page 2-2

2. Allow unit to cool.

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

GAS LED OFF,
FAULT and MIN
pressure 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. 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 4-1

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

FAULT and 70 PSI
indicators flashing.

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. 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.

FAULT and 75 PSI
indicators flashing.

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. 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.

ESAB CUTMASTER 60

Manual 0-5402 SERVICE

5-5

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.

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. Take Torch and Leads (Remote Pendant) to Authorized
Repair Facility.

2. Contact Controller manufacturer.

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

FAULT and 85 PSI
indicators flashing.

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. 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.

No Fault lights ON, no
arc in torch.

1. Failed components in unit. 1. Return to an authorized service center for repair.

FAULT and 85 PSI
indicators flashing

1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that
does not clear the fault, return to an authorized service center
for repair.

Pilot arc is ON but
cutting arc will not
establish

1. Work cable not connected to

work piece.

2. Work cable/connector broken.

3. Failed components in unit.

1. Connect work cable.

2. Replace work cable.

3. Return to an authorized service center for repair.

Torch cutting is
diminished

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. 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.

ESAB CUTMASTER 60

SERVICE Manual 0-5402

5-6

5.06 Power Supply Basic Parts
Replacement

WARNING

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

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

A. Cover Removal

1. Remove the upper and lower screws which
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

Lower
Screws

Art # A-07947

Slots

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.

4. Reinstall and tighten the upper screws.

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).

Art # A-07989

1

2

3

4

5

6mm

ESAB CUTMASTER 60

Manual 0-5402 SERVICE

5-7

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 lter element refer
to the following illustration for disassembly.

Art # A-07990

Filter Element

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.

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.

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

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.

ESAB CUTMASTER 60

SERVICE Manual 0-5402

5-8

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

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

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move
freely.

4. Note the location and orientation of the old Filter Elements.

5. Slide out the old Filter Elements.

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in
Step 4 above.

7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper
torque may damage the gasket.

8. Slowly apply air pressure to the assembly, checking for leaks.

NOTE!

A small amount of air leakage from the bottom tting is normal.

This completes the parts replacement procedures.

ESAB CUTMASTER 60

Manual 0-5402 SERVICE

5T-1

SECTION 5 TORCH:

SERVICE

5T.01 General Maintenance

NOTE!

Refer to Previous "Section 5: System Service" 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.

!

CAUTION

Dry the torch thoroughly before reinstalling.

O-Ring Lubrication

An O-Ring on the Torch Head and ATC Male Con­nector requires lubrication on a scheduled basis.
This will allow the O-Rings to remain pliable and
provide a proper seal. The O-Rings will dry out,
becoming hard and cracked if the lubricant is not
used on a regular basis. This can lead to potential
performance problems.

It is recommended to apply a very light film of O­Ring lubricant (Catalog # 8-4025) to the O-Rings
on a weekly basis.

Upper Groove
with Vent Holes
Must Remain Open

Threads

Upper O-Ring
in Correct Groove

Lower O-Ring

Art # A-03725

Torch Head O-Ring

ATC Male Connector

Art #A-03791

Gas Fitting

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.

ESAB CUTMASTER 60

SERVICE Manual 0-5402

5T-2

5T.02 Inspection and Replacement of

Consumable Torch Parts

WARNING

Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the AC
indicator light of the Power Supply is ON..

Remove the consumable torch parts as follows:

NOTE!

The shield cup holds the tip and starter cartridge in
place. Position the torch with the shield cup facing
upward to prevent these parts from falling out
when the cup is removed.

1. Unscrew and remove the shield cup from the
torch.

NOTE!

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

2. Inspect the cup for damage. Wipe it clean or
replace if damaged.

Art # A-08067

Shield Cups

3. On torches with a shield cup body and a
shield 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 O-Ring.

Drag Shield Cap

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

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.

Art # A-08064_AC

Spring-Loaded

Lower End Fitting
Full Compression

Spring-Loaded
Lower End Fitting at Reset /
Full Extension

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

Worn Electrode

New Electrode

Art # A-03284

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.

ESAB CUTMASTER 60

Manual 0-5402 PARTS LIST

6-1

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 CCC version
400VAC, 3 Phase, with input power cable C559311303

ESAB CUTMASTER 60

PARTS LIST Manual 0-5402

6-2

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 380/400 V Power Supply 9-0218

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 9-8310
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

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

ESAB CUTMASTER 60

Manual 0-5402 PARTS LIST

6-3

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 - foot / 6.1m Leads Assembly with ATC connector 4-7834
1 SL60, 50 - foot / 15.2m Leads Assembly with ATC connector 4-7835
1 SL100, 20 - foot / 6.1m Leads Assembly with ATC connector 4-7836
1 SL100, 50 - foot / 15.2m Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031
10 1 Adaptor for Torch Control Cable (including Item 11)(not shown) 7-3447
11 1 Through-hole Protector(not shown) 9-8103

7

5
6

3

4

2

Art # A-07993_AB

1

8

ESAB CUTMASTER 60

PARTS LIST Manual 0-5402

6-4

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

NOTE!

* Control cable adaptor or through-hole protector is not included.
Refer to Section 6.08 "Replacement Shielded Machine Torch Leads Assemblies".

ESAB CUTMASTER 60

Manual 0-5402 PARTS LIST

6-5

A-07994_AB

1

4

2

3

5 & 6

7

8

9

10

12

11

10

13

ESAB CUTMASTER 60

PARTS LIST Manual 0-5402

6-6

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

A-03684

1

Torch Continuity
('PIP') Switch

Remote Pendant Adapter is
present on Mechanized leads only.

ESAB CUTMASTER 60

Manual 0-5402 PARTS LIST

6-7

6.09 Torch Consumable Parts (SL60)

Start

Cartridge

9-8277

Electrode

9-8215

Tips:

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

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)

Shield Cap, Gouging

9-8241

Shield Cap, Drag

40A 9-8244

40A 9-8208

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

120A 9-8253

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Drag
70-100A 9-8236

Shield

Cup Body,

9-8237

70-120A

50-60A

40A

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Tip:

Tips:

Tips:

Tips:

DRAG TIP

CUTTING

40-120A

GOUGING

CUTTING

CUTTING

CUTTING

Art # A-11505

DRAG SHIELD

CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8281

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Standoff Guide

9-8281

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

STANDOFF CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8251

ESAB CUTMASTER 60

PARTS LIST Manual 0-5402

6-8

6.10 Torch Consumable Parts (SL100)

Starter

Cartridge

9-8277

Electrode

Auto 9-8232

Manual 9-8215

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Tips:

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)

Tip E 9-8254 (60 - 120 Amps)

Shield Cup, Gouging

9-8241

Shield

Cup Body,

9-8237

Tips:

40-120A

GOUGING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Deflector
9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine
50-60A 9-8238

Drag Shield Cup
9-8235

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

Art # A-11506

CUTTING

STANDOFF

70-120A

CUTTING

STANDOFF

20-40A

Shield Cap, Deflector
9-8243

50-60A

CUTTING

STANDOFF

Shield Cap, Deflector
9-8243

Shield Cap, Machine
40A 9-8245

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

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Tip:

Ohmic Clip

Automation Torch

9-8224

Ohmic Clip

Manual Torch

9-8259

ESAB CUTMASTER 60

Manual 0-5402 APPENDIX

A-1

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

ACTION:

ON / OFF switch to ON

RESULT:

AC indicator ON.

GAS indicator ON

when input

pressure is adequate

for power supply operation.

Power circuit ready.

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:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

ACTION:

Connect work cable to workpiece.

Set output amperage.

RESULT:

System is ready

for operation.

ACTION:

RUN /
Rapid Auto Restart /
SET / LATCH switch

to SET

RESULT:

Gas flows to set

pressure.

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:

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)

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fans shut off.

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

PILOT ARC

ACTION:

Torch moved away from work (while

still activated).

RESULT:

Main arc stops.

Pilot arc automatically

restarts.

Art #A-07979_AB

ESAB CUTMASTER 60

APPENDIX Manual 0-5402

A-2

U0=

I

X

U

2

S

U1

I1max I1eff

3ø

3ø

f

1

f

2

3 ~

Model:

Date of Mfr:

Type of Power
Supply (Note 1)

Manufacturer's Name and/or

Logo, Location, Model and
Revision Level, Serial Number
and Production Code

Regulatory Standard Covering
This Type of Power Supply

Plasma Cutting
Symbol

Output Current Type

Duty Cycle Factor

Rated No­Load Voltage

Conventional
Load Voltage

Rated Maximum
Supply Current

Maximum Effective
Supply Current

Output Range (Amperage/
Voltage)

Duty Cycle Data (Note 3)

Input Power
Symbol

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

Degree of
Protection

Rated Supply
Voltage (Note 2)

Manufacturer's Electrical
Schematic File Number
and Revision Level

NOTES:

1. Symbol shown indicates 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.
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.

S/N

Standard Symbols

Ø

AC

DC

Phase

Art # A-12784_AA

APPENDIX 2: DATA TAG INFORMATION

ESAB CUTMASTER 60

Manual 0-5402 APPENDIX

A-3

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram

1

2

3

4

5

6

7

8

5

6

7

8

1

2

3

4

ATC Female Receptacle

Front View

Pilot

Pilot

6 - Open

7 - Open

8 - Open

5 - Open

Negative /
Plasma

6 - Open

7 - Open

5 - Open

2 - PIP

3 - Switch

4 - Switch

1 - PIP

4 - Green /
Switch

2- Orange /
PIP

3 - White /
Switch

1 - Black /
PIP

Negative /
Plasma

8 - Ground

ATC Male Connector

Front View

A-03701

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Female Receptacle

Front View

ATC Male Connector

Front View

Negative / Plasma

3 - White ­Pendant
Connector

4- Black ­Pendant
Connector

2 - Orange /
PIP

1 - Black /
PIP

Pilot

2 - PIP

1 - PIP

6 - Open

7 - Open

5 - Open

8 - Ground

8 - Green ­Pendant
Connector
Ground

5 - White /
Not Used

7 - Green /
Not Used

6 - Open

UNSHIELDED MACHINE TORCH

3 - Switch

4 - Switch

Art # A-03799

Negative / Plasma

Pilot

1

2

3

4

5

6

7

8

5

6

8

1

2

3

4

7

ESAB CUTMASTER 60

APPENDIX Manual 0-5402

A-4

APPENDIX 4: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

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

Pilot

Negative / Plasma

Power
Supply

PIP

Switch

Male

ATC Leads

Connector

AT C Female

Receptacle

Pilot

Negative / Plasma

Black

Orange

Torch
Leads

Torch

Head

To Power Supply

Circuitry

Art # A-03797

1

2

5

6

4

3

8

7

1

2

5

6

4

3

8

7

Torch

Switch

Green

White

To Power Supply

Circuitry

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

Pilot

Negative / Plasma

Power
Supply

To Remote Control

Remote

Pendant

Connector

PIP

Switch

Not

Used

Male

AT C Leads

Connector

AT C Female

Receptacle

Pilot Lead

Negative / Plasma Lead

Torch
Leads

Torch

Head

Art # A-03798

1

2

5

6

4

3

8

7

To Power Supply

Circuitry

Green

To Power Supply

Circuitry

1

2

5

6

4

3

8

7

Black

White

Green

Black

Orange

White

ESAB CUTMASTER 60

Manual 0-5402 APPENDIX

A-5

This Page Intentionally Blank

ESAB CUTMASTER 60

APPENDIX Manual 0-5402

A-6

APPENDIX 5: SYSTEM SCHEMATIC, 380/400V UNITS

A-12767_AA

5

5

4

4

D

C

B

A

24VAC

+12VDC

+12VDC

+12VDC

+5VDC

AB

24 VAC RETURN

J1

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

ERROR INDFAULT

PCB3

8

9

7A

Q2

PRIMARY POWER CONNECTIONS:
USE L1, L2, L3 & GND

*

5

6

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
29
34
35
36
37
38
39

-V_OUT_SIGNAL
/TIP_VOLTS
/TIP_SENSE
/460V_IN
/230V_IN
CUR_SET
/RAR (RAPID AUTO RESTART)
/INRUSH
/W1_ON
/SHDN
/TORCH_SOLENOID
/SOLENOID_ON

/OK_TO_MOVE
/FAN_ON
/LATCH_ACTIVE
/TORCH_SWITCH
/PIP
AC_ON
CSR
/TORCH_SOLENOID_DETECT
/OVERTEMP
V_IN
+12VDC
+12VDC
COMMON
COMMON
MAIN_PCB_ID
460_IN
+3.3VDC
TXD
RXD
COMMON
D

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

L1

L2

L3

L4

T1

T2

T3

T4

PCB2

/SOLENOID

Q1

380/400/415V
OR 600V
3 PH AC INPUT

PCB1

40 PIN RIBBON CABLE SIGNALS

LATCH

SET

RUN

RAR

40 CIRCUIT

RIBBON CABLE

MAX
90
85
80
75
70
65
MIN

J2

7

D1

L1

L2

L3

GND

DC

AIR
INLET

FILTER

REGULATOR

SOLENOID
VALVE

TP1
TP2
TP3
TP4
TP5
TP6
TP7

ATC

MAIN PCB ASSY

LOGIC PCB

INPUT CAPACITOR PCB

GAS CONTROL

GND
+12 VDC
+5 VDC

3.3 VDC

0.v - 5.0 VDC / 0-100PSI

1.8 VDC
POT. DEMAND

TEST POINTS

GND1
GND2
GND3
+12V1
48V1
I_DMD_1
TIP_SEN

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

TEST POINTS

PRESSURE
TRANSDUCER

0-100PSI / 0-4.5VDC

INRUSH

RESISTORS

/INRUSH

3.3VDC
TXD
RXD

D

SERIAL PORT

BIAS
SUPPLY

*

EMI
CHOKE

EMI
FILTER

1

2

3

4

1

2

3

4

*

CE UNITS
ONLY

*CM52/12mm/20mm/A40

C3 & C5 may not be installed

D1D1

PRI 2 PRI 2

J3J3

1
2
3

+

C1-C4*+C1-C4*

W1W1

AC3AC3

7070

W1W1

J4J4

1
2
3
4
5

MTH1MTH1

MTH4MTH4

123

9090

7575

DCDC

PRI 1 PRI 1

6565

J1J1

1
2
3
4
5

SW1SW1

1 3

2 4

MTH7MTH7

8080

PRI 4 PRI 4

AC2AC2

8585

OVERTEMPOVERTEMP

MTH3MTH3

Current ControlCurrent Control

MTH6MTH6

D59 PCRD59 PCR

ERRORERROR

J6J6

1
2

D78 CSRD78 CSR

MTH5MTH5

J5J5

123

MAXMAX

PRI 3PRI 3

GASGAS

MTH8MTH8

MTH2MTH2

AC1AC1

+

C5-C8*+C5-C8*

ACAC

MINMIN

K1K1

SOL1SOL1

ESAB CUTMASTER 60

Manual 0-5402 APPENDIX

A-7

A-12767_AA

3

3

2

2

1

1

D

C

B

A

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

DWG No:

Sheet

of

SupersedesScale

Date:

Drawn: References

DateByRevisionsRev

PCB No:

Assy No:

NOTE: UNLESS OTHERWISE SPECIFIED -

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

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

Chk: App:

TITLE:

Last Modified:

Size

Schematic ESAB Cutmaster 60/80 20'/50' SL60 400V/208-460V 3ph
CE/Non-CE CCC / 1/3ph CSA (Configured for 460V 3ph)

42X1329

11

13:16:29

C

DWG No:

Sheet

of

SupersedesScale

Date:

Drawn: References

DateByRevisionsRev

PCB No:

Assy No:

NOTE: UNLESS OTHERWISE SPECIFIED -

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

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

Chk: App:

TITLE:

Last Modified:

Size

42X1329

11

13:16:29

C

DWG No:

Sheet

of

SupersedesScale

Date:

Drawn: References

DateByRevisionsRev

PCB No:

Assy No:

NOTE: UNLESS OTHERWISE SPECIFIED -

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

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

Chk: App:

TITLE:

Last Modified:

Size

42X1329

11

13:16:29

C

80

PCB4

AUTOMATION
INTERFACE PCB

81
82

}

OK-TO-MOVE

OK-TO-MOVE

83

OK TO MOVE

1TORCH

}

}

E64

E35

78
79

-

+

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

CNC INTERFACE STANDARD ON A40 & A60 UNITS
CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS

(+)

/PIP

/START

NAFNAF

24VAC RETURN

ATC CONNECTOR

/FAN/FAN

24VAC SUPPLY

}

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

K1

To -V OUT 1
on PCB1

}

/START / STOP

**

}

INTRO ECO B1357

DIVIDED ARC VOLTS

(5A @250VAC / 30VDC)

/START / STOP

(+)

(-)

(W/ 100K IN SERIES (2))

(-)

*

ARC VOLTS

J2 PINOUT

13

47

811

1214

(Sink 50mA @12VDC)

AUTOMATION
TORCH SOLENOID

/OVERTEMP

TEMP
CIRCUIT

D3

RWH

AA

RWH 03/31/09

RWH 90/50/509931B OCE

AB

WORK1WORK1

SEC1SEC1

CHOKE1CHOKE1

J1J1

1
2
3
4
5
6
7
8

Q5

PILOT IGBTQ5PILOT IGBT

NTCNTC

J3J3

123

MOT1MOT1

+ -

J7J7

1

2

TIP1TIP1

J1J1

1
2
3
4
5
6
7
8

P10P10

1
2
3
4
5
6
7
8

MOT2MOT2

+

-

J9J9

1
2
3
4
5
6
7

P10P10

1
2
3
4
5
6
7
8

TS1TS1

SEC2SEC2

WORKWORK

E1E1

L1L1

J8J8

1

2

K1K1

-V OUT 1-V OUT 1

J2J2

2
3
4
5
6
7
8

9
10
11
12
13
14

1

T1T1

J11J11

1

2

J10J10

3

5
6
7
8

1
2

4

ELECTRODE1ELECTRODE1

TORCH SWITCHTORCH SWITCH

J2J2

2

3

4

5

6

7

8

9

10

11

12

13

14

1

PIP SWITCHPIP SWITCH

1
2
3
4
5
6
7
8

Wednesday, May 06, 2009

Thursday, March 27, 2008

SEE A-09133

ESAB CUTMASTER 60

APPENDIX Manual 0-5402

A-8

APPENDIX 6: Publication History

Cover Date Rev. Change(s)

Jan. 15, 2015 AA Manual released.

This Page Intentionally Blank

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 Oce
Soa
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]

NORWAY

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

POLAND

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

PORTUGAL

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

ROMANIA

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

RUSSIA

LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel: [phone]
Fax: [phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
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 Pacic
Archereld 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
Tok yo
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
USJ
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Asia/Pacic 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

ESAB subsidiaries and representative oces

www.esab.com.cn

Printed in China

©2015 ESAB Welding and Cutting Products