ESAB CUTMASTER A60, CUTMASTER A40 Operating Manual

CUTMASTER® A60

OUTPUT MAX OUTPUT INPUT POWER

VOLTAGEVOLTAGEVOLTAGE

INPUT POWER

VOLTAGE

AUTOMATED PLASMA CUTTING SYSTEM

Operating

Manual

Revision: AA Issue Date: August 30, 2015 Manual No.: 0-5428

60

AMPS

PHASE PHASE

208-230V

Art # A-12877

600V400V 460V

esab.eu

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new ESAB product. We are proud to have you as our customer
and will strive to provide you with the best service and reliability in the industry. This prod­uct is backed by our extensive warranty and world-wide service network. To locate your
nearest distributor or service agency, visit us on the web at www.esab.eu.

This Operating Manual has been designed to instruct you on the correct use and 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

!

Plasma Cutting Power Supply
Cutmaster® A60
SL100 ™ SV Automated Torch
Operating Manual Number 0-5428

Published by:
ESAB Group Inc.
2800 Airport Rd.
Denton, TX 76208
[phone]

www.esab.eu

Copyright 2015 by ESAB

All rights reserved.

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.

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.

For Printing Material Specification refer to document 47x1909
Original Publication Date: August 30, 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 Power Supply location and Mounting ............................................................. 3-1

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

3.05 Primary Input Power Connections .................................................................. 3-2

3.06 Gas Connections ............................................................................................. 3-4

SECTION 3 TORCH: INSTALLATION ..................................................................... 3T-1

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

3T.02 CNC Connection .............................................................................................3T-1

3T.03 Automation Interface PCB with Ohmic Sense ................................................3T-2

3T.04 Setting Up Automation or Machine Torch ......................................................3T-3

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 Machine and Automated Torch Operation ......................................................4T-1

4T.02 Automation Torch Parts Selection ..................................................................4T-1

4T.03 Machine and Hand Torch Parts Selection .......................................................4T-2

4T.04 Cut Quality .....................................................................................................4T-3

4T.05 General Cutting Information ...........................................................................4T-3

4T.06 Hand Torch Operation ....................................................................................4T-4

4T.07 Gouging .........................................................................................................4T-7

4T.08 Recommended Cutting Speeds for Machine and

Automated Torches With Exposed Tip ...........................................................4T-8

4T.09 Recommended Cutting Speeds for Machine and

Automated Torches With Shielded Tip .........................................................4T-28

TABLE OF CONTENTS

PATENT INFORMATION ................................................................................. 4T-46

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 ................................................................................................. 5-2

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 Torch Replacement Parts SL100SV Torch (w/Solenoid on Mounting Tube) .... 6-3

6.07 Torch Consumable Parts Automation / Machine (SL100)Torch ....................... 6-5

6.08 Torch Consumable Parts Manual (SL60)Torch ................................................ 6-6

6.09 Replacement Parts for Hand Torch ................................................................ 6-7

APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ....................................... A-1

APPENDIX 2: DATA TAG INFORMATION ................................................................. A-2

APPENDIX 3: TORCH PIN - OUT DIAGRAMS ........................................................... A-3

APPENDIX 4: TORCH CONNECTION DIAGRAMS ....................................................... A-4

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS ................................................ A-6

APPENDIX 6: SYSTEM SCHEMATIC, 400V/600V UNITS .............................................. A-8

APPENDIX 7: RAW ARC VOLTAGE ......................................................................A-10

REVISION HISTORY .......................................................................................A-12

This Page Intentionally Blank.

CUTMASTER A60

SECTION 1: SAFETY

1.0 Safety Precautions

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

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

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

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

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

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

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

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

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualified electrician.

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

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

Dispose of electronic equipment at the recycling facility!

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

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

0-5428 GENERAL INFORMATION

1-1

CUTMASTER A60

Arc welding and cutting can be injurious to yourself and others. Take

WARNING

ELECTRIC SHOCK - Can kill.

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

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

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

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

ARC RAYS - Can injure eyes and burn skin.

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

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

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

precautions when welding and cutting. Ask for your employer's safety
practices which should be based on manufacturers' hazard data.

NOISE - Excessive noise can damage hearing.

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

- Warn bystanders of the risk.

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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

Do not use the power source for thawing frozen pipes.

WARNING

Class A equipment is not intended for use in residential locations

CAUTION

CAUTION

CAUTION

where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those lo­cations, due to conducted as well as radiated disturbances.

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

Read and understand the instruction manual before
installing or operating.

!

1-2

GENERAL INFORMATION 0-5428

CUTMASTER A60

!

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specication or part

numbers listed on page i.

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

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

NOTE!

An operation, procedure, or back­ground information which requires
additional emphasis or is helpful in

efcient operation of the system.

CAUTION

!

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

2.02 EquipmentIdentication

The unit’s identication number (specication 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 as-

semblies are identied only by the specication or part

number printed on loosely attached card or the shipping
container. Record these numbers on the bottom of page
i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there

is any damage, notify the carrier immediately to le a

claim. Furnish complete information concerning dam­age claims or shipping errors to the location in your area
listed in the inside back cover of this manual.

Include all equipment identication numbers as described

above along with a full description of the parts in error.

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

WARNING

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.

DANGER

Means immediate hazards which, if

!

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 identica­tion 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

not avoided, will result in immediate,
serious personal injury or loss of life.

http://www.esab.eu

0-5428 INTRODUCTION

2-1

CUTMASTER A60

43 lb / 19.5 kg

t # A-08305

150 mm

2.04 PowerSupplySpecications

CutmasterA60PowerSupplySpecications

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

230 VAC (187 - 253 VAC), 3 Phase, 50/60 Hz

380 VAC (360 - 440 VAC), 3 Phase, 50/60 Hz

Input Power

Input Power Cable

Output Current 20 - 80 Amps, Continuously Adjustable

Power Supply Gas Filtering

Ability

Cutmaster A60 Power Supply Duty Cycle *

400 VAC (360 - 440 VAC), 3 Phase, 50/60 Hz

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

460 VAC (414 - 506 VAC), 3 Phase, 60 Hz

600 VAC (540 - 630), 3 Phase, 60 Hz

Power Supply includes input cable. Cable for 208/230V

input power includes molded plug.

Particulates to 5 Microns

Ambient Temperature

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

IEC Rating

Duty Cycle 40% 60% 100%

All Units

Current

DC Voltage

80 Amps 65 Amps 50 Amps

112 106 100

* 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 fa-

cilitate comparison between power supplies, all manufacturers use this output voltage to determine
duty cycle.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

10"

254 mm

Ar

Art # A-07925_AB

13.78"

350 mm

150 mm

24"

610 mm

20.8"

0.528 m

INTRODUCTION 0-5428

2-2

6"

150 mm

6"

6"

2.05 InputWiringSpecications

Cutmaster A60 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Volts Hz kVA I max I eff Fuse (amps)

208 60 16 75 48 100 6

CUTMASTER A60

Flexible Cord

(Min. AWG)

1 Phase

3 Phase

230 60 17 72 46 100 6

460 60 20 44 28 50 10

208 60 16 40 26 50 8

230 50/60 16 39 25 50 10

380 50/60 11.8 17 11 20 12

400 50/60 11.8 17 11 20 12

460 60 17 21 14 25 12

600 60 9.6 16 10 20 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTE!

Refer to Local and National Codes or local authority having jurisdiction for proper wiring require­ments.
Cable size is de-rated based on the Duty Cycle of the equipment.

0-5428 INTRODUCTION

2-3

CUTMASTER A60

Mounting Rail

ork Cable

and Clamp

Input Power Cord

Automation Interface

Input

2.06 Power Supply Features

Art # A-08306

Power Selection

Filter Assembly

Control Panel

Torch Leads
Receptacle

s

W

Cable Port

Gas Inlet Port

Art # A-08318

INTRODUCTION 0-5428

2-4

CUTMASTER A60

44.5 mm

18.875" / 479 mm

16 mm

1.175" / 30 mm

2.875”
73 mm

t # A-02998

15.875" / 403 mm

16 mm

(95 mm)

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 prop-

erly trained personnel; unqualied 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 ows through the small orice 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 ow is divided inside the torch head. Single - gas

operation provides a smaller sized torch and inexpensive
operation.

2T.03 Specications

A. TorchCongurations

1. Automation Torch, Model

The standard automation torch has a position­ing tube with rack & pinch block assembly and a
solenoid valve.

/

1.75" /

0.625" /

2. Machine Torch, Model

The standard machine torch has a positioning tube

with rack & pinch block assembly.

1.375" / 35 mm

1.75" /

44.5 mm

0.625" /

3. 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.

12.285" / 312 mm

1.375" / 35 mm

4.95" / 126 mm

Art # A-07402_AC

9.285" / 236 mm

1.175" / 30 mm

4.95" / 126 mm

Ar

10.125" (257 mm)

NOTE!

Refer to Section "2T.05 Introduction

to Plasma" on page 2T-2, for a more
detailed description of plasma torch
operation.
Refer to the Appendix Pages for ad-

ditional specications as related to the

Power Supply used.

0-5428 INTRODUCTION

3.75"

Art # A-03322_AB

1.17" (29 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 / Automation Torches are available as fol-

lows:

• 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

2T-1

CUTMASTER A60

!

C

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

H. Direct Contact Hazard

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

2T.04 Options And Accessories

12 VDC circuit rating

E. Type Cooling

Combination of ambient air and gas stream through
torch.

F. Torch Ratings

Automated / Machine Torch Ratings

Ambient

Temperature

Duty Cycle 100% @ 100 Amps @ 400 scfh

Maximum Current 120 Amps

Voltage (V

Arc Striking Voltage 7kV

Ambient

Temperature

Duty Cycle 100% @ 60 Amps @ 400 scfh

Maximum Current 60 Amps

Voltage (V

Arc Striking Voltage 7kV

) 500V

peak

Manual Torch Ratings

) 500V

peak

104° F

40° C

104° F

40° C

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.

G. Gas Requirements

Automated, Manual and Machine Torch Gas

Specications

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and

Gouging)

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh

142 - 235 lpm

WARNING

This torch is not to be used with oxygen

(O2).

NOTE!

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

_

A

Power

Supply

+

B

Workpiece

A-08331

Typical Torch Head Detail

By forcing the plasma gas and electric arc through a

small orice, the torch delivers a high concentration

INTRODUCTION 0-5428

2T-2

of heat to a small area. The stiff, constricted plasma

up

To

up

up

Remote Pendant

To

A-02997

r

arc is shown in Zone C. Direct current (DC) straight

polarity is used for plasma cutting, as shown in the
illustration.

CUTMASTER A60

nected to the workpiece via the work cable and to
the torch through a pilot wire.

E. Parts - In - Place (PIP)

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.

B. Gas Distribution

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

The plasma gas ows into the torch through the

negative lead, through the starter cartridge, around

the electrode, and out through the tip orice.

The secondary gas ows 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

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.

AT C

AT C

PIP Sw itch

CNC Start

PIP Sw itch

Sh ield C

Sh ield C

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 con-

Art # A-08168

Automation To rch

To AT C

PIP Sw itch

Sh ield C

Parts - In - Place Circuit Diagram for Machine Torch

To Control

Torch Switch

Cable Wiring

PIP Switch

Torch Trigge

Shield Cup

Parts - In - Place Circuit Diagram for Hand Torch

0-5428 INTRODUCTION

2T-3

CUTMASTER A60

This Page Intentionally Blank

INTRODUCTION 0-5428

2T-4

SECTION 3 SYSTEM:

!

INSTALLATION

CUTMASTER A60

2. Place the unit in the desired position and mark
where the four keyway holes in the mounting rails

touch.

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 hand holds in the front and
rear panels for hand lifting only. Be sure unit is lifted
and transported safely and securely.

WARNING

Do not touch live electrical parts.
Disconnect input power cord before
moving unit.
FALLING EQUIPMENT can cause
serious personal injury and can damage
equipment.

3. Remove the unit and using these markings,
prepare holes for mounting hardware.

4. Insert proper hardware. If using hardware that

screws into the mounting surface, leave all four
loose enough for the thickness of the rail to slide
under the head and washer if used.

5. Lower the power supply over the mounting

hardware and slide forward or backward until the
keyway stops against the mounting hardware.

6. Secure the hardware to the rail.

3.04 Opening the Contactor Cover

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

• 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 Power Supply location and
Mounting

NOTE!

It is recommended that the unit be
secured to a suitable surface using the
mounting rails.

1. First choose an appropriate location for mount­ing the power supply. Choose one that allows
for free movement of torch leads, complies with

ventilation per Section 2.04 and provides a safe
rm surface where the unit can be secured.

1

2

1

2

Art# A-11478

Contactor cover

0-5428 INSTALLATION

3-1

CUTMASTER A60

Screws

Art # A-08316

Art # A-07984_AB

Art # A-07983_AB

3.05 Primary Input Power Connections

CAUTION

!

Most units are shipped from the factory with a 230 Volt
input power cable wired to the input contactor in the

single - phase conguration. The following illustrations
and directions are for changing that conguration to a

different voltage and or to three - phase operation or back
again if a change had already been made.

A. Cover Removal

Check your power source for correct
voltage before plugging in or connecting
the unit. Check the Voltage Selector at
the rear of the unit for correct setting be­fore plugging in or connecting the unit.
The primary power source, fuse, and
any extension cords used must conform
to local electrical code and the recom­mended circuit protection and wiring

requirements as specied in Section 2.

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

B. Cover Installation

1. Reverse previous procedures for cover installa­tion.

NOTE!

When installing the upper screws, at­tempt to reuse the original threads. The
easiest way to do this is by turning the
screw counter-clockwise until you feel
the threads line up, then begin to turn
the screw clockwise to tighten. Do not

over tighten.

C. Input Power Selection

Set the Input Voltage Selection Switch at the rear of the
unit based on the primary input voltage it is connected

to. Low is 208/230 VAC and high is 460 VAC.

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.

NOTE!

The upper screws and lower screws
are not the same. Do not mix them.
The upper screws are for threading into
the plastic of the front and rear panels.

DO NOT use the ner threaded lower

screws for this.

Upper
Screws

Lower

Slots

Lower
Screws

LO

HI

S

D. Quick Guide to Phase Wiring

Single-Phase (1ø) and Jumper Settings

L1

L2

L3
L4

GND

Single Phase Input Power Wiring

Three-Phase (3ø) and Jumper Settings

Store copper jumper in spare parts box

L1

L2

L3
L4

GND

L1

L2

L3

L4

L1

L2

L3

L4

Jumper L1 -L4

Jumper
L2-L3

Jumper L1 -L4

Three Phase Input Power Wiring

Art # A-08317

INSTALLATION 0-5428

3-2

NOTE!

!

There is only one jumper setting that
changes between the single and three
phase settings. To change from single
phase to three phase, the copper bus
bar jumper connected to L2 and L3
needs to be removed and placed in a
safe place for re-use. We suggest the
spare parts box in the power supply.
See previous illustrations.

E. Connections to Single Phase Input Power

WARNING

!

These instructions are for changing the input power and

or cable on the 208/230, 400, 460 VAC Power Supply to

Single - Phase input power.

1. Remove the Power Supply cover. See "A.

2. Disconnect the original input power cable from

3. Loosen the through - hole protector on the back

4. If the power cable being used is not the factory

5. Pass the cable being used through the access

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

Cover Removal".

the main input contactor and the chassis ground
connection.

panel of the power supply. Pull the original power
cable out of the power supply.

- supplied cable, use a three - conductor input
power cable for the voltage desired and strip back
the insulation on the individual wires.

opening in the back panel of the power supply.
Refer to Section "2.04 Power Supply Speci­cations" for power cable specications.

CAUTION

!

6. Connect the wires as follows.

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

The primary power source and power
cable must conform to local electrical
code and the recommended circuit pro-

tection and wiring requirements (refer to

table in Section 2).

• Set Jumper wire and copper bus bar / jumper
on the contactor. See previous illustrations.

• Green / Yellow wire to Ground.

• Remaining wires to L1 and L2 input. It does
not matter what order these wires are at­tached.

- hole protector to secure the power cable.

CUTMASTER A60

8. Reinstall the Power Supply cover. See "B.
Cover Installation".

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.

F. Connections to Three Phase Input Power

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 208/230, 400, 460 VAC Power Supply to

Three - Phase input power.

1. Remove the Power Supply cover. See "A.
Cover Removal".

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 "2.04 Power Supply Speci­cations" for power cable specications.

CAUTION

!

6. Connect the wires as follows.

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

8. Reinstall the Power Supply cover. See "B.

The primary power source and power
cable must conform to local electrical
code and the recommended circuit pro-

tection and wiring requirements (refer to

table in Section 2).

• Remove the copper bus bar jumper from L2

and L3 on the contactor. See previous illustra­tion.

• Green / Yellow wire to Ground.

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

does not matter what order these wires are
attached. See the previous illustrations.

- hole protector to secure the power cable.

Cover Installation".

0-5428 INSTALLATION

3-3

CUTMASTER A60

rt

Filter Assembly

Gas Supply
Hose

to 1/4” (6mm) Fitting

Art # A-08319

Hose Clam

rt

Filter Assembly

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.

3.06 Gas Connections

Connecting Gas Supply to Unit

The connection is the same for compressed air or high
pressure cylinders. Refer to the following subsections

if an optional air line lter is to be installed.

1. Connect the air line to the inlet port. The illustra-

tion shows typical ttings as an example.

3. Connect the air line to the Filter. The illustration

shows typical ttings as an example.

NOTE!

For a secure seal, apply thread seal-

ant to the tting threads, according

to the manufacturer's instructions.

Do Not use Teon tape as a thread

sealer, as small particles of the tape
may break off and block the small air
passages in the torch. Connect as
follows:

Hose Clamp

Art # A-08320

NOTE!

For a secure seal, apply thread seal-

ant to the tting threads, according

to the manufacturer's instructions.

Do Not use Teon tape as a thread

sealer, as small particles of the tape
may break off and block the small air
passages in the torch.

Inlet Po

1/4 NPT or ISO-R

Inlet Po

p

Gas Supply
Hose

1/4 NPT to 1/4"

(6mm) Fitting

Optional Single - Stage Filter Installation

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s specications for

installation and maintenance procedures for high
pressure regulators.

Air Connection to Inlet Port

Installing Optional Single - Stage Air Filter

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

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

Port.

2. Attach the Filter Assembly to the lter hose.

INSTALLATION 0-5428

3-4

2. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign mate-

rial. Briey 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
ows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the cylinder.

CUTMASTER A60

Regulator/Filter

wo Stage

Art # A-07945_AC

Hose Clamp

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 off and block the small air
passages in the torch.

Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line lter 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 lter 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 off and block the small air
passages in the torch.

2. Connect the two stage lter outlet hose to the

inlet port of the Regulator / Filter Assembly.

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

Assembly

Regulator
Input

Gas Supply
Hose

1/4 NPT to 1/4”
(6mm) Fitting

2-Stage Filter
Inlet Port (IN)

Outlet Port
(OUT)

T
Filter
Assembly

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 specications 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 mate-

rial. Briey 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
ows 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 off and block the small air
passages in the torch.

0-5428 INSTALLATION

3-5

CUTMASTER A60

This Page Intentionally Blank

INSTALLATION 0-5428

3-6

CUTMASTER A60

Automation Interface
Cab

Art # A-08322

Art # A-08323_AB

Plasma

Divided

oltage

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Supply.
Connect only the ESAB model SL100SV / Automation,

SL100 / Mechanical or SL60 / Manual 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. Put the ON / OFF switch in the ON (up)
position.

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

3. Place a welding lter lens in front of the torch and

turn ON the air. Do not start an arc!

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

3T.02 CNC Connection

1. Locate the interface connection port on the rear
of the power supply.

le Port

Check Air Quality

To test the quality of air:

2

1

Art # A-07885

Connecting the Torch to the Power Supply

3. The system is now ready for operation.

2. Note the pin-out of the connector and that the
customer supplied connector matches.

Start / Stop
Signal

Arc
V

Cutting Machine
OK to Move

0-5428 INSTALLATION

3T-1

CUTMASTER A60

GND

-12V

3T.03 Automation Interface PCB with Ohmic Sense

The new Automation Interface PCB with Ohmic Sense adds additional selectable divided voltage ratios and

selectable polarity of the divided signal. The board also has Ohmic sensing for use with the iHC XT via ei­ther the exposed torch tip or via a separate connection to the torch tip. The ohmic sensing will also provide

collision sensing when used with the iHC XT or iCNC.

Signals at the CNC connector (J1 on this board) are START / STOP on J1-3 (common) and J1-4 (+); Isolated

& Divided Arc voltage on J1-5 (-) and J1-6 (+); PLATE CONTACT OUT (relay contact) between J1-10 and
J1-11; OK TO MOVE OUT (relay contact) between J1-12 and J1-14.

Voltage divider;

The 6 position DIP switch, DIV1, makes available the following divide ratios:

DIV1-1 ON = 16.7:1 for SC11; DIV1-2 ON = 20:1 for EASB; DIV1-3 ON = 30:1;

DIV1-4 ON = 40:1 for Inova; DIV1-5 ON = 50:1 for IHT, SC3000 & 3100; Hypertherm®;

DIV1-6 ON = 80:1 for TD iHC

NOTE!

Only one position should be on at a time.

Divided arc voltage signal is isolated, either the positive signal (J1-6) or negative (J1-5) may be grounded

or both can be oating.

Ohmic sensing and Collision via exposed TIP:

With a connection made from the PCB4 terminal TIP to the main board PCB1 terminal TIP1 contact of the

exposed tip with the work while nding height is sensed and activates the signal PLATE CONTACT OUT at

J1-11. SW2 set to 0 can disable this sensing.

During cutting the exposed tip contacting the work will close the relay contact between J1-10 and J1-11

which is interpreted by the iHC as a collision. This feature may be disabled by setting SW3 to 0.

NOTE!

If TIP1 on PCB1 (main board) is not connected to TIP terminal on PCB4 both SW2 and SW3 must
be set to “0” (off) position else the plate contact signal will be active all the time.

Ohmic sensing and Collision via shield cup Ohmic Clip.

The Plasma Adapter Cable for use with the iHC XT for this Automation Interface PCB with Ohmic Sense

includes a connection to pin 13 which can be connected to a wire from the ohmic clip. Note that this adapter

cable is different from the one used with the separate iHC voltage divider board. When the shield cup, with
contact from the ohmic clip, contacts work during height nding it closes the relay between J1-10 and J1-11
providing the PLATE CONTACT signal to the iHC. During cutting the iHC interrupts this contact as a collision

and retracts the torch.

Indicators:

LED indicators START, M-ARC and CONTACT are provided to show when START (torch trigger) is ON,

when OK to Move (M-ARC) is on, and when Plate Contact is active.

Rating:

The OK to Move and the Plate Contact Out are relay contacts rated for maximum of 30VAC or DC at 1 amp

maximum.

Start SW input requires a switch or relay contact rated for at least 12VDC at 3 ma.

START

INSTALLATION 0-5428

3T-2

J1-3

J1-4

3k

CUTMASTER A60

)

DIVIDE RATIO SET BY DIP SW DIV1

DIV1-1 ON = 16.7:1 for SC11
DIV1-2 ON = 20:1 for ESAB
DIV1-3 ON = 30:1

To -V OUT 1
on PCB1

P10

1

2

3

4

5

6

7

8

To TIP1
on PCB1

J2

*

1

2

3

4

5

6

7

8

-V0_1

+12V

START / STOP

TIP

1

1

CONTACT

VOLTAGE
DIVIDER
CIRCUITS

OK TO MOVE

DIV1-4 ON = 40:1 for Inova
DIV1-5 ON = 50:1 for IHT:

DIV1-6 ON = 80:1 for TD iHC

DIV1

123456

ISO GND

-

+

SW1

PCB4

AUTOMATION
INTERFACE PCB
(w / OHMIC)

OHMIC
SENSE
CIRCUITS

M-ARC

OK to MOVE

ISO GND

START

SC3000 & 3100; Hypertherm

J1

1

2

START / STOP (com)

3

START / STOP

4

DIVIDED ARC VOLTAGE (-)

5

DIVIDED ARC VOLTAGE (+

6

7

COMMON

8

9

PLATE CONTACT COM

CONTACT

OK TO MOVE

10

PLATE CONTACT OUT

11

OK TO MOVE

12

13

OK TO MOVE

14

Art # A-09819_AC

OHMIC

®

3. Connect CNC to the power supply.

3T.04 Setting Up Automation or Machine Torch

NOTE!

An adapter is required to be installed in
the power supply if converting a hand
torch system to operate a machine or
automation torch.

The Automation and Machine torch include 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.

WARNING

Disconnect primary power at the source
before disassembling the torch or torch
leads.

0-5428 INSTALLATION

3T-3

CUTMASTER A60

Wo

rkpiece

Automated and Machine Torch Set - Up

Pinch Block
Assembly

Square

A-02585

3. The proper torch parts (shield cup, tip, start car­tridge, and electrode) must be installed for the

type of operation. Refer to Section 4T.08, Torch

Parts Selection for details.

INSTALLATION 0-5428

3T-4

CUTMASTER A60

+

12

3

5

6

7

9

10

Art # A-08170

SECTION 4 SYSTEM:

OPERATION

4.01 Front Panel Controls / Features

SeeIllustrationfornumberingIdentication

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

4

MAX

MIN

A

PSI BAR

MAXMAX

MINMIN

!

+

Art# A-07886

8

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 sufcient

for torch operation.

8. DC Indicator

Indicator is ON when DC output circuit is active.

9. ! Fault Error Indicator

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

4. Air/Gas Pressure Control

The Pressure
"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.

0-5428 OPERATION

Control is used in the

Indicator is ON when Fault circuit is active. See Sec-

tion 5 for explanations of fault lights.

10. Pressure Indicators

PSI BAR

MAX MAX

90 6.3

85 5.9

80

75

70

65

MINMIN

5.5

5.2

4.8

4.5

The Indicators will illuminate according to the pres-

sure set by the Pressure Control Knob (number 4).

4-1

CUTMASTER A60

Art # A-04509

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 (80 amps maximum). Refer to

Section "4T.03 Machine and Hand Torch Parts
Selection".

Torch Connection

Check that the torch is properly connected. Only

ESAB model SL60 / Manual, SL100 / Mechanical or

SL100 / SV Automation Torches may be connected
to this Power Supply. See Section 3T of this manual.

Check Primary Input Power Source

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

NOTE!

Minimum pressure for power supply op­eration is lower than minimum for torch
operation.
The cooling fans will turn ON as soon
as the unit is turned ON. After the unit

is idle for ten (10) minutes the fans will

turn OFF. The fans will come back ON
as soon as the torch switch (Start Sig­nal) is activated or if the unit is turned
OFF, then turned ON again. If an over
temperature condition occurs, the fans
will continue to run while the condition

exists and for a ten (10) minute period

once the condition is cleared.

Set Operating Pressure

1. Place the Power Supply Function Control knob

to the SET position. Gas will ow.

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, Specications.

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.

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 on the next
page for pressure setting details.

Power ON

Place the Power Supply ON / OFF switch to the
ON (up) position. AC indicator turns ON.

OPERATION 0-5428

4-2