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

CUTMASTER A60

1

2

Art# A-07946

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

Cutting Operation

MIN

MAX

A

PSI BAR

MAXMAX

+

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 work-

MINMIN

piece 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.

STANDOFF

Cutmaster A60 Gas Pressure Settings

Leads Length

SL60

(Hand Torch)

(Mechanized Torch)

(Automation Torch)

Up to 25'

(7.6 m)

Each additional

25' (7.6 m)

75 psi

5.2 bar

Add 5 psi

0.4 bar

SL100

SL 100 SV

75 psi

5.2 bar

Add 5 psi

0.4 bar

Typical Cutting Speeds

Cutting speeds vary according to torch output am­perage, the type of material being cut, and operator
skill. Refer to Sections "4T.08 Recommended
Cutting Speeds for Machine and Automated Torches
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.

Postow

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

Release the trigger to stop the cutting arc. Gas con-

tinues to ow for approximately 20 seconds. During
post - ow, if the user moves the trigger release to

the rear and presses the trigger, the pilot arc starts.
The main arc transfers to the workpiece if the torch
tip is within transfer distance to the workpiece.

Cutmaster A60 Gas Pressure Settings

Leads Length

Up to 25'

(7.6 m)

Each additional 25'

(7.6 m)

SL60

(Hand Torch)

80 psi

5.5 bar

Add 5 psi

0.4 bar

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.

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 ow stops.

0-5428 OPERATION

4-3

CUTMASTER A60

This Page Intentionally Blank

OPERATION 0-5428

4-4

SECTION 4 TORCH:

Standoff Distance

OPERATION

4T.01 Machine and Automated Torch

Operation

Cutting With Machine or Automated Torch

These torches are 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.

CUTMASTER A60

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 or Automated Torch

Travel Speed

Proper travel speed is indicated by the trail of the
arc which is seen below the plate. The arc can be
one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiece
surface. This arc is generally recommended
for the best cut using air plasma on stainless or
aluminum.

2. Leading Arc

The leading arc is directed in the same direction
as torch travel. A ve degree leading arc is gen­erally recommended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direc­tion as torch travel.

Direction of Torch Travel

To pierce, 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.

4T.02 Automation Torch Parts Selection

Check the torch for proper consumable parts. The
parts supplied in the torch may not be correct for
the operator’s chosen amperage level or operation

type. Use Deector in mechanized applications that

do not require “Ohmic-Touch” initial height sensing.
Use Shield Cap and Ohmic Clip in mechanized ap­plications that require “Ohmic-Touch” initial height
sensing. The torch parts must correspond with the
type of operation.

Straight Arc

A-02586

Automation and Machine Torch Operation

0-5428 OPERATION

Trailing Arc

Leading Arc

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter Cartridge

NOTE!

Refer to Sections "4T.02 Automation

Torch Parts Selection" and following for
additional information on torch parts.

Change the torch parts for a different operation as fol­lows:

4T-1

CUTMASTER A60

Deflector

A-03510_AB

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. If attached, remove the ohmic clip then unscrew
and remove the shield cup assembly from the
torch head. Wipe it clean or replace if damaged

2. Remove the Electrode by pulling it straight out

of the Torch Head.

Torch Head

Electrode

Start Cartridge

Tip

Art # A-04173_AB

4T.03 Machine and Hand 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.03 Machine and
Hand Torch Parts Selection" and follow-

ing 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.

Ohmic Clip
(If installed)

Shield Cup Body

Shield Cap

Automation Torch Parts

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

6. If used, attach the ohmic clip to the shield cup.

NOTE!

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

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

2. Remove the Electrode by pulling it straight out

of the Torch Head.

Torch Head

Electrode

Start Cartridge

Tip

OPERATION 0-5428

4T-2

Shield Cup

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

Kerf Width

Drag Lines

!

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.04 Cut Quality

CUTMASTER A60

Top - Edge Rounding

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

Bottom Dross Buildup

Molten material which is not blown out of the cut area

and resolidies 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).

NOTE!

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

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

illustrated in the following gure:

Cut Surface
Bevel Angle

Top

Spatter

Top Edge

Rounding

Dross

Build-Up

Cut Surface

A-00007

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 orice has become elongated.

4T.05 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.

Cut Quality Characteristics

Cut Surface

The desired or specied 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 difculties 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.

0-5428 OPERATION

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 signicantly affect

the bevel angle. Reducing standoff will generally
result in a more square cut.

4T-3

CUTMASTER A60

Left Side

A-00512

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

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.

Cut Angle

Right Side

Cut Angle

4T.06 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:

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 difcult 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.

a. For edge starts, hold the torch perpendicular

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

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

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

below.

Torch

Shield Cup

Standoff Distance

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.

OPERATION 0-5428

4T-4

CUTMASTER A60

t # A-03383

Tr igger

Art # A-04034

A-03539

Trigger

Trigger Release

A-02986

5. Bring the torch within transfer distance to the

work. The main arc will transfer to the work, and
the pilot arc will shut OFF.

NOTE!

The gas preow and postow are a

characteristic of the power supply and
not a function of the torch.

1

2

Tr igger Release

3

Shield Cup

Standoff Guide

Torch Tip

Workpiece

Shield Cup With Straight Edge

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

WARNING

The straight edge must be non - con­ductive.

Non-Conductive

Straight Edge

Cutting Guide

4

Ar

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.

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.

4. Keep the torch in contact with the workpiece

during the cutting cycle.

0-5428 OPERATION

4T-5

CUTMASTER A60

t # A-03383

Tr igger

5. Hold the torch away from your body.

Piercing With Hand Torch

6. Slide the trigger release toward the back of the

torch handle while simultaneously squeezing the
trigger. The pilot arc will start.

Trigger

Trigger Release

A-02986

7. Bring the torch within transfer distance to the

work. The main arc will transfer to the work, and
the pilot arc will shut OFF.

NOTE!

The gas preow and postow are a

characteristic of the power supply and
not a function of the torch.

1

2

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 par-

ticles 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.

Tr igger Release

Trigger

3

Trigger Release

A-02986

4

6. Bring the torch within transfer distance to the

Ar

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

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

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 in-

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.

7. Clean spatter and scale from the shield cup and

stalled, 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.

the tip as soon as possible. Spraying the shield
cup in anti - spatter compound will minimize the
amount of scale which adheres to it.

OPERATION 0-5428

4T-6

Cutting speed depends on material, thickness, and the

!

35°

A-00941_AB

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

4T.07 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.

CUTMASTER A60

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.

Torch Head

Standoff Height

Workpiece

CAUTION

!

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 dis-

tance between the torch tip and workpiece (standoff).

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.03 Machine and
Hand Torch Parts Selection".

CAUTION

!

Torch Travel Speed

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

NOTE!

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

Optimum torch travel speed is dependent on current

setting, lead angle, and mode of operation (hand or

machine torch).

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.

0-5428 OPERATION

4T-7

CUTMASTER A60

4T.08 Recommended Cutting Speeds for Machine and Automated Torches With

Exposed Tip

Mild Steel
40A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

20 0.036

16 0.060 103 0.14 140 0.18 0.0 0.05

14 0.075 105 0.14 120 0.18 0.1 0.06

12 0.105 108 0.14 80 0.18 0.2 0.06

10 0.135 110 0.14 60 0.18 0.3 0.06

3/16 0.188 111 0.14 55 0.18 0.4 0.06

1/4 0.250 117 0.14 40 0.18 0.5 0.07

3/8 0.375 119 0.14 25 0.18 1.2 0.07

1/2 0.500 120 0.14 15 0.2 2.0 0.07

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

70 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Tip

9-8208

Torch

Working

Height

101 0.14 160 0.18 0.0 0.05

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-8

CUTMASTER A60

Material

Thickness

(mm)

1

2 105 3.6 2920 4.6 0.1 1.4

3 109 3.6 1810 4.6 0.3 1.5

4 110 3.6 1470 4.6 0.3 1.6

5 112 3.6 1345 4.6 0.4 1.6

6 116 3.6 1100 4.6 0.5 1.7

8 118 3.6 815 4.6 1.0 1.7

10 119 3.6 595 4.6 1.5 1.8

12 120 3.6 435 5.1 2.0 1.8

Gas Pressure

(Air)

Bar

(torch lead

length)

4.8 (7.6m)

5.2 (15.2m)

BOLD TYPE indicates maximum piercing parameters.

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

101 3.6 3990 4.6 0.0 1.1

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-9

CUTMASTER A60

Stainless Steel
40A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

18 0.050

16 0.063 100 0.19 50 0.20 0.00 0.07

14 0.078 105 0.19 45 0.20 0.10 0.07

12 0.109 110 0.19 40 0.20 0.20 0.07

10 0.141 108 0.19 35 0.20 0.30 0.07

3/16 0.188 11 0 0.19 30 0.20 0.40 0.07

1/4 0.250 120 0.19 18 0.20 0.50 0.08

3/8 0.375 126 0.19 10 0.20 2.00 0.08

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.19 60 0.20 0.00 0.07

Tip

9-8208

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

1/2 0.500 118 0.19 8 Edge start 0.09

OPERATION 0-5428

4T-10

CUTMASTER A60

Material

Thickness

(mm)

1

2 105 4.8 1140 5.1 0.1 1.8

3 109 4.8 980 5.1 0.2 1.8

4 109 4.8 845 5.1 0.3 1.8

5 111 4.8 715 5.1 0.4 1.8

6 118 4.8 525 5.1 0.5 2.0

8 123 4.8 350 5.1 1.5 2.0

10 125 4.8 245 5.1 2.0 2.0

12 120 4.8 215 Edge Start 2.2

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.5 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

112 4.8 1670 4.8 0.0 1.7

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-11

CUTMASTER A60

Aluminum
40A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

20 0.040

16 0.063 97 0.16 170 0.16 0.0 0.06

12 0.097 113 0.16 100 0.16 0.2 0.07

11 0.125 115 0.16 90 0.18 0.3 0.07

9 0.160 113 0.18 85 0.18 0.4 0.07

3/16 0.188 11 6 0.18 75 0.18 0.5 0.07

1/4 0.250 128 0.18 30 0.18 1.0 0.08

3/8 0.375 150 0.18 10 Edge Start 0.09

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

70 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Tip

9-8208

Torch

Working

Height

95 0.16 300 0.16 0.0 0.06

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-12

CUTMASTER A60

Material

Thickness

(mm)

1.0

2.0 104 4.1 3500 4.1 0.2

3.0 115 4.1 2350 4.6 0.3

4.0 113 4.6 2170 4.6 0.4

5.0 118 4.6 1740 4.6 0.5

6.0 125 4.6 1015 4.6 0.8

8.0 139 4.6 500 Edge Start

10.0 153 4.6 180 Edge Start

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

4.8 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

95 4.1 7620 4.1 0.0

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

1.5

1.6

1.7

1.7

1.8

1.9

2.0

2.2

0-5428 OPERATION

4T-13

CUTMASTER A60

Mild Steel
60A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.060

14 0.075 120 0.19 285 0.19 0.10 0.08

11 0.120 118 0.19 180 0.19 0.10 0.08

10 0.135 119 0.19 176 0.19 0.10 0.07

3/16 0.188 121 0.19 100 0.19 0.20 0.08

1/4 0.250 122 0.19 80 0.19 0.30 0.08

3/8 0.375 124 0.19 50 0.19 0.50 0.09

1/2 0.500 132 0.19 26 0.19 0.75 0.10

5/8 0.625 135 0.19 19 Edge Start 0.10

3/4 0.750 136 0.19 14 Edge Start 0.08

1 1.000 150 0.19 6 Edge Start 0.11

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Tip

9-8210

Torch

Working

Height

118 0.19 290 0.19 0.00 0.08

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-14

CUTMASTER A60

Material

Thickness

(mm)

1

2 120 4.8 7015 4.0 0.10 1.9

3 11 8 4.8 4570 4.8 0.10 2.1

4 120 4.8 3650 4.8 0.20 1.9

5 121 4.8 2465 4.8 0.20 2.1

6 122 4.8 2145 4.8 0.30 2.0

8 123 4.8 1635 4.8 0.40 2.2

10 125 4.8 1180 4.8 0.60 2.4

12 130 4.8 795 4.8 0.75 2.4

15 134 4.8 530 Edge Start 2.4

20 138 4.8 325 Edge Start 2.2

25 149 4.8 165 Edge Start 2.7

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

115 4.8 7540 4.8 0 2.1

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-15

CUTMASTER A60

Stainless Steel
60A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.063

14 0.078 116 0.19 300 0.20 0.10 0.07

11 0.125 123 0.19 150 0.20 0.10 0.07

10 0.141 118 0.19 125 0.20 0.10 0.08

3/16 0.188 122 0.19 90 0.20 0.20 0.08

1/4 0.250 123 0.19 65 0.20 0.30 0.09

3/8 0.375 130 0.19 30 0.20 0.50 0.09

1/2 0.500 132 0.19 21 0.20 0.90 0.08

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Tip

9-8210

Torch

Working

Height

119 0.19 350 0.20 0.00 0.05

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

5/8 0.625 132 0.19 14 Edge Start 0.11

3/4 0.750 135 0.19 10 Edge Start 0.10

OPERATION 0-5428

4T-16

CUTMASTER A60

Material

Thickness

(mm)

1

2 11 6 4.8 7560 5.1 0.10 1.7

3 122 4.8 4365 5.1 0.10 1.7

4 11 9 4.8 2865 5.1 0.20 2.1

5 122 4.8 2195 5.1 0.20 2.1

6 123 4.8 1790 5.1 0.30 2.2

8 127 4.8 1190 5.1 0.40 2.2

10 130 4.8 725 5.1 0.50 2.2

12 132 4.8 580 5.1 0.90 2.1

15 132 4.8 405 Edge Start 2.6

20

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

124 4.8 10890 5.1 0.00 0.8

136 4.8 230 Edge Start 2.5

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-17

CUTMASTER A60

Aluminum
60A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.064

14 0.079 126 0.25 300 0.25 0.10 0.09

11 0.120 128 0.25 250 0.25 0.10 0.09

3/16 0.188 132 0.25 170 0.25 0.20 0.09

1/4 0.250 132 0.25 85 0.25 0.30 0.09

3/8 0.375 141 0.25 45 0.25 0.50 0.10

1/2 0.500 148 0.25 30 0.25 0.80 0.09

5/8 0.625 145 0.19 18 Edge Start 0.08

3/4 0.750 147 0.19 12 Edge Start 0.10

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

123 0.25 440 0.25 0.00 0.08

Tip

9-8210

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-18

CUTMASTER A60

Material

Thickness

(mm)

1

2 126 6.4 7680 6.4 0.10

3 128 6.4 6410 6.4 0.10

4 130 6.4 5230 6.4 0.20

5 132 6.4 4010 6.4 0.20

6 132 6.4 2640 6.4 0.30

8 137 6.4 1630 6.4 0.40

10 142 6.4 1085 6.4 0.60

12 146 6.4 845 6.4 0.70

15 146 4.8 540 Edge Start 2.1

20 148 4.8 260 Edge Start 2.5

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

118 6.4 17010 6.4 0.00

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

1.8

2.3

2.3

2.3

2.4

2.4

2.4

2.4

2.3

0-5428 OPERATION

4T-19

CUTMASTER A60

Mild Steel
80A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.060

11 0.120

10 0.135

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

7/8 0.875

1 1.000

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

125 0.19 42 0.20

123 0.19 40 0.20

133 0.19 18 0.20

Starter Cartridge

Tip

Heavy Duty Starter

Cartridge

9-8211

Torch

Working

Height

110 0.19 320 0.20

113 0.19 230 0.20

110 0.19 180 0.20

110 0.19 136 0.20

115 0.19 100 0.20

140 0.25 18 Edge Start

150 0.25 10 Edge Start

152 0.25 8 Edge Start

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

0.00

0.10

0.20

0.30

0.40

0.50

0.60 0.09

0.75 0.10

0.06

0.07

0.07

0.07

0.09

0.09

0.11

0.11

0.13

OPERATION 0-5428

4T-20

CUTMASTER A60

Material

Thickness

(mm)

1

2 111 4.8 7415 5.1 0.10 1.7

3 11 3

4 11 0 4.8 4095 5.1 0.30 1.7

5 111

6 11 4

8 120

10 125

12 123

15 130

20 143

25 152

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

109 4.8 8915 5.1 0.00 1.5

Torch

Working

Height

4.8

4.8

4.8

4.8

4.8

4.8

4.8

6.4

6.4

Travel Speed

5915

3325

2745

1775

1060

1025

610

395 Edge Start 2.7

210 Edge Start 3.2

Initial

Piercing

Height

5.1

5.1

5.1

5.1

5.1

5.1

5.1

Pierce Delay

0.10 1.8

0.30 1.8

0.40 2.2

0.50 2.3

0.50 2.3

0.60 2.3

0.75 2.5

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-21

CUTMASTER A60

Stainless Steel
80A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.063

11 0.125

10 0.141

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4

0.750

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

124 0.19 26 0.25 0.80 0.10

133 0.19 16 Edge Start 0.10

136 0.19 10 Edge Start 0.11

Starter Cartridge

Tip

Heavy Duty Starter

Cartridge

9-8211

Torch

Working

Height

110 0.19 340 0.25 0.00

115 .0.19 300 0.25 0.10

115 0.19 280 0.25 0.10

115 0.19 140 0.25 0.20

118 0.19 100 0.25 0.30

119 0.19 45 0.25 0.40

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

0.06

0.06

0.06

0.07

0.08

0.08

OPERATION 0-5428

4T-22

CUTMASTER A60

Material

Thickness

(mm)

1

2 111 4.8 8380 6.4 0.00 1.5

3

4 11 5 4.8 5865 6.4 0.20 1.6

5

6

8

10

12

15

20 137 4.8 205 Edge Start 3.0

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

108 4.8 9020 6.4 0.00 1.5

114 4.8 7730 6.4 0.10 1.5

115 4.8 3410 6.4 0.20 1.8

117 4.8 2765 6.4 0.30 1.9

119 4.8 1815 6.4 0.40 2.0

120 4.8 1070 6.4 0.60 2.1

123 4.8 765 6.4 0.80 2.3

131 4.8 475 Edge Start 2.5

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-23

CUTMASTER A60

Aluminum
80A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16

11

3/16

1/4

3/8

1/2

5/8

3/4

0.064

0.120

0.188

0.250

0.375

0.500

0.625

0.750

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Starter Cartridge

Tip

Heavy Duty Starter

Electrode

Cartridge

9-8211

Torch

Working

Height

116 0.25 350 0.25 0.00

120 0.25 280 0.25 0.10

124 0.25 180 0.25 0.20

130 0.25 110 0.25 0.30

136 0.25 55 0.25 0.40

139 0.25 38 0.25 0.60

136 0.19 26 0.25 0.75 0.10

150 0.19 14 Edge Start 0.12

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

0.10

0.10

0.10

0.09

0.11

0.11

7/8 0.875 153 0.19 10 Edge Start 0.11

OPERATION 0-5428

4T-24

CUTMASTER A60

Material

Thickness

(mm)

1

2 11 7 6.4 8420 6.4 0.00 2.5

3 120 6.4 7170 6.4

4 122 6.4 5710 6.4 0.20 2.5

5 125 6.4 4315 6.4

6 129 6.4 3190 6.4

8 133 6.4 2070 6.4

10 136 6.4 1330 6.4

12 138 6.4 1060 6.4

15 137 4.8 745 6.4

20 151 4.8 325 Edge Start 3.0

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

114 6.4 8890 6.4

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

0.00

0.10

0.20

0.30

0.40

0.50

0.50

0.75

Kerf Width

@ Rec.

Speed

2.4

2.5

2.5

2.4

2.5

2.7

2.9

2.5

0-5428 OPERATION

4T-25

CUTMASTER A60

This page intentionally blank.

OPERATION 0-5428

4T-26

CUTMASTER A60

This page intentionally blank.

0-5428 OPERATION

4T-27

CUTMASTER A60

4T.09 Recommended Cutting Speeds for Machine and Automated Torches With

Shielded Tip

Mild Steel
40A
Air Plasma / Air Shield

Starter Cartridge

Shield Cap Maximum Life Shield Cup Tip

9-8245 9-8237 9-8208

Heavy Duty Starter

Cartridge

9-8213

9-8277

Electrode

9-8232

Material

Thickness

(GA) (in) inch

20 0.036

16 0.060 113 0.16 120 0.16 0.0 0.06

14 0.075 108 0.16 90 0.16 0.1 0.06

12 0.105 111 0.16 75 0.16 0.2 0.06

10 0.135 114 0.16 65 0.16 0.3 0.07

3/16 0.188 11 5 0.16 65 0.16 0.4 0.07

1/4 0.250 118 0.16 45 0.16 0.5 0.07

3/8 0.375 123 0.16 23 0.16 1.2 0.08

1/2 0.500 128 0.16 18 0.16 2.0 0.08

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

107 0.16 130 0.16 0.0 0.06

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-28

CUTMASTER A60

Material

Thickness

(mm)

1

2 108 4.1 2239 4.1 0.0 1.5

3 112 4.1 1794 4.1 0.1 1.7

4 114 4.1 1651 4.1 0.2 1.7

5 115 4.1 1578 4.1 0.3 1.7

6 117 4.1 1256 4.1 0.4 1.7

8 121 4.1 853 4.1 0.5 1.7

10 124 4.1 565 4.1 1.2 1.8

12 127 4.1 485 4.1 2.0 1.9

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.5 (15.2m)

BOLD TYPE indicates maximum piercing parameters.

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

108 4.1 3266 4.1 0.0 1.4

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-29

CUTMASTER A60

Stainless Steel
40A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8245 9-8237 9-8208

Material

Thickness

(GA) (in) inch

18 0.050

16 0.063 108 0.16 50 4.1 0.1 0.07

14 0.078 114 0.16 45 4.1 0.1 0.07

12 0.109 113 0.16 40 4.1 0.2 0.07

10 0.141 116 0.16 35 4.1 0.3 0.07

3/16 0.188 11 5 0.16 30 4.1 0.4 0.07

1/4 0.250 118 0.16 20 4.1 1.2 0.07

3/8 0.375 125 0.16 15 4.1 1.8 0.08

1/2 0.500 127 0.16 10 4.1 2.0 0.08

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.16 60 4.1 0.0 0.06

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-30

CUTMASTER A60

Material

Thickness

(mm)

1

2 114 4.1 1140 4.1 0.1 1.8

3 114 4.1 980 4.1 0.2 1.8

4 116 4.1 845 4.1 0.3 1.8

5 115 4.1 725 4.1 0.4 1.8

6 117 4.1 565 4.1 0.5 2.0

8 122 4.1 440 4.1 1.5 2.0

10 125 4.1 360 4.1 1.8 2.0

12 127 4.1 280 4.1 2.0 2.2

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.5 (15.2m)

BOLD TYPE indicates maximum piercing parameters.

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

109 4.1 1670 4.1 0.0 1.7

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-31

CUTMASTER A60

Aluminum
40A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

9-8245 9-8237 9-8208

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Electrode

9-8232

Material

Thickness

(GA) (in) inch

20 0.040

16 0.063 113 0.19 170 0.20 0.1 0.07

12 0.097 120 0.19 100 0.20 0.2 0.07

11 0.125 125 0.19 90 0.20 0.3 0.07

9 0.160 126 0.19 85 0.20 0.4 0.07

3/16 0.188 128 0.19 70 0.20 0.5 0.07

1/4 0.250 137 0.19 30 0.20 1.0 0.08

3/8 0.375 145 0.19 10 0.20 2.0 0.09

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.19 300 0.20 0.0 0.06

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-32

CUTMASTER A60

Material

Thickness

(mm)

1.0

2.0 116 4.8 3490 5.1 0.2

3.0 124 4.8 2350 5.1 0.3

4.0 126 4.8 2170 5.1 0.4

5.0 129 4.8 1630 5.1 0.6

6.0 135 4.8 990 5.1 1.0

8.0 141 4.8 500 5.1 1.6 2.0

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.5 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

110 4.8 7660 5.1 0.0

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

10.0 146 4.8 180 5.1 2.1 2.3

BOLD TYPE indicates maximum piercing parameters.

Kerf Width

@ Rec.

Speed

1.6

1.8

1.8

1.8

1.8

1.9

0-5428 OPERATION

4T-33

CUTMASTER A60

Mild Steel
60A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8238 9-8237 9-8210

Material

Thickness

(GA) (in) inch

16 0.060

14 0.075 129 0.19 237 0.20 0.10 0.09

11 0.120 126 0.19 200 0.20 0.10 0.08

10 0.135 128 0.19 142 0.20 0.10 0.09

3/16 0.188 132 0.19 115 0.20 0.20 0.09

1/4 0.250 134 0.19 80 0.20 0.30 0.08

3/8 0.375 132 0.19 34 0.20 0.70 0.10

1/2 0.500 144 0.19 23 0.20 0.75 0.10

5/8 0.625 150 0.19 14 Edge Start 0.10

3/4 0.750 145 0.19 14 Edge Start 0.10

1 1.000 160 0.19 4 Edge Start 0.12

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

128 0.19 250 0.20 0.00 0.09

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-34

CUTMASTER A60

Material

Thickness

(mm)

1

2 129 4.8 5942 5.1 0.10 2.2

3 126 4.8 5080 5.1 0.10 0.1

4 130 4.8 3316 5.1 0.20 2.3

5 132 4.8 2794 5.1 0.20 2.2

6 134 4.8 2230 5.1 0.30 2.1

8 133 4.8 1425 5.1 0.40 2.3

10 134 4.8 822 5.1 0.60 2.5

12 141 4.8 646 5.1 0.75 2.5

15 148 4.8 419 Edge Start 2.6

20 147 4.8 318 Edge Start 2.7

25 159 4.8 118 Edge Start 3.0

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

127 4.8 6804 5.1 0 2.2

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-35

CUTMASTER A60

Stainless Steel
60A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8238 9-8237 9-8210

Material

Thickness

(GA) (in) inch

16 0.063

14 0.078 116 0.13 155 0.20 0.10 0.07

11 0.125 118 0.13 125 0.20 0.10 0.07

10 0.141 126 0.13 80 0.20 0.10 0.09

3/16 0.188 125 0.13 75 0.20 0.20 0.09

1/4 0.250 127 0.13 60 0.20 0.30 0.08

3/8 0.375 134 0.13 28 0.20 0.50 0.08

1/2 0.500 136 0.19 17 0.25 0.75 0.09

5/8 0.625 131 0.13 14 Edge Start 0.08

3/4 0.750 142 0.19 10 Edge Start 0.11

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.13 165 0.20 0.00 0.06

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-36

CUTMASTER A60

Material

Thickness

(mm)

1

2 11 6 3.3 3925 5.1 0.10 1.7

3 11 8 3.3 3285 5.1 0.10 1.7

4 126 3.3 1985 5.1 0.20 2.2

5 125 3.3 1850 5.1 0.20 2.1

6 127 3.3 1605 5.1 0.30 2.1

8 131 3.3 1100 5.1 0.40 2.1

10 134 3.3 670 5.1 0.50 2.1

12 136 4.8 490 6.4 0.90 2.2

15 132 3.3 375 Edge Start 2.6

20

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

101 3.3 4590 5.1 0.00 1.2

144 4.8 230 Edge Start 2.5

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5428 OPERATION

4T-37

CUTMASTER A60

Aluminum
60A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

9-8238 9-8237 9-8210

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Electrode

9-8232

Material

Thickness

(GA) (in) inch

16 0.064

14 0.079 118 0.13 350 0.20 0.10 0.08

11 0.120 123 0.13 275 0.20 0.10 0.08

3/16 0.188 125 0.13 140 0.20 0.20 0.08

1/4 0.250 132 0.13 80 0.20 0.30 0.08

3/8 0.375 135 0.13 45 0.20 0.50 0.08

1/2 0.500 140 0.13 26 0.20 0.80 0.08

5/8 0.625 148 0.19 18 Edge start 0.10

3/4 0.750 155 0.19 12 Edge start 0.11

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

118 0.13 350 0.20 0.00 0.07

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-38

CUTMASTER A60

Material

Thickness

(mm)

1

2 11 8 6.4 8890 6.4 0.10

3 123 6.4 7070 6.4 0.10

4 124 6.4 5095 6.4 0.20

5 126 6.4 3335 6.4 0.20

6 130 6.4 2370 6.4 0.30

8 134 6.4 1570 6.4 0.40 2.0

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

118 6.4 8890 6.4 0.00

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

10 136 6.4 1070 6.4 0.60 2.0

12 139 6.4 765 6.4 0.70 2.0

15 146 4.8 515 Edge start 2.4

20 157 4.8 260 Edge start 2.7

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Kerf Width

@ Rec.

Speed

2

2.0

2.1

2.0

2.0

2.0

0-5428 OPERATION

4T-39

CUTMASTER A60

Mild Steel
80A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8211

Material

Thickness

(GA) (in) inch

16 0.060

11 0.120 112 0.13 190 0.20 0.10 0.06

10 0.135 110 0.13 176 0.20 0.20 0.06

3/16 0.188 122 0.19 135 0.20 0.30 0.08

1/4 0.250 127 0.19 100 0.20 0.40 0.09

3/8 0.375 134 0.19 40 0.20 0.50 0.10

1/2 0.500 136 0.19 36 0.20 0.60 0.10

5/8 0.625 145 0.19 18 Edge Start 0.11

3/4 0.750 147 0.19 14 Edge Start 0.11

7/8 0.875 146 0.19 10 Edge Start 0.12

1.000 1.000 152 0.187 8 Edge Start 0.13

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

115 0.13 280 0.20 0.00 0.06

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5428

4T-40

CUTMASTER A60

Material

Thickness

(mm)

1

2 114

3 112

4 115

5 123

6 126 4.8 2735 5.1 0.40 2.2

8 131 4.8 1745 5.1 0.50 2.5

10 134 4.8 1000 5.1 0.50 2.6

12 136 4.8 935 5.1 0.60 2.6

15 143 4.8 580 5.1 0.80 2.8

20 147 4.8 325 Edge Start 2.9

25 151 4.8 210 Edge Start 3.2

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

116

Torch

Working

Height

3.3

3.3

3.3

4.8

4.8

Travel Speed

7895

6395

4895

4025

3300

Initial Piercing

Height

5.1 0.00

5.1

5.1

5.1

5.1

Pierce Delay

0.10 1.6

0.10 1.5

0.30 1.7

0.30 2.0

Kerf Width

@ Rec.

Speed

1.6

0-5428 OPERATION

4T-41

CUTMASTER A60

Stainless Steel
80A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8211

Material

Thickness

(GA) (in) inch

16 0.063

11 0.125

10 0.141

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4

0.750

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

114 0.125 340 0.2 0.00

115 0.125 260 0.2 0.10

116 0.125 250 0.2 0.10

115 0.125 170 0.2 0.20

118 0.125 85 0.2 0.30

127 0.19 45 0.25 0.40

136 0.19 16 0.25 0.75 0.11

143 0.19 10 Edge Start 0.12

146 0.19 8 Edge Start 0.11

Torch

Working

Height

9-8213

9-8277

Travel Speed

Initial Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

0.06

0.06

0.06

0.07

0.08

0.09

OPERATION 0-5428

4T-42

CUTMASTER A60

Material

Thickness

(mm)

1

2

3

4

5

6 117 3.2 2640 5.1 0.30 2.0

8 123 4.8 1630 6.4 0.40 2.1

10 128 4.8 1030 6.4 0.60 2.2

12 134 4.8 565 6.4 0.75 2.6

15 141 4.8 295 Edge Start 3.0

20 147 4.8 185 Edge Start 2.8

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

114

114 3.2 8120 5.1 0.00 1.4

115 3.2 6830 5.1 0.10 1.4

116 3.2 5635 5.1 0.20 1.5

115 3.2 4010 5.1 0.20 1.8

Torch

Working

Height

3.2

Travel Speed

9410

Initial Piercing

Height

5.1 0.00

Pierce Delay

Kerf Width

@ Rec.

Speed

1.5

0-5428 OPERATION

4T-43

CUTMASTER A60

Aluminum
80A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8211

Material

Thickness

(GA) (in) inch

16

11

3/16

1/4

3/8

1/2

5/8

3/4

0.064

0.120

0.188

0.250

0.375

0.500

0.625

0.750

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

115 0.13 320 0.2 0.00

120 0.13 240 0.2 0.10

122 0.13 165 0.2 0.20

124 0.13 100 0.2 0.30

140 0.19 60 0.2 0.40

142 0.19 36 0.2 0.60

148 0.19 26 0.2 0.75 0.11

155 0.19 16 Edge Start 0.12

Torch

Working

Height

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

0.09

0.08

0.08

0.10

0.09

0.11

OPERATION 0-5428

4T-44

CUTMASTER A60

Material

Thickness

(mm)

1

2 11 6 3.3 7595 5.1

3 120 3.3 6165 5.1

4 121 3.3 5045 5.1

5 122 3.3 3955 5.1

6 124 3.3 2905 5.1 0.30 2.3

8 132 4.8 2010 5.1 0.40 2.3

10 140 4.8 1430 5.1 0.50 2.3

12 142 4.8 1045 5.1 0.60 2.6

15 146 4.8 730 5.1 0.75 2.7

20 157 4.8 330 Edge Start 3.2

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

113 3.3 9020 5.1

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

0.00

0.00

0.10

0.20

0.20

Kerf Width

@ Rec.

Speed

2.4

2.2

2.0

2.1

2.2

0-5428 OPERATION

4T-45

CUTMASTER A60

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
9-8232 Electrode US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786;
6703581; D496842; D511280;
D492709; D499620; D504142 Other Pat(s) Pending
9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8233 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

OPERATION 0-5428

4T-46

CUTMASTER A60

Catalog # Description Patent(s)

9-8239 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
9-8244 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8245 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending

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

0-5428 OPERATION

4T-47

CUTMASTER A60

This Page Intentionally Blank

OPERATION 0-5428

4T-48

SECTION 5 SYSTEM: SERVICE

Art # A-07938_AB

5.01 General Maintenance

CUTMASTER A60

Warning!
Disconnect input power before maintaining.

Visual check of
torch tip and electrode

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

Maintain more often
if used under severe
conditions

Each Use

Weekly

Visually inspect the
cables and leads.
Replace as needed

Replace all
broken parts

3 Months

Clean
exterior
of power supply

6 Months

Visually check and
Carefully clean the
interior

0-5428 SERVICE

5-1

CUTMASTER A60

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, worn or when cut performance has dimin­ished.

2. Check plasma and secondary supply and pres­sure.

3. Purge plasma gas line to remove any moisture
build-up.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air

ow.

2. Inspect torch for any cracks or exposed wires,
replace if necessary.

3. Inspect input power cable for damage or exposed
wires, replace if necessary.

Six Months or Every 720 Cutting Hours:

5.03 Common Faults

Problem ­Symptom

Insufcient

Penetration

Main Arc

Extinguishes

Excessive Dross

Formation

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

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

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

Common Cause

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

required.

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

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

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

CAUTION

!

Do not blow air into the power supply
during cleaning. Blowing air into the unit
can cause metal particles to interfere
with sensitive electrical components and
cause damage to the unit.

Short Torch Parts

Life

Difcult Starting 1. Worn torch parts.

1. Oil or moisture in air source.

2. Exceeding system capability
(material too thick).

3. Excessive pilot arc time

4. Gas pressure too low.

5. Improperly assembled torch.

6. Non - Genuine ESAB parts used

2. Non - Genuine ESAB parts
used.

3. Incorrect gas pressure.

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 rst 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.

SERVICE 0-5428

5-2

CUTMASTER A60

1

2

3

4

0

1

2

3

4

5

6

7

5

Art # A-08316

LO

HI

MAX

MIN

A

PSI BAR

MAXMAX

+

S

MINMIN

!

properly installed or tightened.

START ERROR: Indicates that the START SIGNAL

was active (ie. Torch Trigger depressed, hand

held pendant switch ON or CNC signal for torch
ON) during one of three conditions:

PART IN PLACE: Indicates that the shield cup is not

Art# A-07988

When the ! "Fault" indicator is ON or blinking it
will be accompanied by one of the pressure indica­tor lights depending on what the Fault is. Only one
of these faults will be displayed at one time. If more

than one fault exists, when the rst fault is corrected

and cleared, the next fault will then be displayed. It
is possible to have a fault indicated in the function
indicators and another fault indicated in the pressure
indicators. The following table shows each of the
Faults possible.

Pressure

Fault

Indicator

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

1) During initial power up when ON/OFF switch
is turned to ON position

2) When fault which had been disabling the
system is cleared.

3) When the FUNCTION CONTROL SWITCH

Mode is moved from SET position to any of

the other three (3) modes of operation.

CONSUMABLES MISSING: Indicates that the elec-

trode, start cartridge or tip is missing or exces­sively worn.

SHORTED TORCH: Indicates the torch or lead has

a shorted condition between positive and nega­tive leads.

INTERNAL ERROR: Indicates a microprocessor

error.

OVER PRESSURE: Indicates that operating pres-

sure is set too high. The Error Indicator will not

ash when the pressure is above 95 PSI. This

LED will remain ON and the system will operate
but pilot starting and cut performance may be
affected.

NOTE!

The cooling fans will turn ON as soon

NOTE!

Fault explanations are covered in the
following tables.

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 Sig-

Explanation of Faults

UNDER PRESSURE: Indicates that operating pres-

sure is set too low and power supply output power
will be disabled.

INPUT POWER: Indicates primary line voltage is

outside the operating limits of the power supply
as selected by the setting of INPUT VOLTAGE

SELECTION SWITCH at the rear of the unit. Low
is 208/230 VAC and high is 460 VAC.

nal) 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.

0-5428 SERVICE

5-3

CUTMASTER A60

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. Faulty components in unit.

1. Turn primary power disconnect switch to ON position.

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

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

FAULT indicator

ashing, 65 PSI
indicator ashing

TEMPERATURE
indicator ON. FAULT

indicator ashing.

GAS indicator OFF,
FAULT and MIN
pressure indicators

ashing.

FAULT and 70 PSI
indicators ashing.

1. INPUT VOLTAGE SELECTION
SWITCH set for incorrect voltage.

2. Primary input voltage problem.

3. Faulty components in unit.

1. Air ow through or around the

unit is obstructed.

2. Duty cycle of the unit has been
exceeded

3. Failed components in unit

1. Gas supply not connected to
unit.

2. Gas supply not turned ON.

3. Gas supply pressure too low.

4. AIR PRESSURE CONTROL

regulator set too low.

5. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to
power supply.

3. Problem in torch and leads PIP
circuit.

4. Failed components in unit.

1. Turn OFF power to unit then set INPUT VOLTAGE

SELECTION SWITCH to match primary input voltage.

2. Have a qualied person check primary voltage to insure it
meets unit requirements see Section 2.04.

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

1. Refer to clearance information – Section 2.04

2. Allow unit to cool.

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

1. Connect gas supply to unit.

2. Turn gas supply ON.

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

4. Adjust regulator to set air pressure - see Section 4.02.

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

1. Hand tighten the shield cup until it is snug.

2. Insure torch ATC is securely fastened to unit.

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

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

FAULT and 75 PSI
indicators ashing.

SERVICE 0-5428

5-4

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.

CUTMASTER A60

Problem - Symptom Possible Cause Recommended Action

FAULT & 80 PSI

indicators ashing.
Gas ow 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 tting for free movement. Replace if tting

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 ow,

DC LED OFF.

FAULT and 85 PSI
indicators ashing.

No Fault lights ON,
no arc in torch.

FAULT and 85 PSI
indicators ashing

1. Problem in the torch and leads

switch circuit (Remote pendant

switch circuit).

2. CNC Controller device not
providing Start signal.

3. Failed components in unit.

1. Upper O-Ring on torch head is
in wrong position.

2. Torch starter cartridge is stuck.

3. Worn or faulty torch parts.

4. Shorted Torch.

5. Temporary Short indicated by 5

blinks per second.

6. Power Supply Failure (Standard

rate of blinking)

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

1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that

1. Take Torch and Leads (Remote Pendant) to Authorized

Repair Facility.

2. Contact Controller manufacturer.

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

1. Remove shield cup from torch; check upper O-Ring
position; correct if necessary.

2. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter

cartridge lower end tting for free movement. Replace if tting

does not move freely.

3. Inspect torch consumable parts. Replace if necessary.

4. Replace torch and leads or return to an authorized service

center for repair.

5. Release torch switch and reactivate.

6. Return to authorized service center for repair or

replacement.

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

Pilot arc is ON but
cutting arc will not
establish

Torch cutting is
diminished

0-5428 SERVICE

1. Work cable not connected to
work piece.

2. Work cable/connector broken.

3. Failed components in unit.

1. Incorrect current setting.

2. Worn torch consumables.

3. Poor work cable connection to
work piece.

4. Torch being moved too fast.

5. Excessive oil or water in torch.

6. Failed components in unit.

1. Connect work cable.

2. Replace work cable.

3. Return to an authorized service center for repair.

1. Check and adjust to proper setting.

2. Check torch consumables and replace as needed.

3. Check the connection of the Work Lead to the work piece.

4. Reduce cutting speed.

5. Refer to "Check air quality" in Section 3 Torch.

6. Return to an authorized service center for repair.

5-5

CUTMASTER A60

Screws

5.06 Power Supply Basic Parts
Replacement

WARNING

The following procedures should not be
attempted by anyone who has not had
proper training or authorized to do so.

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.

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

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 to 15-18

in. lbs. Do not over tighten.

C. Filter Element Assembly Replacement

The Filter Element Assembly is in the rear panel. For

better system performance, the lter element should be
checked per the Maintenance Schedule (Subsection

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 tting from
the lter assembly. Number 1 in the following

illustration.

4. Hold a wrench or similar tool against the locking
ring on the lter assembly tting, then pull on
the hose to release it. (Numbers 2 and 3 in the

following illustration).

Slots

Lower
Screws

Art # A-08317

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

B. Cover Installation

1. Reverse previous procedures for cover installa­tion.

1

Art # A-07989

2

3

4

5

6mm

SERVICE 0-5428

5-6

5. Remove the tting from the lter element as-

Art # A-07990

led Filter

(Cat.

sembly by inserting a 6 mm hex wrench into the
internal hex tting and turning it counter clock­wise (left). Numbers 4 and 5 in the previous

illustration.

6. Disconnect the input line from the lter element

assembly.

7. Remove the lter element assembly through the

rear opening.

NOTE!

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

Filter Element

CUTMASTER A60

2. Shut OFF air supply and bleed down system
before disassembling Filter to change Filter Ele­ment.

3. Disconnect gas supply hose.

4. Turn the Filter Housing Cover counter-clockwise

and remove it. The Filter Element is located

inside the Housing.

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

No. 9-7743)

Cover

Assemb

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 Lists, for replacement lter element

catalog number.

1. Remove power from power supply.

Barbed

Fitting

Art # A-02476

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and

set Element aside to dry.

6. Wipe inside of housing clean, then insert the
replacement Filter Element open side rst.

7. Replace Housing on Cover.

8. Reattach gas supply.

NOTE!

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

Optional Two-Stage Filter Element Replacement

The Two-Stage Air Filter has two Filter Elements. When
the Filter Elements become dirty the Power Supply will
continue to operate but cut quality may become unac-

ceptable. Refer to Section 6, Parts Lists, for replacement
lter element catalog number.

1. Shut OFF primary input power.

0-5428 SERVICE

2. Shut OFF air supply and bleed down system.

5-7

CUTMASTER A60

First & Second

WARNING

!

3. Loosen the two bolts on the top of the Filter As-

4. Note the location and orientation of the old Filter

5. Slide out the old Filter Elements.

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

sembly enough to allow the Filter Elements to
move freely.

Elements.

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). Im-

proper 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.

SERVICE 0-5428

5-8

SECTION 5 TORCH:

Must Remain Open

Lower O-Ring

Art # A-03725

Art #A-03791_AB

#8-0525

SERVICE

CUTMASTER A60

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.

Upper Groove
with Vent Holes

Upper O-Ring
in Correct Groove

Threads

Torch Head O-Ring

ATC Male Connector

Gas Fitting

CAUTION

!

O-Ring Lubrication

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

It is recommended to apply a very light lm of o­ring lubricant (Catalog # 8-4025) to the o-rings on

a weekly basis.

Dry the torch thoroughly before reinstall­ing.

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.

0-5428 SERVICE

5T-1

CUTMASTER A60

Art # A-08067

Drag Shield Cap

Good Tip

Worn Tip

A-03406

Art # A-08064_AC

Spring-Loaded

Spring-Loaded

Art # A-03284

5T.02 Inspection and Replacement of

Consumable Torch Parts

WARNING

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

Remove the consumable torch parts as follows:

NOTE!

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

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

NOTE!

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

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

4. Remove the tip. Check for excessive wear
(indicated by an elongated or oversized orice).

Clean or replace the tip if necessary.

Example of Tip Wear

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

Lower End Fitting
Full Compression

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 gure.

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

Shield Cups

cap or deector, ensure that the cap or deector

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.

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

New Electrode

Worn Electrode

Electrode Wear

7. Reinstall the Electrode by pushing it straight into

the torch head until it clicks.

8. Reinstall the desired starter cartridge and tip into

the torch head.

9. Hand tighten the shield cup until it is seated on

the torch head. If resistance is felt when installing
the cup, check the threads before proceeding.

This completes the parts replacement procedures.

SERVICE 0-5428

5T-2

CUTMASTER A60

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:

Section "6.03 Power Supply Replacement"

Section "6.04 Replacement Power Supply Parts"

Section "6.05 Options and Accessories"

Section "6.06 Torch Replacement Parts SL100SV Torch (w/Solenoid on Mounting Tube)"

Section "6.07 Torch Consumable Parts Automation / Machine (SL100)Torch"

Section "6.08 Torch Consumable Parts Manual (SL60)Torch"

Section "6.09 Replacement Parts for Hand Torch"

NOTE!

Parts listed without item numbers are not shown, but may be ordered by the catalog number
shown.

B. Returns

If a product must be returned for service, contact your distributor. Materials returned without proper authorization
will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial number of the power supply. Address all inquiries to your
authorized distributor.

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas

pressure regulator / lter, and operating manual.

Qty Description Catalog #

1 Cutmaster A60 Power Supply
208/230 - 460VAC, Single or 3 Phase, 60Hz,
With input power cable and plug 0559311341
Cutmaster A60 Power Supply with 460VAC,
Single or 3 Phase, 60Hz, With input power cable 0559311342
Cutmaster A60 Power Supply
with 400/415VAC, 3 Phase, 50Hz, with input power cable 0559311343
Cutmaster A60 Non CE Power Supply
with 600VAC, 3 Phase, 60Hz, with input power cable 0559311344
Cutmaster A60 CE Power Supply
with 600VAC, 3 Phase, 60Hz, with input power cable 0559311345

0-5428 PARTS LIST

6-1

CUTMASTER A60

led Filter

(Cat.

First & Second

6.04 Replacement Power Supply Parts

Qty Description Catalog #

1 Regulator 9-0115
1 Filter Assembly Replacement Element 9-0116
1 Input Power Cord for 208 / 230 V Power Supply 9-8596
1 Input Power Cord for 400 V Power Supply 9-0218
1 Input Power Cord for 460/600 V Power Supply 9-8593

6.05 Options and Accessories

Qty Description Catalog #

1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two - Stage Filter Kit (includes Hose & Mounting Screws)
1 Bracket, Filter Mounting (not shown)
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
for Start/Stop, OK to move and Divided Arc Voltage 9-8309

1 Automation Harness for Start/Stop and OK to move 9-9385
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008
1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011
1 Nylon Dust Cover 9-7071

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

No. 9-7743)

Cover

Barbed

Fitting

Assemb

Art # A-02476

Stage
Cartridges
(as marked)

Art # A-02942

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

PARTS LIST 0-5428

6-2

CUTMASTER A60

6.06 Torch Replacement Parts SL100SV Torch (w/Solenoid on Mounting Tube)

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 1 PIP Plunger and Return Spring Kit 9-7045
6 Automated Leads Assemblies with ATC connectors
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-3058
1 35 - foot / 10.6 m Leads Assembly with ATC connector 4-3059
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-3060
7 1 Rack 9-9448
8 1 Mounting Tube 9-9445
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 Pinion Assembly (does not include positioning tube) 7-2827
14 1 Torch Holder Sleeve 7-2896
15 1 Pinion Gear-Short 8-6074
16 1 Handwheel (Torch Holder) 9-4514
17 1 Low Prole Torch Holder (1 3/8 Dia) w/o Hardware 9-4515
18 1 Calibrated Torch Holder Bushing 9-4366
19 1 5/32 Dia x 5/8 Lg Slotted Spring Pin See Note 1
20 1 3/8-24 x 3/8 Soc Hd Set Screw, Cup Point See Note 1
21 2 1/4-20 x 5/8 Hex Socket Head Screw See Note 1
22 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point See Note 1
23 1 Solenoid Assembly 9-9447
24 1 Solenoid Cover 9-9446
25 SL100SV Automation Torch and Leads Packages
25 - foot 7-4001
35 - foot 7-4002
50 - foot 7-4003

NOTE 1

Purchase these parts locally.

0-5428 PARTS LIST

6-3

CUTMASTER A60

1

24

10

7

8

10

16

23

19

21

20

9

13

21

2

3

4

5

11

12

17

22

18

14

6

Art # A-07113

15

PARTS LIST 0-5428

6-4

6.07 Torch Consumable Parts Automation / Machine (SL100)Torch

, Deflector

, Deflector

, Deflector

Ohmic Clip

Ohmic Clip

Manual Torch

9-8259

Automation To rch

9-8224

CUTMASTER A60

Electrode

Auto 9-8232

Manual 9-8215

Starter

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Starter Cartridge

Non HF Only 9-8277

70-120A

STANDOFF

CUTTING

Tip:

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

Tips:

50-55A 9-8209

60A 9-8210

Tips:

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine
40A 9-8245

Shield Cap
9-8243

Drag Shield Cup
9-8235

Shield Cap, Machine
50-60A 9-8238

Shield Cap
9-8243

Drag Shield Cup
70-100A 9-8236

Drag Shield Cup
120A 9-8258

Shield Cap, Machine
70-100A 9-8239

Shield Cap, Machine
120A 9-8256

Shield Cap
9-8243

40-120A

GOUGING

Art # A-08066_AG

0-5428 PARTS LIST

Shield

Cup Body,

9-8237

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

6-5

CUTMASTER A60

6.08 Torch Consumable Parts Manual (SL60)Torch

Start

Cartridge

9-8213

DRAG TIP

CUTTING

40A

CUTTING

50-60A

CUTTING

Tips:

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

DRAG SHIELD

CUTTING

Tip:

40A 9-8208

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Tips:

50-55A 9-8209

60A 9-8210

STANDOFF

CUTTING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Deflector

9-8243

Shield Cap, Drag

40A 9-8244

Shield Cap, Deflector

9-8243

Standoff Guide

9-8251

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Deflector

9-8243

Standoff Guide

9-8281

Electrode

9-8215

Art # A-08065_AE

DRAG SHIELD

CUTTING

70-120A

CUTTING

80A 9-8211

90/100A 9-8212

Tips:

70A 9-8231

120A 9-8253

STANDOFF CUTTING

40-120A

GOUGING

Tips:

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

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

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

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

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

O-Ring No. 8-3488

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cap, Drag
70-100A 9-8236

Shield Cap, Deflector

9-8243

Standoff Guide

9-8281

Shield Cap, Gouging

9-8241

NOTE
CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
CutMaster 102 uses 100A and less
CutMaster 152 uses 120A and less

PARTS LIST 0-5428

6-6

CUTMASTER A60

6.09 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 Leads Assembly with ATC connector 4-7834
1 SL60, 50 - foot Leads Assembly with ATC connector 4-7835
1 SL100, 20 - foot Leads Assembly with ATC connector 4-7836
1 SL100, 50 - foot Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031

1

8

2

4

5

6

3

7

0-5428 PARTS LIST

Art # A-07993_AB

6-7

CUTMASTER A60

This Page Intentionally Blank

PARTS LIST 0-5428

6-8

CUTMASTER A60

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

Connect work cable to workpiece.

Set output amperage.

System is ready

for operation.

ON / OFF switch to ON

AC indicator ON.

GAS indicator ON

pressure is adequate

for power supply operation.

ACTION:

RESULT:

ACTION:

RESULT:

when input

Power circuit ready.

ACTION:

RUN /
Rapid Auto Restart /
SET / LATCH switch

to SET

RESULT:

Gas flows to set

pressure.

Torch moved away from work (while

ACTION:

RUN / Rapid Auto Restart /

SET / LATCH

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

or to

LATCH

is used for specific applications

(torch switch can be released

after main arc transfer).

RESULT: Gas flow stops.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate

Torch switch (START)

RESULT:

Fans turn on. Gas flows briefly,

then stops.Gas restarts.

DC indicator ON

Pilot arc established.

ACTION:

Release Torch switch.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

(Fans will continue to run for

10 minutes after the Torch switch

[START] is removed)

PILOT ARC

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fans shut off.

Main arc stops.

Pilot arc automatically

restarts.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

Art #A-07979_AB

0-5428 APPENDIX

A-1

CUTMASTER A60

of the power supply.

Regulatory Standard Covering

Input Power
Specifications
(Phase,
Hertz Rating)

APPENDIX 2: DATA TAG INFORMATION

Mo de l:

Da te of Mf r:

Type of Power
Supply (Note 1)

1/ 3

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

S/N

f

1

f

2

Serial Number
and Production Code

This Type of Power Supply

Plasma Cutting
Symbol

Input Power
Symbol

NOTES:

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

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

3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission.
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

AC or DC

Output Current Type

U

0

Rated No­Load Voltage

Degree of Protection

X

I

=

U

2

Conventional
Load Voltage

U1

Rated Supply
Voltage (Note 2)

Duty Cycle Factor

Rated Maximum
Supply Current

1max 1eff

I

1

1Ø

3Ø

Output Range (Amperage/
Voltage)

Duty Cycle Data (Note 3)

I

1

3Ø1Ø

Standard Symbols

Maximum Effective
Supply Current

AC

DC

Phase

Ø

Art # A-12765_AB

APPENDIX 0-5428

A-2