Thermal Dynamics CUTMASTER 60i Service Manual

SL60QD

OUTPUT MAX OUTPUT

VOLTAGE

INPUT POWER

INPUT POWER

60

CUTMASTER® 60i

PLASMA CUTTING SYSTEM

208-

480V

3

SERVICE
MANUAL

Art # A-13291

Revision: AA Issue Date: April 3, 2017 Manual No.: 0-5475

esab.com

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics 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 call 1-800-426-1888, or visit us on the web at www.esab.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your
Thermal Dynamics 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.

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

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

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

WARNING

Read and understand this entire Manual and your employer’s safety practices

!

before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s
best judgement, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply
CutMaster™ 60i
SL60QD™ 1Torch™
Service Manual Number 0-5475

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

www.esab.com

© Copyright 2017 by
Thermal Dynamics an ESAB brand.

All rights reserved.

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

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

Original Publication Date: April 3, 2017
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,” Booklet 0-5407. 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

PROTECT YOURSELF AND OTHERS!

!

OPERATING.

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.

ATTENTION

VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.

Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.

Si vous n’avez pas une connaissance approfondie des principes de fonctionnement
et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous
vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Wel­ding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux personnes non

qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez

PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces
instructions. Si vous ne comprenez pas bien les instructions, communiquez avec
votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de
Sécurité avant d’installer ou d’opérer cet équipement.

RESPONSABILITÉS DE L’UTILISATEUR

Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement

et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous

devez faire une vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est

pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement.
Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande
de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.

Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant. L’utilisa-

teur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des

dommages, une réparation incorrecte ou une modication par une personne autre que le fabricant ou un centre de service

désigné par le fabricant.

ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT

!

D’INSTALLER OU D’OPÉRER L’UNITÉ.

PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ........................................................................... 1-1

1.01 Notes, Cautions and Warnings ........................................................................ 1-1

1.02 Important Safety Precautions ......................................................................... 1-1

1.03 Publications .................................................................................................... 1-2

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 ..................................................................................... 2-2

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

2.05 Input Wiring Specifications ............................................................................. 2-4

2.06 Power Supply Features ................................................................................... 2-5

SECTION 3 SYSTEM:

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

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

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

3.03 Opening the Main Switch Cover ...................................................................... 3-2

3.04 Primary Input Power Connections, SINGLE Phase ......................................... 3-2

3.05 Primary Input Power Connections, THREE Phase ........................................... 3-3

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

3.07 Work Lead Connections .................................................................................. 3-7

SECTION 4 SYSTEM:

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

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

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

SECTION 5 SYSTEM:

SERVICE ............................................................................................... 5-1

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

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

5.03 Common Faults ............................................................................................... 5-3

5.04 Fault Indicator ................................................................................................. 5-4

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

5.06 Advanced Troubleshooting Guide Pre-Tests .................................................... 5-8

5.07 Power OFF Advanced Troubleshooting .......................................................... 5-10

5.08 Power ON Advanced Troubleshooting ........................................................... 5-19

5.09 Fault Code ..................................................................................................... 5-28

5.10 Advanced Features Menu .............................................................................. 5-33

5.11 Power Supply Basic Parts Replacement ....................................................... 5-34

5.12 Internal Parts Replacement ........................................................................... 5-38

TABLE OF CONTENTS

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

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

6.06 External Replacement Parts (Plastic) ............................................................. 6-3

6.07 Internal Plastics Replacement Parts ............................................................... 6-4

6.08 Left Side Replacement Parts .......................................................................... 6-5

6.09 Right Side Replacement Parts ........................................................................ 6-6

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

6.11 Torch Consumable Parts (SL60) ..................................................................... 6-8

6.12 Torch Consumable Parts ................................................................................ 6-9

APPENDIX 1: DATA TAG INFORMATION ................................................................ A-1

APPENDIX 2: TORCH PIN - OUT DIAGRAMS ........................................................... A-2

APPENDIX 3: TORCH CONNECTION DIAGRAMS ...................................................... A-3

APPENDIX 4: SYSTEM SCHEMATIC, 1PHASE 208/460V UNITS ..................................... A-4

APPENDIX 5: SYSTEM SCHEMATIC, 3PHASE 208/460V UNITS ..................................... A-6

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

CUTMASTER 60i

!

!

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These
highlights are categorized as follows:

NOTE

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

CAUTION

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

WARNING

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

WARNING

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

1.02 Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN­GEROUS AND HAZARDOUS TO YOUR
HEALTH.

Plasma arc cutting produces intense electric
and magnetic emissions that may interfere
with the proper function of cardiac pacemak­ers, hearing aids, or other electronic health
equipment. Persons who work near plasma
arc cutting applications should consult their
medical health professional and the manufac­turer of the health equipment to determine
whether a hazard exists.

To prevent possible injury, read, understand
and follow all warnings, safety precautions
and instructions before using the equipment.
Call 1-603-298-5711 or your local distributor
if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any metals
which may contain one or more of the following:

Antimony Chromium Mercury

Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (SDS/
GHS) that should be supplied with the material
you are using. These SDS/GHSs will give you
the information regarding the kind and amount of
fumes and gases that may be dangerous to your
health.

• For information on how to test for fumes and
gases in your workplace, refer to item 1 in "1.03
Publications" on page 1-2 in this manual.

• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com­bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.

• WARNING: This product contains chemicals,
including lead, known to the State of California to
cause birth defects and other reproductive harm.

Wash hands after handling.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the
operator or others in the workplace.

Manual 0-5475 GENERAL INFORMATION

1-1

CUTMASTER 60i

!

• Never touch any parts that are electrically “live”
or “hot.”

• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is
moist or damp.

• Install and maintain equipment according to NEC
code, refer to item 9 in Section "1.03 Publications"
on page 1-2.

• Disconnect power source before performing any
service or repairs.

• Read and follow all the instructions in the Operat­ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.

• Be sure there is no combustible or flammable mate­rial in the workplace. Any material that cannot be
removed must be protected.

• Ventilate all flammable or explosive vapors from
the workplace.

• Do not cut or weld on containers that may have
held combustibles.

• Provide a fire watch when working in an area where
fire hazards may exist.

• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under­water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis­sipated. Trapped hydrogen gas that is ignited will
cause an explosion.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your eyes
and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding helmet
or shield. Also always wear safety glasses with side
shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protect
your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:

Minimum Protective Suggested
Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc
is clearly seen. Experience has shown that
lighter filters may be used when the arc is
hidden by the workpiece.

WARNING

WARNING: This product contains chemicals, includ­ing lead, known to the State of California to cause birth
defects and other reproductive harm.

Wash hands after

handling.

1.03 Publications

NOISE

Noise can cause permanent hearing loss. Plasma arc
processes can cause noise levels to exceed safe limits.
You must protect your ears from loud noise to prevent
permanent loss of hearing.

• To protect your hearing from loud noise, wear pro­tective ear plugs and/or ear muffs. Protect others
in the workplace.

• Noise levels should be measured to be sure the
decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item
1 in Section "1.03 Publications", in this manual.

GENERAL INFORMATION Manual 0-5475

1-2

Refer to the following standards or their latest revisions
for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Docu­ments, U.S. Government Printing Office, Washington,
D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Govern­ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC­CUPATION AND EDUCATIONAL EYE AND FACE

PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broad­way, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standards Insti­tute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS­TIBLES, obtainable from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO­CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Associa­tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Pro­tection Association, Batterymarch Park, Quincy, MA
02269

CUTMASTER 60i

11. CGA Pamphlet P-1, SAFE HANDLING OF COM­PRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the
Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Asso­ciation, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA­TORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018

Manuel 0-5436 INFORMATIONS GÉNÉRALES

1-3

CUTMASTER 60i

This Page Intentionally Blank

GENERAL INFORMATION Manual 0-5475

1-4

CUTMASTER 60i

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just product(s) listed on page i.

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

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

NOTE!

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

CAUTION

!

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

WARNING

!

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

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the ESAB
web site listed below and clicking on "Product Support" / "ESAB Documentation": / "Download Library", then
navigate to "Plasma Equipment" and then "Manual".

http://www.esab.com

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.

2.02 Equipment Identification

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

Manual 0-5475 INTRODUCTION

2-1

CUTMASTER 60i

2.03 Receipt Of Equipment

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

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

Included items:

• 60i Power Supply

• SL60QD™ Torch and Leads

• Work Lead with Work Clamp

• Spare Parts Kit ( 2 Electrodes, 2 Tips, 6 O-rings)

• Operating Manual

• Filter Wrench

Art# A-13290

Move the equipment to the installation site before un-boxing the unit. Use care to avoid damaging the equipment when
opening the box.

2.04 Power Supply Specifications

1 Phase

60i 1 Phase Power Supply Specifications

Input Power 208 - 480 VAC(187 - 528 VAC), Single Phase, 50/60 Hz

1 Phase Input Power Cable

Output Current 10 - 60 Amps, Continuously Adjustable

Power Supply Gas Filtering

Ability

Maximum Inlet Pressure 125 PSI (8.6 bar)

Power Supply includes 9' single phase 8AWG 3/C input

cable with NEMA 6-50P Plug..

Particulates to 5 Microns

60i Power Supply Duty Cycle *

Ambient Air Temperature

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

Rating

Duty Cycle 50% 60% 100%

All Units

* 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.

INTRODUCTION Manual 0-5475

2-2

Current

DC Voltage

60 Amps 50 Amps 40 Amps

126 122 119

3 Phase

CUTMASTER 60i

60i 3 Phase Power Supply Specifications

Input Power 208 - 480 VAC(187 - 528 VAC), 3 Phase, 50/60 Hz

3 Phase Input Power Cable

Output Current 10 - 60 Amps, Continuously Adjustable

Power Supply Gas Filtering

Ability

Maximum Inlet Pressure 125 PSI (8.6 bar)

Power Supply includes 9' single phase 12AWG 4/C input

cable without plug..

Particulates to 5 Microns

60i Power Supply Duty Cycle *

Ambient Air Temperature

Duty Cycle 50% 60% 100%

All Units

DC Voltage

* 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.

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

Current

60 Amps 50 Amps 40 Amps

126 122 119

Rating

60i Cut Capacity

Recommended Pierce Maximum

5/8" 5/8" 1 1/4"

Generator Recommendations

When using generators to power the 60i Plasma Cutting System, the following ratings are a minimum and are to
be used along with the ratings listed above.

A60i Generator Specifications

Generator Output Rating 60i Output Current Arc Characteristic

15 kW 60A Full

12 kW

10 kW

NOTE!

Due to circuitry, age and condition two generators with the same ratings
may produce different results. Adjust the amperage accordingly.

60A Limited
45A Full
45A Limited
30A Full

Manual 0-5475 INTRODUCTION

2-3

CUTMASTER 60i

7.847

199.3 mm

14.146"

359.3 mm

Art # A-13252

15"

381 mm

6"

150 mm

35 lb / 15.875 kg

21.121"

536.47 mm

Art # A-13247

15"

381 mm

6"

150 mm

Power Supply Dimensions & Weight Ventilation Clearance Requirements

2.05 Input Wiring Specifications

WARNING

Each CutMaster 60i system is a dedicated 1 Phase OR 3 Phase
system and cannot be reconfigured to the other. Personal injury
could occur if changing the phase is attempted..

1 Phase

1 Phase CutMaster 60i Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Flexible Cord (Min.

Volts Hz kVA I max I1eff Fuse (amps)

208 50/60 8.9 43 30.5 50 8 AWG (10mm2)

AWG)

230 50/60 8.9 38.9 27.6 50 10 AWG (10mm2)
380 50/60 8.9 23.5 16.7 30 12 AWG (2.5mm2)

1 Phase

400 50/60 8.9 22.4 15.9 30 14 AWG (2.5mm2)
415 50/60 8.9 21.6 15.3 30 14 AWG (2.5mm2)
480 50/60 8.9 18.6 13.2 30 14 AWG (2.5mm2)

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

Single Phase

INTRODUCTION Manual 0-5475

2-4

3 Phase

CUTMASTER 60i

3 Phase CutMaster 60i Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Flexible Cord (Min.

Volts Hz kVA I max I1eff Fuse (amps)

208 50/60 9.1 26 18.5 40 12 AWG (2.5mm2)
230 50/60 9.1 23.3 16.5 30 12 AWG (2.5mm2)

AWG)

3 Phase

380 50/60 8.9 13.8 9.8 20 14 AWG (2.5mm2)
400 50/60 8.9 13.2 9.4 20 14 AWG (2.5mm2)
415 50/60 9.1 12.8 9.1 20 16 AWG (1.5mm2)
480 50/60 9.2 11.3 8.0 15 16 AWG (1.5mm2)

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

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.

2.06 Power Supply Features

Three Phase

Handle and Leads Wrap

Control Panel

Art # A-13258

Input Power ON/OFF Switch

Input Power Cord

Port for Optional Automation
Interface Cable

Gas Inlet Port

Filter Assembly

Manual 0-5475 INTRODUCTION

Torch Leads Receptacle

Work Lead Receptacle

Art # A-13275

2-5

CUTMASTER 60i

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INTRODUCTION Manual 0-5475

2-6

CUTMASTER 60i

SECTION 3 SYSTEM:

INSTALLATION

3.01 Unpacking

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

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

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

3.02 Lifting Options

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

WARNING

Do not touch live electrical parts.

• Only persons of adequate physical strength should lift the unit.

• Lift unit by the handles, using two hands. Do not use straps for lifting.

• Use optional cart or similar device of adequate capacity to move unit.

• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.

Disconnect input power cord be­fore moving unit.

FALLING EQUIPMENT can cause
serious personal injury and can
damage equipment.

HANDLES are not for mechanical
lifting.

Manual 0-5475 INSTALLATION

3-1

CUTMASTER 60i

Art # A-13244

!

Art # A-13279

3.03 Opening the Main Switch Cover

Systems are configured for and come with power cord connected for single phase or three phase configuration
depending on system purchased. The input power switch is located on the rear panel along the top. To access the
input locations, remove the screw at the top of the cover and flip down.

CAUTION

Disconnect power before removing the
cover.

Main Switch Cover

3.04 Primary Input Power Connections, SINGLE Phase

WARNING

Each CutMaster 60i system is a dedicated 1 Phase OR 3 Phase
system and cannot be reconfigured to the other. Personal injury
could occur if changing the phase is attempted..

CAUTION

The primary power source, fuse, and any extension cords used must
conform to local electrical code and the recommended circuit protec­tion and wiring requirements as specified in Section 2.

Single-Phase (1ø)

Power Switch

Line

Power Cord

GND

Single Phase Input Power Wiring

INSTALLATION Manual 0-5475

3-2

3.05 Primary Input Power Connections, THREE Phase

Art # A-13336

WARNING

Each CutMaster 60i system is a dedicated 1 Phase OR 3 Phase
system and cannot be reconfigured to the other. Personal injury
could occur if changing the phase is attempted..

CAUTION

!

The primary power source, fuse, and any extension cords used must
conform to local electrical code and the recommended circuit protec­tion and wiring requirements as specified in Section 2.

Three-Phase (3ø)

Power Switch

CUTMASTER 60i

Line

Three Phase Input Power Wiring

NOTE!

Power
Cord

GND

As long as the power supply is connected to
input power ranging from 208 VAC to 480
VAC, the system will automatically detect
this and run accordingly.

Manual 0-5475 INSTALLATION

3-3

CUTMASTER 60i

Art# A-13262

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 two subsections
if an optional air line filter is to be installed.

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

NOTE!

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

1/4 NPT Inlet Port

Hose Clamp

Gas Supply
Hose

Filter
Assembly

3/8 barb to
1/4 NPT”
(6mm) Fitting

Air Connection to Inlet Port

NOTE!

Filter replacement part numbers can be
found in Section 6 of this manual

INSTALLATION Manual 0-5475

3-4

CUTMASTER 60i

Installing Optional Single - Stage Air Filter

An optional filter kit (7-7507) is recommended for improved filtering with compressed air, to keep moisture and
debris out of the torch.

1. Attach the Single - Stage Filter Hose to the Inlet Port 1/4" NPT of the system filter.

2. Attach the Filter Assembly to the filter hose.

3. Connect the air line to the Filter using the 1/4" NPT. The illustration shows typical fittings as an example.

NOTE!

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

1/4 NPT
Inlet Port

Hose Clamp

Gas Supply
Hose

Optional Single - Stage Filter Installation

System Filter
Assembly

Art # A-13261

NOTE!

Filter replacement part numbers can be
found in Section 6 of this manual

Manual 0-5475 INSTALLATION

3-5

CUTMASTER 60i

Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line filter (9-9387) is also for use on compressed air shop systems. Filter removes mois­ture and contaminants to at least 5 microns.

Connect the air supply as follows:

1. Attach the Two Stage Filter bracket to the back of the power supply with the screws supplied.

NOTE!

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

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

3. Use customer - supplied fittings to connect the air line to the Filter. A 5/16 (8mm) O.D. smooth tubing should
be used with the press in fitting.

Outlet Port
(OUT)

2-Stage Filter
Inlet Port (IN)

Two Stage
Filter
Assembly

5/16 (8mm)
O.D.
Gas
Supply Tubing

Art # A-13288

Air/Gas
Input

System Filter
Assembly

Optional Two - Stage Filter Installation

NOTE!

Filter replacement part numbers can be
found in Section 6 of this manual

INSTALLATION Manual 0-5475

3-6

CUTMASTER 60i

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure
regulators.

2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly
open each cylinder valve to blow out any dust which may be present.

3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up
to 120 psi (8.3 bar) maximum and flows of least 300-500 scfh / 5 - 8.3 CFM (142-235 lpm).

4. Connect supply hose to the cylinder.

NOTE!

Pressure should be set at 120 psi (8.3 bar)
at the high pressure cylinder regulator.

3.07 Work Lead Connections

Connect the Work Lead to the power supply and the work piece.

1. Attache the Dinse type connection of the work lead to the power supply front panel as shown below. Push
in and turn clockwise to the right until tight.

2. Connect the work clamp to the workpiece or cutting table. The area must be free from oil, paint and rust.
Connect only to the main part of the work piece; do not connect to the part to be cut off.

3

2

Art# A-13249

1

Manual 0-5475 INSTALLATION

3-7

CUTMASTER 60i

This Page Intentionally Blank

INSTALLATION Manual 0-5475

3-8

SECTION 4 SYSTEM:

4.01 Front Panel Controls / Features

See Illustration for numbering Identification

2
3

4
5

6
7
8

9

10

11

CUTMASTER 60i

OPERATION

1

16

14
15

13

12

17

18

Art # A-13250

1. Numeric Display

• Displays software revision at start up

• Displays amperage values (Factory default)

• Displays error codes

• Displays pre-set (preview) maintenance functions

2. AC Indicator

Steady light indicates power supply is ready for operation. Blinking light indicates the input voltage is outside
of operating range or internal fault.

3. DC Indicator

Indicator is ON when DC output circuit is active.

4. Latch/Lock

Indicator is ON when unit is in "Latch" mode.

Manual 0-5475 OPERATION

4-1

CUTMASTER 60i

5. Set Mode Indicator

Indicator is ON when unit is flowing gas and pressure can be set.

6. Shield Cup In Place Indicator

Indicator is Blinking when any of the following are not in place or connected: Shield Cup, ATC leads or Quick
Disconnect.

7. Gouge Mode Indicator

Indicator is ON when unit is in "Gouge" mode and all Cutting Indicators (#8) are illuminated.

8. Type of Cutting Indicator

Different segments will be illuminated to indicate different types of cutting.

• Gouging - All illuminated

• Normal Cutting and Latch Mode - Center indicator will be off.

• RAR (Rapid Auto Restart) Cutting - Every other indicator will be off.

• Set Mode - All indicators will be off.

9. Fault Indicator

Indicator is ON when unit is in fault condition. See error codes appendix for fault light explanations. Flashing
when active.

Factory default: Off

10. EOL (End Of Life) Indicator

Indicator is normally off. It is also off during Drag Cutting.

When on it is to inform user that consumable failure is imminent

Active and/or operable in all cutting modes except Drag..

11. Over Temp Indicator

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

OPERATION Manual 0-5475

4-2

CUTMASTER 60i

12. Gas Pressure Indicator

Indicator used to show low, optimal and high gas pressure. Torch type, lead length, cutting mode and amperage
should all be set prior to setting the gas pressure. (90 - 125 PSI / 6.2 - 8.6 bar)

One of 7 segments will always be on when unit is on. The gas bottle will be illuminated and flash during a gas
pressure fault. Bottle will flash when pressure is below a minimum threshold. Bottle will be on continuously
when acceptable.

Factory default: One, or two segments and gas bottle will be illuminated depending on the gas pressure level.
The green indicator in the middle indicates the recommended pressure for the process (Amps, torch type, lead
length). Different processes have different optimum pressures.

Yellow indicates above or below optimum pressure and red indicates unacceptable pressure for good cutting. Each
LED represents 5 psi. Two adjacent LEDs will represent a value in between the two or 2.5 lb. pressure change..

13. Gas Pressure Selector

Rotate the lower knob to set the gas pressure.

14. Torch Type Indicator

Used for selecting one of the three torch options and torch length for each. SLV will be automatically detected.

Factory default: On, SL60 which includes SL60QD™ (Quick Disconnect)

Press and release the lower knob without rotating it to step through selection of torch type.

NOTE!

If you have gone past the desired setting, you will need to continue to step through
all the other torch types and lengths to get back to return to it..

15. Lead Length Indicator

Used for selecting torch lead length for each torch type ranging between 20’ and 100’ leads.

Factory default: On, 20’

Press and release the lower knob without rotating it to step through selection of torch type followed by lead
length.

Up to 35’ Lead (10.7 m)

Above 35' to 50’ Lead (15.2 m)

Above 50' to 75’ Lead (22.9 m)

Above 75' to 100’ Lead (30.5 m)

NOTE!

If you have gone past the desired setting, you will need to continue to step through
all the other torch types and lengths to get back to return to it..

Manual 0-5475 OPERATION

4-3

CUTMASTER 60i

16. Upper Knob - Amp and Mode Selector

Rotate knob to increase or decrease amperage. Indicator is ON when numeric display is showing amper­age output.

Press and release knob without turning to step through the different Modes.

Factory default: On

Numeric display

17. Torch Quick Disconnect Receptacle

Torch Leads are connected here by aligning the connectors, pressing in and turning locking ring clockwise-to­the-right to secure. Connection should only be snug with no tools used.

18. Work Lead Dinse type receptacle

Align Dinse type connector on work lead with receptacle, press in and turn clockwise to the right until tight.

4.02 Preparations for Operation

At the start of each operating session:

WARNING

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

Torch Parts Selection

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

Torch Connection

Check that the torch is properly connected. Only Thermal Dynamics models SL60, SL60QD™ / Manual or
SL100 / Mechanical Torches may be connected to this Power Supply. See Section 3T of this manual.

Check Primary Input Power Source

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

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

Air Source

Ensure source meets requirements (refer to Section 2). Check connections and turn air supply ON.

OPERATION Manual 0-5475

4-4

CUTMASTER 60i

Art # A-04509

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.

Power ON

Place the Power Supply ON / OFF switch to the ON (right) position. AC indicator turns ON.
The Control Board performs several tests to determine the system is ready to operate. During the self-tests the

digital display first shows (revision) followed by the firmware revision number which includes
decimals. 1.1.0 is an example of a production released code revision that may be displayed.

Next displayed is the “checksum” a combination of letters and numbers that are unique to the firmware revi­sion. These are used by service personal to determine if the firmware has been corrupted.

If there are no issues detected the output current setting will be displayed with the letter "A" to the right, show­ing the output current setting. Should a problem be detected the fault code in the format Exxx will display and
the “A” will not be illuminated. Refer to Section 5.04 for fault code explanations.

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

fan turns ON. (90 - 125 PSI / 6.2 - 8.6 bar)

NOTE!

Minimum pressure for power supply
operation is lower than minimum for torch
operation.

The cooling fan will turn ON as soon as the unit is turned ON. After a short amount of time the fan
switches to low speed. The fan will return to high speed as soon as the torch switch (Start Signal) is ac­tivated or if the unit is turned OFF, then turned ON again. If an over temperature condition occurs, the
fan will continue to run at high speed while the condition exists and for a five (5) minute period once
the condition is cleared.

Manual 0-5475 OPERATION

4-5

CUTMASTER 60i

Select Cutting Mode

1

2

Art # A-13251

1. Press and release the upper knob without turning to enter the mode selection menu. Place the system in
one of the four cutting modes available by pressing and releasing the knob until you reach the desired
mode.:

RUN

LATCH .

RAPID AUTO RESTART

GOUGE

SET/PURGE (gas flow only)

2. After selecting the cutting mode, set the output current by turning the knob.

Set Torch Parameters

1. Press and release the bottom knob without rotating to enter the torch type and leads length selections.

OPERATION Manual 0-5475

4-6

CUTMASTER 60i

Set Operating Pressure

NOTE!

Before the gas pressure is set, the torch type, leads length, type
of cutting and amperage should all be set as they will affect the
pressures required. If any of those are changed, the pressure
should be checked again to make sure it is optimized.

1. Gas pressure must be set in the cutting mode to be used, not in the SET/PURGE mode. Each mode may
require a different pressure for optimal cutting. (90 - 125 PSI / 6.2 - 8.6 bar)

2. Set the gas pressure/flow using the lower knob, 2. Changes will show on the Gas Pressure Interlock
The green indicator in the center is the ideal setting. Each indicator when lit separately is equal to 5 lbs. from
the segment next to it. Each will show 5, 10 or 15 lbs or more below or above the ideal. When two segments
are illuminated together then the change is half as much or 2.5 lbs.. The pressure settings will all be affected
by the other settings for torch, torch length and type of cutting and will require adjustments to the pressure
setting.

Cutting Operation

When the torch leaves the workpiece during cutting operations in the RUN mode, there is a brief delay in restart­ing the pilot arc. With the system in the RAPID AUTO RESTART mode, when the torch leaves the workpiece
the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arc contacts the workpiece.
(Use the 'Rapid Auto Restart' mode when cutting expanded metal or gratings, or trimming operations when
an uninterrupted restart is desired).

With the system in the LATCH mode the main cutting arc will be maintained after the torch switch is released.
To exit or cancel the LATCH mode, press and release the trigger again or lift the torch from the cutting surface
so the arc goes out.

Typical Cutting Speeds

Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill.
Refer to Section "4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip" and following
for greater details.

Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, or using
a template or cutting guide while still producing cuts of excellent quality.

Postflow

Release the trigger to stop the cutting arc. Gas continues to flow for approximately 20 seconds. During post ­flow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc
transfers to the workpiece if the torch tip is within transfer distance to the workpiece.

Shutdown

Turn the ON / OFF switch to OFF, to the left as you face the unit from the rear. After a short delay all Power
Supply indicators and fan shut OFF. Unplug the input power cord or disconnect input power. Power is re­moved from the system.

Manual 0-5475 OPERATION

NOTE!

To maximize the longevity of the internal electronics, allow the
power supply to continue running (without cutting) until the cool­ing fan speed changes to slow.. This may take a few minutes

4-7

CUTMASTER 60i

This Page Intentionally Blank

OPERATION Manual 0-5475

4-8

5.01 General Maintenance

CUTMASTER 60i

SECTION 5 SYSTEM:

SERVICE

Warning!
Disconnect input power before maintaining.

Visually inspect the torch body,
consumables and Quick Connect

Maintain more often
if used under severe
conditions

Each Use

Visual check of
torch tip and electrode

Weekly

Visually inspect the
cables and leads.
Replace as needed

Replace all
broken parts

Art# A-13084_AB

3 Months

Clean
exterior
of power supply

6 Months

Visually check and
Carefully clean the
interior

Manual 0-5475 SERVICE

5-1

CUTMASTER 60i

5.02 Maintenance Schedule

NOTE!

The actual frequency of maintenance may
need to be adjusted according to the oper­ating environment.

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Check plasma and secondary supply and pressure/flow.

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

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air flow.

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

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

Six Months or Every 720 Cutting Hours:

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

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

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.

SERVICE Manual 0-5475

5-2

5.03 Common Faults

Problem - Symptom Common Cause

Insufficient
Penetration

CUTMASTER 60i

1. Cutting speed too fast.

2. Torch tilted too much.

3. Metal too thick.

4. Worn torch parts

5. Cutting current too low.

6. Non - Genuine Thermal Dynamics parts used

7. Incorrect gas pressure

Main Arc

Extinguishes

Excessive Dross

Formation

Short Torch Parts Life1. Oil or moisture in air source.

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Cutting current too high.

4. Work cable disconnected.

5. Worn torch parts.

6. Non - Genuine Thermal Dynamics parts used

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine Thermal Dynamics parts used

6. Incorrect gas pressure

2. Exceeding system capability (material too thick).

3. Excessive pilot arc time

4. Gas pressure too low.

5. Improperly assembled torch.

6. Non - Genuine Thermal Dynamics parts used

Difficult Starting 1. Worn torch parts.

Manual 0-5475 SERVICE

2. Non - Genuine Thermal Dynamics parts used.

3. Incorrect gas pressure.

5-3

CUTMASTER 60i

5.04 Fault Indicator

At initial power up, the system goes through a series of self checks before it is ready for use. If during those checks
it detects something is not within proper operating parameters, a fault will occur. If that happens the Fault indicator

will light followed by the Error Code , and number in the digital display.

Error Code Indicator

Indicates when there is something that needs to be adjusted or repaired.

E001, E002, etc. Light up fault indicator also.

Error Code Description

E001 Over Temp Ambient temperature too high, duty cycle exceeded, fan failure or other internal
fault.

E002 Input Fault Input voltage outside the range of the unit or internal fault resulting in low bus
voltage.

1phase / 3phase jumpers J300 on Bias PCB set wrong.

E004 PIP Fault Parts in Place fault. Shield cup not in place or tight.

E005 PIC Fault Parts in Contact fault. Missing or worn tip/start cartridge or electrode.

Inlet pressure exceeds rating causing continuous gas flow.

E009 Fan Fault Fan failed or disconnected.

E010 Low Output Current

Work Lead current less than output current setting. Shorted pilot switch or defec
tive current sensor possible.

E012 Output Fault Tip to electrode voltage too low. Consumables fail to separate when gas flows,
start cartridge stuck, failed power supply, no output or shorted torch body.

E014 Trigger Fault Torch trigger (start signal) active at start up.

E016 Pressure Fault Low Air/Gas pressure. Output pressure too low for selected parameters.

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.

SERVICE Manual 0-5475

5-4

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

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

CUTMASTER 60i

Fault indicator
flashing, Error Code
E002

TEMPERATURE
indicator ON.
FAULT indicator
flashing. Error Code
E001

GAS LED OFF,
FAULT and MIN
pressure indicators
flashing. Error Code
E016

FAULT and indicators
flashing. Error Code
E004

FAULT and indicators
flashing. Error Code
E014

1. Primary input voltage problem.

2. Faulty components in unit.

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

2. Duty cycle of the unit has been
exceeded.

3. Failed components in unit.

1. Gas supply not connected to
unit.

2. Gas supply not turned ON.

3. Gas supply pressure too low.

4. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to
power supply.

3. Problem in torch and leads PIP
circuit.

4. Failed components in unit.

1. Start signal is active when ON/
OFF SWITCH is turned to ON
position.

2. Problem in the torch and leads
switch circuit.

3. Failed components in unit.

1. Have qualified person check primary voltage to insure it
meets unit requirements see Section "2.05 Input Wiring
Specifications" on page <?>.

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

1. Refer to clearance information – see Section "2.04 Power
Supply Specifications" on page <?>

2. Allow unit to cool.

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

1. Connect gas supply to unit.

2. Turn gas supply ON.

3. Set air supply inlet pressure to unit to 120 psi. Set leads
length to match the actual length being used.

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

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

2. Insure torch ATC is securely fastened to unit.

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

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

1. Start can be active for one of the following:

• Hand torch switch held closed

• Hand pendant switch held closed

• CNC START signal is active low
Release the START signal source

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

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

FAULT indicators
flashing. Error code
E005

Manual 0-5475 SERVICE

1. Torch shield cup is loose.

2. Torch tip, electrode or starter
cartridge missing.

3. Torch start cartridge is stuck.

4. Unit inlet gas pressure is too
high causing continuous gas flow.

5. Open conductor in torch leads.

6. Problem in the torch and leads
switch circuit.

7. Failed components in unit.

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

2. Turn OFF power supply. Remove shield cup. Install missing
parts.

3. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and start cartridge. Check start cartridge
lower end fitting for free movement. Replace if fitting does not
move freely.

4. Decrease gas supply pressure to 125 PSI or less.

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

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

7. Return to authorized service center for repair or replacement

5-5

CUTMASTER 60i

Problem - Symptom Possible Cause Recommended Action

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

1. Problem in the torch and leads
switch circuit (Remote pendant
switch circuit).

2. CNC Controller device not
providing Start signal.

3. Failed components in unit.

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

2. Contact Controller manufacturer.

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

FAULT indicators
flashing. Error code
E012

No Fault lights ON, no
arc in torch.

FAULT indicators
flashing Error code
E024 or E031

Pilot arc is ON but
cutting arc will not
establish

FAULT indicator.
Work Lead Current
is less than output
current setting. Error
code E010 Low
Output Current.

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

2. Torch starter cartridge is stuck.

3. Worn or faulty torch parts.

4. Shorted Torch.

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

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

1. Work cable not connected to
work piece.

2. Work cable/connector broken.

3. Failed components in unit.

1. Inverter board pilot IGBT may be
shorted

2. HCT1 Current Sensor or harness
is bad.

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

2. Turn OFF power supply. Bleed down system pressure. Remove
shield cup, tip and starter cartridge. Check starter cartridge lower
end fitting for free movement. Replace if fitting does not move
freely.

3. Inspect torch consumable parts. Replace if necessary.

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

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

1. Connect work cable.

2. Replace work cable.

3. Return to an authorized service center for repair.

1. Perform the resistance tests at #7 in section "Power Off Tests".

2. With the ouput current set at 60A, test the voltage at J601-3
(J601-4 common). It should be 2.4V. If it is, then the sensor
is bad. If it is higher than 2.4V then check the harness for
continuity.

Torch cutting is
diminished

SERVICE Manual 0-5475

5-6

1. Incorrect current setting.

2. Worn torch consumables.

3. Poor work cable connection to
work piece.

4. Torch being moved too fast.

5. Excessive oil or water in torch.

6. Failed components in unit.

1. Check and adjust to proper setting.

2. Check torch consumables and replace as needed.

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

4. Reduce cutting speed.

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

6. Return to an authorized service center for repair.

Sequence of Operation (Block Diagram)

CUTMASTER 60i

ACTION:

Close external

ON / OFF switch to ON

disconnect switch.

RESULT:

Power to system.

AC indicator ON.

GAS indicator

pressure is adequate

for power supply operation.

ACTION:

Connect work cable to workpiece.

RESULT:

System is ready

for operation.

ACTION:

RESULT:

ON when input

Power circuit ready.

ACTION:

Set Torch Type and
Lead Length. Select

SET/PURGE

mode to

confirm the gas

operation and purge

the torch if needed

Torch moved away from work (while

ACTION:

Select desired Operating mode

RUN,

LATCH,

Rapid Auto Restart (RAR),

Gouge.

Set desired Operating Current

Set the Gas pressure to

the green (nominal) indicator.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate

Torch switch (START)

RESULT:

Fan goes to high speed. 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

5 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-13266

Manual 0-5475 SERVICE

5-7

CUTMASTER 60i

5.06 Advanced Troubleshooting Guide Pre-Tests

Circuit description.

The Cutmaster 60i includes single phase models and 3 phase models. They cannot be switched from one to the
other. There are also specific models to meet CE requirements.

(+)

Tip

(+)

Work

Art # A-13333

(-)

E lectrode

SIMP LIFIED DIA GRAM

***

AC

SCR

D300

BIAS

PF C &

BOOS T

*

INVERTER

CONTROL & DISPLA Y

Input Rectifier and Bias Supply

The basic system includes an input rectifier, a Bias Supply board, a Power Factor Correction and Boost board, an
Inverter board and a Control & Display board. The A Series units include an Automation Interface board and the
CE (European) units have an EMI/RFI filter before the input rectifier.

Both single and 3 phase power enter through a 3 phase circuit breaker on the rear panel that also acts as ON/OFF
switch. Exiting the breaker AC power goes through the input rectifier, D300, which includes an internal SCR at its
positive output. CE units place the EMI filter between the circuit breaker and the input rectifier. The Bias Supply
board also mounts on D300. Initially the rectified DC power passes through inrush resistors R300-303 on the Bias
Supply board to limit the current while charging the bulk capacitors. After about 4 seconds to allow capacitor charg­ing the SCR in the D33 module is turned on, bypassing the inrush resistors.

Power Factor Control (PFC)

The rectified DC voltage from D300 varies with the incoming line voltage but the Power Factor Control (PFC) &
Boost circuit accepts the rectified DC from any AC line voltage, 208VAC to 480VAC, and boosts it to the same regu­lated 750 VDC at the bulk capacitors. Variations in the AC line voltage have no effect on the output of the Plasma
power supply.

Inverter board

The Inverter board takes the 750 VDC and converts it to a high frequency square wave for the transformer primary.
Signals from the Control & Display board control the pulse width of the square wave to control the output current.
At the transformer secondary the high frequency is rectified back to DC by the output diodes and filtered by the
output inductor to provide clean DC current for the plasma torch. The Inverter board also accepts inputs such as
the torch trigger (START), Parts in Place (PIP), output current signal from the Hall Effect transducer HCT1 and gas
pressure passing them to the Control & Display board and accepting control signals for OK to Move, the propor­tional gas control solenoid and the fan. Also controlled is a transistor (IGBT) switch to turn the pilot on and off at
the correct times.

Control & Display board

The control & Display board holds the microprocessor with the program that operates the system. Along with the
Display it allows setting the output current, selecting different modes of operation, configuring the system for dif­ferent torches and lead lengths. Also displays status information including any faults that may occur.

SERVICE Manual 0-5475

5-8

CUTMASTER 60i

Art # A-00307

Cathode

Resistance and Diode Tests

The following tests require a meter with both a resistance (ohms), preferable X1, scale and diode measuring scale.
You need to become familiar with how your meter measures diodes. Most meters apply a positive voltage on the +
or red lead. I will refer to + and – leads. For + use whichever color your meter applies the + voltage.

Diodes will conduct in one direction, referred to as the “forward” direction and show an open or high resistance
in the reverse direction.

0.75

Forward Bias

Diode Conducting

Diode Test Symbol

Anode

+

VR

COM

_

A

You need to be familiar with how your meter reads the forward direction of a diode on the diode measuring scale.
Some digital meters such as Fluke show a voltage, usually 0.3 to 0.5V for forward resistance of a power diode such
as we will be measuring here. I will refer to this measurement as resistance/voltage to cover either type of meter.
Smaller diodes usually read a little higher, perhaps 0.6-0.7V. Whatever your meter reads for one diode in the forward
direction expect twice that for two diodes in series.

When measuring diodes connected to capacitors, as many of these are, the reverse direction may show a low re­sistance/voltage at first but the reading gradually rises as the capacitor charges. Reversing the meter will slowly
discharge the capacitors, reading going down, then increasing in the opposite direction until the value stabilizes.
Let the reading come to a stable value or go off scale before you decide what the actual reading is.

Manual 0-5475 SERVICE

5-9

CUTMASTER 60i

5.07 Power OFF Advanced Troubleshooting

Power OFF Tests

Checks before applying power with the power cord not plugged in:

Cover Removal

WARNING

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

1. Remove input power from the system then remove the ten, M5x0.8x16mm hex screws (5 on each side) that
secure the cover assembly to the power supply. Do not remove the screws securing the handles to the cover.

Art # A-13308

2. Carefully lift cover up and away. All handles and side bezels should be connected to the cover.

Art # A-13309

SERVICE Manual 0-5475

5-10

CUTMASTER 60i

On all of these measurements measure on the terminal or the PCB pad, not the screw head. The screw has a coating
that may not be conductive.

1. Measure inrush resistors.

Set meter to Ohms scale. Measure from Bridge+ to square pad to the right of Bridge+. Normal resistance
should be 47 ohms +/- 3.

E300

CHASSIS
GND

GRN/YEL

(3Ø ONLY)

ORANGE

AC2

MOV305

J302

D302

+15V PRI

D303

+

BRIDGE+

ORANGE

J304

VIOLET

AC3

+

D306

MOV300 MOV301 MOV302

MOV303

1

T300

D305

Q301Q300

1

HS300 HS301

J301

D301

1

K300

MOV306

R300

R301

-

R303

R302

C302

J305

1

Art # A-13325

BLACK

2

1

J300

AC1

3Ø

5

6

1Ø

MOV304

GND PRI

D300

+15V

J303

+

46

+24V

13

C304

HS302

+

C306

D307

+

C307

TP8 TP23

TP22

HI LINE

TP4

ACINSEN

1

U300

1

C303

D304

+

C305

BLACK

LO LINE15 UV

TP21
BUS CHK

C301

+

U301

C300

T301

-15V

a. If higher, including open, or if resistors show sign of excess heat, discolored or cracked, replace the Bias

PCB

NOTE!

The cause of the open inrush resistor may
be on another board. Before applying power
complete the rest of these resistance tests.

b. If lower such as zero or only a few ohms the inrush SCR in the main rectifier bridge D300, (under the

Bias PCB) is shorted. Replace the bridge which requires removing the Bias board. Perform the inrush
resistor test (1) before reinstalling the Bias board.

Manual 0-5475 SERVICE

5-11

CUTMASTER 60i

2. Measure bridge rectifier diodes

On diode scale measure from each of the three AC terminals to GND_PRI .then measure each of the AC terminals
to the terminal next on the right of BRIDGE+. .

E300

CHASSIS
GND

GRN/YEL

(3Ø ONLY)

ORANGE

AC2

MOV305

BRIDGE+

-

J302

D302

+15V PRI

D303

+

AC3

ORANGE

J304

VIOLET

D306

D305

MOV300 MOV301 MOV302

MOV303

D301

1

T300

HS300 HS301

Q301Q300

1

J301

1

K300

MOV306

R300

R301

R303

R302

C302

J305

1

Art # A-13326

BLACK

2

1

J300

AC1

3Ø

5

6

1Ø

MOV304

GND PRI

D300

ACINSEN

C303

+15V

J303

+

46

+24V

13

C304

C306

D304

HS302

+

D307

+

C307

TP8 TP23

TP22

HI LINE

TP4

1

U300

1

T301

+

C305

-15V

BLACK

LO LINE15 UV

TP21
BUS CHK

+

C301

+

U301

C300

SERVICE Manual 0-5475

5-12

CUTMASTER 60i

Details:

a. Meter + lead on GND_PRI and - lead to each of the 3 AC terminals. Normally it should measure as one

diode in the forward direction (about 0.4V to 0.5V with Fluke meter).

b. Reversing the leads, + on AC, - on GND_PRI, it should measure higher with voltage/resistance increas-

ing (charging a capacitor).

c. Now repeat the measurement for the terminal to the right of BRIDGE + with the leads as follows: Me-

ter – lead on the terminal to the right of BRIDGE + and the +lead on each AC terminal normal should
measure as one diode in the forward direction (about 0.4V to 0.5V with Fluke meter).

E300

CHASSIS
GND

GRN/YEL

(3Ø ONLY)

ORANGE

VIOLET

AC2

AC3

MOV300 MOV301 MOV302

MOV303

J301

D301

HS300 HS301

1

+

K300

MOV306

R300

R301

-

R303

R302

C302

J305

1

MOV305

BRIDGE+

ORANGE

J302

D302

+15V PRI

D303

+

C301

1

T300

D305

D306

Q301Q300

J304

1

Art # A-13327

BLACK

2

1

J300

AC1

3Ø

5

6

1Ø

MOV304

GND PRI

D300

+15V

J303

+

46

+24V

13

C304

HS302

+

C306

D307

+

C307

TP8 TP23

TP22

HI LINE

TP4

ACINSEN

1

U300

1

C303

D304

+

C305

BLACK

LO LINE15 UV

TP21
BUS CHK

+

U301

C300

T301

-15V

d. Reversing the leads, - lead on each of the AC terminals and + lead on the terminal to the right of BRIDGE

+, should measure higher with voltage/resistance increasing (charging a capacitor).

If any of these read the same in either direction, high (open) or low or near zero then remove the Bias board
and measure the bridge separately. If results are the same then replace the bridge rectifier.

Manual 0-5475 SERVICE

5-13

CUTMASTER 60i

!

3. PFC Board Diode Test. Measure between Bridge + and J305-3 (assumes PFC inductors L1 & L2 remain con-

nected.)

E300

CHASSIS
GND

GRN/YEL

(3Ø ONLY)

ORANGE

MOV305

J302

D302

+15V PRI

D303

+

BRIDGE+

ORANGE

J304

AC3

VIOLET

D306

MOV300 MOV301 MOV302

MOV303

1

T300

D305

Q301Q300

1

HS300 HS301

J301

D301

1

K300

MOV306

R300

R301

R303

R302

C302

-

J305

1

Art # A-13328

BLACK

2

1

J300

3Ø

5

6

1Ø

D300

TP8 TP23

TP22

HI LINE

TP4

+

ACINSEN

1

U300

1

T301

C303

+15V

J303

+

46

+24V

13

C304

C306

D304

HS302

+

+

+

C305

D307

C307

-15V

AC1

MOV304

GND PRI

LO LINE15 UV

U301

BLACK

C300

TP21
BUS CHK

+

AC2

C301

a. With meter + lead on BRIDGE + and meter – lead on J305-3 meter on diode scale should read as a diode

in the forward direction, a bit lower resistance than the bridge diodes. about 0.3V to 0.4V on Fluke meter.

b. Reverse the leads, meter - lead on BRIDGE + and meter +lead on J305-3. Meter should show slowly

increasing resistance/voltage (capacitor charging) until meter goes over range.

c. If either or both of these read a short or an open in both directions replace the PFC board.

CAUTION

Single phase and 3 phase PFC boards are different, have different
catalog numbers! Using the wrong one may cause it to fail.

SERVICE Manual 0-5475

5-14

CUTMASTER 60i

!

4. PFC Board IGBT Test. Measure between Bridge + to GND PRI (assumes PFC inductors L1 & L2 remain con­nected.).

CAUTION

Single phase and 3 phase PFC boards are different, have different
catalog numbers! Using the wrong one may cause it to fail.

E300

CHASSIS
GND

GRN/YEL

(3Ø ONLY)

ORANGE

AC2

MOV305

BRIDGE+

J302

D302

+15V PRI

D303

+

AC3

ORANGE

J304

VIOLET

-

D306

D305

MOV300 MOV301 MOV302

MOV303

D301

R300

1

T300

R302

HS300 HS301

Q301Q300

1

J301

1

K300

MOV306

R301

R303

C302

J305

1

Art # A-13329

BLACK

2

1

J300

AC1

3Ø

5

6

1Ø

MOV304

GND PRI

D300

ACINSEN

C303

+15V

J303

+

46

+24V

13

C304

C306

D304

HS302

+

D307

+

C307

TP8 TP23

TP22

HI LINE

TP4

1

U300

1

+

C305

-15V

BLACK

LO LINE15 UV

TP21
BUS CHK

+

C301

+

U301

C300

T301

a. With meter on the diode scale place + meter lead on GND_PRI and – lead on BRIDGE +. It should read

as a diode in the forward direction with value similar to the PFC Diode, a little lower than the bridge
rectifier (step 2), (about 0.3V to 0.4V on Fluke meter.)

b. If reading is much lower (short) replace the PFC board.

c. If the reading is higher or slowly increasing, capacitor charging, you may have mixed up your + and –

meter leads. Reverse them and if the reading is still high, high in both directions, replace the PFC board.

Manual 0-5475 SERVICE

5-15

CUTMASTER 60i

5. Inverter Board IGBT Test. Measure J305-3 to GND PRI.

BLACK

2

1

J300

AC1

3Ø

5

6

1Ø

MOV304

GND PRI

D300

TP8 TP23

LO LINE15 UV

TP22

HI LINE

TP4

+

ACINSEN

1

U300

U301

1

T301

C303

+15V

J303

Art # A-13330

+

46

+24V

13

C304

C306

D304

HS302

+

+

+

C305

D307

C307

-15V

BLACK

C300

TP21
BUS CHK

+

ORANGE

AC2

MOV305

+15V PRI

C301

(3Ø ONLY)

BRIDGE+

ORANGE

J302

D302

D303

+

J304

GRN/YEL

VIOLET

AC3

MOV300 MOV301 MOV302

D305

D306

1

E300

CHASSIS
GND

MOV303

J301

D301

1

K300

MOV306

R300

HS300 HS301

R301

R303

R302

C302

1

T300

-

Q301Q300

J305

1

a. With meter on diode scale place + lead on GND PRI and – lead on J305-3. Normal reading should be two

times that of a diode in the forward direction, as it is measuring 2 diodes in series. (About 0.6V to 0.7V
with Fluke.)

b. Half of that, one forward diode, while rare, may indicate one shorted IGBT. If that is the case replace the

Inverter board.

c. Lower resistance/voltage including at or near zero indicate shorted IGBTs, replace the Inverter board.

d. If the reading is higher or slowly increasing, capacitor charging, you may have mixed up your + and –

meter leads. Reverse them and if the reading is still high, high in both directions, indicates open IGBTs,
replace the Inverter board.

SERVICE Manual 0-5475

5-16

CUTMASTER 60i

6. Inverter Board Output Diode Test. With the torch removed, measure Work to NEG at the front panel ATC
connector.

+

-

Art # A-13331

a. With meter on diode scale place the + lead on the negative terminal of the ATC connector and the – lead

on the Work lead Dinse receptacle.

b. The normal reading is that of a diode in the forward direction. (0.3V to 0.5V with Fluke.) If shorted replace

the Inverter board.

c. If above reads open, reverse the leads, you may have gotten + and – leads reversed.

d. If open in both directions check the connections from the work receptacle to the Inverter board stud la-

beled WORK. Also check for continuity from the ATC negative terminal to the SEC1 and SEC2 terminals
on the Inverter board. If these are OK replace the Inverter board

Manual 0-5475 SERVICE

5-17

CUTMASTER 60i

7. Inverter Board Pilot IGBT Test. Measure Tip to Work. (Torch removed from ATC) .

+

Art # A-13332

-

a. With meter on diode scale place the + lead on the pilot terminal of the ATC connector and the – lead on

the Work lead Dinse receptacle.

b. The normal reading is that of a diode in the forward direction. (0.3V to 0.5V with Fluke.) If shorted,

replace the Inverter board.

c. If above reads open, reverse the leads, you may have gotten + and – leads reversed. If open in both di-

rections check the connection from the ATC (red wire) to the Inverter board terminal labeled TIP. If OK
replace the Inverter board.

SERVICE Manual 0-5475

5-18

CUTMASTER 60i

5.08 Power ON Advanced Troubleshooting

Power on tests.

WARNING!

Only qualified technicians using the proper equipment should attempt these
tests. In all cases when advised to remove power to disconnect or replace
something wait for at least one minute for capacitors to bleed down before
touching internal parts.

Important: Before applying power check that the Inrush SCR gate connector (J301) is present and its Faston connec­tor properly connected to the gate terminal of the bridge rectifier. Especially important if the Bias board has been
replaced.

Art # A-13300

Refer to the operators’ manual or the “Quick Start “guide (steps 1-4) for connecting work lead, torch, gas and power.
Plug the power cord into the proper voltage that matches the cord connector.

WARNING!

Units with the single phase NEMA 50-6 plug should be connected to 208-230
VAC. To operate at 480V a different plug will be required. Do not use NEMA50-6
plug to connect the unit to 480V supply..

It is preferred to have a switched outlet so the unit can be plugged in with the outlet de-energized but in any case
make sure the rear panel circuit breaker is off then plug in the power cord.

Measuring voltages:

Manual 0-5475 SERVICE

5-19

CUTMASTER 60i

!

APPLY RTV TO COMPLETELY COVER PINS IF NEEDED

Unless otherwise stated GND _PRI is the common for all primary side voltage measurements. For secondary mea­surements the Work lead or its Dinse socket can be used for secondary common. The following tests are intended
to done in the sequence presented. Skipping steps, unless direct to, can result in incorrect diagnosis.

Power ON / Start Up

CAUTION

This procedure assumes the previous resistance tests have been
performed. If not go do them now.

1. Turn on the rear panel circuit breaker and energize the outlet, if it was de-energized. At power on several
things occur, the Bias supply starts up, the display comes on and the fan starts at low speed. There is a short
purge of gas testing for gas pressure.

2. Bias Supply checks at Power On

In approximately 4 seconds expect Bias board 4 LEDs, +15V PRI (D327); +15V (D336); -15V (D340); +24V (D337),
to light on the Bias board and one LED, D101, on the rear of the Control board followed by a second Control
board LED, D135, that blinks slowly. If all expected Bias and control board LEDs light skip to step #3.

E300

CHASSIS
GND

+15V

+24V

GRN/YEL

(3Ø ONLY)

ORANGE

BLACK

2

1

J300

AC1

3Ø

5

6

1Ø

MOV304

GND PRI

D300

BLACK

TP8 TP23

LO LINE15 UV

TP22

HI LINE

TP4

ACINSEN

C303

+15V

J303

+

46

+24V

13

C304

D304

HS302

+

C306

D307

+

C307

TP21
BUS CHK

1

U300

U301

C300

1

T301

-15V

+

C305

-15V

VIOLET

AC2

AC3

MOV300 MOV301 MOV302

MOV303

J301

D301

MOV305

BRIDGE+

ORANGE

J302

D302

+15V PRI

D303

+

C301

+

1

T300

+15V

1

K300

MOV306

R300

R301

R303

R302

C302

HS300 HS301

R171
C140

C141
R184
R188
C145

C147
R198
R201

R204
R207

C154

C155
R212
R214

TP1_

J102

D135

PRI

D305

D306

Q301Q300

J304

1

J305

1

TP100_

15V

R164
R166

R168

1

1

GND

C117

+

+

+

C115

C116

R120

R121

R122

C118

1

R123

C119

C123

R134

C127

C

C128

U108

GND

NORM

PROG

1

OPEN

START

ISP

GREEN

YELLOW

C

ORANGE

RED

BROWN

BLACK

C120

1

R128

R127

R131

C124

C122

R135

U104

U101

D101

C109C107

Y100

R172

U110

1

C144

C148

D101

1

R213

R215

D159

R219

D162

D135

R222

1

1

J103

J101

R136
R137

C106

R109

1

1

U112

R244

R245
R246

R247
R248
R249

R250

C125

C104

R110

C110

L102

C112

R139
R144
R150
R152

R158

C138
D147

C156

C159

D159

R125

R124

R132

R107

33

C130
R147

R112

C108

R113

U102

R169

R265
R173

D149

D150

R190

R194
C149

D156

R202

R223
R227
D165
R230

D158

D167
D168

R216

R240

D170

C157

C167

R217

R255

D161

D173
C172

R221

R264

J100

R130R129

C121

R133

R126

U106

1

D179

C126

C174

C129

R138

1

R161

R167

R170

C139

R174

D152

R179

R185

D151

R186

R191
R195

C146

U109

U113

R193

R200

R199

D154

C150

R206

R205

R209

C153

C158

R218

R220

D163

C160

R224

R228

C161

R226

D164

1

D166

C162

C163

R234

R236
C165

R239

R241

R251

R243

R254

D171

D172

C169

C170

D174

R259

R258

C173

R261

D175

R262

502

R111

49

D178

R140

D144

C

C132

R145

R149

R148

C134

R153

C135

R154

R108

C136

R162

D146

D148

R143

U107

1

R146
R151

R267

R155

R160
R163

R268

R165

U111

R177

R175

R176

R178

R180
R183

R187

R192

R197

R203

C151
R208

R229

C164

R237

C166
R252

R260
D176

R181

R182

C142

1

C143
R189

R196

D153

D155

C152

R210

R211

D157

C

R233

R232

R231

1

R235

R238

D169

R242
R253
C168

U114

R256

R257

C171

D177

R263

C

R266

Art # A-13303

a. If all Bias LEDS light but either of the Control & Display LEDs do not, skip to step #2e.

b. If none of the Bias LEDs light test for input power.

i. Verify the unit is plugged in and the outlet has power. Verify the rear panel circuit breaker (CB1) is

turned on. Test for AC input voltage between the 2 AC terminals of the D300 bridge rectifier if single
phase or all 3 AC terminals if 3 phase.

ii. Measure for DC voltage between the GND PRI (-) and BRIDGE+ terminals. DC Voltage should be

approximately the same as the phase to phase AC voltage.

iii. Now measure from GND PRI (-) to J305-3. The voltage may be as high as 750VDC. The Bias board

should operate at any voltage over 230 VDC. If not replace the Bias board.

c. If some of the Bias LEDs don’t light but at least one does, shut off power to the unit. Allow at least one

minute for capacitor bleed down then disconnect J302 & 303 on the Bias board. Turn power back on. If
all the LEDs still don’t light replace the Bias board.

SERVICE Manual 0-5475

5-20

CUTMASTER 60i

APPLY RTV TO COMPLETELY COVER PINS IF NEEDED

Art # A-13301

d. If all the LEDS now light there is a short at the other end of either the J302 or J303 harness. Plug them in

one at a time to determine which one is loading the Bias down.

i. J302 goes to the PFC board at J800 and the Inverter board at J610. Disconnect each of these in turn

and replace the board that was loading it down.

ii. J303 goes to the Inverter board. If J303 is loading the Bias down, disconnect the ribbon cables at J600,

the fan at J608, the current transducer at J601. If the unit is equipped with an Automation Interface
board disconnect its harness at J609.

iia. Now if any of the Bias supply LEDs are being loaded down replace the Inverter board.
Otherwise reconnect the removed connectors one at a time to find what component is causing
the problem and replace that.

e. Control board LED D101 illuminated indicates +15V is supplied to the board and the blinking “Heartbeat”

LED, D135, indicates the microprocessor is operating.

f. If D101 does not light it may indicate +15V not getting to the board. If the display, front of the board, is

dark, measure for +15V at TP100_15V relative to TP1_GND on the back side of the Control & Display
board If +15V is present it may be only the LED is defective.

TP100_

15V

R164
R166

R168

R171

C140

C141
R184
R188
C145

C147
R198
R201

R204

R207

C154

C155
R212
R214

TP1_

1

1

J102

1

GND

C115

C

D135

START

ISP

C

GND

OPEN

+

C116

R123

C119

C123

R134
C127
C128

U108

NORM

PROG

GREEN

YELLOW

ORANGE

RED

BROWN

BLACK

+

R172

J101

C117

+

R120

R121

R122

C118

1

U104

U101

D101

U110

C148

1

R213

D135

C109C107

Y100

D101

1

C144

R215

D159

R219

D162

R222

R131

R135

C120

C124

R136
R137

C106

R109

1

U112

D149

R107

R265
R173

R190

R124

R169

R112

C108

R113

R223
R227
D165
R230
D167
D168
R240

D170
C167
R255
D173
C172
R264

R125

C130
R147

R202

R126

U106

C121

1

U109

U113

C126

R199

R170

C139

C150

C160

R138

C158

R127

1

C110

C112

R139
R144
R150
R152

R158

C138

D147

C156

C122

C125

R132

C104

R110

33

U102

L102

D150

R194

C149

D156

D158

R216
C157

R217

D161

R221

C159

1

R128

D159

R244

R245
R246

R247
R248

1

1

J103

R249

R250

D174

R261

D171

J100

502

1

R167

R133

R130R129

C129

R161

R174

R179

D151

R186

R191
R195

C146

R200

R205

C153

R185

D152

R206

R209

D179

C174

R193

D154

R180
R183

R187

R192

R203

R111

R143
R146

R151

R267

R155

R160

R163
R268
R165

R175

R197

C151
R208

R108

D157

D178

R153
C136
R162

U111
R176

1

R140
C132
R148

49

D144

C

R145

R149

C134

C135

R154

D146

D148

U107

1

R177

R178

R181

R211

R189

R196

D153

D155

C152

R210

R182

C143

C142

C

R218

R220

D163

C161

R258

R262

C169

C163

R251

R224

D164
D166

R236
C165

R241

D172

D175

R226

R259

C162

R234

R237

R239

R254

C170

R229

C164

C166
R252

R260
D176

R232

1

R263

U114

R257

R233

R242
R253

C168

R256

R231
R235

D169

D177

R266

R238

C171

C

R228

1

R243

C173

i. +15V comes over the ribbon cable from the Inverter board. If no +15V and no display on the Control

board remove the ribbon cable from the Control & Display board and measure for +15V on the end
of the disconnected ribbon cable at pins 5 & 6 with ground on any of pins 2, 4, 8, or 10 of the ribbon
cable connector. You will need a small probe, no more than 0.025” dia. A paper clip is too big and can
damage the connector.

Manual 0-5475 SERVICE

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CUTMASTER 60i

ii. If +15V is present on the ribbon cable replace the Control & Display board.

iii. Unlikely that both pin 5 and pin 6 of the ribbon are open at the same time but to be sure check them

for continuity. If OK and the header for J602 is OK, no bent or broken pins we need to determine if
+15V is getting to the Inverter board.

iv. +15V comes from the Bias Supply at J303-6 (wire #33) and goes to the Inverter board at J603-6. Mea-

sure for +15V relative to common at J603-8 (or the work lead). If +15V is present at J603-8 and not
on the ribbon cable (after confirming the ribbon cable has continuity (iii)) replace the Inverter board.
Otherwise check for harness between J303 and J603 for continuity and check for +15V at J3-3-6. If
+15V is not present replace the Bias board.

g. If D101 is lighted but D135 is not blinking then the microprocessor is not working. Replace the Control

& Display board.

3. Display

As the Control & Display board starts, the display shows a sequence of information, up to 4 digits of seven
segments plus decimal.

a. First are the letters meaning revision.

b. Next is the firmware code revision in 3 digits, first digit represents a major revision, the 2nd a minor revi-

sion and the 3rd should always be zero unless it is experimental code that is being tested before released
for production.

c. Next is a combination of letters and numbers called a checksum that can be used to determine if the code

is corrupted. This changes with each revision of the code. If you call our service dept. you may be asked
for the checksum.

d. Lastly if there are no issues detected during power up the display will show the amperage the unit was

set at previously. If there is a problem it will show the letter E plus 3 digits indicating what the issue is.
If a fault code is displayed go to Fault Code section following this section..

4. Fan

As soon as the Bias Supply starts up the fan should run at low speed, very little fan noise. Fan goes to high
speed when the torch trigger (Start) is pressed.

If the fan is shorted, disconnected or open you should have seen a fault code of E009 in which case replace the
fan. However there are other possible fan problems that do not show a code.

Fan not turning:

a. At the Inverter board with the fan connector, J608, still connected, measure for 24 to 26VDC between

J608-1 (+) and J608-2. If it’s there replace the fan.

b. If the voltage is not there measure from J608-1 (+) to the work lead connector (secondary common). If

voltage now present likely cause is the Inverter board.

i. Other possible cause is the fan control signal FAN ON at pin 20 of the ribbon from the Control &

Display board. You can measure for a short on the ribbon cable, after removing both ends, between
pins 20 and 21. If shorted replace the ribbon cable.

SERVICE Manual 0-5475

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CUTMASTER 60i

Fan runs only high speed prior to pressing the torch trigger:

J608-3, speed control wire, is typically 6-7V in high speed and pulled to near zero by the Inverter board for
low speed.

a. Measure J608-3(+) to J608-2 (or work lead), if near zero volts replace the fan. If higher, greater than 1V

(typically 6-7V), replace the Inverter board. If it is 24V it could be both Inverter and fan are bad.

Fan won’t run high speed:

Momentarily press the torch trigger (Start), fan should switch to high speed. J608-3 is typically 6-7V in high
speed.

a. Measure J608-3(+) to J608-2 (or work lead), if near zero volts replace Inverter board. If higher, greater

than 1V (typically 6-7V), replace the fan. If it is 24V could be both Inverter and fan are bad.

5. Gas Purge

At the end of the startup time, as the display is showing the amperage setting, gas should flow from the torch
for one to two seconds. This is a test to confirm gas is connected to the unit and the solenoid works.

The basic unit has an internal proportional solenoid, SOL1, which controls the gas flow/pressure. A-Series Au­tomation units also control an on/off solenoid on the torch. It is activated the same time as SOL1. Whether or
not it is an automation unit, an LED, TORCH SOLENOID ON (D644), on the Inverter board illuminates when
the SOL1 should be on.

D

2

1

5

1

J603

8

J606

Art # A-13295

Torch
Sol On

J608

1

4

1

F

C656

+

TORCH SOL ON

C610

J601

+

C633

C669

+

8

4

START

J607

J602

+

1

SEC

6

3

5

1

T600

U608

U618

1

1

PRI

J610

3

4

1

2

PRI

SEC

C667

+

J600

4

SEC

PRI

1

PRI

SEC

C608

+

OK TO MOVE

18

9

J609

SEC

PRI

50

49

SEC

PRI

Q602

Q603

Q606

J604

K600

10

1

B

PRI 1

K

1

PRI

SEC

R658

R655

R653

E E

BUS+

C612

+

C613

+

C614

+

T601

UP

C612_2

C618

GND_PRI

E

+

PRI

SEC

SEC

C619

PRI

+

SEC

PRI

C620

+

PRI 2

PRI

B

SEC

PIC OK

Q605

D633

R705

D635

C634

Q608

D629 D631

1

U610

J611

ELECTRODE

SEC

PRI

D

PRI

SEC

B

SEC 2

C645

C649

B

C648

SEC 1

R647

C630

C631

R643

R652

U605

TP21
PILOT GATE

RED

B

TIP

U607

1

C636

+

GND

B

WORK

BLACK

F

Art # A-13302

Manual 0-5475 SERVICE

5-23

CUTMASTER 60i

If there is no gas flow, after a couple seconds the display should show E016. If it does show E016 skip to “d.”. If it
does not and it is not an SL100SV (automation) torch then the PS1 pressure sensor may be defective. Skip to “e.”

a. If a manual (hand) torch is available install it and if still no purge skip to “d.” and continue test.

b. Check for continuity to the torch mounted solenoid. Disconnect J607 and measure resistance on the

harness connector between pins 5 and 7. Normal is between 15 to 25 ohms. If less, the torch solenoid or
wires to it in the torch lead or mounting tube may be shorted. If open the solenoid or the wires in the
torch lead may be open. Disconnect the torch lead from the CM60i and measure between pins 5 and 7 of
the ATC. If still open or shorted replace the torch.

c. If the torch solenoid measures OK reconnect J607 and measure voltage at J607-5(+) to J607-7 or work lead

(common). During the 2 second purge voltage about 22V for ½ second then about 6V for the remainder
of the 2 sec. If not, Inverter board may be defective. Skip to “g.” to test for 24V into the Inverter board.

d. After confirming gas is connected to the rear panel, measure J600-5(+) to J600-6(common) or work lead.

A defective PS1 sensor can make it appear that there is enough pressure. With no pressure it should read
near zero volts. If higher, like 3-5V, the sensor is defective. You can also go to the Advanced Features
Menu and select PRES to see what pressure the system thinks it’s seeing. See sub section 5.10.

If voltage at J600-5 is near zero:

e. Check that the two wires are connected to the gas solenoid. Remove one (or both) and measure the re-

sistance of the solenoid coil. It should be about 26 ohms +/- 10%. If not, replace the solenoid.

f. If resistance is OK reconnect the coil wires leaving room to measure voltage. The solenoid is controlled

by a pulse width modulated 24VDC. The voltage measured with gas flowing will be an average some­where between zero and 24V of either polarity, may be + or -, it doesn’t matter. Since no gas is flowing,
the voltage should be close to the full 24V. If it is replace the solenoid.

g. If no voltage at the solenoid then the Inverter board may be defective. Confirm that there is 24VDC enter-

ing the Inverter board between J603-1(+) and J603-5 (-) or common at the work lead. If there is voltage
replace the Inverter board. Otherwise check for 24 VDC from the Bias board at J303-1 to common.

i. Other possible cause is the solenoid control signal GAS_PWM at pin 23 of the ribbon from the Control

& Display board.

Pilot & Transfer

At this point all the “startup” initializing procedures have been performed. Refer to the Operating manual or
the “Quick Start “guide to use the front panel controls to select current, cutting mode, torch type and lead length
as well as gas pressure. Set the cutting mode to RUN which is the normal cutting mode. Next step is press the
torch trigger or apply Start if automation unit. This should initiate a short “preflow” of gas which then stops
momentarily and restarts initiating the pilot arc. Bringing the torch near the work should initiate arc transfer
at the selected output current. If this is all OK proceed to testing the other cutting modes. If there is a problem
a fault code is likely to be displayed. Common faults and brief explanation of the fault codes are found in sub
section 5.04 of this manual. We’ll cover more detailed troubleshooting in the Fault Code section.

Some faults do not set a code. Look for your symptom here.

1. Gas flows all the time.

a. Unit is set in SET/PURGE mode, change to a cutting mode.

b. Gas inlet pressure is too high forcing the solenoid open. Maximum inlet pressure should be 125 PSI.

Reduce inlet pressure.

c. Solenoid (SOL1) is stuck open. Remove one of the wires to the coil. If gas continues to flow replace the

solenoid.

d. If gas stopped flowing with wire removed Inverter board may be faulty. Remove the ribbon cable at J602.

If gas still flows replace the Inverter board.

e. Control & Display board could be faulty keeping the signal GAS_PWM on pin 23 always high. Replace

the Control & Display board.

SERVICE Manual 0-5475

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CUTMASTER 60i

2. Pull torch trigger or apply Start, nothing happens. (Trigger or Start problem).

a. START LED (D643) on the Inverter board should come on when the torch trigger is on or CNC Start (if

equipped) is applied. If it does not measure voltage at J607-3(+) to J607-4 or work lead (common). Volt­age should be high, 12 to 15V, with the trigger/Start off and go to near zero with the trigger/Start on.

i. If it’s a manual torch and voltage remains high likely a problem with the torch, try another if available

or check for continuity at the torch ATC pins 3 to 4 when the trigger is pulled. If no continuity, torch is
faulty, possibly pins in the ATC or QD (torch handle quick disconnect) are pushed back. If continuity go
to “c.”

b. If it is an automation unit using the Automation Interface board and applying START at the rear panel

CNC connector, jumper pin 3 to pin 4.

WARNING!

The torch may pilot! If the START LED lights problem was in the CNC..

c. If when jumping CNC pins 3 to 4, or there was continuity in step a., and the START LED does not light

then go to J607 and jump pins 3 to 4.

WARNING!

The torch may pilot!

If it still doesn’t light replace Inverter board. If it does light but nothing else happens, no gas flow, replace

the Control & Display board.

3. No pilot, rapid cycling of gas, about once a second (no DC)

You can confirm that the issue is no DC by going to sub section 5:10 Advanced Features Menu and selecting
display of output volts. At idle it shows about 12V, it’s actually negative 12 but the sign isn’t shown, then when
you pull the torch trigger, if no DC, it will show zero or less than 12V as the gas cycles on and off.

a. One cause of no DC in too much current in the main transformer primary. This will latch on a red LED

(D159) on the back of the Control & Display board. It will stay on until the torch trigger (Start) is recycled
and will light again if the fault is still present. Cause can be a problem with the main transformer or the
Inverter board.

i. Inspect the transformer for broken or cracked ferrite cores. Also make the transformer leads are not

shorting to anything. There could still be an internal problem that can’t be detected without special
instruments.

ii. If there are no obvious problems with the transformer the Inverter board may be at fault. If you haven’t

already performed the resistance tests in the first section, Resistance and Diode Tests, go back and
perform steps 5 & 6.

iii. If no fault found, it still could be either an internal fault, such as shorted turns in the transformer or

a problem on the Inverter board. You may have to replace both or one at a time to find the problem.

b. If D159 is not being lit another likely cause of no DC is a defective Inverter board. However PWM signals

that control the Inverter board power output come from the Control & Display board on pins 1 & 3 of
the ribbon cable.

i. You can get an idea if the signals are present by measuring from the work lead (common) to J603-3.

There is no wire in pin 3 so you may need to extend your meter probe to fit through the empty plug
position to contact the pin in the header. At idle this voltage should be about zero and with the torch
trigger pulled will be above zero by some amount. If so, you are getting the PWM signals and the
cause of no DC output is likely the Inverter board. Replace Inverter board.

c. If the voltage at J603-3 does not change, while it is still possible the fault is in the Inverter board, it is

more likely that the Control & Display board is at fault. Also the ribbon cable (removing both ends) for
shorts pin 1 to 2 and pin 3 to both 2 and 4. If the ribbon is OK replace the Control & Display board.

Manual 0-5475 SERVICE

5-25

CUTMASTER 60i

4. No pilot, slow cycling of gas, about once every 5 seconds (No pilot connection).

a. No or intermittent connection somewhere between the torch tip and the stud labeled TIP on the inverter

board. This is an unlikely fault because if this connection is open during startup it results in E005 fault.
However if it becomes open after startup this could be the result. Look for pins or sockets pushed back
in the QD (torch handle quick disconnect) or the rectangular pin/socket in the ATC.

5. No pilot, brief preflow of gas followed by no gas and the DC symbol is on. (Pilot Switch not ON).

a. Inspect the parts. Check the start cartridge. Make sure the plunger moves freely. Try new parts or try a

different torch if available.

b. There is a possibility of an internal short in the torch lead or handle. If available, try another torch. Or

disconnect the torch from the plasma supply, remove the shield cup and tip. Measure at the torch head
from the electrode to the brass threads the shield cup screws on to. It should show open, several hundred
thousand ohms. If low resistance the torch is faulty.

c. Pilot IGBT switch may not be turned on. Measure voltage from TP21 (IGBT gate) to stud labeled TIP on

the Inverter board. If near zero disconnect the ribbon cable at J602 on the Inverter board. Measure TP21
again, it should be about 2.7V. If still zero replace the Inverter board.

d. If TP21 does measure 2.7V with J602 disconnected reconnect J602 and remove the ribbon cable from J100

on the Control & Display board. If TP21 still zero the ribbon cable is shorted pin 26 to 27. If TP21 not read

2.7V replace the Control & Display board.

6. No pilot, gas flows steady, DC symbol is on. (Short between tip and electrode).

Tip and electrode fail to separate when gas flows.

a. Inspect the parts. Check the start cartridge. Make sure the plunger moves freely. Try new parts or try a

different torch if available.

b. There is a possibility of an internal short in the torch lead or handle. If available, try another torch. Or

disconnect the torch from the plasma supply, remove the shield cup and tip. Measure at the torch head
from the electrode to the brass threads the shield cup screws on to. Should show open, several hundred
thousand ohms. If low resistance the torch is faulty.

7. No pilot, no gas flow, DC symbol is on. Torch is Automation (SL100SV) Advanced Menu, pressure.

a. If the automation torch solenoid doesn’t open the parts will remain closed acting as a short. There will

not be a pressure fault as the SOL1 is on putting full pressure on the sensor. Go to the section Power ON,
Startup, section #4.b. & c. to test for faulty torch solenoid.

8. Extremely strong pilot, damages tip immediately.

The HCT1 current transducer outputs a voltage relative the current through the electrode. A problem with the
transducer, or more likely its harness, may prevent the voltage reaching the Inverter board allowing it to go to
full maximum output well above 60A even for pilot.

a. Confirm the harness is plugged into HCT1 and to J601 on the Inverter board. Check continuity of each

wire in the harness between HCT1 and J601. Refer to the unit schematic for harness wiring and colors.

b. If the harness is OK, reconnect J601 and with the unit at idle measure J401 (HTC1 end of the harness)

from J401-4 (common) to J601-1, should be +15V; and to J601-2, should be -15V.

c. Reconnect J401. With the unit at idle measure voltage from J601-4 (common) to J601-3, should be near

zero. If not replace the HCT1.

SERVICE Manual 0-5475

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CUTMASTER 60i

9. Poor cut quality, short tip life, especially at higher current setting.

May be caused by a shorted pilot IGBT.

a. With shorted pilot SW total output current doesn’t change but some of the total will flow through the

shorted SW instead of cutting the metal and increases the tip wear. At lower current setting may have
difficulty transferring or keeping the arc on. Moving the torch away from the work will go immediately
to pilot as though it was in the RAR mode. This should have been found in the resistance tests. Go to the
first section, Resistance & Diode Tests #7.

10. Pilot, But No Arc Transfer.

There is a current sensor (U610) in the work lead circuit on the Inverter board. When the pilot is close enough
to the work some current will flow into the work lead. When the current reaches about 5A, as sensed by U610,
the pilot switch is shut off and transfer is completed. At the same time the current, 25A when piloting, changing
to the output current setting between 10 and 60A and the OK to Move relay is energized as indicated by the OK
to MOVE LED (D642) on the Inverter board. Failure to transfer may be caused by:

a. Work lead not connected or not making good electrical connection to either the plasma supply or the

work piece.

b. U610 on the inverter board defective not sensing the work current. With a DC Ammeter measure the

work current while trying to transfer. If at least 5A and the OK to Move LED does not light (refer to #10
for OK to Move) replace the Inverter board.

11. No OK to Move.

OK to Move, is a relay on the Inverter board. It is only needed for automation units where its contacts, rated for
24 VAC/DC, @ 1A, are connected to the rear panel CNC connector. However it is activated in all units when
work lead current exceeds 5A. (Refer to #9). There is an LED, OK to MOVE, (D642) that turns on when its relay
coil is energized and can be used to indicate arc transfer.

a. OK to MOVE LED on but no contact closure at the CNC connector J1-12 & 14. The OK to Move contacts

connect through J609-12 & 14 and pass directly through the Automation Interface board to the CNC
connector J1 on pins 12 & 14. Check for continuity from J1 through the board and harness to J609. If OK
replace the Inverter board.

b. If the OK to Move LED on the Inverter board does not come on and you do clearly have arc transfer, are

cutting metal, for the OK to Move signal on J609-11 (+) to J609-10 (common, work lead). If it is low, less
than 2 volts, replace the Inverter board.

c. If J609-11 is high, the problem could be either the Control & Display board or the Inverter board.

12. End of Life Indicator (EOL)

Circuits measure the electrode to tip voltage. If while cutting the voltage exceeds what is normal it indicates the
electrode or possibly the tip has reached the end of its life and the EOL indicator blinks to indicate this. It does
not prevent continuing to cut. Note that the EOL is inactive during drag cutting and at currents below 20A.

a. Replace the tip and electrode and recycle the power. If EOL still blinks with a new tip and electrode the

pilot switch may be shorted. Refer back to #8 in this section and also #7 in the first section, Resistance &
Diode Tests.

b. An error measuring tip volts could also be the cause. Perform the test in Fault Code Section #6, E012,

Output Fault, step c.

Manual 0-5475 SERVICE

5-27

CUTMASTER 60i

!

5.09 Fault Code

Fault Code Section

All fault codes also illuminate the fault symbol.

1. E001, Over Temp.

E001 illuminates the temperature symbol as well as the fault symbol. A temperature fault that is not due to
exceeding the duty cycle, i.e. shows up at power on or soon after, is likely a hardware problem. Temperature is
measured on the heatsink of both the PFC board and the Inverter board.

a. Rev AB Inverter board requires J606 be a jumper. Confirm it is in place. Later revisions will eliminate the

need for the jumper.

b. Confirm that J800 and J610 are plugged in to the PFC and the Inverter boards. Not plugged in will cause

the fault. Measure J800-6 (+) to GND_PRI. Normally about 14V, if so PFC board is OK. If J800-6 is low
skip to “d.”

c. Problem could be the ribbon cable /OVERTEMP signal on pin 19 shorted to pin 18 (GND). Disconnect

both ends of the ribbon cable and measure for open circuit between pins 18 and 19.

d. Either the PFC or the Inverter board can pull J800-6 low. Only way to tell which is to remove the wire

from J800-6 using an EXTRACTION TOOL #11-03-0044 from Molex. After removing the wire, if E001
remains, replace the Inverter board. If E001 goes away replace the PFC board.

2. E002, Input Fault

Circuits on the Bias board measure the incoming AC voltage plus the boosted DC voltage on the bulk capacitors.
Bias Supply board jumpers set wrong, AC voltage that is too low or sags when loaded with increased current
during transfer, or is missing a phase if unit is 3 phase, will set the fault. Also a defective PFC board.

CAUTION

Single phase and 3 phase PFC boards are different, have different
catalog numbers! Using the wrong one may cause it to fail.

It is normal for E002 to show during power down as input voltage has been removed but the control power
remains for a few seconds.

a. The jumpers at J300 must be set according to if the unit is single phase or 3 phase as shown on the System

Schematic. Confirm they are set right.

J300 - 1 PHASE

J300 - 3 PHA SE

Art # A-13341

SERVICE Manual 0-5475

5-28

CUTMASTER 60i

!

b. Low or sagging line. Low can be measured, should be at least 185 VAC. A line sagging under load is

difficult to detect as it only sags during the load and as soon as the fault appears the load gets removed.
Best to insure the circuit supplying the AC outlet is rated for the full Imax capacity from the input wiring
specifications in the operators manual.

c. Missing phase, measure all 3 phases, L1 to L2, L2 to L3, L3 to L1. If missing look for blown fuse in the

AC supply.

d. E002 at idle due to Low bulk capacitor voltage.

The PFC board boosts the capacitor voltage to about 750V. Note when the E002 occurs. The PFC has 2 sec­tions, one section operating can boost the voltage OK at idle and piloting and even transfer at low current
but if one section is not working the increased load of transfer at higher current, above 40A, will cause the
voltage to droop resulting in the E002 code at that time.

i. Measure DC voltage from GND PRI (-) to J305-3(+). Normally the voltage should be about 750VDC.

Without the PFC boost this voltage will be about 1.4 times the incoming AC voltage. For example for
230 VAC the DC would be about 320VDC. If that is the case it means the PFC board is not working.
Continue to determine the cause.

ii. Incorrect routing of the PFC inductor leads where they attach at studs labeled IND1_OUT and

IND2_OUT can be critical. If the leads are not routed as shown but are closer to the T800 and T801
current sense transformer it can cause the one or both halves of the PFC to not work. Usually this
would not be a problem unless the board has just been replaced. Loosen and move the leads so they
look like the pictures.

iii. First confirm the board is enabled. Measure J800-7(+) to GND_PRI, normally about 8V, if low the PFC

is being disabled. Remove J610 from the Inverter board. You will get E001 fault but the PFC should
still run and boost the capacitor voltage to about 750V. If not replace the PFC board.

CAUTION

Single phase and 3 phase PFC boards are different, have different
catalog numbers! Using the wrong one may cause it to fail.

iv. The Control & Display board determines when to disable the PFC by activating a circuit on the In-

verter board. Reinstall J610 and remove J800 from the PFC. Measure resistance from J800-7 to J800-8.
It should be open, if low, from zero to a few hundred ohms, replace the Inverter board. Otherwise
Replace the Control & Display board.

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Art # A-13304

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CUTMASTER 60i

!

e. E002 at Transfer:

i. An AC line that can’t supply enough current can cause the incoming voltage to sag as discussed in

step a. Assuming that is not the case it is likely only half of the PFC is working. Check the routing of
the inductor leads as explained in d. ii. above. If the routing is OK as shown in the pictures above
replace the PFC board.

CAUTION

Single phase and 3 phase PFC boards are different, have different
catalog numbers! Using the wrong one may cause it to fail.

3. E004, Parts in Place (PIP) fault

The torch shield cup, when fully screwed in place activates a micro switch that closes the connection between
pins 1 & 2 of the ATC. The most common cause of E004 fault is the shield cup not in place or the torch not con­nected to the plasma supply.

a. The ATC pins 1&2 connect to J607 pins 1&2. Either remove the torch from the plasma supply and check

pins 1&2 for continuity or remove J607 and measure on the harness connector for continuity on pins 1&2.

b. If everything is OK up to J607, with J607 still disconnected, measure voltage at the J607 PCB header pin

1 (+) to pin 2 or work lead (common). Should be 12 to 15V. If not replace the Inverter board.

i. If voltage is correct reconnect J607 and measure voltage at pin 1 again. It should be near zero. If not

there is still an open between pins 1&2. Go back to step a.

ii. If it is correct, near zero, and still showing E004, either the Inverter board or the Control & Display

is defective.

4. E005, Parts in Contact (PIC)

This tests if all the torch parts, tip, electrode and start cartridge, are in place and there is electrical contact be­tween them when no gas is flowing.

NOTE!

If the inlet gas pressure is higher than the 125 PSI max specification, gas
could be forced through the closed solenoid keeping the parts open. There
should be no gas flow, except for 20 sec postflow following pilot or cut,

when in RUN mode and the system is idle..

A circuit applies -12 to -15V on the TIP and looks for the voltage to be present at the electrode. If there is no
contact it causes the E005 fault. Most common cause is the tip and/or start cartridge is worn, arced and pitted,
so there is no electrical contact. Also a weak spring in the start cartridge along with the shield cup not fully
screwed on tight may not allow electrical contact.

SERVICE Manual 0-5475

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CUTMASTER 60i

Art # A-13306

Other common cause is one of the parts, tip, electrode or start cartridge, is missing. Install new parts. If still
E005 do the following:

a. If the Inverter board has just been replaced, a common cause of E005 is the wire #6 from the brass fitting

at the back of the front panel ATC isn’t connected to the Faston tab J611 (Electrode).

b. If new parts don’t solve the problem, make sure the torch tip is not grounded, not touching work or other

ground, measure for -12 to -15V volts between the torch tip and work.

c. If no voltage at the tip, measure from work to the Inverter board stud labeled TIP. If the voltage is at TIP

then there is a poor connection from TIP to the ATC pilot receptacle or through the torch lead or handle
to the torch head. Possibly at the torch handle Quick Disconnect.

Art # A-13307

d. If no voltage at the TIP stud replace the Inverter board.

e. If -12 to -15V volts is at the torch tip, measure for same voltage from work to the ATC electrode connection

(the brass fitting at the back of the front panel ATC). If it is there and the #6 wire as described in step a. is
connected then replace the Inverter board. If the -12 to -15V volts is not on the ATC electrode connection
then there is a poor connection between there and the electrode in the torch head. Possibly at the torch
handle Quick Disconnect. Could be damaged or missing canted coil spring.

5. E009, Fan Fault

Refer back to Power ON section, step #3.

Manual 0-5475 SERVICE

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CUTMASTER 60i

6. E010, Low Output Current Fault

a. If the inverter board pilot IGBT is shorted some current will return through the IGBT bypassing the work

lead current sensor. Perform the resistance tests at #7 of the "Power Off Tests".

b. If the IGBT tests OK, fault may be the HCT1 current sensor or its wire harness. For 60A output the cur-

rent sensor output voltage at J601-3 (J601-4 common) should be 2.4V. If it is 2.4V and the current is not
60A, then the sensor is defective. If the voltage is higher than 2.4V the harness may be defective. Test for
continuity.

Art # A-13342

7. E012, Output Fault

While most faults will clear when the problem is resolved, E012 requires recycling the power after correcting
the cause. Circuits monitor the voltage between torch electrode and work. Less than about 30V during pilot or
attempting to pilot and transfer will set the fault. The pilot arc starts by passing current through the electrode,
via the start cartridge to the tip. Then gas flow forces the start cartridge away from the tip resulting in an arc
with voltage exceeding 30v by a significant amount. If the parts fail to separate in the required time the voltage
will remain low and the fault is set.

Common cause is failure of the torch parts to separate with gas flow. The fault requires shutting off the power
which you should do anyway while inspecting the parts. Check the start cartridge. Make sure the plunger
moves freely. Try new parts.

An automation torch (SL100SV) whose solenoid fails to open does not set a pressure fault but prevents the parts
from separating which can cause an E012 fault. Refer to Power ON section, step #4, Gas Purge, to troubleshoot
the torch mounted solenoid.

Another, probably rare, cause of E012 is a sudden loss of pressure while piloting or cutting such as when the gas
supply hose comes off or bursts. The parts come back together causing low voltage before the pressure sensor
detects the loss of pressure. If the fault cause is not from loss of pressure, try these steps:

a. Possible short in the torch lead or handle. If available, try another torch or disconnect the torch from the

plasma supply, then remove the shield cup and tip. Measure at the torch head from the electrode to the
brass threads that the shield cup screws on to. It should be open, several hundred thousand ohms. If low
resistance the torch is faulty.

b. A problem with the HTC1 current transducer causing its output to signal current when there is none can

also set the E012. With the unit at idle on the Inverter board at J601 measure voltage from J601-4 (com­mon) to J601-3. It should be near zero. If it is positive refer to #8 in the section Pilot & Transfer under
“Some faults don’t set a code” to test the transducer and its harness.

c. This would be rare but a short in the ribbon cable with the signal V_SENSE on pin 13 is shorted to gnd

(pin 14) can set the E012. Remove both ends of the ribbon cable and check resistance from pin 13 to 14.
It should be open.

SERVICE Manual 0-5475

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CUTMASTER 60i

d. A faulty voltage measurement circuit on the Inverter board might cause the unit to not recognize that

there was voltage on the electrode. You can remove the ribbon cable from the Control & Display board
and with the unit powered up (the display will not be on). Measure between common at pin 50 of the
ribbon cable connector (or the work lead) and pin 13. Also from common to pin 49. Both should be zero,
less than 0.01V. If higher the Inverter board may be faulty.

e. If step d. was OK now remove the red pilot wire for the ATC to Inverter board stud marked TIP. Now

measure common to ribbon cable pin 13. Now it should read 0.05V. If not, if still zero or if much higher
replace the Inverter board.

f. Another possibility is the Control & Display board but the only way to tell is replace it.

8. E014, Trigger Fault

During power up the trigger or Start signal should not be on as it could cause an unexpected pilot and perhaps
transfer. Pulling the trigger or applying Start any time before start up purge will also set the E014 fault. In that
case the system ignores the signal and sets the fault to show what the problem is. Releasing the trigger or re­moving Start resets the fault and you can use the torch. There is an LED (D643) labeled START that is on if the
Start/Trigger input is active.

a. If the START LED was not on during or after power up and E014 is showing, replace the Control & Dis-

play board.

b. If the START LED is on and trigger is not pulled or CNC Start is not on, disconnect the torch ATC. If the

START LED goes out, problem was in the torch. You can further confirm that by measuring resistance
between pins 3 & 4 of the torch lead ATC. They should be open, if not, problem is in the torch. If not that,
check for a short between pin 3 and either the pilot or negative.

c. If using automation torch (SL100SV) with rear panel CNC cable remove the cable. If E014 goes away the

problem was in the CNC or the cable.

d. Remove J607 from the Inverter board. If START LED remains on and unit has the Automation Interface

board remove J609. If START LED is now off, the problem is in either the J609 harness or the Interface
board. Check the harness for correct wiring. If OK replace the Automation Interface board.

e. If START LED is still on with J607 and J609 (if equipped) remove the ribbon cable from the inverter board

at J602. If START LED is still on, replace the Inverter board.

f. If START LED went out when the ribbon cable was removed reinstall it at J602 and disconnect it from

J103 on the Control & Display board. If START LED remains on the ribbon cable is shorted. Otherwise
replace the Control & Display board.

9. E016, Pressure Fault.

Go to the section Power ON Tests, Startup #4 Gas Purge.

Manual 0-5475 SERVICE

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CUTMASTER 60i

5.10 Advanced Features Menu

Advanced Features Menu

Entering the advanced features menu allows monitoring the following:

• Pressure (in PSI)

• Number of Pilot Starts

• Volts electrode to work

• Current, both pilot and transferred.

• Arc hours displayed in tenths of hours.

You enter the advanced menu by pressing both upper and lower knobs simultaneously for 3-5 seconds. Once
in the advanced menu you cycle through the parameters being measured by repeatedly pressing the bottom
button. Pressing the top button repeatedly cycles between the parameter name and the number.

In the advanced menu you will remain in whatever mode you were in before (RUN, LATCH, RAPID AUTO
RESTART (RAR), GOUGE or SET/PURGE). In order to see the pressure for SET/PURGE, you must be in SET/
PURGE before entering the advanced menu. In the SET/PURGE mode you will not see current or arc voltage.
In cutting modes you will not see pressure until you trigger the torch.

Upon entering the advanced menu the display shows indicating pressure.

Pressing the top knob changes the display to the number in PSI.

Pressing the bottom knob switches to meaning Starts. Pressing the top knob shows the
cumulative number of starts.

Pressing the bottom knob again switches to meaning volts. Pressing the top knob changes
the display to the actual volts. At idle, the volts display shows 10 to 15 which is the voltage described under the
E005 fault code description which is applied to the tip for testing if the tip and electrode are in contact. During
pilot or transfer it is the actual electrode to tip (pilot) or to work (transferred) voltage.

Pressing the bottom knob again switches to meaning current. Pressing the top knob changes
the display to the actual current. During pilot it shows pilot current, usually 24-26A. Once the arc is transferred
it is the actual current +/- one amp.

Pressing the bottom knob again switches to meaning hours. Pressing the top knob changes
the display to show tenths of arc hours.

You exit the advanced menu returning to pervious operating mode by momentarily pressing both knobs again.

SERVICE Manual 0-5475

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CUTMASTER 60i

5.11 Power Supply Basic Parts Replacement

WARNING

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

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

A. Filter Assembly Replacement

The Filter Element Assembly (9-0116) is in the rear panel. For better system performance, the filter element should
be checked per the Maintenance Schedule (Section 5.02), and either cleaned or replaced.

Regulator/Filter
Assembly

Art # A-13255

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

2. Remove the clear filter bowl with wrench provided with the system. 9-9675

NOTE!

Filter replacement part numbers can be
found in Section 6 of this manual

Manual 0-5475 SERVICE

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CUTMASTER 60i

Art # A-07990

3. Remove the filter element and clean or replace..

NOTE!

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

Filter Element

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

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

SERVICE Manual 0-5475

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CUTMASTER 60i

led Filter

(Cat.

Optional Single-Stage Filter Element Replacement

These instructions apply to power supplies where the optional Single-Stage Filter has been installed.

The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter
Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to Section
6, Parts List, for replacement filter element catalog number.

1. Remove power from power supply.

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

3. Disconnect gas supply hose.

4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located inside the
Housing.

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

No. 9-7743)

Cover

Barbed

Fitting

Assemb

Art # A-02476

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and set Element aside to dry.

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

7. Replace Housing on Cover.

8. Reattach gas supply.

NOTE!

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

Manual 0-5475 SERVICE

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CUTMASTER 60i

!

First & Second

Optional Two-Stage Filter Element Replacement

The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will
continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter
element catalog number.

1. Shut OFF primary input power.

2. Shut OFF air supply and bleed down system.

WARNING

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

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

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

5. Slide out the old Filter Elements.

Stage
Cartridges
(as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

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

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

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

NOTE!

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

NOTE!

Filter replacement part numbers can be
found in Section 6 of this manual

SERVICE Manual 0-5475

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CUTMASTER 60i

5.12 Internal Parts Replacement

Cover Removal

WARNING

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

1. Remove input power from the system then remove the ten, M5x0.8x16mm hex screws (5 on each side) that
secure the cover assembly to the power supply. Do not remove the screws securing the handles to the cover.

Art # A-13308

2. Carefully lift cover up and away. All handles and side bezels should be connected to the cover.

Art # A-13309

Proedure is now complete.

Manual 0-5475 SERVICE

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CUTMASTER 60i

Fan Replacement

After cover removal you can access fan on the top of the power supply. To remove the fan do the following:

NOTE!

Note the orientation of the fan and where the wires are routed from the
fan so you are able to install the new fan exactly the same way.

1. Locate the fan wiring harness and unplug from the PCB.

Fan Harness
Plug

Art # A-13310

2. Spread the two retaining clips apart only enough to remove the fan

Retaining Clips

Art A-13311

Proedure is now complete.

SERVICE Manual 0-5475

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CUTMASTER 60i

Art # A-13312

Pressure Control Solenoid

After the cover is removed, you can access the Pressure Control Solenoid which is located on the inside of the power
supply and attached to the back of the input air filter. To replace, do the following:

1. Disconnect the two wires vis the presson connectors located below the tubing and on the side of the solenoid.

Remove these
two wires

Pressure
Control
Solenoid

2. Disconnect the two air line tubesfrom the fittings on the solenoid.

Remove these
two tubes

Pressure
Control
Solenoid

Art # A-13313

Manual 0-5475 SERVICE

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CUTMASTER 60i

3. Remove the two M5x0.8x16mm hex screws, at the rear of the unit holding the filter assembly in place.

Remove these
two screws

Art # A-13314

4. Remove the entire assembly out through the rear of the unit

Remove the
assembly

Proedure is now complete.

Art # A-13315

SERVICE Manual 0-5475

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CUTMASTER 60i

Control Panel

WARNING

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

The cover does not have to be removed to replace the Control Panel. The following illustrations show the cover
removed.

1. Remove the two M5x0.8x12mm hex screws at the bottom corners of the Control Panel.

Art # A-13316

2. Carefully pull the bottom of the Control Panel outward and allow the panel to move down enough to release
the locking tabs along the top.

3. Move the Control Panel out from the power supply only enough to access the ribbon cable harness where
it attaches to the rear of the Control Panel.

Locking tabs

Art # A-13317

4. Push the two locking tabs out from the ribbon cable connector to release and detach the cable from the
Control Panel.

Procedure is complete.

Manual 0-5475 SERVICE

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CUTMASTER 60i

Art # A-13318

Bias Supply PCB removal

WARNING

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

The Bias Supply PCB is located to the rear of the center chassis on the right side of the unit under the input power
switch. After the cover is removed it can be removed by following these steps.

1. Locate and identify each wire or harness attached to the Bias PCB for re-attachment later.

2. Disconnect each wire or harness at location indicated in the following illustration with a dotted line circle.

3. Disconnect the one jumper wire indicated with the dotted line triangle in the illustration below. DO NOT
LOSE it. This jumper will be used on the new PCB. .

4. Remove the remaining screws indicated by the dotted line squares in the illustration below. The Bias PCB
is now ready to remove.

NOTE!

DO NOT LOSE the plastic spacer behind the board at the bottom
screw. This will need to be replaced when reinstalling a new board.

Proedure is now complete.

SERVICE Manual 0-5475

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CUTMASTER 60i

PFC PCB removal

WARNING

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

The PFC PCB is located on the right side of the system behind the air shroud. After the cover is removed it can

be removed by following these steps.

1. Remove the four T-15 Torx screws (6-19x1/2" trilobe) from the fan tray and the two Philips #1 nylon screws
holding the air shroud in place as seen in the following illustration.

NOTE!

DO NOT LOSE the nylon screws. The nylon screws must be used
when remounting the air shroud. DO NOT replace with metal

screws..

Art # A-13319

Four screws
next to fan.

Two nylon
screws

Front of unit

Manual 0-5475 SERVICE

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CUTMASTER 60i

2. Locate and identify each wire or harness attached to the PFC PCB for re-attachment later.

3. Disconnect each wire or harness at location indicated in the following illustration with a dotted line circle.

4. Remove the three nuts along the top and loosen the two bottom ones indicated by the dotted line squares
in the illustration below. The PFC PCB is now ready to be removed.by lifting up and away.

Proedure is now complete.

Art # A-13320

SERVICE Manual 0-5475

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CUTMASTER 60i

Inverter PCB removal

WARNING

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

Overview: In this process you will remove the cover, remove the fan assembly, remove the filter assembly and
disconect all wires, harnesses before removing the Inverter PCB .

The Inverter PCB is located on the left side of the system behind the air shroud. After the cover is removed it can
be removed by following these steps.

1. Remove the filter assembly per the "Pressure Control Solenoid" instructions earlier, only this time keep as
much tubing connected as possible as seen in the following illustration.

Art # A-13321

2. Disconnect the fan harness, ribbon cable and any other harness from the Inverter PCB that are routed over
and around the air shroud or fan assembly plastics.

3. Remove the four T-15 Torx screws from the fan tray on top of the system and the two Philips #1 nylon screws
holding the air shroud in place.

NOTE!

DO NOT LOSE the nylon screws. The nylon screws must be used
when remounting the air shroud. DO NOT replace with metal

screws..

Manual 0-5475 SERVICE

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CUTMASTER 60i

4. Remove the fan assembly and the air shroud as shown in following illustration.

Art # A-13322

5. Disconnect the remaining electrical connections to the Inverter PCB which will include 6 ring terminals with
nuts and one fast-on connection located at the bottom right of the board.

Art # A-13323

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CUTMASTER 60i

6. Everything should be disconnected from the Inverter PCB at this time. Next remove the five (5) nuts along
the top of the PCB and only loosen the two (2) in the bottom corners.

Art # A-13324

Loosen ONLY

7. Tip the top of the PCB toward you and lift it out.

Proedure is now complete.

HCT1 Current Sensor Removal

1. Remove the cover. See first step in subsection 5.12.

WARNING

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

2. Locate the HCT1, Current Sensor next to the ATC connector at the front of the unit.

Manual 0-5475 SERVICE

Art # A-13337

HCT1

5-49

CUTMASTER 60i

3 Unplug the harness from the HCT1 and disconnect the air/gas tube and connector from the brass tube on

the ATC connector.

Art # A-13338

4. Remove nut and ring terminal and lead that runs through the HCT1 from ATC as shown

Art # A-13339

5. Slide the HCT1 off the lead.

Procedure is now complete.

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CUTMASTER 60i

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:

6.03 Power Supply Replacement

6.04 Miscellaneous Replacement Power Supply Parts

6.05 Options and Accessories

6.06 External Replacement Parts (Plastic)

6.07 Internal Plastics Replacement Parts

6.08 Left Side Replacement Parts

6.09 Right Side Replacement Parts

6.10 Replacement Parts for SL60QD™ Hand Torch

6.11 Torch Consumable Parts (SL60 / SL60QD™)

6.12 Torch Consumable Parts SL100

NOTE!

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

B. Returns

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

6.02 Ordering Information

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

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas
pressure regulator / filter, and operating manual.

Qty Description Catalog #

1 CutMaster 60i Power Supply
208/230 - 480VAC, SINGLE Phase, 60Hz,
with input power cable and plug for 208/230VAC 3-5630-1

208/230 - 480VAC, THREE Phase, 60Hz,
with input power cable and plug for 208/230VAC 3-5630-2

Manual 0-5475 PARTS LIST

6-1

CUTMASTER 60i

led Filter

(Cat.

First & Second

6.04 Miscellaneous Replacement Power Supply Parts

Qty Description Catalog #

1 Filter Assembly Replacement Element (Factory filter) 9-0116
1 SINGLE phase Input Power Cord for 208/230 V Power Supply 9-9701
1 THREE phase Input Power Cord for 208/480 V Power Supply 9-9706

6.05 Options and Accessories

Qty Description Catalog #

1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two - Stage Filter Kit (includes Hose & Mounting Screws) 9-9387
1 Two - Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Work Cable #8 with 50mm Dinse plug 9-9692
1 Multi - Purpose Cart 7-8888
1 Filter Wrench (Factory Filter) 9-9675
1 Kit, Chassis CM60i 9-9667
1 Kit, Cover CM60i 9-9699
1 Kit, Hardware CM60i 9-9660
1 Kit, Harnesses 9-9661
1 Kit, Pneumatic Hoses/Fitting 9-9662

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

No. 9-7743)

Cover

Barbed

Fitting

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

Assemb

Art # A-02476

Stage
Cartridges
(as marked)

Art # A-02942

PARTS LIST Manual 0-5475

6-2

CUTMASTER 60i

6.06 External Replacement Parts (Plastic)

Item # Qty Description Catalog #

1 1 Handle, Case Top 9-9702
2 1 Bezel, Side Frame RH 9-9703
3 1 Handle, CM60i (3 total) 9-9665
4 1 Foot, Case Front 9-9694
5 1 Bezel, Side Frame LH 9-9704
6 1 Foot, Case Rear 9-9693
Screws and nuts can be obtained at a local hardware store.
a M5x0.8x12mm screw
b M5x0.8x16mm screw
c M5x0.8 nut

1

3

2

c

b

a

b

c

3

a

6

c

a

b

a

a

5

a

a

4

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CUTMASTER 60i

6.07 Internal Plastics Replacement Parts

Item # Qty Description Catalog #

1 1 Fan, 24V 2.63A, 283CFM 9-9670
2 1 Shroud, Inverter Fan MNT (mount) 9-9684
3 1 Shroud, PFC 10.2KW 9-9690
4 1 Shroud, Inverter 10.2KW 9-9691
5 1 Mount, Switch 3PH SB 9-9676
6 1 Switch, CB 63A 460VAC 3P 9-9687

1

6

5

4

2

3

PARTS LIST Manual 0-5475

6-4

CUTMASTER 60i

6.08 Left Side Replacement Parts

1 1 PCB, Inverter 10.2KW 9-9671
2 1 Pressure Transducer Assy. 9-9681
3 1 PCB, Control BRD CMi 9-9688
4 1 Assy, Control Board 9-9677
5 1 Knob, 25mm 6mmx4mm D shaft 9-9678
6 1 Assy, ATC conn pwr sup 9-9668
7 1 Assy, Transformer 300V 30K 9-9672
8 1 HCT1 Current Sensor 9-9689
9 1 Inductor, CM60i 9-9679
10 1 Assy, Gas Control CM60i/A40i 9-9666
10a 1 Housing, Filter 9-9707

1

10

10a

2

3

4

5

9

8

Manual 0-5475 PARTS LIST

7

6

6-5

CUTMASTER 60i

6.09 Right Side Replacement Parts

Item # Qty Description Catalog #

1 1 PFC, 1Phase 10.2KW 9-9673
1 1 PFC, 3 Phase 10.2 KW 9-9705
2 1 Bridge Rectifier, 3Phase 9-9686
3 1 PCB, Bias 1PH/3PH 10.2 KW 9-9674
4 1 Inductor, PFC, CM60i (2 total) 9-9685
5 1 Connector, 50mm Dinse Panel Mount 9-9683

1

2

5

4

3

PARTS LIST Manual 0-5475

6-6

CUTMASTER 60i

6.10 Replacement Parts for Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Assembly Replacement 7-5680
2 Leads Assemblies with ATC connector and Quick Connectors
1 SL60QD™, 20 - foot Leads Assembly with ATC and QD connectors 4-5604
1 SL60QD™, 50 - foot Leads Assembly with ATC connector 4-5605
1&2 1 Torch and Leads Assembly, 20 - foot 7-5604
1&2 1 Torch and Leads Assembly, 50 - foot 7-5605

1

2

Art # A-13248

Manual 0-5475 PARTS LIST

6-7

CUTMASTER 60i

6.11 Torch Consumable Parts (SL60)

Replace Consumables.

Remplacer les consommables.

8-3487 8-3486

23x6005

Torch Head

9-8215 Std Life
9-8214 Ext Life

9-8213

9-8252

(60A)

9-8210

(60A)

9-8226 B

(60A)

9-8218

9-8237

9-8218

9-8237

9-8235

9-8243

9-8281

9-8241

Art # A-13147_AC

PARTS LIST Manual 0-5475

6-8

6.12 Torch Consumable Parts

CUTMASTER 60i

Electrode

Auto 9-8232

Manual 9-8215

Start

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Start Cartridge

Non HF Only 9-8277

Tip:

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

Tips:

50-55A 9-8209

60A 9-8210

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine
40A 9-8245

Shield Cap, Deflector
9-8243

Drag Shield Cup
9-8235

Shield Cap, Machine
50-60A 9-8238

Shield Cap, Deflector
9-8243

40-120A

GOUGING

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

Art # A-13148

Manual 0-5475 PARTS LIST

6-9

CUTMASTER 60i

This Page Intentionally Blank

PARTS LIST Manual 0-5475

6-10

APPENDIX 1: DATA TAG INFORMATION

CUTMASTER 60i

Type of Power
Supply (Note 1)

Plasma Cutting
Symbol

Input Power
Symbol

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

Model:

Date of Mfr:

f

1 or 3

Rated No­Load Voltage

Degree of Protection

1

f

2

Output Current Type

U

0

X

I

=

U

2

Conventional
Load Voltage

U1

Rated Supply
Voltage (Note 2)

Hermosillo, Sonora, Mexico

S/N

Duty Cycle Factor

Rated Maximum
Supply Current

1max 1e

I

1

1Ø

3Ø

Made in Mexico

I

1

3Ø1Ø

Manufacturer's Name and/or
Logo, Location, Model and
Revision Level, Serial Number
and Production Code

Regulatory Standard Covering
This Type of Power Supply

Output Range (Amperage/
Voltage)

Duty Cycle Data (Note 3)

Maximum Eective
Supply Current

Manufacturer's Electrical
Schematic File Number
and Revision Level

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 on the bottom of the unit showing input
voltage requirements for the power supply as built.

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

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

Standard Symbols

AC

DC

Phase

Ø

Art # A-13265

Manual 0-5475 APPENDIX

A-1

CUTMASTER 60i

3 - Switch

2- Orange
PIP

2 - Orange
PIP

4 - Switch

Art # A-03799

ATC Female Receptacle -

ATC Male Connector -

3 - Open

2 - Orange
PIP

2 - PIP Circuit

APPENDIX 2: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram

ATC Male Connector

Negative /
Plasma

4 - Green /
Switch

3 - White /
Switch

1 - Black /
PIP

4
3

/

2

1

Pilot

Front View

8
7

6

5

8 - Open

5 - Open

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector

4- Black ­Pendant
Connector

3 - White ­Pendant
Connector

Front View

/

4

3

2

1

UNSHIELDED MACHINE TORCH

Negative / Plasma

8 - Green ­Pendant
Connector
Ground

8

7

6
5

7 - Green /
Not Used

6 - Open

7 - Open

6 - Open

8 - Ground

7 - Open

6 - Open

5 - Open

8 - Ground

7 - Open

6 - Open

ATC Female Receptacle

Front View

8
7

6
5

Pilot

ATC Female Receptacle

8
7

6

5

2
1

Front View

4
3

2
1

Negative /
Plasma

4 - Switch

4
3

2 - PIP

1 - PIP

A-03701

Negative / Plasma

3 - Switch

2 - PIP

C. Automation SL100SV Torch Pin - out Diagram

APPENDIX Manual 0-5475

A-2

1 - Black /
PIP

4- Open

4

3

2

/

1

1 - Black /
PIP

Front View

5 - White /
Not Used

Pilot

Negative / Plasma

8

7

6

5

Pilot

8 - Open

7 - Green /

- Torch
Solenoid

6 - Open

5 - White /

- Torch
Solenoid

5 - Open

Negative / Plasma

8 - Open

7 - Torch
Solenoid

6 - Open

5 - Torch
Solenoid

Pilot

Front View

8
7

6

5

Pilot

4
3

2
1

1 - PIP Circuit

1 - PIP

4 - Not Used

3 - Not Used

Art # A-07114

APPENDIX 3: TORCH CONNECTION DIAGRAMS

Art # A-13334

A. Hand Torch Connection Diagram

Torch: SL60QD / SL60 / SL100 Hand Torch
Leads: Torch Leads with ATC Connector
Power Supply: 60i

Torch

Head

PIP

Switch

Torch

Switch

Torch
Leads

Black

Orange

Green

White

Negative / Plasma

Pilot

Male

ATC Leads

Connector

ATC Female

Receptacle

1

2

5

6

4

3

8

7

1

2

5

6

4

3

8

7

CUTMASTER 60i

Power
Supply

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

B. Mechanized Torch Connection Diagram

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

Male

ATC Leads

Connector

Torch

Head

PIP

Switch

Not

Used

Pilot Lead

Torch
Leads

Black

Orange

White

Green

Negative / Plasma Lead

To Remote Control

Remote

Pendant

Connector

Black

White

Green

ATC Female

Receptacle

Power
Supply

1

1

2

2

5

5

6

6

4

4

3

3

8

8

7

7

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-13335

Manual 0-5475 APPENDIX

A-3

CUTMASTER 60i

APPENDIX 4: SYSTEM SCHEMATIC, 1PHASE 208/460V UNITS

A

B

C

D

1

208-480 VAC
+/- 10%
1 Phase.

CB1

Earth

AIR IN

2

3

4

5

L1

L2

RECT+

1

Notch
= pin 1

5

2

3

4

PFC PCB

IND2 OUT

PFC
CONTROL

PFC TEMP SIG

GNDPRI

6

7

8

J400

3

4

1

2

+

SIG

PS1

GND

IND1 OUT

GNDPRI

(25)
(26)
(27)
(18)

VIOLET
BLACK
ORANGE

5

6

To TORCH ATC

INPUT & BIAS SUPPLY PCB

1 (+)

D300

7 (K)

1

BLUE

6 (G)

2

J301

0

*

J304 - HIPOT

1

CHASSIS GND

GND

J300 - 1 PHASE

+15V_PRI

*

2 (-)

BIAS SUPPLY SECTION

PRIMARY

SECONDARY

+24V

+15V

-15V

AIR FILTER

GND PRI

+15V PRI

+15VPRI / BUS UV

GNDPRI

+24V

SUPPLY OK

+15V

-15V

OR

+

*

(16)

3
2
1

2

J305

1

BK

-

GND

1
2
3
4
5

J302

1
2
3
4
5
6

J303

+15V PRI

J800

(8)

(9)

(10)

(29)
(30)

(31)
(32)
(33)
(34)
(35)

SOL1

PRESSURE CONTROLSOLENOID

(16)

BUS_+

GND_PRI

MULTIFUNCTION DISPLAY & CONTROL PCB

E

AC

DC

TORCH

& LEADS

MODE

FAULT

F

*

DISPLAY_7SEG_ QUAD

END OF LIFE OVERTEMP

PRESSURE

KNOB ­ Rotate to Set Current,
Press to Select Mode

D101

+15V (under knob)

KNOB ­Rotate to Set Pressure
Press to Select Torch
& Lead Lenght

D135

HEARTBEAT(under knob)

J100 - 50PIN RIBBONCABLE

J101-J103 Pro gramming

1
2
3
4
5
6

J101

D159

PRI _OC(behind PCB)

3
2
1

J102

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

J103

GND

Art # A-13280_AB

1

APPENDIX Manual 0-5475

A-4

2

3

4

5

CUTMASTER 60i

6

INVERTER PCB

IN_+

PRI 1

PRI 2

GND_PRI

GNDPRI

4

2

3

1

+15V PRI

1

PFC TEMP SIG

2

/PFC_OFF

3
4

J610

GNDPRI

(29)

1

(30)

2
3

(31)

4

(32)
(33)
(34)
(35)

J603

+15V

5
6
7
8

GND

J600

50 PINRIBBON CABLE SIGNALS (all others areGND or unused)

PIN NAME (Description) “ /” means signal active low.
1, 3 GATE B, GATE A (Gate drive signals)
5, 6 +15V
7, 9 I_PRI_A, I_PRI_B, (PrimaryCurrent Sensesignals)
12 /PFC_OFF (Disables PFC)
13 V_SENSE(Output Voltage signal)
17 I_SENSE(Output Current signal)
19 /OVERTEMP (System over temperature)
20 FAN_ON(Signal turnsFan on)
23 GAS_PWM (Proportional Gas Solenoiddrive)
25 /RAR (Rapid Auto Restart Mode)
26 PILOT_SW_O
28 /PIC ( Tip & Electrodein contact before preflow)
31 /PIP (Torchshield cup is inplace)
33 /TRIG_ON( Torch triggeror Start on)
35 SUPPLY_OK ( Inputvoltage in rangeand Bias Supply OK)
36 SPARE
37 FAN_FAULT
38 -15V
39 PRESSURE_IN (Reserved forinput pressuresignal, not used)
40 PRESSURE_OUT(Analog signalgas pressureto the torch)
41 SPARE9_IN (Spareinput)
42 I_WORK_SENSE (WorkCurrent Signal)
43 /TORCH_SOL_DETECT (Automation TorchSole
45 TOR_SOL_ON (24VPWM drive to automation torchsolenoid)
46 /OK_TO_MOVE (turnson OK to Move relay)
48 +3.3V
49 TIP_VOLTS (Signalrelative to voltage on tip)

Rev

AA Production Release DAT 12/07/2016

AB DAT 3/23/2017VCN 01479 & J301-1

J604 - HIPOT

+24V

SUPPLY OK

-15V

24V_PWM

+5V

123

456

BK

OR

VIO

N ( Signal turnsPilot IGBT on)

Revision

6

J602 - 50PIN RIBBONCABLE

Date

By

7

T1

noid detected)

Rev

7

FAN1

Revision

D625

D643

D644

TORCHSOL ON

J608

L3

J601

2
1

J606

GND

SEC 1

SEC 2

PIC OK

START

D642

OK TOMOVE

+24V

GND

1

2

3

BLUE

RED

BLACK

HARNESS TO J609

By

8

OR

1

W

2

VI

3

BK

4

5

ELECTRODE

J401

1
2
3
4
5
6
7
8

GND

J607

(6)

+15V

D633

123

4

GND

-15V

TIP

D635

Q608

WORK

BASIC CNC

(OPTIONAL)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

GND

J609

AUTOMATION INTERFACE (A-SERIES ONLY)

SW3

-15V
+15V

1 2 3 4 5 6

(11)

1

(12)

2

(13)

3

(14)

4

(15)

5
6

(17)

7
8
9

(20)

10

(21)

11

(22)

12

(23)

13

(24)

14
15
16
17

(28)

18

J2

Date

The information contained hereinis proprietaryto Victor Technologies.

Not for release, reproduction or distribution withoutwritten consent.

Title

8

DIVIDER RATIO

ISOLATED
VOLTAGE

GND

DIVIDER

CIRCUITS

ISO_GND

OHMIC
SENSE
CIRCUITS

CONTACT

SW1 ON = Ohmic via TIP
SW2 ON = Collision via TIP

AUTOMATIONINTERFACE
PCB (w / OHMIC)

SCHEMATIC

CM60i 208 -480VAC, 1 PH ASE

9

HCT1

Hall Effect Sensor

(1)
(2)
(3)
(4)
(5)

(7)

(13)

(14)

(22)

(24)

-

+

9

ATC

-

+

1TORCH

PIP SW

TORCH TRIGGER

1
2
3
4
5
6

SOL *

7
8

*
AUTOMATION

TORCHONLY

(-)

(+)

Electrode

Tip

(+)

Work

J1

1

2

START / STOP

3

4

START / STOP (ret)

5

6

7

8

9

10

11

12

OK TO MOVE *

13

14

OK TO MOVE *

* MAX 30 V AC/DC @ 1A

J1

1

2

3

START / STOP
START / STOP (ret)

4

DIVIDED ARV VOLTAGE (-)

5

DIVIDED ARV VOLTAGE (+)

6

7

COMMON

8

9

PLATE CONTACT COM

10

PLATE CONTACT OUT

11

OK TO MOVE *

12

13

OK TO MOVE *

14

OHMIC

Art # A-13280_AB

Victor Technologies Headquarters

16052Swingley RidgeR oad,Suite 300

St Louis,Missouri63017 USA

Date Printed

3/23/2017

Drawn

DAT

Size

C

Drawing Number

042X1369

10

Date Revised

Date

Sheet

10

3/23/2017

10/21/2015

of

1 1

A

B

C

D

E

F

Manual 0-5475 APPENDIX

A-5

CUTMASTER 60i

APPENDIX 5: SYSTEM SCHEMATIC, 3PHASE 208/460V UNITS

A

B

208-480 VAC
+/- 10%
3 Phase.

C

D

1

2

3

4

5

L1

CB1

Earth

AIR IN

L2

RECT+

1

Notch
= pin 1

5

2

3

4

PFC PCB

IND2 OUT

PFC
CONTROL

PFC TEMP SIG

GNDPRI

6

7

8

J400

3

4

1

2

+

SIG

PS1

GND

IND1 OUT

GNDPRI

(25)
(26)
(27)
(18)

VIOLET
BLACK
ORANGE

5

6

To TORCH ATC

INPUT & BIAS SUPPLY PCB

1 (+)

D300

7 (K)

1

BLUE

6 (G)

2

J301

0

*

J304 - HIPOT

1

CHASSIS GND

GND

J300 - 3 PHASE

+15V_PRI

*

AIR FILTER

2 (-)

BIAS SUPPLY SECTION

PRIMARY

SECONDARY

+24V

+15V

-15V

GND PRI

+15V PRI

+15VPRI / BUS UV

GNDPRI

+24V

SUPPLY OK

+15V

-15V

OR

+

*

(16)

3
2
1

2

J305

1

BK

-

GND

1
2
3
4
5

J302

1
2
3
4
5
6

J303

+15V PRI

J800

(8)

(9)

(10)

(29)
(30)

(31)
(32)
(33)
(34)
(35)

SOL1

PRESSURE CONTROLSOLENOID

(16)

BUS_+

GND_PRI

MULTIFUNCTION DISPLAY & CONTROL PCB

E

AC

DC

TORCH

& LEADS

MODE

FAULT

F

*

DISPLAY_7SEG_ QUAD

END OF LIFE OVERTEMP

PRESSURE

KNOB ­ Rotate to Set Current,
Press to Select Mode

D101

+15V (under knob)

KNOB ­Rotate to Set Pressure
Press to Select Torch
& Lead Lenght

D135

HEARTBEAT(under knob)

J100 - 50PIN RIBBONCABLE

J101-J103 Pro gramming

1
2
3
4
5
6

J101

D159

PRI _OC(behind PCB)

3
2
1

J102

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

J103

GND

Art # A-13340

1

APPENDIX Manual 0-5475

A-6

2

3

4

5