Thermal Dynamics an ESAB Brand Thermal Dynamics an Brand Cutmaster 58 PLASMA CUTTING SYSTEM Instruction manual

Download

SL60QD

OUTPUT MAX OUTPUT

VOLTAGE

CutMaster® 58

PLASMA CUTTING SYSTEM

208-

460V

460V 600V

INPUT POWER

OPERATING MANUAL

Art # A-13750_AB

Revision: AA Issue Date: 11-07-2018 Manual No.: 0-5544

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™ 58 SL60QD™ 1Torch™ Operating Manual Number 0-5544

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

www.esab.com

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

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

For Material Print Speciﬁcations, refer to document 47x1948 Original Publication Date: 11-07-2018 Revision Date:

Record the following information for Warranty purposes:

Where Purchased:_______________________________ __________________

Purchase Date:__________________________________ __________________

Power Supply Serial #:___________________________ ___________________

Torch Serial #:___________________________________ _________________

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

OPERATING.

PROTECT YOURSELF AND OTHERS!

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

VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.

MISE EN GARDE

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

SECTION 2 SYSTEM:

INTRODUCTION ..................................................................................... 2-1

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

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

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

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

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

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

SECTION 2 TORCH:

INTRODUCTION .................................................................................... 2T-1

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

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

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

2T.04 Quick Connection Torch ................................................................................2T-2

2T.05 Options And Accessories ...............................................................................2T-2

2T.06 Introduction to Plasma ..................................................................................2T-2

SECTION 3 SYSTEM:

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

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

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

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

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

3.05 Gas Connections ............................................................................................. 3-3

SECTION 3 TORCH:

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

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

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

SECTION 4 SYSTEM:

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

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

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

SECTION 4 TORCH:

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

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

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

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

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

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

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

4T.07 Parts Selection for Manual Torch Cutting .......................................................4T-8

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

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

TABLE OF CONTENTS

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

SECTION 5 SYSTEM:

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

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

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

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

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

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

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

SECTION 5 TORCH:

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

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

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

SECTION 6:

PARTS LISTS ......................................................................................... 6-1

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

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

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

6.04 Replacement Power Supply Parts ................................................................... 6-1

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

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

6.07 Torch Consumable Parts (SL60) ..................................................................... 6-4

6.08 Torch Consumable Parts (SL100) ................................................................... 6-5

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM) .................................................................................. A-1

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

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

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

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

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

APPENDIX 7: PUBLICATION HISTORY .................................................................A-10

CUTMASTER 58

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 ecient operation of the system.

CAUTION

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

WARNING

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

WARNING

Gives information regarding possible electrical shock injury.

Manual 0-5544 GENERAL INFORMATION

1-1

CUTMASTER 58

WARNING

1. Cutting sparks can cause explosion or ﬁre.

1.1 Do not cut near ﬂammables.

1.2 Have a ﬁre extinguisher nearby and ready to use.

1.3 Do not use a drum or other closed container as a cutting table.

2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.

2.1 Turn o power before disassembling torch.

2.2 Do not grip the workpiece near the cutting path.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric shock or burn.

3.1 Wear insulating gloves. Replace gloves when wet or damaged.

3.2 Protect from shock by insulating yourself from work and ground.

3.3 Disconnect power before servicing. Do not touch live parts.

4. Plasma fumes can be hazardous.

4.1 Do not inhale fumes.

4.2 Use forced ventilation or local exhaust to remove the fumes.

4.3 Do not operate in closed spaces. Remove fumes with ventilation.

5. Arc rays can burn eyes and injure skin.

5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of ﬁlter.

6. Become trained.

Only qualiﬁed personnel should operate this equipment. Use torches speciﬁed in the manual. Keep non-qualiﬁed personnel and children away.

7. Do not remove, destroy, or cover this label.

Replace if it is missing, damaged, or worn.

AVERTISSEMENT

1. Les étincelles de coupage peuvent provoquer une explosion ou un incendie.

1.1 Ne pas couper près des matières inﬂammables.

1.2 Un extincteur doit être à proximité et prêt à être utilisé.

1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.

2. L’arc plasma peut blesser et brûler; éloigner la buse de soi. Il s’allume instantanément quand on l’amorce.

2.1 Couper l’alimentation avant de démonter la torche.

2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.

2.3 Se protéger entièrement le corps.

3. Tension dangereuse. Risque de choc électrique ou de brûlure.

3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommagés.

3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.

3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.

4. Les fumées plasma peuvent être dangereuses.

4.1 Ne pas inhaler les fumées.

4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.

4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.

5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles contre le bruit. Utiliser un masque de soudeur avec un ﬁltre de nuance appropriée.

6. Suivre une formation.

Seul le personnel qualiﬁé a le droit de faire fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le manual. Le personnel non qualiﬁé et les enfants doivent se tenir à l’écart.

7. Ne pas enlever, détruire ni couvrir cette étiquette.

La remplacer si elle est absente, endommagée ou usée.

Art # A-13294

GENERAL INFORMATION Manual 0-5544

1-2

CUTMASTER 58

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to Thermal Dynamics® and ESAB CutMaster 58 systems

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

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

NOTE!

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

CAUTION

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

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 identied only by the specication or part number printed on loosely attached card or the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

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

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

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

WARNING

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

WARNING

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

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 identication numbers.

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

http://www.esab.com

Manual 0-5544 INTRODUCTION

2-1

CUTMASTER 58

Art # A-07941_AB

150 mm

2.04 Power Supply Specications

CutMaster 58 Power Supply Speciﬁcations

208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz 230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

Input Power

400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz 600 VAC (540 - 630), Three Phase, 60 Hz

Input Power Cable

Cable for 208/230V input power includes molded plug.

Power Supply includes input cable.

Output Current 20 - 60 Amps, Continuously Adjustable

Power Supply Gas

Filtering Ability

Particulates to 5 Microns

CutMaster 58 Power Supply Duty Cycle *

Ambient Temperature

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

IEC Rating

Duty Cycle 40% 60% 100%

All Units

Current

DC Voltage

60 Amps 50 Amps 30 Amps

104 100 92

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

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

NOTE!

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

Power Supply Dimensions & Weight Ventilation Clearance Requirements

10,75"

273 mm

16,375"

416 mm

24"

22,5"

43 lb / 19,5 kg

571,5 mm

INTRODUCTION Manual 0-5544

2-2

610 mm

150 mm

Art # A-07925_AB

150 mm

2.05 Input Wiring Specications

CutMaster 58 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Volts Hz kVA I max I1eff Fuse (amps)

208 60 10.4 47 30 50 10

CUTMASTER 58

Flexible Cord

(Min. AWG)

1 Phase

3 Phase

NOTE!

230 60 10.8 45 29 50 10

460 60 15.2 31 20 35 12

208 60 5.4 26 17 30 12

230 50/60 5.8 24 16 30 12

380 50/60 6.1 16 11 20 14

400 50/60 6.4 16 11 20 14

460 60 7.4 16 10 20 12

600 60 7.8 13 11 15 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.

Cable size is de-rated based on the Duty Cycle of the equipment.

Manual 0-5544 INTRODUCTION

2-3

CUTMASTER 58

Handle and Leads Wrap

and Clamp

Input Power Cord

Input

2.06 Power Supply Features

t # A-07942

Control Panel

To rch Leads Receptacl

Work Cable

Port for Optional Automation Interface Cable

Power Selection

Filter Assembly

Gas Inlet Port

Art # A-07981

INTRODUCTION Manual 0-5544

2-4

CUTMASTER 58

(95 mm)

t # A-02998

15.875" / 403 mm

16 mm

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL60, SL60QD™ and SL100/Mechanized Plasma Cutting Torches. Service of this equipment is restricted to properly trained personnel; unqualiﬁed personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

2T.02 General Description

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

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

2T.03 Specications

A. Torch Congurations

1. Hand/Manual Torch, Model SL60QD™

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

10.125" (257 mm)

3.75"

1.17" (29 mm)

2. Mechanized Torch, Model

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

9.285" / 236 mm

1.375" / 35 mm

1.75" /

44.5 mm

0.625" /

B. Torch Leads Lengths

4.95" / 126 mm

Art # A-13246

1.175" / 30 mm

CAUTION

Torch Leads are flexible but internal wires can be broken. Do not exceed a 2" radius bend and avoid repeated tight bends when possible.

NOTE!

Refer to Section "2T.05 Introduction to Plasma", for a more detailed description of plasma torch operation.

Refer to the Appendix Pages for additional specications as related to the Power Supply used.

Hand Torches are available as follows:

• 20 ft / 6.1 m, with ATC connectors

• 50 ft / 15.2 m, with ATC connectors

Machine Torches are available as follows:

• 5 foot / 1.5 m, with ATC connectors

• 10 foot / 3.05 m, with ATC connectors

• 25 foot / 7.6 m, with ATC connectors

• 50 foot / 15.2 m, with ATC connectors

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

15 VDC circuit rating

E. Type Cooling

Combination of ambient air and gas stream through torch.

Manual 0-5544 INTRODUCTION

2T-1

CUTMASTER 58

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

Duty Cycle 100% @ 60 Amps @ 400 scfh

Maximum Current 60 Amps

Voltage (V

Arc Striking Voltage 500V

Ambient

Temperature

Duty Cycle 100% @ 100 Amps @ 400 scfh

Maximum Current 120 Amps

Voltage (V

Arc Striking Voltage 500V

) 500V

peak

Mechanized Torch Ratings

) 500V

peak

104° F

40° C

104° F

40° C

G. Gas Requirements

Manual and Mechanized Torch Gas Speciﬁcations

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

90 - 120 psi

6.2 - 8.3 bar

2T.04 Quick Connection Torch

The new SL60QD™ (Quick Disconnect) torch allows for a quick change of the torch handle assembly from the leads. To change the torch handle assembly do the following.

1. Remove the torch handle assembly by grasping the torch handle in one hand and the coupler nut and leads in the other.

2. Rotate the nut a minimum of one full turn to the left (counter clockwise) and pull the torch handle assembly out from the leads in a straight line.

3. To reattach, grasp both as before and carefully align the internal connecting parts.

4. Carefully press the two together in a straight line.

5. Align the mark on the coupler nut with that on the top of the torch handle and rotate to the right (clockwise) drawing the two together and seating the connections inside. Do not use tools to tighten.

2T.05 Options And Accessories

For options and accessories, see Section 6.

2T.06 Introduction to Plasma

Maximum Input Pressure 125 psi / 8.6 bar

5 - 8.3 SCFM

Gas Flow (Cutting and Gouging)

300 - 500 scfh

142 - 235 lpm

WARNING

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

The SL60QD torch should not be used on an HF system.

NOTE!

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

H. Direct Contact Hazard

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

A. Plasma Gas Flow

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

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

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

INTRODUCTION Manual 0-5544

2T-2

A-02997

Power

Supply

CUTMASTER 58

D. Main Cutting Arc

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

E. Parts - In - Place (PIP)

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

Workpiece

A-00002

Typical Torch Head Detail

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

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

B. Gas Distribution

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

The plasma gas ows into the torch through the negative lead, through the starter cartridge, around the electrode, and out through the tip orice.

To Control

Torch Switch

Cable Wiring

PIP Switch

Torch Trigge

Shield Cup

Parts - In - Place Circuit Diagram for Hand Torch

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

C. Pilot Arc

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

Manual 0-5544 INTRODUCTION

2T-3

CUTMASTER 58

This Page Intentionally Blank

INTRODUCTION Manual 0-5544

2T-4

SECTION 3 SYSTEM:

Art# A-11478

Art # A-07984_AB

Art # A-07983_AB

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.

CUTMASTER 58

Contactor cover

3.04 Primary Input Power Connections

3.02 Lifting Options

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

securely.

WARNING

Do not touch live electrical parts.

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

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

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

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

Disconnect input power cord before moving unit.

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

HANDLES are not for mechanical lifting.

3.03 Opening the Contactor Cover

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

CAUTION

Check your power source for correct volt-

age before plugging in or connecting the unit. Check the Voltage Selector at the rear of the unit for correct setting before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as speciﬁed in Section 2.

Most units are shipped from the factory with a 230Volt input power cable wired to the input contactor in the single - phase conﬁguration. The following illustrations and directions are for changing that conﬁguration to a different voltage and or to three - phase operation or back again if a change had already been made.

Single-Phase (1ø) and Jumper Settings

L3 L4

GND

Jumper L1 -L4

Jumper L2-L3

Single Phase Input Power Wiring

Three-Phase (3ø) and Jumper Settings

Store copper jumper in spare parts box

L3 L4

GND

Jumper L1 -L4

Three Phase Input Power Wiring

Manual 0-5544 INSTALLATION

3-1

CUTMASTER 58

NOTE!

There is only one jumper setting that changes between the single and three phase settings. To change from single phase to three phase, the jumper connected to L2 needs to be removed and placed on the other L3 connection so both ends of the jumper are attached to the same electrical point. See previous

illustrations..

A. Connections to Single Phase Input Power

WARNING

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

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

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

2. Disconnect the original input power cable from

the main input contactor and the chassis ground connection.

3. Loosen the through - hole protector on the back

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

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

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

5. Pass the cable being used through the access

opening in the back panel of the power supply. Refer to Section 2 for power cable speciﬁcations.

CAUTION

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

6. Connect the wires as follows.

• Set Jumper wires on the contactor. See previous illustrations.

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

- hole protector to secure the power cable.

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

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

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

B. Connections to Three Phase Input Power

WARNING

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

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

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

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

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

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

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

CAUTION

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

• Green / Yellow wire to Ground.

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

INSTALLATION Manual 0-5544

3-2

CUTMASTER 58

Regulator/Filter

Gas Supply Hose

to 1/4” (6mm) Fitting

t # A-07944

Hose Clam

Regulator/Filter

6. Connect the wires as follows.

• Set Jumper wires on the contactor. See previous illustrations..

• Green / Yellow wire to Ground.

• Remaining wires to L1, L2 and L3 input. It does not matter what order these wires are attached.

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

- hole protector to secure the power cable.

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

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

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

3.05 Gas Connections

Connecting Gas Supply to Unit

The connection is the same for compressed air or high pressure cylinders. Refer to the following two subsections if an optional air line ﬁlter is to be installed.

Installing Optional Single - Stage Air Filter

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

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

2. Attach the Filter Assembly to the ﬁlter hose.

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

NOTE!

For a secure seal, apply thread sealant to the ﬁtting threads, according to 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.

Assembly

Inlet Port

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

NOTE!

Assembly

Inlet Port

Hose Clamp

1/4 NPT or ISO-R

Gas Supply Hose

1/4 NPT to 1/4"

(6mm) Fitting

Optional Single - Stage Filter Installation

Art # A-07943

Air Connection to Inlet Port

Manual 0-5544 INSTALLATION

3-3

CUTMASTER 58

Regulator/Filter

wo Stage

Art # A-07945_AC

Hose Clamp

Installing Optional Two - Stage Air Filter Kit

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

Connect the air supply as follows:

1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the ﬁlter assembly.

NOTE!

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

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

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

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

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

3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100 psi (6.9 bar) maximum and ﬂows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the cylinder.

NOTE!

Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.

Supply hose must be at least 1/4 inch (6 mm) I.D.

Gas Supply Hose

Assembly

Regulator Input

1/4 NPT to 1/4” (6mm) Fitting

Optional Two - Stage Filter Installation

2-Stage Filter Inlet Port (IN)

Outlet Port (OUT)

T Filter Assembly

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.

INSTALLATION Manual 0-5544

3-4

CUTMASTER 58

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Supply. Connect only the ESAB model SL60, SL60QD™ or SL100 / Mechanical Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions.

WARNING

Disconnect primary power at the source before connecting the torch.

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

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

3. Place a welding ﬁlter lens in front of the torch and turn

ON the air. Do not start an arc!

Any oil or moisture in the air will be visible on

the lens.

3T.02 Setting Up Mechanical Torch

NOTE!

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

WARNING

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

The mechanical torch includes a positioning tube with rack and pinch block assembly.

1. Mount the torch assembly on the cutting table.

Art # A-07885

Connecting the Torch to the Power Supply

3. The system is ready for operation.

Check Air Quality

To test the quality of air:

1. Put the ON / OFF switch in the ON (up) position.

2. To obtain a clean vertical cut, use a square to align the torch perpendicular to the surface of the workpiece.

Pinch Block Assembly

Square

rkpiece

A-02585

Mechanical Torch Set - Up

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

Manual 0-5544 INSTALLATION

3. The proper torch parts (shield cup, tip, start cartridge, and electrode) must be installed for the type of operation. Refer to Section "4T.01 Torch Parts Selection" on page 4T-1 for details.

3T-1

CUTMASTER 58

This Page Intentionally Blank

INSTALLATION Manual 0-5544

3T-2

CUTMASTER 58

Art # A-08170

SECTION 4 SYSTEM:

OPERATION

4.01 Front Panel Controls / Features

See Illustration for numbering Identication

1. Output Current Control

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

2. Function Control

Function Control Knob; Used to select between the dierent operating modes.

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

RUN Used for general cutting operations

RAPID AUTO RESTART Allows for faster

restarting of the Pilot Arc for uninterrupted cutting.

1 2

MAX

MIN

PSI BAR

MAX MAX

MIN MIN

Art# A-13751

6. Temp Indicator

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

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

3. ON OFF Power Switch

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

4. Air/Gas Pressure Control

The Pressure

Control is used in the "SET" mode to adjust the air/gas pressure. Pull the knob OUT to adjust and push IN to lock.

5. AC Indicator

Steady light indicates power supply is ready for op-

eration. Blinking light indicates unit is in protective interlock mode. Shut unit OFF, shut OFF or disconnect input power, correct the fault, and restart the unit. Refer to Section 5 for details.

7. Gas Indicator

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

8. DC Indicator

Indicator is ON when DC output circuit is active.

9. ! Fault Error Indicator

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

10. Pressure Indicators

PSI BAR

MAX MAX

90 6.3

85 5.9

MINMIN

5.5

5.2

4.8

4.5

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

Manual 0-5544 OPERATION

4-1

CUTMASTER 58

Art # A-04509

Art# A-07946

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 model SL60QD or SL60 / Manual or SL100 / Mechanical Torches may be connected to this Power Supply. See Section 3T of this manual.

Check Primary Input Power Source

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

NOTE!

Minimum pressure for power supply operation is lower than minimum for torch operation. The cooling fans will turn ON as soon as the unit is turned ON. After the unit is idle for ten (10) minutes the fans will turn OFF. The fans will come back ON as soon as the torch switch (Start Signal) is activated or if the unit is turned OFF, then turned ON again. If an over temperature condition occurs, the fans will continue to run while the condition exists and for a ten (10) minute period once the condition is cleared.

Set Operating Pressure

1. Place the Power Supply Function Control knob to the

SET position. Gas will ﬂow.

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

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

Air Source

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

Connect Work Cable

Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut o.

Power ON

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

turns ON if there is sucient gas pressure for power

supply operation and the cooling fans turn ON.

MIN

MAX

PSI BAR

MAXMAX

MINMIN

STANDOFF

CutMaster 58 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

SL60QD

(Hand Torch)

75 psi

5.2 bar

(Mechanized Torch)

SL100

75 psi

5.2 bar

Each

additional

25'

Add 5 psi

0.4 bar

Add 5 psi

0.4 bar

(7.6 m)

OPERATION Manual 0-5544

4-2

CUTMASTER 58

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

DRAG

CutMaster 58 Gas Pressure Settings

Leads Length

Up to 25'

(7.6 m)

Each additional 25'

(7.6 m)

SL60QD

(Hand Torch)

80 psi

5.5 bar

Add 5 psi

0.4 bar

Select Current Output Level

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

RUN ,

RAPID AUTO RESTART

or LATCH . Gas ﬂow stops.

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

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.

Postow

Release the trigger to stop the cutting arc. Gas continues to ow for approximately 20 seconds. During post

- ow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece.

Shutdown

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

Cutting Operation

When the torch leaves the workpiece during cutting operations with the Function Control Knob in the RUN position, there is a brief delay in restarting the pilot arc. With the knob in the RAPID AUTO RESTART position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arc contacts the workpiece. (Use the 'Rapid Auto Restart' position when cutting expanded metal or gratings, or in gouging or trimming operations when an uninterrupted restart is desired). And with the knob in the LATCH position the main cutting arc will be maintained after the torch switch is released.

Manual 0-5544 OPERATION

4-3

CUTMASTER 58

This Page Intentionally Blank

OPERATION Manual 0-5544

4-4

SECTION 4 TORCH:

A-03510_AB

OPERATION

CUTMASTER 58

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

2. Remove the Electrode by pulling it straight out of the Torch Head.

4T.01 Torch Prts Selection

Depending on the type of operation to be done determines the torch parts to be used.

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Start Cartridge

NOTE!

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

Change the torch parts for a dierent operation as follows:

WARNING

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

NOTE!

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

Large O-Ring

Torch Head

Electrode

Start Cartridge

Shield Cup

Torch Parts

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

4. Install the start cartridge and desired tip for the operation into the torch head.

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

Small O-Ring

Tip

4T.02 Cut Quality

NOTE!

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

Cut quality requirements dier depending on application. For instance, nitride build - up and bevel angle may be major factors when the surface will be welded after cutting. Dross

- free cutting is important when nish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in the following gure:

Manual 0-5544 OPERATION

4T-1

CUTMASTER 58

Kerf Width

Cut Surface Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

Cut Quality Characteristics

Cut Surface

The desired or specied condition (smooth or rough) of the face of the cut.

4T.03 General Cutting Information

WARNING

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

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

CAUTION

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

Nitride Build - Up

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

Bevel Angle

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

Top - Edge Rounding

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

Bottom Dross Buildup

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

Kerf Width

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

Top Spatter (Dross)

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

NOTE!

Handle torch leads with care and protect them from damage.

Piloting

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

Torch Standoff

Improper stando (the distance between the torch tip and workpiece) can adversely aect tip life as well as shield cup life. Stando may also signicantly aect the bevel angle. Reducing stando will generally result in a more square cut.

Edge Starting

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

Direction of Cut

OPERATION Manual 0-5544

4T-2

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

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

Side Characteristics Of Cut

Shield Cup

Torch

Standoff Distance

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

CUTMASTER 58

NOTE!

The tip should never come in contact with the workpiece except during drag cutting operations.

2. Depending on the cutting operation, do one of the following:

a. For edge starts, hold the torch perpendicular to

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

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

Dross

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

4T.04 Hand Torch Operation

Standoff Cutting With Hand Torch

NOTE!

For best performance and parts life, always use the correct parts for the type of operation.

b. For stando cuing, hold the torch 1/8 - 3/8 in

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

Standoff Distance

3. Hold the torch away from your body.

4. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

Manual 0-5544 OPERATION

Trigger

Trigger Release

Art # A-13150

5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.

NOTE!

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

4T-3

CUTMASTER 58

t # A-03383

Tr igger

Art # A-04034

A-03539

Tr igger Release

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

WARNING

The straight edge must be non - conductive.

Non-Conductive

Straight Edge Cutting Guide

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when cutting 3/16

inch (4.7 mm) solid metal with relatively smooth surface.

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

NOTE!

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

8. For a consistent stando height from the workpiece, install the stando guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the stando guide against the workpiece.

Shield Cup

Standoff Guide

Torch Tip

Workpiece

Shield Cup With Straight Edge

Drag Cutting With a Hand Torch

Drag cutting works best on metal 1/4" (6 mm) thick or less.

NOTE!

For best parts performance and life, always use the correct parts for the type of operation.

1. Install the drag cutting tip and set the output current.

2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

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

5. Hold the torch away from your body.

6. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

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

OPERATION Manual 0-5544

4T-4

Trigger

t # A-03383

Tr igger

Trigger Release

Art # A-13150

7. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.

NOTE!

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

Tr igger Release

CUTMASTER 58

Piercing With Hand Torch

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement.

NOTE!

The tip should never come in contact with the workpiece except during drag cutting operations.

2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete.

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

4. Hold the torch away from your body.

5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

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

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

NOTE!

Trigger

Trigger Release

Art # A-13150

6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.

NOTE!

The gas preow and postow are a characteristic of the power supply and not a function of the torch. When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.

Manual 0-5544 OPERATION

4T-5

CUTMASTER 58

35°

Workpiece

Torch Head

Standoff Height

A-00941_AB

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

Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance:

• Torch parts wear

• Air quality

• Line voltage uctuations

• Torch stando height

• Proper work cable connection

4T.05 Gouging

WARNING

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

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

Current Setting

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

Lead Angle

The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.

CAUTION

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

Gouging Parameters

Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (stando).

CAUTION

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

Torch Travel Speed

NOTE!

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

Gouging Angle and Standoff Distance

Standoff Distance

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

Slag Buildup

Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels, can be removed easily in most cases. Slag does not obstruct the gouging process if it accumulates to the side of the gouge path. However, slag build - up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc. The build - up is most often a result of improper travel speed, lead angle, or stando height.

OPERATION Manual 0-5544

4T-6

4T.06 Mechanized Torch Operation

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

Cutting With Mechanized Torch

The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC.

1. To start a cut at the plate edge, position the center of the torch along the edge of the plate.

Travel Speed

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

1. Straight Arc

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

2. Leading Arc

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

3. Trailing Arc

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

CUTMASTER 58

For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer.

Travel speed also aects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required.

Piercing With Machine Torch

To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This stando helps avoid having molten metal blow back onto the front end of the torch.

When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled until the arc penetrates the bottom of the plate. As motion begins, torch stando should be reduced to the recommended 1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cut quality. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

Manual 0-5544 OPERATION

Mechanized Torch Operation

4T-7

CUTMASTER 58

4T.07 Parts Selection for Manual Torch Cutting

Art # A-13753

OPERATION Manual 0-5544

4T-8

CUTMASTER 58

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

Type Torch: SL60QDQD With Exposed Tip Type Material: Mild Steel

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

Thickness Tip Output Amperage

Inches

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

0.06 1.5 9-8208 108 40 250 6.35 0.19 4.8 70 4.8 55 170 0.10 0.2 5.1

0.075 1.9 9-8208 108 40 190 4.83 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 110 40 105 2.67 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 113 40 60 1.52 0.19 4.8 70 4.8 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 111 40 40 1.02 0.19 4.8 70 4.8 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 124 40 21 0.53 0.19 4.8 70 4.8 55 170 NR NR NR

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

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

Thickness Tip Output Amperage

Inches

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

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

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

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

0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 70 4.8 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 124 40 20 0.51 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 122 40 15 0.38 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 126 40 10 0.25 0.187 4.8 70 4.8 55 170 NR NR NR

(Cat.

No.)

Type Torch: SL60QD With Exposed Tip Type Material: Stainless Steel

(Cat.

No.)

Volts

(VDC)

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

Volts

(VDC)

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

Speed (Per

Minute)

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Plasma Gas

Press

Flow (CFH) Pierce

Delay (Sec)

Flow (CFH) Pierce

Delay (Sec)

Pierce Height

Inches mm

Pierce Height

Inches mm

Type Torch: SL60QD With Exposed Tip Type Material: Aluminum

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

Thickness Tip Output Amperage

(Cat.

No.)

Inches

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

0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 70 4.8 55 170 0.10 0.2 5.1

0.064 1.6 9-8208 112 40 250 6.35 0.187 4.8 70 4.8 55 170 0.10 0.2 5.1

0.079 2.0 9-8208 112 40 200 5.08 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1

0.125 3.2 9-8208 118 40 100 2.54 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 120 40 98 2.49 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1

0.250 6.4 9-8208 123 40 50 1.27 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 134 40 16 0.41 0.187 4.8 70 4.8 55 170 NR NR NR

Manual 0-5544 OPERATION

Volts

(VDC)

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

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay (Sec)

Pierce

Height

Inches mm

4T-9

CUTMASTER 58

Type Torch: SL60QD With Exposed Tip Type Material: Mild Steel

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

Thickness Tip Output Amperage

Inches

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

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

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

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

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

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

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

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

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

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

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

(Cat.

No.)

Volts

(VDC)

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

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay (Sec)

Pierce

Height

Inches mm

Type Torch: SL60QD With Exposed Tip Type Material: Stainless Steel

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

Thickness Tip Output Amperage

Inches

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

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

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

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

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

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

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

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

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

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

(Cat.

No.)

Volts

(VDC)

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

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Pierce Height

Inches mm

OPERATION Manual 0-5544

4T-10

CUTMASTER 58

Type Torch: SL60QD With Exposed Tip Type Material: Aluminum

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

Thickness Tip Output Amperage

Inches

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

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

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

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

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

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

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

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

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

(Cat.

No.)

Volts

(VDC)

NOTE!

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

Speed (Per

Minute)

Standoff

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to Section "Set Operating Pressure" on page 4T-1. ** Total ow rate includes plasma and secondary gas ow

Plasma Gas

Press

Flow (CFH) Pierce

Delay (Sec)

Pierce

Height

Inches mm

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

Type Torch: SL60QD With Shielded Tip Type Material: Mild Steel

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

Thickness Tip Output Amperage

Inches

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

0.06 1.5 9-8208 120 40 90 2.29 0.19 4.8 70 4.8 55 170 0.10 0.2 5.1

0.075 1.9 9-8208 121 40 80 2.03 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 122 40 75 1.91 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 123 40 30 0.76 0.19 4.8 70 4.8 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 125 40 25 0.64 0.19 4.8 70 4.8 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 138 40 11 0.28 0.19 4.8 70 4.8 55 170 NR NR NR

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

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

(Cat. No.)

Volts

(VDC)

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

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Pierce Height

Inches mm

Manual 0-5544 OPERATION

4T-11

CUTMASTER 58

Type Torch: SL60QD With Shielded Tip Type Material: Stainless Steel

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

Thickness Tip Output Amperage

Inches

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

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

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

0.078 2.0 9-8208 120 40 65 1.65 0.187 4.8 70 4.8 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 125 40 25 0.64 0.187 4.8 70 4.8 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 132 40 20 0.51 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 130 40 15 0.38 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 130 40 10 0.25 0.187 4.8 70 4.8 55 170 NR NR NR

Thickness Tip Output Amperage

Inches

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

0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1

0.064 1.6 9-8208 118 40 180 4.57 0.187 4.8 70 4.8 55 170 0.10 0.2 5.1

0.079 2.0 9-8208 116 40 150 3.81 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1

0.125 3.2 9-8208 130 40 75 1.91 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 132 40 60 1.52 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1

0.250 6.4 9-8208 134 40 28 0.71 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 143 40 11 0.28 0.187 4.8 70 4.8 55 170 NR NR NR

(Cat.

No.)

Type Torch: SL60QD With Shielded Tip Type Material: Aluminum

(Cat.

No.)

Volts

(VDC)

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

Volts

(VDC)

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

Speed (Per

Minute)

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Plasma Gas

Press

Flow (CFH) Pierce

Delay

(Sec)

Flow (CFH) Pierce

Delay (Sec)

Pierce

Height

Inches mm

Pierce

Height

Inches mm

Type Torch: SL60QD With Shielded Tip Type Material: Mild Steel

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

Thickness Tip Output Amperage

Inches

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

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

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

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

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

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

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

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

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

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

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

OPERATION Manual 0-5544

4T-12

(Cat. No.)

Volts

(VDC)

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

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay (Sec)

Pierce Height

Inches mm

CUTMASTER 58

Type Torch: SL60QD With Shielded Tip Type Material: Stainless Steel

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

Thickness Tip Output Amperage

Inches

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

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

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

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

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

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

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

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

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

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

(Cat.

No.)

Type Torch: SL60QD With Shielded Tip Type Material: Aluminum

Volts

(VDC)

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

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay (Sec)

Pierce Height

Inches mm

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

Thickness Tip Output Amperage

(Cat.

No.)

Inches

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

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

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

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

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

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

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

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

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

Volts

(VDC)

NOTE!

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

Speed (Per

Minute)

Standoff

Plasma Gas

Press

Flow (CFH) Pierce

Delay (Sec)

Pierce

Height

Inches mm

Manual 0-5544 OPERATION

4T-13

CUTMASTER 58

PATENT INFORMATION

Plasma Cutting Torch Patents

The following parts are covered under U.S. and Foreign Patents as follows:

Catalog # Description Patent(s)

9-8215 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786; 6703581; D496842; D511280; D492709; D499620; D504142 Other Pat(s) Pending 9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8241 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8243 Shield Cap US Pat No(s) 6914211; D493183 Other Pat(s) Pending 9-8235 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8236 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633 Other Pat(s) Pending 9-8238 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8239 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8244 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending

OPERATION Manual 0-5544

4T-14

CUTMASTER 58

Catalog # Description Patent(s)

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

The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:

Catalog # Description

9-8235 Shield Cap 9-8236 Shield Cap 9-8237 Shield Cup 9-8238 Shield Cap 9-8239 Shield Cap 9-8244 Shield Cap 9-8245 Shield Cap

Manual 0-5544 OPERATION

4T-15

CUTMASTER 58

OPERATION Manual 0-5544

4T-16

5.01 General Maintenance

Art # A-07938_AB

CUTMASTER 58

SECTION 5 SYSTEM:

SERVICE

Warning! Disconnect input power before maintaining.

Visual check of torch tip and electrode

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

Maintain more often if used under severe conditions

Each Use

Weekly

Visually inspect the cables and leads. Replace as needed

Replace all broken parts

3 Months

Clean exterior of power supply

6 Months

Visually check and Carefully clean the interior

Manual 0-5544 SERVICE

5-1

CUTMASTER 58

5.02 Maintenance Schedule

NOTE!

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

Daily Operational Checks or Every Six Cutting

Hours:

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

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

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

Weekly or Every 30 Cutting Hours:

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

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

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

Six Months or Every 720 Cutting Hours:

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

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

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

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

CAUTION

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

5.03 Common Faults

Problem - Symptom Common Cause

Insufﬁcient Penetration

Main Arc

Extinguishes

Excessive Dross

Formation

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

Difﬁcult Starting 1. Worn torch parts.

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

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

2. Non - Genuine Thermal Dynamics parts used.

3. Incorrect gas pressure.

SERVICE Manual 0-5544

5-2

CUTMASTER 58

5.04 Fault Indicator

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

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

7 6

5 4

3 2 1

MAX

MIN

PSI BAR

MAX MAX

MIN MIN

Art# A-13752

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

Pressure

Fault

Indicator Max Over Pressure 90 Internal Error 85 Shorted Torch 80 Consumables Missing 75 Start Error 70 Parts in Place 65 Input Power Min Under Pressure

NOTE!

Fault explanations are covered in the following tables.

Manual 0-5544 SERVICE

5-3

CUTMASTER 58

5.05 Basic Troubleshooting Guide

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

Problem - Symptom Possible Cause Recommended Action

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

Fault indicator ﬂashing, 65 PSI indicator ﬂashing

TEMPERATURE indicator ON. FAULT indicator ﬂashing.

1. Primary power disconnect is in OFF position.

2. Primary fuses / breakers are blown or tripped.

3. Units internal fuse blown.

4. Faulty components in unit.

1. INPUT VOLTAGE SELECTION SWITCH set for incorrect voltage.

2. Primary input voltage problem.

3. Faulty components in unit.

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

2. Duty cycle of the unit has been exceeded.

3. Failed components in unit.

1. Turn primary power disconnect switch to ON position.

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

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

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

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

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

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

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

2. Allow unit to cool.

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

GAS LED OFF, FAULT and MIN pressure indicators ﬂashing.

FAULT and 70 PSI indicators ﬂashing.

FAULT and 75 PSI indicators ﬂashing.

1. Gas supply not connected to unit.

2. Gas supply not turned ON.

3. Gas supply pressure too low.

4. AIR PRESSURE CONTROL regulator set too low.

5. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to power supply.

3. Problem in torch and leads PIP circuit.

4. Failed components in unit.

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

2. Problem in the torch and leads switch circuit.

3. Failed components in unit.

1. Connect gas supply to unit.

2. Turn gas supply ON.

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

4. Adjust regulator to set air pressure - see Section "4. Air/Gas Pressure Control" on page 4-1

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

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

2. Insure torch ATC is securely fastened to unit.

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

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

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

• Hand torch switch held closed

• Hand pendant switch held closed

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

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

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

SERVICE Manual 0-5544

5-4

Problem - Symptom Possible Cause Recommended Action

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

1. Torch shield cup is loose.

2. Torch tip, electrode or starter cartridge missing.

3. Torch start cartridge is stuck.

4. Open conductor in torch leads.

5. Problem in the torch and leads switch circuit.

6. Failed components in unit.

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

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

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

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

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

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

CUTMASTER 58

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

FAULT and 85 PSI indicators ﬂashing.

No Fault lights ON, no arc in torch.

FAULT and 85 PSI indicators ﬂashing

Pilot arc is ON but cutting arc will not establish

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

2. CNC Controller device not providing Start signal.

3. Failed components in unit.

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

2. Torch starter cartridge is stuck.

3. Worn or faulty torch parts.

4. Shorted Torch.

5. Temporary Short indicated by 5 blinks per second.

6. Power Supply Failure (Standard rate of blinking)

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

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

1. Work cable not connected to work piece.

2. Work cable/connector broken.

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.

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

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

3. Inspect torch consumable parts. Replace if necessary.

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

5. Release torch switch and reactivate.

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

does 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.

Torch cutting is diminished

Manual 0-5544 SERVICE

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.

5-5

CUTMASTER 58

Screws

5.06 Power Supply Basic Parts Replacement

WARNING

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

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

A. Cover Removal

1. Remove the upper and lower screws which secure the cover to the main assembly. Do not loosen the lower screws inside the cut out slots in the bottom of the cover.

Upper Screws

Lower

C. Filter Element Assembly Replacement

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

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

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

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

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

Slots

Lower Screws

Art # A-07947

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

B. Cover Installation

1. Reconnect the ground wire, if necessary.

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

3. Tighten lower screws.

Art # A-07989

6mm

4. Reinstall and tighten the upper screws.

SERVICE Manual 0-5544

5-6

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

CUTMASTER 58

Art # A-07990

led Filter

(Cat.

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

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

NOTE!

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

Filter Element

Optional Single-Stage Filter Element

Replacement

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

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

1. Remove power from power supply.

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

3. Disconnect gas supply hose.

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

Housing

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

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

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

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 0-5544 SERVICE

5-7

CUTMASTER 58

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 tting is normal..

This completes the parts replacement procedures.

SERVICE Manual 0-5544

5-8

SECTION 5 TORCH:

Must Remain Open

Lower O-Ring

Art # A-03725

Art #A-03791_AB

SERVICE

5T.01 General Maintenance

NOTE!

Refer to Previous “Section 5: System” for common and fault indicator descriptions.

CUTMASTER 58

Upper Groove with Vent Holes

Upper O-Ring in Correct Groove

Threads

Cleaning Torch

Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can aect the pilot arc initiation and the overall cut quality of the torch.

WARNING

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

The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.

CAUTION

Dry the torch thoroughly before reinstalling.

Torch Head O-Ring

ATC Male Connector

Gas Fitting

O-Ring Lubrication

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

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

Manual 0-5544 SERVICE

O-Ring

ATC O-Ring

NOTE!

DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.

5T-1

CUTMASTER 58

Art # A-08067

Drag Shield Cap

Good Tip

Worn Tip

A-03406

Art # A-08064_AC

Spring-Loaded

Art # A-03284

5T.02 Inspection and Replacement of

Consumable Torch Parts

WARNING

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

Remove the consumable torch parts as follows:

NOTE!

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

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

NOTE!

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

Example of Tip Wear

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

Lower End Fitting Full Compression

Lower End Fitting at Reset / Full Extension

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

Shield Cups

3. On torches with a shield cup body and a shield cap or deﬂector, ensure that the cap or deﬂector is threaded snugly against the shield cup body. In shielded drag cutting operations (only), there may be an O-Ring between the shield cup body and drag shield cap. Do not lubricate the O-Ring.

Shield

Cup Body

O-Ring No. 8-3488

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

New Electrode

Worn Electrode

Electrode Wear

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

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

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

This completes the parts replacement procedures.

Art # A-03878

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

SERVICE Manual 0-5544

5T-2

CUTMASTER 58

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

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

6.03 Power Supply Replacement

6.04 Replacement Power Supply Parts

6.05 Options and Accessories

6.06 Replacement Parts for Hand Torch

6.07 Replacement Parts - for Machine Torches with Unshielded Leads

6.08 Replacement Shielded Machine Torch Leads Assemblies

6.09 Torch Consumable Parts (SL60)

6.10 Torch Consumable Parts (SL100)

NOTE!

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

B. Returns

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

6.02 Ordering Information

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

6.03 Power Supply Replacement

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

Qty Description Catalog #

1 CutMaster 58 Power Supply 208/230 - 460VAC, Single or 3 Phase, 60Hz, with input power cable and plug 3-5830-1 460VAC, Single or 3 Phase, 60Hz, with input power cable 3-5830-2 600VAC, 3 Phase, 60Hz, with input power cable 3-5830-5

6.04 Replacement Power Supply Parts

Qty Description Catalog #

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

Manual 0-5544 PARTS LIST

6-1

CUTMASTER 58

led Filter

(Cat.

First & Second

NOTE!

*9-0115 regulator, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will be needed to replace not only the regulator (9-0115) but the logic PCB as well. Another way to tell if the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom tting. If there is a transducer and wire harness instead of the tube, the kit is not needed

6.05 Options and Accessories

Qty Description Catalog #

1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507 1 Replacement Filter Body 9-7740 1 Replacement Filter Hose (not shown) 9-7742 2 Replacement Filter Element 9-7741 1 Two - Stage Filter Kit (includes Hose & Mounting Screws) 9-9387 1 Two - Stage Air Filter Assembly 9-7527 1 First Stage Cartridge 9-1021 1 Second Stage Cartridge 9-1022 1 Extended Work Cable (50 ft / 15.2 m) with Clamp 9-8529 1 Multi - Purpose Cart 7-8888 1 Automation Interface Kit 9-8311 1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008 1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010 1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011 1 Nylon Dust Cover 9-7071

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

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 0-5544

6-2

CUTMASTER 58

6.06 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 and QD connectors 4-5605 1&2 1 Torch and Leads Assembly, 20 - foot 7-5604 1&2 1 Torch and Leads Assembly, 50 - foot 7-5605

Art # A-13248_AB

Manual 0-5544 PARTS LIST

6-3

CUTMASTER 58

6.07 Torch Consumable Parts (SL60)

Art # A-13753

PARTS LIST Manual 0-5544

6-4

6.08 Torch Consumable Parts (SL100)

CUTMASTER 58

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 Cap 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 0-5544 PARTS LIST

6-5

CUTMASTER 58

This Page Intentionally Blank

PARTS LIST Manual 0-5544

6-6

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

CUTMASTER 58

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

Connect work cable to workpiece.

Set output amperage.

System is ready

for operation.

ON / OFF switch to ON

AC indicator ON.

GAS indicator ON

pressure is adequate

for power supply operation.

ACTION:

RESULT:

ACTION:

RESULT:

when input

Power circuit ready.

ACTION:

RUN / Rapid Auto Restart / SET / LATCH switch

to SET

RESULT:

Gas flows to set

pressure.

Torch moved away from work (while

ACTION:

RUN / Rapid Auto Restart /

SET / LATCH

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

or to

LATCH

is used for specific applications

(torch switch can be released

after main arc transfer).

RESULT: Gas flow stops.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate

Torch switch (START)

RESULT:

Fans turn on. Gas flows briefly,

then stops.Gas restarts.

DC indicator ON

Pilot arc established.

ACTION:

Release Torch switch.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

(Fans will continue to run for

10 minutes after the Torch switch

[START] is removed)

PILOT ARC

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fans shut off.

Main arc stops.

Pilot arc automatically

restarts.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

Art #A-08793

Manual 0-5544 APPENDIX

A-1

CUTMASTER 58

of the power supply.

Revision Level, Serial Number

Input Power Specifications (Phase, Hertz Rating)

APPENDIX 2: DATA TAG INFORMATION

Type of Power Supply (Note 1)

Plasma Cutting Symbol

Input Power Symbol

AC or DC

Mo de l:

Da te of Mf r:

1/ 3

Rated NoLoad Voltage

Degree of Protection

Output Current Type

Conventional Load Voltage

Rated Supply Voltage (Note 2)

West Lebanon, NH USA 03784

S/N

Duty Cycle Factor

Rated Maximum Supply Current

1max 1eff

1Ø

3Ø

Made in USA

3Ø1Ø

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

and Production Code

Regulatory Standard Covering This Type of Power Supply

Output Range (Amperage/ Voltage)

Duty Cycle Data (Note 3)

Maximum Effective 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 at the input power cord showing input voltage requirements for the power supply as built.

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

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

Standard Symbols

Phase

Art # A-03288_AC

APPENDIX Manual 0-5544

A-2

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

3 - Switch

2- Orange PIP

2 - Orange PIP

4 - Switch

Art # A-03799

A. Hand Torch Pin - Out Diagram

CUTMASTER 58

ATC Male Connector

Negative / Plasma

4 - Green / Switch

3 - White / Switch

1 - Black / PIP

2 1

Pilot

Front View

8 - Open

8 7

5 - Open

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector

4- Black Pendant Connector

3 - White Pendant Connector

Front View

4 3

UNSHIELDED MACHINE TORCH

Negative / Plasma

8 - Green Pendant Connector Ground

8 7

7 - Green / Not Used

6 - Open

7 - Open

6 - Open

8 - Open

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

2 1

Front View

4 3

2 1

Negative / Plasma

4 - Switch

4 3

2 - PIP

1 - PIP

A-03701_AB

Negative / Plasma

3 - Switch

2 - PIP

1 - Black / PIP

Pilot

5 - White / Not Used

Manual 0-5544 APPENDIX

5 - Open

1 - PIP

Pilot

A-3

CUTMASTER 58

Art # A-03797_AB

Art # A-03798

APPENDIX 4: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

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

Torch

Head

PIP

Switch

Torch

Switch

Torch Leads

Black

Orange

Green

White

Negative / Plasma

Pilot

Male

ATC Leads

Connector

ATC Female

Receptacle

Power Supply

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

B. Mechanized Torch Connection Diagram

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

Male

AT C Leads

Connector

Torch

Head

PIP

Switch

Not

Used

Pilot Lead

Torch Leads

Black

Orange

White

Green

Negative / Plasma Lead

To Remote Control

Remote

Pendant

Connector

Black

White

Green

AT C Female

Receptacle

Power Supply

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

APPENDIX Manual 0-5544

A-4

CUTMASTER 58

This Page Intentionally Blank

Manual 0-5544 APPENDIX

A-5

CUTMASTER 58

A-09131_AC

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

SW1SW1

1 3

2 4

SW2SW2

W1W1

SERIAL PORT

W1W1

PRIMARY AC INPUT

JUMPER

PRIMARY POWER CONNECTIONS:

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

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

GND

INPUT VOLTAGE SELECTOR (Closed for 230VAC input)

40 PIN RIBBON CABLE SIGNALS

-V_OUT_SIGNAL /TIP_VOLTS

/TIP_SENSE

3 4

/460V_IN

/230V_IN

CUR_SET

/RAR (RAPID AUTO RESTART)

/INRUSH

/W1_ON

/SHDN

/TORCH_SOLENOID

/SOLENOID_ON

/OK_TO_MOVE

/FAN_ON

/LATCH_ACTIVE

/TORCH_SWITCH

/PIP

AC_ON

CSR

/TORCH_SOLENOID_DETECT

/OVERTEMP

V_IN

+12VDC

COMMON

MAIN_PCB_ID

460_IN

+3.3VDC

TXD

RXD

COMMON

J3J3

1 2 3

J12J12

123

+12VDC

BIAS SUPPLY

J1J1

1 2 3 4 5

INRUSH

RESISTORS

AC1AC1

AC2AC2

AC3AC3

J3J3

460_IN

1 2

J6J6

24 VAC RETURN

J4J4

3.3VDC

TXD

RXD

3 4

M-L M-L

ACAC

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

OVERTEMPOVERTEMP

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

GASGAS

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

DCDC

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

ERRORERROR

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

Current ControlCurrent Control M-L M-L M-L L-M

LATCH

M-L M-L

SET

L-M M-L

RUN

RAR

/INRUSH

24VAC

/460

K1K1

D59 PCRD59 PCR

D78 CSRD78 CSR

ERROR IND FAULT

MAX 90 85 80 75 70 65 MIN

TEST POINTS

TP1 TP2 TP3 TP4 TP5 TP6 TP7

+12VDC

PCB3

/230

K1K1

PCB2

PCB1

40 CIRCUIT

RIBBON CABLE

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

GND +12 VDC +5 VDC

3.3 VDC

0.v - 5.0 VDC / 0-100PSI

1.8 VDC POT. DEMAND

D1D1

LOGIC PCB

MAIN PCB ASSY

K5, K6K5, K6

MTH1MTH1

C1-C4*+C1-C4*

MTH3MTH3

K2K2

K5K5

MTH5MTH5

INPUT CAPACITOR PCB

K1-K4K1-K4

MTH2MTH2

MTH4MTH4

K3K3

K6K6

MTH6MTH6

C5-C8*+C5-C8*

MTH7MTH7

* CM52 & A40 C3 & C5 not installed

0-100PSI / 0-4.5VDC

K4K4

MTH8MTH8

MAXMAX

9090

8585

8080

7575

7070

6565

MINMIN

+5VDC

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

/SOLENOID

PRI 1 PRI 1

PRI 4 PRI 4

PRI 3PRI 3

PRI 2 PRI 2

+12VDC

J5J5

GND1 GND2 GND3 +12V1 48V1 I_DMD_1 TIP_SEN

123

SOL1SOL1

TEST POINTS

GAS CONTROL

REGULATOR

SOLENOID

ATC

VALVE

FILTER

AIR INLET

J3J3

1 2 3

PRESSURE TRANSDUCER

123

T1T1

APPENDIX Manual 0-5544

A-6

CM82 / A60 ONLY

TS1TS1

CUTMASTER 58

1TORCH

PIP SWITCHPIP SWITCH

TORCH SWITCHTORCH SWITCH

AUTOMATION

TORCH SOLENOID

3 4 5 6 7 8

WORKWORK

J2 PINOUT

811

1214

-V OUT 1-V OUT 1

ELECTRODE1ELECTRODE1

WORK1WORK1

L1L1

ATC CONNECTOR

J1J1

1 2 3 4 5 6 7 8

J2J2

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

OK TO MOVE

}

(5A @250VAC / 30VDC)

/START / STOP

}

(Sink 50mA @12VDC)

E64

TIP1TIP1

E35

J9J9

5 6

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

P10P10

J10J10

J11J11

+12VDC

TEMP

/OVERTEMP

CIRCUIT

NTCNTC

SEC2SEC2

/START

24VAC RETURN

24VAC SUPPLY

OK-TO-MOVE

CHOKE1CHOKE1

PILOT IGBTQ5PILOT IGBT

/PIP

+12VDC

SEC1SEC1

+12VDC

J7J7

+ -

MOT1MOT1

+12VDC

/FAN/FAN

J8J8

+ -

MOT2MOT2

P10P10

NAFNAF

INTRO ECO B534

ECO B855

AC AD

ECO B1357

Monday, March 30, 2009

Last Modified:

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

To -V OUT 1 on PCB1

1 2 3 4 5 6 7 8

J1J1

1 2 3 4 5 6 7 8

J3J3

E1E1

+12VDC

K1K1

PCB4

Date

ByRevisionsRev

RWH 07/23/07

MNC 04/23/08ECO B890

MNC 05/09/08

MNC 10/03/08ECO B1159

RWH 03/31/09

13:16:29

123

AUTOMATION INTERFACE PCB

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

J2J2

1 2 3

/START / STOP

}

(-)

DIVIDED ARC VOLTS

}

(+)

6 7

(-)

ARC VOLTS

}

(W/ 100K IN SERIES (2))

(+)

9 10 11 12

OK-TO-MOVE

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE: UNLESS OTHERWISE SPECIFIED -

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

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

TITLE:

CUTMASTER 52/82/A40/A60 230/460V

}

SCHEMATIC,

VICTOR TECHNOLOGIESVICTOR TECHNOLOGIESVICTOR TECHNOLOGIES 16052 Swingley Ridge Road

16052 Swingley Ridge Road

16052 Swingley Ridge Road Suite 300

Suite 300

Suite 300 St Louis, MO 63017 USA

St Louis, MO 63017 USA

A-09131_AC

PCB No:

Assy No:

Date:

Thursday, March 27, 2008

Drawn: References

RWH

Chk: App:

DWG No:

Size

DWG No:

Size

DWG No:

Size

42X1298

SupersedesScale

Sheet

Manual 0-5544 APPENDIX

A-7

CUTMASTER 58

A-09133_AD

APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS

CE UNITS

ONLY

GND

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

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

40 PIN RIBBON CABLE SIGNALS

-V_OUT_SIGNAL

/TIP_VOLTS

/TIP_SENSE

/460V_IN

/230V_IN

CUR_SET

/RAR (RAPID AUTO RESTART)

/INRUSH

/W1_ON

/SHDN

/TORCH_SOLENOID

/SOLENOID_ON

/OK_TO_MOVE

/FAN_ON

/LATCH_ACTIVE

/TORCH_SWITCH

/PIP

AC_ON

CSR

/TORCH_SOLENOID_DETECT

/OVERTEMP

22 23 24 25

26 29 34 35 36 37 38 39

V_IN +12VDC +12VDC COMMON COMMON MAIN_PCB_ID 460_IN +3.3VDC TXD RXD COMMON D

EMI FILTER

EMI

CHOKE

W1W1

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

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

1 3

2 4

SW1SW1

SERIAL PORT

Current ControlCurrent Control

LATCH

SET

RUN

RAR

W1W1

ACAC

OVERTEMPOVERTEMP

GASGAS

DCDC

ERRORERROR

J1J1

1 2 3 4 5

J6J6

1 2

J4J4

1 2 3 4 5

BIAS SUPPLY

INRUSH

RESISTORS

AC1AC1

AC2AC2

AC3AC3

24VAC

24 VAC RETURN

3.3VDC TXD RXD

ERROR INDFAULT

MAX 90 85 80 75 70 65 MIN

TEST POINTS

TP1 TP2 TP3 TP4 TP5 TP6 TP7

+12VDC

PCB3

+12VDC

K1K1

/INRUSH

D59 PCRD59 PCR

D78 CSRD78 CSR

40 CIRCUIT

RIBBON CABLE

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

GND +12 VDC +5 VDC

3.3 VDC

0.v - 5.0 VDC / 0-100PSI

1.8 VDC POT. DEMAND

D1D1

LOGIC PCB

MTH2MTH2

MTH1MTH1

C1-C4*+C1-C4*

MTH3MTH3

MTH4MTH4

MTH8MTH8

MTH6MTH6

C5-C8*+C5-C8*

MTH5MTH5

MTH7MTH7

PCB2

INPUT CAPACITOR PCB

*CM52/12mm/20mm/A40 C3 & C5 may not be installed

MAIN PCB ASSY

PCB1

0-100PSI / 0-4.5VDC

MAXMAX

9090

8585

8080

7575

7070

6565

MINMIN

+5VDC

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

/SOLENOID

PRI 1 PRI 1

PRI 4 PRI 4

PRI 3PRI 3

PRI 2 PRI 2

+12VDC

J5J5

GND1 GND2 GND3 +12V1 48V1 I_DMD_1 TIP_SEN

SOL1SOL1

TEST POINTS

123

GAS CONTROL

REGULATOR

SOLENOID

ATC

VALVE

FILTER AIR INLET

J3J3

1 2 3

PRESSURE TRANSDUCER

123

APPENDIX Manual 0-5544

A-8

CUTMASTER 58

TS1TS1

T1T1

-V OUT 1-V OUT 1

ELECTRODE1ELECTRODE1

WORK1WORK1

L1L1

ATC CONNECTOR

J1J1

1 2 3 4 5 6 7 8

J2J2

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

OK TO MOVE

}

(5A @250VAC / 30VDC)

/START / STOP

}

(Sink 50mA @12VDC)

E64

TIP1TIP1

E35

J9J9

5 6

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

P10P10

J10J10

J11J11

+12VDC

TEMP

/OVERTEMP

CIRCUIT

NTCNTC

SEC2SEC2

/START

24VAC RETURN

24VAC SUPPLY

OK-TO-MOVE

CHOKE1CHOKE1

PILOT IGBTQ5PILOT IGBT

/PIP

+12VDC

SEC1SEC1

1TORCH

PIP SWITCHPIP SWITCH

TORCH SWITCHTORCH SWITCH

AUTOMATION

TORCH SOLENOID

3 4 5 6 7 8

WORKWORK

J2 PINOUT

811

1214

+12VDC

J7J7

+ -

MOT1MOT1

+12VDC

/FAN/FAN

INTRO ECO B1357

Last Modified:

J8J8

NAFNAF

MOT2MOT2

Wednesday, May 06, 2009

DateByRevisionsRev

RWH 03/31/09

RWH 90/50/509931B OCE

13:16:29

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

To -V OUT 1 on PCB1

P10P10

1 2 3 4 5 6 7 8

E1E1

J1J1

+12VDC

1 2

K1K1

3 4 5 6 7 8

PCB4

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE: UNLESS OTHERWISE SPECIFIED -

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

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

TITLE:

CM52/82/12mm/20mm/25mm/A40/A60 380/400/415/600V

SCHEMATIC,

To configure DIVIDED ARC VOLTS signal output

No jumper installed for ARC VOLTS /16.67 Jumper pins 1 & 2 for ARC VOLTS / 30 Jumper pins 2 & 3 for ARC VOLTS / 50

123

J3J3

AUTOMATION INTERFACE PCB

VICTOR TECHNOLOGIESVICTOR TECHNOLOGIESVICTOR TECHNOLOGIES 16052 Swingley Ridre Road,

16052 Swingley Ridre Road,

16052 Swingley Ridre Road, Suite 300

Suite 300

Suite 300 St Louis, MO 63017 USA

St Louis, MO 63017 USA

J2J2

1 2 3

}

4 5

}

6 7 8

}

9 10 11 12 13 14

/START / STOP

(-)

DIVIDED ARC VOLTS

(+) (-)

ARC VOLTS

(W/ 100K IN SERIES (2))

(+)

OK-TO-MOVE

}

A-09133_AD

PCB No:

Assy No:

Date:

Thursday, March 27, 2008

Drawn: References

RWH

Chk: App:

Size

DWG No:

42X1329

SupersedesScale

Sheet

Manual 0-5544 APPENDIX

A-9

CUTMASTER 58

APPENDIX 7: Publication History

Cover Date Rev. Change(s)

July 11, 2018 AA Manual released.

APPENDIX Manual 0-5544

A-10

This Page Intentionally Blank

THE AMERICAS

Denton, TX USA U.S. Customer Care

Ph 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph 1-940-381-1212 Fax: 1-940-483-8178

Miami, FL USA Sales Office, Latin America

Ph 1-954-727-8371 Fax: 1-954-727-8376

Oakville, Ontario, Canada Canada Customer Care

Ph 1-905-827-4515 Fax: 1-800-588-1714 (tollfree)

U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 Canada Customer Care: 905-827-4515 / FAX 800-588-1714 International Customer Care: 940-381-1212 / FAX 940-483-8178

Thermal Dynamics an ESAB Brand Thermal Dynamics an Brand Cutmaster 58 PLASMA CUTTING SYSTEM Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

2.01 How To Use This Manual

2.03 Receipt Of Equipment

2.06 Power Supply Features

2T.01 Scope of Manual

2T.02 General Description

2T.04 Quick Connection Torch

2T.05 Options And Accessories

2T.06 Introduction to Plasma

3.01 Unpacking

3.04 Primary Input Power Connections

3.02 Lifting Options

3.03 Opening the Contactor Cover

3.05 Gas Connections

3T.01 Torch Connections

3T.02 Setting Up Mechanical Torch

4.01 Front Panel Controls / Features

4.02 Preparations for Operation

4T.01 Torch Prts Selection

4T.02 Cut Quality

4T.03 General Cutting Information

4T.04 Hand Torch Operation

4T.05 Gouging

4T.06 Mechanized Torch Operation

4T.07 Parts Selection for Manual Torch Cutting

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

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

PATENT INFORMATION

5.01 General Maintenance

5.02 Maintenance Schedule

5.03 Common Faults

5.04 Fault Indicator

5.05 Basic Troubleshooting Guide

5.06 Power Supply Basic Parts Replacement

5T.01 General Maintenance

6.01 Introduction

6.02 Ordering Information

6.03 Power Supply Replacement

6.04 Replacement Power Supply Parts

6.05 Options and Accessories

6.06 Replacement Parts for Hand Torch

6.07 Torch Consumable Parts (SL60)

6.08 Torch Consumable Parts (SL100)

APPENDIX 2: DATA TAG INFORMATION

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

APPENDIX 4: TORCH CONNECTION DIAGRAMS

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS

APPENDIX 7: Publication History