ESAB A-14032 User manual

Revision: AA Issue Date: 15 February, 2019 Manual No.: 0-5562
CUTMASTER®60i
PLASMA CUTTING SYSTEM
Art # A-14032
esab.com
60 400V
SL60QD OUTPUT MAX OUTPUT VOLTAGE INPUT POWER
3
OPERATING
MANUAL

EU DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016
The EMC Directive 2014/30/EU, entering into force 20 April 2016
The RoHS Directive 2011/65/EU, entering into force 2 January 2013
Type of equipment
PLASMA CUTTING SYSTEM
Type designation etc.
CutMaster 60i, from serial number MX1723XXXXXX
Brand name or trade mark
ESAB
Manufacturer or his authorised representative
Name, address, telephone No:
ESAB Group Inc.
2800 Airport Rd
Denton TX 76207 USA
Phone: [phone], FAX [phone]
The following harmonised standard in force within the EEA has been used in the design:
IEC/EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.
IEC/EN 60974-10:2014 + AMD 1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10:
Electromagnetic compatibility (EMC) requirements
Additional Information: Restrictive use, Class A equipment, intended for use in location other than
residential.
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s
authorised representative , that the equipment in question complies with the safety require-
ments stated above.
Date Signature Position
9 June, 2017
Flavio Santos General Manager
Accessories and
Adjacencies
2017

TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION.....................................................11
1.01Notes, Cautions and Warnings...............................................................................11
SECTION 1: INFORMATIONS GÉNÉRALES ..............................................13
1.01Remarques, avertissements et mises en garde......................................................13
SECTION 2 SYSTEM: INTRODUCTION ....................................................15
2.01How To Use This Manual........................................................................................15
2.02Equipment Identication......................................................................................15
2.03Receipt Of Equipment...........................................................................................15
2.04Power Supply Specications .................................................................................16
2.05Input Wiring Specications ...................................................................................18
2.06Power Supply Features..........................................................................................19
SECTION 2TORCH: INTRODUCTION ......................................................21
2T.01Scope of Manual..................................................................................................21
2T.02General Description.............................................................................................21
2T.03Specications .....................................................................................................21
2T.04Quick Connection Torch .......................................................................................22
SECTION 3 SYSTEM: INSTALLATION ......................................................23
3.01Unpacking ............................................................................................................23
3.02Lifting Options......................................................................................................23
3.03Opening the Main Switch Cover............................................................................23
3.04Primary Input Power Connections, 3 Phase...........................................................24
3.05Gas Connections....................................................................................................24
3.06Work Lead Connections.........................................................................................27
SECTION 3 TORCH:
INSTALLATION....................................................................................29
3T.01Torch Connections ...............................................................................................29
3T.02Setting Up MechanicalTorch ...............................................................................29
SECTION 4 SYSTEM: OPERATION ..........................................................31
4.01Front Panel Controls / Features .............................................................................31
4.02Preparations for Operation....................................................................................34
SECTION 4TORCH: OPERATION.............................................................39
4T.01Torch Parts Selection ...........................................................................................39
4T.02Hand Torch Operation..........................................................................................39
4T.03Gouging ..............................................................................................................42
4T.04Mechanized Torch Operation ...............................................................................43
4T.05Recommended Cutting Speeds With ExposedTip ................................................45
4T.06Recommended Cutting Speeds With ShieldedTip ...............................................48

TABLE OF CONTENTS
PATENT INFORMATION........................................................................51
SECTION 5 SYSTEM: SERVICE................................................................53
5.01General Maintenance............................................................................................53
5.02Maintenance Schedule..........................................................................................53
5.03Common Faults.....................................................................................................54
5.04Fault Indicator.......................................................................................................55
5.05Basic Troubleshooting Guide.................................................................................56
5.06Power Supply Basic Parts Replacement.................................................................59
SECTION 5TORCH: SERVICE .................................................................63
5T.01General Maintenance ..........................................................................................63
5T.02Inspection and Replacement of ConsumableTorch Parts.....................................64
SECTION 6: PARTS LISTS......................................................................65
6.01Introduction..........................................................................................................65
6.02Ordering Information............................................................................................65
6.03Power Supply Replacement ..................................................................................65
6.04Replacement Power Supply Parts .........................................................................66
6.05Options and Accessories........................................................................................66
6.06External Replacement Parts (Plastic) ...................................................................67
6.07Replacement Parts for HandTorch ........................................................................68
6.08Torch Consumable Parts (SL60).............................................................................69
6.09Torch Consumable Parts (SL100)...........................................................................70
APPENDIX 1: DATA TAG INFORMATION .................................................71
APPENDIX 2: TORCH PIN  OUT DIAGRAMS ...........................................72
APPENDIX 3: TORCH CONNECTION DIAGRAMS......................................73
APPENDIX 4: PUBLICATION HISTORY ...................................................74

CUTMASTER 60i
0-5562 INTRODUCTION 15
SECTION 2 SYSTEM: INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just product(s) listed on page i.
To ensure safe operation, read the entire manual, including the chapter on safety instructions and
warnings.
Additional copies of this manual may be purchased by contacting ESAB at the address and phone
number in your area listed on back cover of this manual. Include the 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 go-
ing 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
2.02 Equipment Identication
The unit’s identication number (specication or part number), model, and serial number usually appear
on a data tag attached to the 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 imme-
diately to le a claim. Furnish complete information concerning damage claims or shipping errors to
the location in your area listed on the back cover of this manual.
Include all equipment identication numbers as described above, along with a full description of the
parts in error.
Included items:
• 60i Power Supply
• SL60QD™ Torch and Leads
• Work Lead with Work Clamp
• Spare Parts Kit ( 2 Electrodes, 2Tips, 1 Shield
cup)
• Operating Manual
• Filter Wrench
Move the equipment to the installation site before
un-boxing the unit. Use care to avoid damaging
the equipment when opening the box.

CUTMASTER 60i
INTRODUCTION 0-5562
16
2.04 Power Supply Specications
2.04.01 3 Phase
60i 208 - 480 VAC 3 Phase Power Supply Specifications
Input Power 208 - 480 VAC(187 - 528 VAC), 3 Phase, 50/60 Hz
3 Phase Input Power Cable Power Supply includes 9' three phase 12AWG 4/C input
cable without plug.
Output Current 10 - 60 Amps, Continuously Adjustable
Power Supply Gas Filtering
Ability Particulates to 5 Microns
Maximum Inlet Pressure 125 PSI (8.6 bar)
60i 400 VAC 3 Phase CE Power Supply Specifications
Input Power 400 VAC, 3 Phase, 50/60 Hz
3 Phase Input Power Cable Power Supply includes 9' three phase 12AWG 4/C input
cable with plug.
Output Current 10 - 60 Amps, Continuously Adjustable
Power Supply Gas Filtering
Ability Particulates to 5 Microns
Maximum Inlet Pressure 125 PSI (8.6 bar)
2.04.02 Additional Power Supply Specications
60i Power Supply Duty Cycle *
Ambient Air Temperature Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
Rating
All Units
Duty Cycle 50% 60% 100%
Current 60 Amps 50 Amps 40 Amps
DC Voltage 126 122 119
* 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.
60i Cut Capacity
Recommended Pierce Maximum
3/4" (19.05mm) 5/8" (15.86mm) 1 1/2" (38mm)

CUTMASTER 60i
0-5562 INTRODUCTION 17
Generator Recommendations
When using generators to power the 60i Plasma Cutting System, the following ratings are a minimum
and are to be used along with the ratings listed above.
A60i Generator Specifications
Generator Output Rating 60i Output Current Arc Characteristic
15 kW 60A Full
12 kW 60A Limited
45A Full
10 kW 45A Limited
30A Full
NOTE!
Due to circuitry, age and condition two generators with the same ratings may produce dierent results. Adjust the
amperage accordingly.
Power Supply Dimensions & Weight Ventilation Clearance Requirements

CUTMASTER 60i
INTRODUCTION 0-5562
18
2.05 Input Wiring Specications
WARNING
Each CutMaster 60i system is a dedicated 1 Phase OR 3 Phase system and cannot be recongured to the other.
Personal injury could occur if changing the phase is attempted.
3 Phase
3 Phase CutMaster 60i Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I max I1eff
Fuse
(amps)
Flexible Cord (Min.
AWG)
3 Phase
208 50/60 9.1 26 18.5 40 12 AWG (2.5mm2)
230 50/60 9.1 23.3 16.5 30 12 AWG (2.5mm2)
380 50/60 8.9 13.8 9.8 20 14 AWG (2.5mm2)
400 50/60 8.9 13.2 9.4 20 14 AWG (2.5mm2)
415 50/60 9.1 12.8 9.1 20 16 AWG (1.5mm2)
480 50/60 9.2 11.3 8.0 15 16 AWG (1.5mm2)
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
Three Phase
NOTE!
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.

CUTMASTER 60i
0-5562 INTRODUCTION 19
2.06 Power Supply Features

CUTMASTER 60i
0-5562 INTRODUCTION 21
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; unqualied personnel are strictly cau-
tioned against attempting repairs or adjustments
not covered in this manual, at the risk of voiding
the Warranty.
Read this manual thoroughly. A complete under-
standing of the characteristics and capabilities
of this equipment will assure the dependable
operation for which it was designed.
2T.02 General Description
CAUTION
Torch Leads are exible but internal wires can
be broken. Do not exceed a 2" radius bend and
avoid repeated tight bends when possible.
NOTE!
Refer to Section "4Torch", for a more detailed
description of plasma torch operation.
Refer to the Appendix Pages for
additional specications as related
to the Power Supply used.
2T.03 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.
2. Mechanized Torch, Model
The standard machine torch has a po-
sitioning tube with rack & pinch block
assembly.
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20 ft / 6.1 m, with ATC connectors
• 50 ft / 15.2 m, with ATC connectors
Machine Torches are available as
follows:
• 5 foot / 1.5 m, with ATC connectors
• 10 foot / 3.05 m, with ATC connectors
• 25 foot / 7.6 m, with ATC connectors
• 50 foot / 15.2 m, with ATC connectors
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch Head has built - in switch
15 VDC circuit rating
E. Type Cooling
Combination of ambient air and gas stream
through torch.
F. Torch Ratings
Manual Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 60 Amps @ 400
scfh
Maximum
Current 60 Amps
Voltage (Vpeak)500V
Arc Striking
Voltage 500V