ESAB THERMAL DINAMICS CUTMASTER 60i User manual

60 208-
480V
esab.com
SL60QD OUTPUT MAX OUTPUT VOLTAGE INPUT POWER
400V
Art # A-14029
INPUT POWER INPUT POWER
3
Revision: AA Issue Date: 25 February, 2019 Manual No.: 0-5561
OPERATING
MANUAL
CUTMASTER® 60i
PLASMA CUTTING
SYSTEM

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 innova-
tion, 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.

i
Plasma Cutting Power Supply
CutMaster™ 60i
SL60QD™ 1Torch™
Operating Manual Number 0-5561
Published by:
ESAB Group Incorporated
2800 Airport Rd.
Denton, Texas 76207
www.esab.com
© Copyright 2019 by
Thermal Dynamics an ESAB brand.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for
any loss or damage caused by any error or omission in this Manual, whether such
error results from negligence, accident, or any other cause.
For Material Print Specications, refer to document 47x1961
Original Publication Date: 25 February, 2019
Revision Date:
See website for Warranty Information.
Record the following information for Warranty purposes:
Where Purchased:____________________________________________________
Purchase Date:__________________________ ____________________________
Power Supply Serial #:_______________________________ _________________
Torch Serial #:______________________________ _________________________
!
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 judgment, the Manufacturer
assumes no liability for its use.
i

Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully
familiar with the principles of operation and safe practices for arc welding
and cutting equipment, we urge you to read our booklet, “Precautions and
Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do
NOT permit untrained persons to install, operate, or maintain this equip-
ment. 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 mainte-
nance, 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 FOUR-
NISSEUR.
MISE EN GARDE
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.
Si vous n’avez pas une connaissance approfondie des principes de fonctionne-
ment 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 per-
sonnes 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 com-
prendre ces instructions. Si vous ne comprenez pas bien les instructions, commu-
niquez 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’accompagne-
ment 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’utilisateur 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

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
Thermal Dynamics
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 manufactur-
er’s authorised representative , that the equipment in question complies with the safety
requirements stated above.
Date Signature Position
9 June, 2017
Flavio Santos General Manager
Accessories and
Adjacencies
2017

This Page Intentionally Blank

TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION.......................................................... 11
1.01 Notes, Cautions and Warnings ................................................................................. 11
SECTION 1: INFORMATIONS GÉNÉRALES ................................................... 13
1.01 Remarques, avertissements et mises en garde........................................................ 13
SECTION 2 SYSTEM: INTRODUCTION ......................................................... 15
2.01 How To Use This Manual .......................................................................................... 15
2.02 Equipment Identication......................................................................................... 15
2.03 Receipt Of Equipment.............................................................................................. 15
2.04 Power Supply Specications.................................................................................... 16
2.04.01 1 Phase.......................................................................................................... 16
2.04.02 3 Phase ......................................................................................................... 16
2.04.03 Additional Power Supply Specications......................................................... 17
2.05 Input Wiring Specications...................................................................................... 19
2.05.01 1 Phase Input CableWiring Requirements ..................................................... 19
2.05.02 3 Phase Input CableWiring Requirements ..................................................... 19
2.06 Power Supply Features ............................................................................................ 20
SECTION 2TORCH: INTRODUCTION ........................................................... 21
2T.01 Scope of Manual...................................................................................................... 21
2T.02 General Description................................................................................................. 21
2T.03 Specications ......................................................................................................... 21
2T.04 Quick Connection Torch ........................................................................................... 22
SECTION 3 SYSTEM: INSTALLATION ........................................................... 23
3.01 Unpacking............................................................................................................... 23
3.02 Lifting Options......................................................................................................... 23
3.03 Opening the Main Switch Cover............................................................................... 23
3.04 Primary Input Power Connections ........................................................................... 24
3.04.01 1 Phase ......................................................................................................... 24
3.04.02 3 Phase ......................................................................................................... 24
3.05 Gas Connections ...................................................................................................... 25
3.06 Work Lead Connections ........................................................................................... 28
SECTION 3 TORCH:
INSTALLATION......................................................................................... 29
3T.01 Torch Connections.................................................................................................... 29
3T.02 Setting Up Mechanical Torch....................................................................................29

TABLE OF CONTENTS
SECTION 4 SYSTEM: OPERATION ............................................................... 31
4.01 Front Panel Controls / Features................................................................................ 31
4.02 Preparations for Operation ...................................................................................... 34
SECTION 4TORCH: OPERATION.................................................................. 39
4T.01 Torch Parts Selection ............................................................................................... 39
4T.02 Hand Torch Operation .............................................................................................. 39
4T.03 Gouging................................................................................................................... 42
4T.04 Mechanized Torch Operation.................................................................................... 43
4T.05 Recommended Cutting SpeedsWith Exposed Tip .................................................... 45
4T.06 Recommended Cutting SpeedsWith Shielded Tip....................................................48
PATENT INFORMATION............................................................................. 51
SECTION 5 SYSTEM: SERVICE..................................................................... 53
5.01 General Maintenance .............................................................................................. 53
5.02 Maintenance Schedule ............................................................................................ 53
5.03 Common Faults........................................................................................................ 54
5.04 Fault Indicator ......................................................................................................... 55
5.05 Basic Troubleshooting Guide.................................................................................... 56
5.06 Power Supply Basic Parts Replacement ................................................................... 59
SECTION 5TORCH: SERVICE ...................................................................... 63
5T.01 General Maintenance .............................................................................................. 63
5T.02 Inspection and Replacement of ConsumableTorch Parts......................................... 64
SECTION 6: PARTS LISTS........................................................................... 65
6.01 Introduction ............................................................................................................ 65
6.02 Ordering Information .............................................................................................. 65
6.03 Power Supply Replacement..................................................................................... 65
6.04 Replacement Power Supply Parts............................................................................ 66
6.05 Options and Accessories .......................................................................................... 66
6.06 External Replacement Parts (Plastic) ...................................................................... 67
6.07 Replacement Parts for Hand Torch .......................................................................... 68
6.08 Torch Consumable Parts (SL60)................................................................................ 69
6.09 Torch 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
0-5561 GENERAL INFORMATION 11
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.

CUTMASTER 60i
GENERAL INFORMATION 0-5561
12
AVERTISSEMENT
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.
6. Become trained.
Only qualified personnel should
operate this equipment. Use torches
specified in the manual. Keep
non-qualified personnel and children
away.
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.
7. Do not remove, destroy, or cover
this label.
Replace if it is missing, damaged,
or worn.
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

CUTMASTER 60i
0-5561 GENERAL INFORMATION 13
SECTION 1 : INFORMATIONS GÉNÉRALES
1.01 Remarques, avertissements et mises en garde
Le présent manuel est ponctué de remarques, d’avertissements et de mises en garde qui attirent
l’attention sur des informations importantes. Ces repères sont classés comme suit :
REMARQUE:
Fonction, procédé ou renseignement de base qui nécessite une plus grande attention ou contribue au
bon fonctionnement du système.
!
ATTENTION
Procédé qui, s’il n’est pas suivi correctement, peut endommager l’équipement.
!
AVERTISSEMENT
Procédé qui, s’il n’est pas suivi correctement, peut causer des lésions à l’utilisateur ou aux personnes
dans la zone d’exploitation.
AVERTISSEMENT
Fournit des renseignements relatifs à d’éventuelles blessures se devant à une décharge électrique.

CUTMASTER 60i
GENERAL INFORMATION 0-5561
14
AVERTISSEMENT
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.
6. Become trained.
Only qualified personnel should
operate this equipment. Use torches
specified in the manual. Keep
non-qualified personnel and children
away.
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.
7. Do not remove, destroy, or cover
this label.
Replace if it is missing, damaged,
or worn.
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

CUTMASTER 60i
0-5561 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 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 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.
Art# A-13290
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 0-5561
16
2.04 Power Supply Specications
2.04.01 1 Phase
60i 208 - 480 VAC 1 Phase Power Supply Specifications
Input Power 208 - 480 VAC(187 - 528 VAC), Single Phase, 50/60 Hz
1 Phase Input Power Cable Power Supply includes 9' single phase 8AWG 3/C input
cable with NEMA 6-50P 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 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)

CUTMASTER 60i
0-5561 INTRODUCTION 17
60i 400 VAC 3 Phase CCC Power Supply Specifications
Input Power 380 - 415 VAC(342 - 456 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)
2.04.03 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) 3/4" (19.05mm) 1 1/2" (38mm)

CUTMASTER 60i
INTRODUCTION 0-5561
18
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.
60i 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.
21.121"
536.47 mm
35 lb / 15.875 kg
7.847
199.3 mm
14.146"
359.3 mm
Art # A-13252
15"
381 mm
6"
150 mm
15"
381 mm
6"
150 mm
Art # A-13247
Power Supply Dimensions & Weight Ventilation Clearance Requirements

CUTMASTER 60i
0-5561 INTRODUCTION 19
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.
2.05.01 1 Phase Input Cable Wiring Requirements
1 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)
1 Phase
208 50/60 8.9 43 30.5 50 8 AWG (10mm2)
230 50/60 8.9 38.9 27.6 50 10 AWG (10mm2)
380 50/60 8.9 23.5 16.7 30 12 AWG (2.5mm2)
400 50/60 8.9 22.4 15.9 30 14 AWG (2.5mm2)
415 50/60 8.9 21.6 15.3 30 14 AWG (2.5mm2)
480 50/60 8.9 18.6 13.2 30 14 AWG (2.5mm2)
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
Single Phase
2.05.02 3 Phase Input Cable Wiring Requirements
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
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
INTRODUCTION 0-5561
20
2.06 Power Supply Features
Handle and Leads Wrap
Torch Leads Receptacle
Control Panel
Work Lead Receptacle
Art # A-13258
Input Power Cord
Port for Optional Automation
Interface Cable
Gas Inlet Port
Filter Assembly
Input Power ON/OFF Switch
Art # A-13275