Thermal Dynamics CutMaster 58 User manual

60 208-
460V
esab.com
SL60QD OUTPUT MAX OUTPUT VOLTAGE
INPUT POWER
VOLTAGE VOLTAGE
Art # A-13750_AB
INPUT POWER
3
460V 600V
Revision: AA Issue Date: 11-07-2018 Manual No.: 0-5544
OPERATING
MANUAL
CutMaster®58
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 innovation, competitive prices, excel-
lent 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.

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
© Copyright 2018 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 negli-
gence, 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 #:___________________________________ _________________
i
!
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.

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 equip-
ment 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 main-
tenance, 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 Wel-
ding, 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
Manual 0-5544 GENERAL INFORMATION 1-1
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These high-
lights are categorized as follows:
NOTE!
An operation, procedure, or background information which requires additional emphasis or is helpful in ecient opera-
tion 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 58
GENERAL INFORMATION Manual 0-5544
1-2
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 58
Manual 0-5544 INTRODUCTION 2-1
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies toThermal 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 wordsWARNING, 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.
!
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operat-
ing 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
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 com-
plete 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.

CUTMASTER 58
INTRODUCTION Manual 0-5544
2-2
2.04 Power Supply Specications
CutMaster 58 Power Supply Specifications
Input Power
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
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 Power Supply includes input cable.
Cable for 208/230V input power includes molded plug.
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
All Units
Duty Cycle 40% 60% 100%
Current 60 Amps 50 Amps 30 Amps
DC Voltage 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 calculat-
ing an output voltage based upon power supply rated current. To facilitate comparison between power supplies, all manufac-
turers use this output voltage to determine duty cycle.
Power Supply Dimensions & Weight Ventilation Clearance Requirements
22,5"
571,5 mm
43 lb / 19,5 kg
10,75"
273 mm
16,375"
416 mm
Art # A-07941_AB
6"
150 mm
24"
610 mm
6"
150 mm
6"
150 mm
Art # A-07925_AB

CUTMASTER 58
Manual 0-5544 INTRODUCTION 2-3
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)
Flexible Cord
(Min. AWG)
1 Phase
208 60 10.4 47 30 50 10
230 60 10.8 45 29 50 10
460 60 15.2 31 20 35 12
3 Phase
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
NOTE!
Refer to Local and National Codes or local authority having jurisdiction for proper wiring require-
ments.
Cable size is de-rated based on the Duty Cycle of the equipment.

CUTMASTER 58
INTRODUCTION Manual 0-5544
2-4
2.06 Power Supply Features
Handle and Leads Wrap
To rch Leads Receptacl
e
Control Panel
Ar
t # A-07942
Work Cable
and Clamp
Art # A-07981
Input Power Cord
Port for Optional Automation
Interface Cable
Gas Inlet Port
Filter Assembly
Input
Power Selection

CUTMASTER 58
Manual 0-5544 INTRODUCTION 2T-1
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.
!
CAUTION
Torch Leads are flexible but in-
ternal 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.
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"
(95 mm)
1.17" (29 mm)
Art # A-13246
2. Mechanized Torch, Model
The standard machine torch has a positioning tube
with rack & pinch block assembly.
Ar
t # A-02998
1.75" /
44.5 mm
1.375" / 35 mm
15.875" / 403 mm
0.625" /
16 mm
4.95" / 126 mm
1.175" / 30 mm
9.285" / 236 mm
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20 ft / 6.1 m, with ATC connectors
• 50 ft / 15.2 m, with ATC connectors
Machine 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.

CUTMASTER 58
INTRODUCTION Manual 0-5544
2T-2
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
Mechanized Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum Current 120 Amps
Voltage (Vpeak)500V
Arc Striking Voltage 500V
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
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow (Cutting and Gouging)
5 - 8.3 SCFM
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, operat-
ing 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.
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
A. Plasma Gas Flow
Plasma is a gas which has been heated to an extremely
high temperature and ionized so that it becomes electri-
cally 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.

CUTMASTER 58
Manual 0-5544 INTRODUCTION 2T-3
A-00002
Workpiece
Power
Supply
+
_
C
B
A
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 nega-
tive lead, through the starter cartridge, around the elec-
trode, and out through the tip orice.
The secondary gas ows down around the outside of
the torch starter cartridge, and out between the tip and
shield cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established be-
tween the electrode and cutting or gouging tip. This
pilot arc creates a path for the main arc to transfer to
the work.
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 con-
nected 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.
A-02997
Torch Trigge
r
PIP Switch Shield Cup
To Control
Cable Wiring
Torch Switch
Parts - In - Place Circuit Diagram for Hand Torch

CUTMASTER 58
INTRODUCTION Manual 0-5544
2T-4
This Page Intentionally Blank

CUTMASTER 58
Manual 0-5544 INSTALLATION 3-1
SECTION 3 SYSTEM:
INSTALLATION
3.01 Unpacking
1. Use the packing lists to identify and account for
each item.
2. Inspect each item for possible shipping damage.
If damage is evident, contact your distributor and
/ or shipping company before proceeding with
the installation.
3. Record Power Supply and Torch model and serial
numbers, purchase date and vendor name, in the
information block at the front of this manual.
3.02 Lifting Options
The Power Supply includes a handle for hand lifting
only. Be sure unit is lifted and transported safely and
securely.
WARNING
Do not touch live electrical parts.
Disconnect input power cord be-
fore moving unit.
FALLING EQUIPMENT can cause
serious personal injury and can
damage equipment.
HANDLES are not for mechanical
lifting.
• Only persons of adequate physical strength should
lift the unit.
• Lift unit by the handles, using two hands. Do not
use straps for lifting.
• Use optional cart or similar device of adequate
capacity to move unit.
• Place unit on a proper skid and secure in place
before transporting with a fork lift or other vehicle.
3.03 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.
Art# A-11478
1
2
2
1
Contactor cover
3.04 Primary Input Power Connections
!
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 plug-
ging 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 protec-
tion 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.
Art # A-07984_AB
Single-Phase (1ø) and Jumper Settings
L1
L2
L3
L4
Jumper L1 -L4
Jumper
L2-L3
L1
L2
L3
GND
L4
Single Phase Input Power Wiring
Art # A-07983_AB
Three-Phase (3ø) and Jumper Settings
L1
L2
L3
L4
Jumper L1 -L4
L1
L2
L3
GND
L4
Store copper jumper in spare parts box
Three Phase Input Power Wiring

CUTMASTER 58
INSTALLATION Manual 0-5544
3-2
NOTE!
There is only one jumper setting that
changes between the single and three
phase settings. To change from single
phase to three phase, the jumper con-
nected 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 con-
form to local electrical code
and the recommended circuit
protection and wiring re-
quirements (refer to table in
Section 2).
6. Connect the wires as follows.
• Set Jumper wires on the contactor. See previ-
ous illustrations.
• Green / Yellow wire to Ground.
• Remaining wires to L1 and L2 input. It does
not matter what order these wires are at-
tached.
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 con-
form to local electrical code
and the recommended circuit
protection and wiring re-
quirements (refer to table in
Section 2).
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).