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