Thermal Dynamics CUTMASTER 60i User manual

60 208-
480V
esab.com
SL60QD OUTPUT MAX OUTPUT VOLTAGE INPUT POWER
Art # A-13285_AB
INPUT POWER
3
Revision: AB Issue Date: April 3, 2017 Manual No.: 0-5436
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 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™ 60i
SL60QD™ 1Torch™
Operating Manual Number 0-5436
Published by:
ESAB Group Incorporated
2800 Airport Rd.
Denton, Texas 76207
www.esab.com
© Copyright 2016 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: December 12, 2016
Revision Date: April 3, 2017
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
1.02 Important Safety Precautions ......................................................................... 1-1
1.03 Publications.................................................................................................... 1-2
1.04 Note, Attention et Avertissement..................................................................... 1-3
1.05 Précautions De Sécurité Importantes ............................................................. 1-3
1.06 Documents De Reference ............................................................................... 1-6
1.07 Statement of Warranty.................................................................................... 1-7
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 ..................................................................................... 2-2
2.04 Power Supply Specifications .......................................................................... 2-2
2.05 Input Wiring Specifications............................................................................. 2-4
2.06 Power Supply Features ................................................................................... 2-5
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 Main Switch Cover...................................................................... 3-2
3.04 Primary Input Power Connections, SINGLE Phase ......................................... 3-2
3.05 Primary Input Power Connections, THREE Phase........................................... 3-3
3.06 Gas Connections............................................................................................. 3-4
3.07 Work Lead Connections.................................................................................. 3-7
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.............................................................................. 4-4

TABLE OF CONTENTS
SECTION 4 TORCH:
OPERATION .......................................................................................... 4T-1
4T.01 Torch Parts 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 and Mechanized Torch Cutting ............................4T-8
4T.08 Recommended Cutting Speeds With Exposed Tip .........................................4T-9
4T.09 Recommended Cutting Speeds With Shielded Tip.......................................4T-12
PATENT INFORMATION ................................................................................. 4T-15
SECTION 5 SYSTEM:
SERVICE............................................................................................... 5-1
5.01 General Maintenance ...................................................................................... 5-1
5.02 Maintenance Schedule.................................................................................... 5-2
5.03 Common Faults............................................................................................... 5-3
5.04 Fault Indicator................................................................................................. 5-4
5.05 Basic Troubleshooting Guide .......................................................................... 5-4
5.06 Power Supply Basic Parts Replacement ......................................................... 5-8
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................................................................... 6-2
6.05 Options and Accessories ................................................................................ 6-2
6.06 External Replacement Parts (Plastic) ............................................................. 6-3
6.07 Replacement Parts for Hand Torch ................................................................ 6-4
6.08 Torch Consumable Parts (SL60)..................................................................... 6-5
6.09 Torch Consumable Parts (SL100)................................................................... 6-6
APPENDIX 1: DATA TAG INFORMATION ................................................................ A-1
APPENDIX 2: TORCH PIN - OUT DIAGRAMS........................................................... A-2
APPENDIX 3: TORCH CONNECTION DIAGRAMS ...................................................... A-3
APPENDIX 4: SYSTEM SCHEMATIC, 1PHASE 208/460V UNITS..................................... A-4
APPENDIX 5: SYSTEM SCHEMATIC, 3PHASE 208/460V UNITS..................................... A-6
APPENDIX 6: PUBLICATION HISTORY .................................................................. A-8

CUTMASTER 60i
Manual 0-5436 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
highlights are categorized as follows:
NOTE
An operation, procedure, or background
information which requires additional em-
phasis or is helpful in efficient operation of
the system.
CAUTION
Aprocedure which, if not properly followed,
may cause damage to the equipment.
!
WARNING
Aprocedure which, if not properly followed,
may cause injury to the operator or others in
the operating area.
WARNING
Gives information regarding possible electri-
cal shock injury. Warnings will be enclosed
in a box such as this.
1.02 Important Safety Precautions
!
WARNING
OPERATION AND MAINTENANCE OF
PLASMAARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric
and magnetic emissions that may interfere
with the proper function of cardiac pacemak-
ers, hearing aids, or other electronic health
equipment. Persons who work near plasma
arc cutting applications should consult their
medical health professional and the manufac-
turer of the health equipment to determine
whether a hazard exists.
To prevent possible injury, read, understand
and follow all warnings, safety precautions
and instructions before using the equipment.
Call 1-603-298-5711 or your local distributor
if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any metals
which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (SDS/
GHS) that should be supplied with the material
you are using. These SDS/GHSs will give you
the information regarding the kind and amount of
fumes and gases that may be dangerous to your
health.
• For information on how to test for fumes and
gases in your workplace, refer to item 1 in "1.03
Publications" on page 1-2 in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where com-
bustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• WARNING: This product contains chemicals,
including lead, known to the State of California to
cause birth defects and other reproductive harm.
Wash hands after handling.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the
operator or others in the workplace.

CUTMASTER 60i
GENERAL INFORMATION Manual 0-5436
1-2
• Never touch any parts that are electrically “live”
or “hot.”
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Section "1.03 Publications"
on page 1-2.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operat-
ing Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable mate-
rial in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis-
sipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc
processes can cause noise levels to exceed safe limits.
You must protect your ears from loud noise to prevent
permanent loss of hearing.
• To protect your hearing from loud noise, wear pro-
tective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the
decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item
1 in Section "1.03 Publications", in this manual.
PLASMA ARC RAYS
PlasmaArc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your eyes
and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding helmet
or shield. Also always wear safety glasses with side
shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect
your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc
is clearly seen. Experience has shown that
lighter filters may be used when the arc is
hidden by the workpiece.
!
WARNING
WARNING: This product contains chemicals, includ-
ing lead, known to the State of California to cause birth
defects and other reproductive harm. Wash hands after
handling.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETYAND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Docu-
ments, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETYAND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Govern-
ment Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATION AND EDUCATIONAL EYE AND FACE