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

CUTMASTER 60i
Manuel 0-5436 INFORMATIONS GÉNÉRALES 1-3
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broad-
way, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standards Insti-
tute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPAStandard 70, NATIONALELECTRICALCODE,
obtainable from the National Fire ProtectionAssocia-
tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from
the Compressed GasAssociation, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the
Canadian StandardsAssociation, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSAbooklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Asso-
ciation, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERSAND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-
TORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et “aver-
tissement” sont utilisés pour mettre en relief des infor-
mations à caractère important. Ces mises en relief sont
classifiées comme suit :
NOTE
Toute opération, procédure ou renseigne-
ment général sur lequel il importe d’insister
davantage ou qui contribue à l’efficacité de
fonctionnement du système.
ATTENTION
Toute procédure pouvant résulter l’endom-
magement du matériel en cas de non-res-
pect de la procédure en question.
!
AVERTISSEMENT
Toute procédure pouvant provoquer des bles-
sures de l’opérateur ou des autres personnes
se trouvant dans la zone de travail en cas de
non-respect de la procédure en question.
AVERTISSEMENT
Fournit l'information concernant des dom-
mages possibles de choc électrique. Des
avertissements seront enfermés dans une
boîte de ce type.
1.05 Précautions De Sécurité
Importantes
!
AVERTISSEMENTS
L’OPÉRATION ET LAMAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit
de l’énergie électrique haute tension et des
émissions magnétique qui peuvent interférer
la fonction propre d’un “pacemaker” car-

CUTMASTER 60i
INFORMATIONS GÉNÉRALES Manuel 0-5436
1-4
diaque, les appareils auditif, ou autre matériel
de santé electronique. Ceux qui travail près
d’une application à l’arc au jet de plasma
devrait consulter leur membre professionel de
médication et le manufacturier de matériel de
santé pour déterminer s’il existe des risques
de santé.
Il faut communiquer aux opérateurs et au
personnel TOUS les dangers possibles. Afin
d’éviter les blessures possibles, lisez, compre-
nez et suivez tous les avertissements, toutes
les précautions de sécurité et toutes les consi-
gnes avant d’utiliser le matériel. Composez le
+ 603-298-5711 ou votre distributeur local si
vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers
de santé.
• Eloignez toute fumée et gaz de votre zone de respi-
ration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “SDS/GHS”); celles-ci
devraient être fournies avec le matériel que vous uti-
lisez. Les SDS/GHS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• AVERTISSEMENT: Ce produit contient des produits
chimiques, notamment du plomb, reconnu par l'État
de la Californie pour causer des malformations congé-
nitales et d'autres dommages touchant le système
reproductif. Se laver les mains après manipulation.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.
• Réparez ou remplacez toute pièce usée ou endomma-
gée.
• Prenez des soins particuliers lorsque la zone de travail
est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout tra-
vail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des
scories chaudes, des étincelles ou de l’arc de plasma. Le
procédé à l’arc de plasma produit du métal, des étincelles,
des scories chaudes pouvant mettre le feu aux matiè-
res combustibles ou provoquer l’explosion de fumées
inflammables.

CUTMASTER 60i
Manuel 0-5436 INFORMATIONS GÉNÉRALES 1-5
• Soyez certain qu’aucune matière combustible ou
inflammable ne se trouve sur le lieu de travail. Proté-
gez toute telle matière qu’il est impossible de retirer
de la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent bles-
ser vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons
ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur. Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement protec-
teur approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou compor-
tant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:
Nuance MinimumNuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est
observé clairement. L’experience a démon-
trer que les filtres moins foncés peuvent être
utilisés quand l’arc est caché par moiceau de
travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger
les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections auri-
culaires. Protégez également les autres personnes se
trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
!
AVERTISSEMENT
AVERTISSEMENT: Ce produit contient des produits
chimiques, notamment du plomb, reconnu par l'État de
la Californie pour causer des malformations congénitales
et d'autres dommages touchant le système reproductif.
Se laver les mains après manipulation.

CUTMASTER 60i
GENERAL INFORMATION Manual 0-5436
1-6
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible
auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la
Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET
AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
4. NormeANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET
DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards
Institute), 1430 Broadway, New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE
SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS
AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550
N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ
AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS,
disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
11. Brochure GCAP-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible
auprès de l’Association des Gaz Comprimés (Compressed GasAssociation), 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Asso-
ciation des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LASÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale
de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES
POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT REN-
FERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National
Standards Institute, 1430 Broadway, New York, NY 10018

CUTMASTER 60i
Manual 0-5436 GENERAL INFORMATION 1-7
1.07 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, ESAB warrants to the original retail
purchaser that new Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of this
warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within
the applicable period stated below, ESAB shall, upon notification thereof and substantiation that the product has been
stored operated and maintained in accordance with Thermal Dynamics’ specifications, instructions, recommendations
and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or tness for a particular purpose.
ESAB will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or
workmanship within the time periods set out below. ESAB must be notified within 30 days of any failure, at which time
ESAB will provide instructions on the warranty procedures to be implemented.
ESAB will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the
date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Product Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
U.S. Non U.S.
CUTMASTER™ 60i 4 Years 3 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o-rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused
based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of ESAB :
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized ESAB
service station. Product returned for service is at the owner’s expense and no reimbursement of travel or transportation
is authorized.
LIMITATION OF LIABILITY: ESAB shall not under any circumstances be liable for special or consequential damages such
as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of ESAB
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from
the manufacture, sale, delivery, resale, or use of the goods covered by or furnished by ESAB whether arising out of contract,
negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of
the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance
of any Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective December 12, 2016

CUTMASTER 60i
GENERAL INFORMATION Manual 0-5436
1-8
This Page Intentionally Blank

CUTMASTER 60i
Manual 0-5436 INTRODUCTION 2-1
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.
Throughout this manual, the words WARNING, 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 efficient 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 fol-
lowed, may cause injury to the operator or
others in the operating 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
identification 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 iden-
tified only by the specification or part number printed on loosely attached card or the shipping container. Record
these numbers on the bottom of page i for future reference.

CUTMASTER 60i
INTRODUCTION Manual 0-5436
2-2
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 file 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 identification 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, 2 Tips, 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.
2.04 Power Supply Specifications
1 Phase
60i 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)
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.

CUTMASTER 60i
Manual 0-5436 INTRODUCTION 2-3
3 Phase
60i 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' single 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 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
5/8" 5/8" 1 1/4"
Generator Recommendations
When using generators to power the 60i Plasma Cutting System, the following ratings are a minimum and are to
be used along with the ratings listed above.
A60i Generator Specifications
Generator Output Rating 60i Output Current Arc Characteristic
15 kW 60A Full
12 kW 60A Limited
45A Full
10 kW 45A Limited
30A Full
NOTE!
Due to circuitry, age and condition two generators with the same ratings
may produce different results. Adjust the amperage accordingly.

CUTMASTER 60i
INTRODUCTION Manual 0-5436
2-4
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
2.05 Input Wiring Specifications
WARNING
Each CutMaster 60i system is a dedicated 1 Phase OR 3 Phase
system and cannot be reconfigured to the other. Personal injury
could occur if changing the phase is attempted..
1 Phase
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