Thermal Dynamics CUTMASTER 60i User manual

esab.com
Art # A-13291
60 208-
480V
SL60QD OUTPUT MAX OUTPUT VOLTAGE INPUT POWER INPUT POWER
3
Revision: AA Issue Date: April 3, 2017 Manual No.: 0-5475
SERVICE
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™
Service Manual Number 0-5475
Published by:
ESAB Group Incorporated
2800 Airport Rd.
Denton, Texas 76207
www.esab.com
© Copyright 2017 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.
Original Publication Date: April 3, 2017
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.
ATTENTION
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
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 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 4 SYSTEM:
OPERATION .......................................................................................... 4-1
4.01 Front Panel Controls / Features....................................................................... 4-1
4.02 Preparations for Operation.............................................................................. 4-4
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 .......................................................................... 5-5
5.06 Advanced Troubleshooting Guide Pre-Tests.................................................... 5-8
5.07 Power OFF Advanced Troubleshooting.......................................................... 5-10
5.08 Power ON Advanced Troubleshooting........................................................... 5-19
5.09 Fault Code..................................................................................................... 5-28
5.10 Advanced Features Menu.............................................................................. 5-33
5.11 Power Supply Basic Parts Replacement ....................................................... 5-34
5.12 Internal Parts Replacement........................................................................... 5-38

TABLE OF CONTENTS
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 Miscellaneous Replacement Power Supply Parts ........................................... 6-2
6.05 Options and Accessories ................................................................................ 6-2
6.06 External Replacement Parts (Plastic) ............................................................. 6-3
6.07 Internal Plastics Replacement Parts ............................................................... 6-4
6.08 Left Side Replacement Parts .......................................................................... 6-5
6.09 Right Side Replacement Parts ........................................................................ 6-6
6.10 Replacement Parts for Hand Torch ................................................................ 6-7
6.11 Torch Consumable Parts (SL60)..................................................................... 6-8
6.12 Torch Consumable Parts ................................................................................ 6-9
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 0-5475 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
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 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 0-5475
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
Plasma Arc 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, SAFETY AND 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, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Associa-
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 CONTAINERS AND 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

CUTMASTER 60i
GENERAL INFORMATION Manual 0-5475
1-4
This Page Intentionally Blank

CUTMASTER 60i
Manual 0-5475 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 0-5475
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, 6 O-rings)
• 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 0-5475 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 0-5475
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

CUTMASTER 60i
Manual 0-5475 INTRODUCTION 2-5
3 Phase
3 Phase CutMaster 60i Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I max I1eff Fuse (amps)
Flexible Cord (Min.
AWG)
3 Phase
208 50/60 9.1 26 18.5 40 12 AWG (2.5mm2)
230 50/60 9.1 23.3 16.5 30 12 AWG (2.5mm2)
380 50/60 8.9 13.8 9.8 20 14 AWG (2.5mm2)
400 50/60 8.9 13.2 9.4 20 14 AWG (2.5mm2)
415 50/60 9.1 12.8 9.1 20 16 AWG (1.5mm2)
480 50/60 9.2 11.3 8.0 15 16 AWG (1.5mm2)
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
Three Phase
NOTE!
Refer to Local and National Codes or local authority having jurisdiction for
proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
2.06 Power Supply Features
Handle and Leads Wrap
Torch Leads Receptacle
Control Panel
Work Lead Receptacle
Art # A-13258
Input Power Cord
Port for Optional Automation
Interface Cable
Gas Inlet Port
Filter Assembly
Input Power ON/OFF Switch
Art # A-13275

CUTMASTER 60i
INTRODUCTION Manual 0-5475
2-6
This Page Intentionally Blank

CUTMASTER 60i
Manual 0-5475 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 infor-
mation block at the front of this manual.
3.02 Lifting Options
The Power Supply includes handles 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.

CUTMASTER 60i
INSTALLATION Manual 0-5475
3-2
3.03 Opening the Main Switch Cover
Systems are configured for and come with power cord connected for single phase or three phase configuration
depending on system purchased. The input power switch is located on the rear panel along the top. To access the
input locations, remove the screw at the top of the cover and flip down.
CAUTION
Disconnect power before removing the
cover.
Art # A-13244
Main Switch Cover
3.04 Primary Input Power Connections, SINGLE Phase
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..
!
CAUTION
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.
Line
GND
Single-Phase (1ø)
Art # A-13279
Power Cord
Power Switch
Single Phase Input Power Wiring