ESAB A-14032 Operating Manual
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ESAB A-14032 Operating Manual

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CUTMASTER ® 60i
PLASMA CUTTING SYSTEM
OPERATING
MANUAL
SL60QD
OUTPUT
Revision: AA
Issue Date: 15 February, 2019
Art # A-14032
MAX OUTPUT
VOLTAGE
60
400V
Manual No.: 0-5562
esab.com
INPUT POWER
3

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Summary of Contents for ESAB A-14032

  • Page 1 CUTMASTER ® 60i PLASMA CUTTING SYSTEM OPERATING MANUAL Art # A-14032 INPUT POWER SL60QD OUTPUT MAX OUTPUT VOLTAGE 400V Revision: AA Issue Date: 15 February, 2019 Manual No.: 0-5562 esab.com...
  • Page 2 Brand name or trade mark ESAB Manufacturer or his authorised representative Name, address, telephone No: ESAB Group Inc. 2800 Airport Rd Denton TX 76207 USA Phone: +01 800 426 1888, FAX +01 603 298 7402 The following harmonised standard in force within the EEA has been used in the design: IEC/EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION.............11 1.01 Notes, Cautions and Warnings................11 SECTION 1 : INFORMATIONS GÉNÉRALES ..........13 1.01 Remarques, avertissements et mises en garde............13 SECTION 2 SYSTEM: INTRODUCTION ............15 2.01 How To Use This Manual ..................15 2.02 Equipment Identification ..................15 2.03 Receipt Of Equipment ...................15 2.04 Power Supply Specifications .................16 2.05 Input Wiring Specifications ...................18...
  • Page 4 TABLE OF CONTENTS PATENT INFORMATION ................51 SECTION 5 SYSTEM: SERVICE ..............53 5.01 General Maintenance ....................53 5.02 Maintenance Schedule ..................53 5.03 Common Faults .....................54 5.04 Fault Indicator .......................55 5.05 Basic Troubleshooting Guide .................56 5.06 Power Supply Basic Parts Replacement ..............59 SECTION 5 TORCH: SERVICE ..............63 5T.01 General Maintenance ..................63 5T.02 Inspection and Replacement of Consumable Torch Parts ........64 SECTION 6: PARTS LISTS ..............65...

  • Page 5: Section 2 System: Introduction

    Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by go- ing to the ESAB web site listed below and clicking on "Product Support" / "ESAB Documentation": / "Download Library", then navigate to "Plasma Equipment" and then "Manual".

  • Page 6: Power Supply Specifications

    CUTMASTER 60i 2.04 Power Supply Specifications 2.04.01 3 Phase 60i 208 - 480 VAC 3 Phase Power Supply Specifications Input Power 208 - 480 VAC(187 - 528 VAC), 3 Phase, 50/60 Hz Power Supply includes 9' three phase 12AWG 4/C input 3 Phase Input Power Cable cable without plug.
  • Page 7 CUTMASTER 60i 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 Full Limited...

  • Page 8: Input Wiring Specifications

    CUTMASTER 60i 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. 3 Phase 3 Phase CutMaster 60i Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes...

  • Page 9: Power Supply Features

    CUTMASTER 60i 2.06 Power Supply Features 0-5562 INTRODUCTION...

  • Page 10: Section 2 Torch: Introduction

    CUTMASTER 60i SECTION 2 TORCH: INTRODUCTION Mechanized Torch, Model The standard machine torch has a po- 2T.01 Scope of Manual sitioning tube with rack & pinch block assembly. This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL60, SL60QD™ and SL100/ Mechanized Plasma Cutting Torches.

  • Page 11: 04 Quick Connection Torch

    CUTMASTER 60i 2T.04 Quick Connection Torch Mechanized Torch Ratings Ambient 104° F The new SL60QD™ (Quick Disconnect) torch allows Temperature 40° C for a quick change of the torch handle assembly from the leads. To change the torch handle assem- 100% @ 100 Amps @ 400 Duty Cycle bly do the following.

  • Page 12: Section 3 System: Installation

    CUTMASTER 60i SECTION 3 SYSTEM: INSTALLATION 3.01 Unpacking Use the packing lists to identify and account for each item. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the information block at the front of this manual.

  • Page 13: Primary Input Power Connections, 3 Phase

    CUTMASTER 60i 3.04 Primary Input Power Connections, 3 Phase 3 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 protection and wiring requirements as specified in Section 2.
  • Page 14 CUTMASTER 60i NOTE! Filter replacement part numbers can be found in Section 6 of this manual. Installing Optional Single - Stage Air Filter An optional filter kit (7-7507) is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch. Attach the Single - Stage Filter Hose to the Inlet Port 1/4"...
  • Page 15 CUTMASTER 60i Installing Optional Two - Stage Air Filter Kit This optional two - stage air line filter (9-9387) is also for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns. Connect the air supply as follows: Attach the Two Stage Filter bracket to the back of the power supply with the screws supplied.

  • Page 16: Work Lead Connections

    CUTMASTER 60i 3.06 Work Lead Connections Connect the Work Lead to the power supply and the work piece. Attach the Dinse type connection of the work lead to the power supply front panel as shown below. Push in and turn clockwise to the right until tight. Connect the work clamp to the workpiece or cutting table.

  • Page 17: Section 3 Torch

    Any oil or moisture in the air will If necessary, connect the torch to the Power Sup- be visible on the lens. ply. Connect only the ESAB model SL60, SL60QD™ or SL100 / Mechanical Torch to this power supply. 3T.02 Setting Up Mechanical Torch Maximum torch leads length is 100 feet / 30.5 m,...

  • Page 18: Section 4 System: Operation

    CUTMASTER 60i SECTION 4 SYSTEM: OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification Numeric Display • Displays software revision at start up • Displays amperage values (Factory default) • Displays error codes • Displays pre-set (preview) maintenance functions AC Indicator Steady light indicates power supply is ready for operation.
  • Page 19 CUTMASTER 60i Set Mode Indicator Indicator is ON when unit is flowing gas and pressure can be set. Shield Cup In Place Indicator Indicator is Blinking when any of the following are not in place or connected: Shield Cup, ATC leads or Quick Disconnect.
  • Page 20 CUTMASTER 60i One of 7 segments will always be on when unit is on. The gas bottle will be illuminated and flash during a gas pressure fault. Bottle will flash when pressure is below a minimum threshold. Bottle will be on continuously when acceptable. Factory default: One, or two segments and gas bottle will be illuminated depending on the gas pressure level.

  • Page 21: Preparations For Operation

    Refer to Section 4T.07 and following for torch parts selection. Torch Connection Check that the torch is properly connected. Only ESAB models SL60, SL60QD™ / Manual or SL100 / Mechanical Torches may be connected to this Power Supply. See Section 3T of this manual.
  • Page 22 CUTMASTER 60i Connect Work Cable Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off. Power ON Place the Power Supply ON / OFF switch to the ON (right) position.
  • Page 23 CUTMASTER 60i Select Cutting Mode Press and release the upper knob without turning to enter the mode selection menu. Place the system in one of the four cutting modes available by pressing and releasing the knob until you reach the desired mode.: LATCH .
  • Page 24 CUTMASTER 60i Set the gas pressure/flow using the lower knob, 2. Changes will show on the Gas Pressure Interlock. The green indicator in the center is the ideal setting. Each indicator when lit separately is equal to 5 lbs. from the segment next to it. Each will show 5, 10, or 15 lbs or more below or above the ideal.

  • Page 25: Section 4 Torch: Operation

    CUTMASTER 60i SECTION 4 TORCH: OPERATION 4T.01 Torch Parts Selection Install the replacement Electrode by pushing it straight into the torch head until it clicks. Depending on the type of operation to be done determines the torch parts to be used. Install the start cartridge and desired tip Type of operation: for the operation into the torch head.
  • Page 26 CUTMASTER 60i Cut as usual. Simply release the trigger Torch assembly to stop cutting. Follow normal recommended cutting practices as provided in the power supply operator's manual. NOTE! Shield Cup When the shield cup is properly installed, there Standoff Distance 1/8"...
  • Page 27 CUTMASTER 60i Trigger The crown shield cup functions best when cutting 3/16 inch (4.7 mm) solid metal with relatively smooth surface. Drag Cutting With a Hand Torch Drag cutting works best on metal 1/4" (6 Trigger Release mm) thick or less. NOTE! For best parts performance and life, always use the correct parts for the type of operation.
  • Page 28 CUTMASTER 60i Angle the torch slightly to direct blow- 4T.03 Gouging back particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete. WARNING Be sure the operator is equipped with proper In a portion of the unwanted metal start gloves, clothing, eye and ear protection and that the pierce off the cutting line and then...

  • Page 29: 04 Mechanized Torch Operation

    CUTMASTER 60i Lead Angle 4T.04 Mechanized Torch Operation The angle between the torch and workpiece Cutting With Mechanized Torch depends on the output current setting and torch travel speed. The recommended lead The mechanized torch can be activated angle is 35°. At a lead angle greater than 45° by remote control pendant or by a remote the molten metal will not be blown out of interface device such as CNC.
  • Page 30 CUTMASTER 60i For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer.

  • Page 31: 05 Recommended Cutting Speeds With Exposed Tip

    CUTMASTER 60i 4T.05 Recommended Cutting Speeds With Exposed Tip CutMaster® 60i With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Out- Amper- Speed (Per Standoff Plasma Gas Flow (SCFH) Pierce Pierce Height Minute) Pressure* Inches mm (Cat.
  • Page 32 CUTMASTER 60i CutMaster® 60i With Exposed Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Out- Amper- Speed (Per Standoff Plasma Gas Flow (SCFH) Pierce Pierce Height Minute) Pressure* Inches mm (Cat. Volts (Amps) Inches Meters Inches mm Plasma Total** Delay Inches mm No.)
  • Page 33 CUTMASTER 60i CutMaster® 60i With Exposed Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Out- Amper- Speed (Per Standoff Plasma Gas Flow (SCFH) Pierce Pierce Height Minute) Pressure* Inches mm (Cat. Volts (Amps) Inches Meters Inches mm Plasma Total** Delay Inches mm...

  • Page 34: 06 Recommended Cutting Speeds With Shielded Tip

    CUTMASTER 60i 4T.06 Recommended Cutting Speeds With Shielded Tip CutMaster® 60i With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Out- Amper- Speed (Per Standoff Plasma Gas Flow (SCFH) Pierce Pierce Height Minute) Pressure* Inches mm...
  • Page 35 CUTMASTER 60i CutMaster® 60i With Shielded Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Out- Amper- Speed (Per Standoff Plasma Gas Flow (SCFH) Pierce Pierce Height Minute) Pressure* Inches mm (Cat. Volts (Amps) Inches Meters Inches mm Plasma Total** Delay Inches mm No.)
  • Page 36 CUTMASTER 60i CutMaster® 60i With Shielded Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Out- Amper- Speed (Per Standoff Plasma Gas Flow (SCFH) Pierce Pierce Minute) Pressure* Height Inches mm (Cat. Volts (Amps) Inches Meters Inches mm Plasma Total** Delay Inches mm...

  • Page 37: Patent Information

    CUTMASTER 60i PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S. and Foreign Patents as follows: Catalog # Description Patent(s) 9-8215 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786; 6703581; D496842;...
  • Page 38 CUTMASTER 60i The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512: Catalog # Description 9-8235 Shield Cap 9-8236 Shield Cap 9-8237 Shield Cup 9-8238 Shield Cap 9-8239 Shield Cap 9-8244 Shield Cap 9-8245 Shield Cap Patents Pending for the following: Quick Disconnect Torch and Quick Disconnect Torch Leads OPERATION 0-5562...

  • Page 39: Section 5 System: Service

    CUTMASTER 60i SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the cables and leads. Replace as needed Visually inspect the torch body, consumables and Quick Connect 3 Months...

  • Page 40: Common Faults

    CUTMASTER 60i Six Months or Every 720 Cutting Hours: Check the in-line air filter(s), clean or replace as required. Check cables and hoses for leaks or cracks, replace if necessary. CAUTION Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

  • Page 41: Fault Indicator

    CUTMASTER 60i 5.04 Fault Indicator At initial power up, the system goes through a series of self checks before it is ready for use. If during those checks it detects something is not within proper operating parameters, a fault will occur. If that happens the Fault indicator will light followed by the Error Code , and number in the digital display.

  • Page 42: Basic Troubleshooting Guide

    CUTMASTER 60i 5.05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Problem - Possible Cause Recommended Action Symptom...
  • Page 43 CUTMASTER 60i Problem - Possible Cause Recommended Action Symptom Nothing happens 1. Problem in the torch and leads switch 1. Take Torch and Leads (Remote Pendant) to Authorized Repair Facility. when torch switch circuit (Remote pendant switch circuit). or remote switch 2.
  • Page 44 CUTMASTER 60i Sequence of Operation (Block Diagram) ACTION: ACTION: ACTION: ACTION: ON / OFF switch to ON Close external Select desired Operating mode Set Torch Type and disconnect switch. Lead Length. Select RESULT: RUN, RESULT: SET/PURGE mode AC indicator Power to system. LATCH, GAS indicator Rapid Auto Restart (RAR),...

  • Page 45: Power Supply Basic Parts Replacement

    CUTMASTER 60i 5.06 Power Supply Basic Parts Replacement WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply. This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual. Filter Element Assembly Replacement The Filter Element Assembly (9-0116) is in the rear panel.
  • Page 46 CUTMASTER 60i Optional Single-Stage Filter Element Replacement These instructions apply to power supplies where the optional Single-Stage Filter has been installed. The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry.
  • Page 47 CUTMASTER 60i WARNING Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could result. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely. Note the location and orientation of the old Filter Elements.

  • Page 48: Section 5 Torch: Service

    CUTMASTER 60i SECTION 5 TORCH: SERVICE 5T.01 General Maintenance Upper Groove with Vent Holes Must Remain Open NOTE! Refer to Previous “Section 5: System” for com- Upper O-Ring in Correct Groove mon and fault indicator descriptions. Threads Cleaning Torch Lower O-Ring Art # A-03725 Even if precautions are taken to use only Torch Head O-Ring...

  • Page 49: 02 Inspection And Replacement Of Consumable Torch Parts

    CUTMASTER 60i Remove the tip. Check for excessive 5T.02 Inspection and Replacement of wear (indicated by an elongated or Consumable Torch Parts oversized orifice). Clean or replace the tip if necessary. WARNING Worn Tip Good Tip Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 50: Section 6: Parts Lists

    CUTMASTER 60i SECTION 6: PARTS LISTS 6.01 Introduction Parts List Breakdown The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows: 6.03 Power Supply Replacement 6.04 Replacement Power Supply Parts 6.05 Options and Accessories 6.06 External Replacement Parts (Plastic) 6.07...
  • Page 51 CUTMASTER 60i 6.04 Replacement Power Supply Parts Description Catalog # Filter Assembly Replacement Element (Factory filter) 9-0116 THREE phase Input Power Cord for 208/480 V Power Supply 9-9706 6.05 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter & Hose) 7-7507 Replacement Filter Body 9-7740...
  • Page 52 CUTMASTER 60i 6.06 External Replacement Parts (Plastic) Item # Description Catalog # Handle, Case Top 9-9702 Bezel, Side Frame RH 9-9703 Handle, CM60i (3 total) 9-9665 Foot, Case Front 9-9694 Bezel, Side Frame LH 9-9704 Foot, Case Rear 9-9693 Screws and nuts can be obtained at a local hardware store. M5x0.8x12mm screw M5x0.8x16mm screw M5x0.8 nut...

  • Page 53: Replacement Parts For Hand Torch

    CUTMASTER 60i 6.07 Replacement Parts for Hand Torch Item # Description Catalog # SL60QD™ Torch Handle Assembly (PKG) 7-5681 Leads Assemblies with ATC connector and Quick Connectors SL60QD™, 20 - foot Leads Assembly with ATC and QD connectors 4-5620 SL60QD™, 50 - foot Leads Assembly with ATC and QD connectors 4-5650 1&2...

  • Page 54: Torch Consumable Parts (Sl60)

    CUTMASTER 60i 6.08 Torch Consumable Parts (SL60) 0-5562 PARTS LIST...

  • Page 55: Torch Consumable Parts (Sl100)

    CUTMASTER 60i 6.09 Torch Consumable Parts (SL100) PARTS LIST 0-5562...

  • Page 56: Appendix 1: Data Tag Information

    CUTMASTER 60i APPENDIX 1: DATA TAG INFORMATION 0-5562 APPENDIX...

  • Page 57: Appendix 2: Torch Pin - Out Diagrams

    CUTMASTER 60i APPENDIX 2: TORCH PIN - OUT DIAGRAMS Hand Torch Pin - Out Diagram Mechanized (Machine) Torch Pin - Out Diagram Automation SL100SV Torch Pin - out Diagram APPENDIX 0-5562...

  • Page 58: Appendix 3: Torch Connection Diagrams

    CUTMASTER 60i APPENDIX 3: TORCH CONNECTION DIAGRAMS Hand Torch Connection Diagram Mechanized Torch Connection Diagram 0-5562 APPENDIX...

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