ESAB THERMAL DYNAMICS CUTMASTER 58 Service Manual
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ESAB THERMAL DYNAMICS CUTMASTER 58 Service Manual

ESAB THERMAL DYNAMICS CUTMASTER 58 Service Manual

Plasma cutting system
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CUTMASTER
PLASMA CUTTING SYSTEM
Service
Manual
SL60QD
58
™
Revision: AA
Issue Date: 11-07-2018
OUTPUT
MAX OUTPUT
VOLTAGE
60
208-
460V
VOLTAGE
VOLTAGE
460V 600V
INPUT POWER
INPUT POWER
3
Art # A-13750_AB
Manual No.: 0-5545
esab.com

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Summary of Contents for ESAB THERMAL DYNAMICS CUTMASTER 58

  • Page 1 SL60QD OUTPUT MAX OUTPUT VOLTAGE VOLTAGE VOLTAGE 208- 460V 600V 460V CUTMASTER INPUT POWER INPUT POWER ™ PLASMA CUTTING SYSTEM Service Manual Art # A-13750_AB Revision: AA Issue Date: 11-07-2018 Manual No.: 0-5545 esab.com...
  • Page 2 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.
  • Page 3 2800 Airport Rd. Denton, Texas 76207 www.esab.com Copyright 2018 by Thermal Dynamics an ESAB brand All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negli- gence, accident, or any other cause.

  • Page 4: User Responsibility

    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,”...

  • Page 5: Responsabilités De L'utilisateur

    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 qualifiés seulement. Si vous n’avez pas une connaissance approfondie des principes de fonctionnement et des règles de sécurité...
  • Page 6 This Page Intentionally Blank...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ..............1-1 1.01 Notes, Cautions and Warnings ................ 1-1 1.02 Remarques, avertissements et mises en garde ..........1-1 1.03 Statement of Warranty ..................1-4 SECTION 2 SYSTEM: INTRODUCTION ..............2-1 2.01 How To Use This Manual ................2-1 2.02 Equipment Identification .................
  • Page 8 TABLE OF CONTENTS PATENT INFORMATION ................. 4T-16 SECTION 5 SYSTEM: SERVICE ................5-1 5.01 General Maintenance ..................5-1 5.02 Maintenance Schedule ..................5-2 5.03 Common Faults ....................5-2 5.04 Fault Indicator ....................5-3 5.05 Basic Troubleshooting Guide ................5-4 5.06 Power Supply Basic Parts Replacement ............
  • Page 9 TABLE OF CONTENTS APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........A-1 APPENDIX 2: DATA TAG INFORMATION ..............A-2 APPENDIX 3: TORCH PIN - OUT DIAGRAMS ............A-3 APPENDIX 4: TORCH CONNECTION DIAGRAMS ............A-4 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS ..........A-6 APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS .............
  • Page 10 This Page Intentionally Blank...

  • Page 11: Section 1: General Information

    CUTMASTER 58 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 emphasis or is helpful in efficient opera- tion of the system.
  • Page 12 CUTMASTER 58 WARNING AVERTISSEMENT 1. Cutting sparks can cause explosion 1. Les étincelles de coupage peuvent or fire. provoquer une explosion ou un incendie. 1.1 Do not cut near flammables. 1.2 Have a fire extinguisher nearby and 1.1 Ne pas couper près des matières ready to use.
  • Page 13 CUTMASTER 58 This Page Intentionally Blank 0-5545 GENERAL INFORMATION...

  • Page 14: Statement Of Warranty

    CUTMASTER 58 1.03 STATEMENT OF WARRANTY LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics Corporation 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.

  • Page 15: Section 2 System: Introduction

    Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link: http://www.esab.com 0-5545 INTRODUCTION...

  • Page 16: Power Supply Specifications

    CUTMASTER 58 2.04 Power Supply Specifications CutMaster 58 Power Supply Specifications 208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz 230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz Input Power 400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 460 VAC (414 - 506 VAC), Single Phase, 60 Hz...

  • Page 17: Input Wiring Specifications

    CUTMASTER 58 2.05 Input Wiring Specifications CutMaster 58 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Flexible Cord Volts I max Fuse (amps) (Min. AWG) 10.4 1 Phase 10.8 15.2 50/60 50/60 3 Phase 50/60 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTE!

  • Page 18: Power Supply Features

    CUTMASTER 58 2.06 Power Supply Features Handle and Leads Wrap Control Panel Torch Leads Receptacle Art # A-07942 Work Cable and Clamp Port for Optional Automation Interface Cable Input Power Selection Filter Assembly Gas Inlet Port Art # A-07981 Input Power Cord INTRODUCTION 0-5545...

  • Page 19: Section 2 Torch: Introduction

    CUTMASTER 58 2T.03 Specifications SECTION 2 TORCH: INTRODUCTION A. Torch Configurations 1. Hand/Manual Torch, Models The hand torch head is at 75° to the torch handle. The 2T.01 Scope of Manual hand torches include a torch handle and torch trigger This manual contains descriptions, operating assembly.

  • Page 20: 04 Options And Accessories

    CUTMASTER 58 F. Torch Ratings 2T.04 Options And Accessories For options and accessories, see Section 6. Manual Torch Ratings Ambient 104° F 2T.05 Quick Connection Torch Temperature 40° C The new SL60QD™ (Quick Disconnect) torch allows for a Duty Cycle 100% @ 60 Amps @ 400 scfh quick change of the torch handle assembly from the leads.
  • Page 21 CUTMASTER 58 C. Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work. D. Main Cutting Arc DC power is also used for the main cutting arc.
  • Page 22 CUTMASTER 58 This Page Intentionally Blank INTRODUCTION 0-5545 2T-4...

  • Page 23: Section 3 System: Installation

    CUTMASTER 58 3.03 Primary Input Power Conn. SECTION 3 SYSTEM: CAUTION INSTALLATION Check your power source for correct volt- age before plugging in or connecting the 3.01 Unpacking unit. Check the Voltage Selector at the rear of the unit for correct setting before plug- 1.
  • Page 24 CUTMASTER 58 Check the setting of the input voltage selection 7. With a little slack in the wires, tighten the through - hole protector to secure the power switch at the rear of the unit before you plug it in. cable.

  • Page 25: Gas Connections

    CUTMASTER 58 7. With a little slack in the wires, tighten the Installing Optional Single - Stage Air Filter through - hole protector to secure the power An optional filter kit is recommended for improved cable. filtering with compressed air, to keep moisture and 8.
  • Page 26 CUTMASTER 58 1. Refer to the manufacturer’s specifications for Installing Optional Two - Stage Air Filter installation and maintenance procedures for high pressure regulators. This optional two - stage air line filter is also 2. Examine the cylinder valves to be sure for use on compressed air shop systems.

  • Page 27: Section 3 Torch: Installation

    CUTMASTER 58 Check Air Quality SECTION 3 TORCH: To test the quality of air: INSTALLATION 1. Put the switch in the ON ON / OFF (up) position. 3T.01 Torch Connections 2. Put the Function Control switch in the SET If necessary, connect the torch to the Power Sup- position.
  • Page 28 CUTMASTER 58 Pinch Block Assembly Square Workpiece A-02585 Mechanical Torch Set - Up 3. The proper torch parts (shield cup, tip, start cartridge, and electrode) must be installed for the type of operation. Refer to Section "4T.07 Parts Selection for Manual and Mechanized Torch Cutting"...

  • Page 29: Section 4 System: Operation

    CUTMASTER 58 SECTION 4 SYSTEM: OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification 1. Output Current Control Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or standoff cutting.

  • Page 30: Preparations For Operation

    CUTMASTER 58 turns ON if there is sufficient gas pressure for power supply 4.02 Preparations for Operation operation and the cooling fans turn ON. At the start of each operating session: NOTE! WARNING Minimum pressure for power supply operation is Disconnect primary power at the source lower than minimum for torch operation.
  • Page 31 CUTMASTER 58 3. For Drag cutting, adjust gas pressure from Postflow 75 - 95 psi / 5.2 - 6.5 bar (LED's in center Release the trigger to stop the cutting arc. Gas continues of control panel). Refer to the Drag Cutting to flow for approximately 20 seconds.
  • Page 32 CUTMASTER 58 This Page Intentionally Blank OPERATION 0-5545...

  • Page 33: Section 4 Torch: Operation

    CUTMASTER 58 SECTION 4 TORCH: Large O-Ring Small O-Ring Torch Head OPERATION Electrode 4T.01 Torch Parts Selection Depending on the type of operation to be done determines the torch parts to be used. Start Cartridge Type of operation: Drag cutting, standoff cutting or gouging Torch parts: Shield Cup, Cutting Tip, Electrode and Starter Cartridge Shield Cup...

  • Page 34: 02 Cut Quality

    CUTMASTER 58 4T.02 Cut Quality Bottom Dross Buildup Molten material which is not blown out of the cut area NOTE! and resolidifies on the plate. Excessive dross may require Cut quality depends heavily on setup and parameters secondary cleanup operations after cutting. such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.

  • Page 35: 04 Hand Torch Operation

    CUTMASTER 58 Edge Starting 4T.04 Hand Torch Operation For edge starts, hold the torch perpendicular to the work- Standoff Cutting With Hand Torch piece with the front of the tip near (not touching) the edge of the workpiece at the point where the cut is to start. NOTE! When starting at the edge of the plate, do not pause at the For best performance and parts life, always use the...
  • Page 36 CUTMASTER 58 3. Hold the torch away from your body. 8. For a consistent standoff height from the 4. Slide the trigger release toward the back workpiece, install the standoff guide by slid- of the torch handle while simultaneously ing it onto the torch shield cup. Install the squeezing the trigger.
  • Page 37 CUTMASTER 58 Trigger Drag Cutting With a Hand Torch Drag cutting works best on metal 1/4" (6 mm) thick or less. NOTE! For best parts performance and life, always use the correct parts for the type of operation. Trigger Release 1.

  • Page 38: 05 Gouging

    CUTMASTER 58 3. In a portion of the unwanted metal start the 4T.05 Gouging pierce off the cutting line and then continue WARNING the cut onto the line. Hold the torch perpen- Be sure the operator is equipped with dicular to the workpiece after the pierce is proper gloves, clothing, eye and ear complete.

  • Page 39: 06 Mechanized Torch Operation

    CUTMASTER 58 Current Setting 4T.06 Mechanized Torch Operation Current settings depend on torch travel speed, mode of Cutting With Mechanized Torch operation (hand or machine torch), and the amount of material to be removed. The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC.
  • Page 40 CUTMASTER 58 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 41: 07 Parts Selection For Manual And Mechanized Torch Cutting

    CUTMASTER 58 4T.07 Parts Selection for Manual and Mechanized Torch Cutting Tips: Shield DRAG TIP Cup Body, Shield Cap, Deflector 9-8237 9-8243 CUTTING 20A 9-8205 30A 9-8206 Shield Cup 40A 9-8207 9-8218 60A 9-8252 O-Ring No. 8-3488 Shield Cap, Drag DRAG SHIELD 40A 9-8244 CUTTING...

  • Page 42: 08 Recommended Cutting Speeds For Mechanized Torch With Exposed Tip

    CUTMASTER 58 4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip Type Torch: SL60 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height...
  • Page 43 CUTMASTER 58 Type Torch: SL60 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters...

  • Page 44: 09 Recommended Cutting Speeds For Mechanized Torch With Shielded Tip

    CUTMASTER 58 Type Torch: SL60 With Exposed Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters...
  • Page 45 CUTMASTER 58 Type Torch: SL60 With Shielded Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches (Cat. No.) Volts(VDC) (Amps) Inches Meters...
  • Page 46 CUTMASTER 58 Type Torch: SL60 With Shielded Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches (Cat. No.) Volts(VDC) (Amps) Inches Meters...

  • Page 47: Patent Information

    CUTMASTER 58 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;...
  • Page 48 CUTMASTER 58 Catalog # Description Patent(s) 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 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...

  • Page 49: Section 5 System: Service

    CUTMASTER 58 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 tip, electrode, start cartridge and shield cup 3 Months...

  • Page 50: Maintenance Schedule

    CUTMASTER 58 5.02 Maintenance Schedule 5.03 Common Faults Problem - Symptom Common Cause NOTE! Insufficient 1. Cutting speed too fast. The actual frequency of maintenance may need to be Penetration 2. Torch tilted too much. adjusted according to the operating environment. 3.

  • Page 51: Fault Indicator

    CUTMASTER 58 5.04 Fault Indicator Explanation of Faults " UNDER PRESSURE: Indicates that operating pressure is set At initial power up, two lights will temporarily illuminate for 2-3 too low and power supply output power will be disabled. seconds to show the version of software used. INPUT POWER: Indicates primary line voltage is outside To determine the first digit, count the function indicators left the operating limits of the power supply as selected by...

  • Page 52: Basic Troubleshooting Guide

    CUTMASTER 58 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 - Symptom Possible Cause Recommended Action ON / OFF Switch 1.
  • Page 53 CUTMASTER 58 Problem - Symptom Possible Cause Recommended Action FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten. indicators flashing. 2. Torch tip, electrode or starter 2. Turn OFF power supply. Remove shield cup. Install missing Gas flow is cycling cartridge missing.

  • Page 54: Power Supply Basic Parts Replacement

    CUTMASTER 58 5.06 Power Supply Basic Parts C. Filter Element Assembly Replacement Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be checked WARNING per the Maintenance Schedule (Subsection 5.02), and either Disconnect primary power to the system cleaned or replaced.
  • Page 55 CUTMASTER 58 NOTE! If replacing or cleaning just the filter element refer Housing to the following illustration for disassembly. Filter Element (Cat. No. 9-7741) Spring Filter Element O-ring (Cat. No. 9-7743) Assembled Filter Cover Barbed Fitting Art # A-02476 Optional Single-Stage Filter Element Replacement Remove the Filter Element from the Housing and set Element aside to dry.

  • Page 56: Circuit Fault Isolation

    CUTMASTER 58 Upper Screws Lower Screws Slots Lower Screws First & Second Stage Cartridges (as marked) Art # A-02942 Optional Two-Stage Filter Replacement Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step Art # A-07947 4 above.
  • Page 57 CUTMASTER 58 CAUTION DRAG Due to the close proximity of the Main PCB CutMaster 58 Gas Pressure Settings to the Capacitor PCB, It is recommended SL60 SL100 to use an insulated meter probe when Leads Length (Hand Torch) (Mechanized Torch) making measurements on the J2 connec- Up to 25' 80 psi...
  • Page 58 CUTMASTER 58 11. Start a cut, and release the torch switch G. Main Arc and Controls Test • Main cutting arc will remain ON until the torch is Connect work Cable to the work piece, Close torch switch lifted away from the plate approximately ¾” (19 (Pendant switch or activate CNC Start) to establish a pilot mm) or until the torch is brought OFF the edge of arc.

  • Page 59: Main Input And Internal Power Problems

    CUTMASTER 58 a) J2-9 (+) to J2-7 (-) Three Phase Input Power Wiring b) J2-5 (+) to J2-6 (-) (Auto Interface PCB J3 con- W1 contactor points are stuck closed nector with jumper installed between pins 1 and 2) a) Check per Section 5.11-A. = ARC VOLTS divided by 50 Primary plug not wired correctly.
  • Page 60 CUTMASTER 58 4. Defective Logic PCB E. INPUT POWER FAULT. AC LED ON, FAULT Indicator and 65 PSI LED is flashing. a) Measure the voltage on Main PCB between J2-17 to test point GND1 for 12VDC. If the voltage is less INPUT VOLTAGE SELECTOR SWITCH (SW2) set for than 2VDC, replace Logic PCB incorrect voltage...
  • Page 61 CUTMASTER 58 Spring-Loaded Spring-Loaded J. AC LED ON, TEMP, GAS, DC LED's are OFF, Lower End Fitting Lower End Fitting at Reset / FAULT Indicator is flashing. MIN PRESSURE Full Compression Full Extension LED is flashing. Gas is not flowing. Gas supply not connected to unit a) Connect gas supply to unit Gas supply not turned ON...

  • Page 62: Pilot Arc Problems

    CUTMASTER 58 N. AC LED ON, TEMP LED OFF, GAS LED ON, Gas 5.09 Pilot Arc Problems does not flow in SET mode using a machine torch A. AC LED ON, TEMP LED OFF, GAS LED ON. with remote solenoid. Nothing happens when torch switch or remote Disconnect the gas solenoid SOL1 from the back of the ATC switch is closed (Or CNC START signal is active)
  • Page 63 CUTMASTER 58 C. AC LED ON, TEMP LED OFF, GAS LED ON, gas flowing, DC LED OFF, Fault Indicators OFF, No arc in torch Defective Logic PCB Upper Groove with Vent Holes a) Measure voltage at Main PCB between test point Must Remain Open GND1 to J2-10.

  • Page 64: Main Arc And Controls Problems

    CUTMASTER 58 5.10 Main Arc and Controls Problems 5.11 CNC Interface Problems A. Main arc will not establish, LED D59 ON Main A. Nothing happens when jumper is installed PCB remains ON while pilot arc is striking the between J2-3 to J2-4. work piece.
  • Page 65 CUTMASTER 58 CutMaster 52 & 82 C. Input Capacitor PCB Test Cover Screws W1 contactor wired for 1PH Using an ohmmeter check continuity between the fol- lowing points: Actuator Button Input Capacitors Actuator Arm Meter (+) Meter (-) Indication MTH 2 MTH 4 Charging MTH 4...
  • Page 66 CUTMASTER 58 E. Output Diode Module Test Disconnect transformer wires from Main PCB terminal SEC 1. Using an ohmmeter perform the tests in the chart Output Diode Module Meter (+) Meter (-) Indication SEC 1 WORK 1 Forward Bias SEC 1 CHOKE 1 Reverse Bias WORK 1...
  • Page 67 CUTMASTER 58 MTH8 MTH5 MTH6 MTH1 MTH3 MTH4 MTH2 MTH7 Art # A-08841 *J3 CONNECTOR PINOUT CAPACITOR PCB SIGNALS Signal Source-Destination J1-1 Capacitor bank A+ J1-5 Capacitor bank A- J2-1 Capacitor Bank B+ J2-5 Capacitor Bank B- J3-1 +12 VDC J3-2 /460 Active low for 460VAC input J3-3...
  • Page 68 CUTMASTER 58 LOGIC PCB LAYOUT PCB3 D1 TP3 *J1 Pinout Art # A-08179 SERVICE 0-5545 5-20...

  • Page 69: Output Voltage

    CUTMASTER 58 LOGIC PCB SIGNALS (Same for MAIN PCB J2) Signal Source/Destination J1-1 -VOUT (-) OUTPUT VOLTAGE J1-2 /TIP VOLTS Active high when tip is installed J1-3 TIP_SEN Approx. 100VDC while cutting with tip not in contact w/work piece, Active low when tip contact work during cut (Drag Mode) J1-4 /460V_IN...

  • Page 70: Test Points

    CUTMASTER 58 LED INDICATORS NORMAL INDICATION FIRMWARE VERSION ERROR MESSAGE +12VDC MAX PRESSURE Over Pressure 90 PSI Internal Error 85 PSI Shorted torch 80 PSI Tip Missing 75 PSI Start Signal active during power up 70 PSI Parts-In-Place Fault (PIP) 65 PSI Input Power Fault MIN PRESSURE...
  • Page 71 CUTMASTER 58 *J2 PINOUT PRI_4 J4 J3 I_DMD1 PRI_1 GND1 PRI_3 PRI_2 TIP1 SEC1 ELECTRODE1 +48V2 +12V2 -V_OUT1 +48V1 J8 J7 J6 J5 GND2 Art # A-08518_AB CHOKE1 SEC2 +12V1 WORK_1 0-5545 SERVICE 5-23...
  • Page 72 CUTMASTER 58 MAIN PCB SIGNALS LED INDICATORS PCR Indicates Pilot IGBT gate signal is ON J1-1 L1 Primary AC Line CSR Indicates cutting arc has been established J1-2 Not used J1-3 Not used MAIN PCB TEST POINTS J1-4 Not used GND1 Common J1-5...

  • Page 73: Section 5 Torch: Service

    CUTMASTER 58 SECTION 5 TORCH: SERVICE Upper Groove 5T.01 General Maintenance with Vent Holes Must Remain Open NOTE! Refer to previous "Section 5 System" for common and Upper O-Ring in Correct Groove fault indicator descriptions. Threads Cleaning Torch Lower O-Ring Art # A-03725 Even if precautions are taken to use only clean air with a Torch Head O-Ring...

  • Page 74: 02 Inspection And Replacement Of Consumable Torch Parts

    CUTMASTER 58 4. Remove the tip. Check for excessive wear (indicated 5T.02 Inspection and Replacement of by an elongated or oversized orifice). Clean or replace Consumable Torch Parts the tip if necessary. WARNING Good Tip Worn Tip Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 75: Introduction

    CUTMASTER 58 SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows: Section "6.03 Power Supply Replacement" Section "6.04 Major External Replacement Parts" Section "6.05 Front Panel Replacement Parts"...

  • Page 76: Major External Replacement Parts

    CUTMASTER 58 6.04 Major External Replacement Parts Item # Description Catalog # Cover with labels 9-0120 Base Enclosure Assembly 9-0118 Tube, roll handle 9-0121 Front Panel 9-0100 Rear Panel 9-0101 Art # A-08120 NOTE! Illustration may vary slightly from unit. PARTS LIST 0-5545...

  • Page 77: Front Panel Replacement Parts

    CUTMASTER 58 6.05 Front Panel Replacement Parts Item# Description Ref. Catalog # Output Current Control and Function Control Knobs 9-8527 Toggle - ON/OFF Switch 9-0109 Work Cable with Clamp, 20 Ft / 6.1 m 9-0184 Art # A-08123 NOTE! Illustration may vary slightly from unit. 0-5545 PARTS LIST...

  • Page 78: Left Side Replacement Parts

    CUTMASTER 58 6.06 Left Side Replacement Parts Item # Description Catalog # Main PCB Assembly non 600V PCB 1 9-0108 Main PCB Assembly 600V Only PCB 1 9-0165 Logic PCB PCB 3 9-0107* Logic PCB (for 600V systems) PCB 3 9-0169 Center Chassis Molded Plastic 9-0102...

  • Page 79: Right Side Replacement Parts

    CUTMASTER 58 6.07 Right Side Replacement Parts Item # Description Catalog # Contactor, 4 Pole 9-8587 Solenoid, 12V SOL1 9-0114 Spare Parts Box 7-3267 Spare Parts Box Cover 7-3266 Console Quick Disconnect 9-0161 Regulator, with knob and mounting nut 9-0115* Assembly, PCB, Input Capacitors non 600V PCB 2 9-0167...

  • Page 80: Options And Accessories

    CUTMASTER 58 6.08 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter & Hose) 7-7507 Replacement Filter Body 9-7740 Replacement Filter Hose (not shown) 9-7742 Replacement Filter Element 9-7741 Two - Stage Filter Kit (includes Hose & Mounting Screws) 9-9387 Two - Stage Air Filter Assembly 9-7527...

  • Page 81: Replacement Parts For Hand Torch

    CUTMASTER 58 6.09 Replacement Parts for Hand Torch Item # Description Catalog # Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 Trigger Assembly Replacement Kit 9-7034 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 Torch Head Assembly Replacement Kit (includes items No.

  • Page 82: Replacement Parts - For Mechanized Torches With Unshielded Leads

    CUTMASTER 58 6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads Item No. Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O-Ring 8-3487 Small O-Ring 8-3486 PIP Switch Kit 9-7036 Unshielded Automated Leads Assemblies with ATC connectors 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850 10 - foot / 3.05 m Leads Assembly with ATC connector...
  • Page 83 CUTMASTER 58 5 & 6 A-07994_AB 0-5545 PARTS LIST...

  • Page 84: Torch Consumable Parts Manual And Mechanized Torches

    CUTMASTER 58 6.11 Torch Consumable Parts Manual and Mechanized Torches Tips: Shield DRAG TIP Cup Body, Shield Cap, Deflector 9-8237 9-8243 CUTTING 20A 9-8205 30A 9-8206 Shield Cup 40A 9-8207 9-8218 60A 9-8252 O-Ring No. 8-3488 Shield Cap, Drag DRAG SHIELD 40A 9-8244 CUTTING Shield...

  • Page 85: Section 7: Replacement Procedures

    CUTMASTER 58 B. Procedure SECTION 7: REPLACEMENT 1. Open the wrist strap and unwrap the first PROCEDURES two folds of the band. Wrap the adhesive side firmly around your wrist. 2. Unroll the rest of the band and peel the liner 7.01 Scope from the copper foil at the opposite end.

  • Page 86: Major External Parts

    CUTMASTER 58 7.04 Major External Parts C. Tube Handle Replacement Tools required: T20 Torx Driver A. Cover Removal 1. Disconnect the Torch and Leads from the Tools required: T20 Torx Driver unit. 1. Remove the upper and lower screws which 2.

  • Page 87: Front Panel Parts Replacement

    CUTMASTER 58 7.05 Front Panel Parts Replacement D. Air Regulator Replacement Tools required: T20 Torx Driver Refer to Section "6.05 Front Panel Replace- 1. Remove the cover per subsection 7.04-A. ment Parts" and an overall detailed drawing. 2. Remove the three (3) air hoses from the regulator per subsection 7.05-C.

  • Page 88: Left Side Internal Parts Replacement

    CUTMASTER 58 G. ON/OFF Switch (SW1) Replacement 7.06 Left Side Internal Parts Tools required: T20 Torx Driver Replacement 1. Remove the cover per subsection 7.04-A. A. Fan Replacement 2. Disconnect the wires on the rear of the Tools required: T20 Torx Driver switch, noting the location and orientation 1.

  • Page 89: Rear Panel Parts Replacement

    CUTMASTER 58 13. Remove the two screws securing the Main 7.07 Rear Panel Parts Replacement Transformer to the base. 14. Remove the Main Transformer, carefully A. Filter Element Assembly Replacement The Filter Element Assembly is in the rear guiding all its wires through from the right panel.
  • Page 90 CUTMASTER 58 5. Remove the fitting from the filter element C. Input Power Cable Replacement assembly by inserting a 6 mm hex wrench Tools required: T20 Torx Driver, Phillips into the internal hex fitting and turning it Head Screwdriver, Flathead Screwdriver, counter clock-wise (left).

  • Page 91: Right Side Internal Parts Replacement

    CUTMASTER 58 5. Remove the Filter Element from the Housing 7.08 Right Side Internal Parts and set Element aside to dry. Replacement 6. Wipe inside of housing clean, then insert the replacement Filter Element open side A. Capacitor PCB (PCB 2) Replacement Tools required: T20 Torx Driver first.
  • Page 92 CUTMASTER 58 This Page Intentionally Blank PARTS REPLACEMENT 0-5545...

  • Page 93: Appendix 1: Sequence Of Operation

    CUTMASTER 58 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: RUN / Rapid Auto Restart / ON / OFF switch to ON Close external RUN / SET / LATCH disconnect switch. Rapid Auto Restart / switch to RUN RESULT: SET / LATCH switch RESULT:...

  • Page 94: Appendix 2: Data Tag Information

    CUTMASTER 58 APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and ® Revision Level, Serial Number M odel : and Production Code Made in USA Dat e of M f r : Type of Power Regulatory Standard Covering 1/ 3...

  • Page 95: Appendix 3: Torch Pin - Out Diagrams

    CUTMASTER 58 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Open 4 - Green / Switch 4 - Switch 3 - Switch...

  • Page 96: Appendix 4: Torch Connection Diagrams

    CUTMASTER 58 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power Torch Supply Torch Head Leads Black...
  • Page 97 CUTMASTER 58 This Page Intentionally Blank 0-5545 APPENDIX...

  • Page 98: Appendix 5: System Schematic, 208/460V Units

    CUTMASTER 58 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS K1-K4 K1-K4 K5, K6 K5, K6 PRI 1 PRI 1 PRI 2 PRI 2 PRI 4 PRI 4 PRI 3 PRI 3 +12VDC BIAS SUPPLY MTH1 MTH1 MTH2 MTH2 C1-C4* C1-C4* /INRUSH MTH3 MTH3 MTH4...
  • Page 99 CUTMASTER 58 CM82 / A60 ONLY 1TORCH PIP SWITCH PIP SWITCH SEC1 SEC1 SEC2 SEC2 CHOKE1 CHOKE1 +12VDC TORCH SWITCH TORCH SWITCH TEMP /OVERTEMP ATC CONNECTOR CIRCUIT AUTOMATION TORCH SOLENOID -V OUT 1 -V OUT 1 ELECTRODE1 ELECTRODE1 TIP1 TIP1 PILOT IGBT PILOT IGBT WORK1...

  • Page 100: Appendix 6: System Schematic, 600V Units

    CUTMASTER 58 APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS PRI 2 PRI 2 PRI 1 PRI 1 PRI 4 PRI 4 PRI 3 PRI 3 BIAS SUPPLY MTH2 MTH2 MTH1 MTH1 +12VDC + C1-C4* + C1-C4* CHOKE /INRUSH CE UNITS ONLY MTH3 MTH3 MTH4...
  • Page 101 CUTMASTER 58 1TORCH PIP SWITCH PIP SWITCH SEC1 SEC1 SEC2 SEC2 CHOKE1 CHOKE1 +12VDC TORCH SWITCH TORCH SWITCH TEMP /OVERTEMP CIRCUIT ATC CONNECTOR AUTOMATION TORCH SOLENOID -V OUT 1 -V OUT 1 ELECTRODE1 ELECTRODE1 TIP1 TIP1 PILOT IGBT PILOT IGBT WORK1 WORK1 WORK...

  • Page 102: Appendix 7: Publication History

    CUTMASTER 58 APPENDIX 7: Publication History Cover Date Rev. Change(s) 11-07-2018 Manual released. APPENDIX 0-5545 A-10...
  • Page 103 This Page Intentionally Blank...
  • Page 104 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 Canada Customer Care: 905-827-4515 / FAX 800-588-1714 International Customer Care: 940-381-1212 / FAX 940-483-8178 © 2016 ESAB Group Incorporated. www.esab.com...

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