ESAB A-14032 User manual

Revision: AA Issue Date: 15 February, 2019 Manual No.: 0-5562

CUTMASTER®60i

PLASMA CUTTING SYSTEM

Art # A-14032

esab.com

60 400V

SL60QD OUTPUT MAX OUTPUT VOLTAGE INPUT POWER

OPERATING

MANUAL

EU DECLARATION OF CONFORMITY

According to

The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016

The EMC Directive 2014/30/EU, entering into force 20 April 2016

The RoHS Directive 2011/65/EU, entering into force 2 January 2013

Type of equipment

PLASMA CUTTING SYSTEM

Type designation etc.

CutMaster 60i, from serial number MX1723XXXXXX

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.

IEC/EN 60974-10:2014 + AMD 1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10:

Electromagnetic compatibility (EMC) requirements

Additional Information: Restrictive use, Class A equipment, intended for use in location other than

residential.

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s

authorised representative , that the equipment in question complies with the safety require-

ments stated above.

Date Signature Position

9 June, 2017

Flavio Santos General Manager

Accessories and

Adjacencies

2017

TABLE OF CONTENTS

SECTION 1: GENERAL INFORMATION.....................................................11

1.01Notes, Cautions and Warnings...............................................................................11

SECTION 1: INFORMATIONS GÉNÉRALES ..............................................13

1.01Remarques, avertissements et mises en garde......................................................13

SECTION 2 SYSTEM: INTRODUCTION ....................................................15

2.01How To Use This Manual........................................................................................15

2.02Equipment Identication......................................................................................15

2.03Receipt Of Equipment...........................................................................................15

2.04Power Supply Specications .................................................................................16

2.05Input Wiring Specications ...................................................................................18

2.06Power Supply Features..........................................................................................19

SECTION 2TORCH: INTRODUCTION ......................................................21

2T.01Scope of Manual..................................................................................................21

2T.02General Description.............................................................................................21

2T.03Specications .....................................................................................................21

2T.04Quick Connection Torch .......................................................................................22

SECTION 3 SYSTEM: INSTALLATION ......................................................23

3.01Unpacking ............................................................................................................23

3.02Lifting Options......................................................................................................23

3.03Opening the Main Switch Cover............................................................................23

3.04Primary Input Power Connections, 3 Phase...........................................................24

3.05Gas Connections....................................................................................................24

3.06Work Lead Connections.........................................................................................27

SECTION 3 TORCH:

INSTALLATION....................................................................................29

3T.01Torch Connections ...............................................................................................29

3T.02Setting Up MechanicalTorch ...............................................................................29

SECTION 4 SYSTEM: OPERATION ..........................................................31

4.01Front Panel Controls / Features .............................................................................31

4.02Preparations for Operation....................................................................................34

SECTION 4TORCH: OPERATION.............................................................39

4T.01Torch Parts Selection ...........................................................................................39

4T.02Hand Torch Operation..........................................................................................39

4T.03Gouging ..............................................................................................................42

4T.04Mechanized Torch Operation ...............................................................................43

4T.05Recommended Cutting Speeds With ExposedTip ................................................45

4T.06Recommended Cutting Speeds With ShieldedTip ...............................................48

TABLE OF CONTENTS

PATENT INFORMATION........................................................................51

SECTION 5 SYSTEM: SERVICE................................................................53

5.01General Maintenance............................................................................................53

5.02Maintenance Schedule..........................................................................................53

5.03Common Faults.....................................................................................................54

5.04Fault Indicator.......................................................................................................55

5.05Basic Troubleshooting Guide.................................................................................56

5.06Power Supply Basic Parts Replacement.................................................................59

SECTION 5TORCH: SERVICE .................................................................63

5T.01General Maintenance ..........................................................................................63

5T.02Inspection and Replacement of ConsumableTorch Parts.....................................64

SECTION 6: PARTS LISTS......................................................................65

6.01Introduction..........................................................................................................65

6.02Ordering Information............................................................................................65

6.03Power Supply Replacement ..................................................................................65

6.04Replacement Power Supply Parts .........................................................................66

6.05Options and Accessories........................................................................................66

6.06External Replacement Parts (Plastic) ...................................................................67

6.07Replacement Parts for HandTorch ........................................................................68

6.08Torch Consumable Parts (SL60).............................................................................69

6.09Torch Consumable Parts (SL100)...........................................................................70

APPENDIX 1: DATA TAG INFORMATION .................................................71

APPENDIX 2: TORCH PIN  OUT DIAGRAMS ...........................................72

APPENDIX 3: TORCH CONNECTION DIAGRAMS......................................73

APPENDIX 4: PUBLICATION HISTORY ...................................................74

CUTMASTER 60i

0-5562 INTRODUCTION 15

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.

Additional copies of this manual may be purchased by contacting ESAB at the address and phone

number in your area listed on back cover of this manual. Include the Operating Manual number and

equipment identication numbers.

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".

http://www.esab.com

2.02 Equipment Identication

The unit’s identication number (specication 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 identied only by the specication or part number printed on loosely attached

card or the shipping container. Record these numbers on the bottom of page i for future reference.

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 imme-

diately to le 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 identication numbers as described above, along with a full description of the

parts in error.

Included items:

• 60i Power Supply

• SL60QD™ Torch and Leads

• Work Lead with Work Clamp

• Spare Parts Kit ( 2 Electrodes, 2Tips, 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.

CUTMASTER 60i

INTRODUCTION 0-5562

2.04 Power Supply Specications

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

3 Phase Input Power Cable Power Supply includes 9' three 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 400 VAC 3 Phase CE Power Supply Speciﬁcations

Input Power 400 VAC, 3 Phase, 50/60 Hz

3 Phase Input Power Cable Power Supply includes 9' three phase 12AWG 4/C input

cable with 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)

2.04.02 Additional Power Supply Specications

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

3/4" (19.05mm) 5/8" (15.86mm) 1 1/2" (38mm)

CUTMASTER 60i

0-5562 INTRODUCTION 17

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 dierent results. Adjust the

amperage accordingly.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

CUTMASTER 60i

INTRODUCTION 0-5562

2.05 Input Wiring Specications

WARNING

Each CutMaster 60i system is a dedicated 1 Phase OR 3 Phase system and cannot be recongured 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

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.

CUTMASTER 60i

0-5562 INTRODUCTION 19

2.06 Power Supply Features

CUTMASTER 60i

0-5562 INTRODUCTION 21

SECTION 2 TORCH: INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operating

instructions and maintenance procedures for

the 1Torch Models SL60, SL60QD™ and SL100/

Mechanized Plasma Cutting Torches. Service of

this equipment is restricted to properly trained

personnel; unqualied personnel are strictly cau-

tioned against attempting repairs or adjustments

not covered in this manual, at the risk of voiding

the Warranty.

Read this manual thoroughly. A complete under-

standing of the characteristics and capabilities

of this equipment will assure the dependable

operation for which it was designed.

2T.02 General Description

CAUTION

Torch Leads are exible but internal wires can

be broken. Do not exceed a 2" radius bend and

avoid repeated tight bends when possible.

NOTE!

Refer to Section "4Torch", for a more detailed

description of plasma torch operation.

Refer to the Appendix Pages for

additional specications as related

to the Power Supply used.

2T.03 Specications

A. Torch Congurations

1. Hand/Manual Torch, Model

SL60QD™

The hand torch head is at 75° to the torch

handle. The hand torches include a torch

handle and torch trigger assembly.

2. Mechanized Torch, Model

The standard machine torch has a po-

sitioning tube with rack & pinch block

assembly.

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20 ft / 6.1 m, with ATC connectors

• 50 ft / 15.2 m, with ATC connectors

Machine Torches are available as

follows:

• 5 foot / 1.5 m, with ATC connectors

• 10 foot / 3.05 m, with ATC connectors

• 25 foot / 7.6 m, with ATC connectors

• 50 foot / 15.2 m, with ATC connectors

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

15 VDC circuit rating

E. Type Cooling

Combination of ambient air and gas stream

through torch.

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

104° F

40° C

Duty Cycle 100% @ 60 Amps @ 400

scfh

Maximum

Current 60 Amps

Voltage (Vpeak)500V

Arc Striking

Voltage 500V

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