ESAB Cutmaster 60 Operating Manual
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ESAB Cutmaster 60 Operating Manual

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esab Cutmaster
Plasma Cutting system
sL60 1Torch
Operating
Manual
Revision:
AA
TM
Art # A-12773
Issue Date:
January 15, 2015
60
Manual No.:
0-5402
esab.com.cn
60
®
380/400V

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  • Page 1 Cutmaster ® Plasma Cutting system sL60 1Torch Operating Manual Art # A-12773 380/400V Revision: Issue Date: Manual No.: January 15, 2015 0-5402 esab.com.cn...
  • Page 2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new ESAB 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 lo- cate your nearest distributor or service agency, visit us on the web at www.esab.com.cn...
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judge- ment, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply ESAB Cutmaster 60 with SL60 1Torch™ ® Operating Manual Number 0-5402...
  • Page 4 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: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY ..........................1-1 Safety Precautions ..................1-1 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 ..................2-1 2.04 Power Supply Specifications ................2-2 2.05 Input Wiring Specifications ................
  • Page 6 TABLE OF CONTENTS 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 ............5-6 SECTION 5 TORCH: SERVICE ............................5T-1 5T.01...

  • Page 7: Section 1: Safety

    SECTION 1: SAFETY Safety Precautions Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
  • Page 8 ESAB CuTmASTEr 60 Arc welding and cutting can be injurious to yourself and others. WARNING Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill.

  • Page 9: Section 2 System: Introduction

    Warnings will be enclosed in a box such as this. Additional copies of this manual may be purchased by contacting ESAB at the address and phone num- ber in your area listed on back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

  • Page 10: Power Supply Specifications

    ESAB CuTmASTEr 60 2.04 Power Supply Specifications ESAB Cutmaster 60 Power Supply Specifications ® Three Phase 380 VAC (360 - 440 VAC), , 50/60 Hz Input Power Three Phase 400 VAC (360 - 440 VAC), , 50/60 Hz Power Supply includes input cable.

  • Page 11: Input Wiring Specifications

    ESAB CuTmASTEr 60 2.05 Input Wiring Specifications ESAB Cutmaster 60 Power Supply Input Cable Wiring requirements ® Input voltage Freq Power Input Suggested Sizes Flexible Cord (Min. Volts Fuse (amps) AWG) 1max 1eff 50/60 14# (around 2.5mm 3 phase 50/60 14# (around 2.5mm...

  • Page 12: Power Supply Features

    ESAB CuTmASTEr 60 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 Filter Assembly Gas Inlet Port Art # A-08544 Input Power Cord...

  • Page 13: Section 2 Torch: Introduction

    ESAB CuTmASTEr 60 SECTION 2 TORCH: 2T.03 Specifications INTRODUCTION A. Torch Configurations 1. Hand/Manual Torch, Models 2T.01 Scope of Manual The hand torch head is at 75° to the torch handle. The hand torches include a torch This manual contains descriptions, operating instruc- handle and torch trigger assembly.

  • Page 14: 04 Options And Accessories

    ESAB CuTmASTEr 60 F. Torch Ratings 2T.05 Introduction to Plasma manual Torch ratings A. Plasma Gas Flow Ambient 104° F Temperature 40° C Plasma is a gas which has been heated to an extremely high temperature and ionized so that it...
  • Page 15 ESAB CuTmASTEr 60 B. Gas Distribution E. Parts - In - Place (PIP) The single gas used is internally split into plasma The torch includes a 'Parts - In - Place' (PIP) cir- and secondary gases. cuit. When the shield cup is properly installed, it closes a switch.
  • Page 16 ESAB CuTmASTEr 60 This Page Intentionally Blank INTRODUCTION Manual 0-5402 2T-4...

  • Page 17: Section 3 System: Installation

    ESAB CuTmASTEr 60 SECTION 3 SYSTEM: 3.03 Primary Input Power Connections INSTALLATION CAUTION Check your power source for correct voltage before plugging in or connecting the unit. The primary 3.01 Unpacking power source, fuse, and any extension cords used must conform to local electrical code and the 1.

  • Page 18: Gas Connections

    ESAB CuTmASTEr 60 Installing Optional Single - Stage Air Filter 6. Connect the wires as follows. • Wiring to L1, L2 and L3 input. See the previ- An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and ous illustration and power label. It does not matter what order these wires are attached.
  • Page 19 ESAB CuTmASTEr 60 Installing Optional Two - Stage Air Filter Kit This optional two - stage air line filter 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: 1.
  • Page 20 ESAB CuTmASTEr 60 This Page Intentionally Blank INSTALLATION Manual 0-5402...

  • Page 21: Section 3 Torch: Installation

    If necessary, connect the torch to the Power Sup- WARNING ply. Connect only the ESAB model SL60 / Manual Disconnect primary power at the source before or SL100 / Mechanical Torch to this power supply. disassembling the torch or torch leads.
  • Page 22 ESAB CuTmASTEr 60 This Page Intentionally Blank INSTALLATION Manual 0-5402 3T-2...

  • Page 23: Section 4 System: Operation

    ESAB CuTmASTEr 60 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 higher for standoff cutting.

  • Page 24: Preparations For Operation

    Check that the torch is properly connected. Only for a ten (10) minute period once the condition is ESAB model SL60 / Manual or SL100 / Mechanical cleared. Torches may be connected to this Power Supply.
  • Page 25 ESAB CuTmASTEr 60 Typical Cutting Speeds STANDOFF ESAB Cutmaster 60 Gas Pressure Settings Cutting speeds vary according to torch output ® amperage, the type of material being cut, and Leads SL60 SL100 operator skill. Refer to Section "4T.08 Length (Hand Torch)
  • Page 26 ESAB CuTmASTEr 60 This Page Intentionally Blank OPERATION Manual 0-5402...

  • Page 27: Section 4 Torch: Operation

    ESAB CuTmASTEr 60 SECTION 4 TORCH: 5. Hand tighten the shield cup assembly until it is seated on the torch head. If resistance is OPERATION felt when installing the cup, check the threads before proceeding. 4T.01 Torch Parts Selection 4T.02 Cut Quality...

  • Page 28: 03 General Cutting Information

    ESAB CuTmASTEr 60 Bottom Dross Buildup Direction of Cut Molten material which is not blown out of the In the torches, the plasma gas stream swirls as it cut area and resolidifies on the plate. Excessive leaves the torch to maintain a smooth column of dross may require secondary cleanup operations gas.

  • Page 29: 04 Hand Torch Operation

    ESAB CuTmASTEr 60 5. Bring the torch within transfer distance to the 4T.04 Hand Torch Operation work. The main arc will transfer to the work, Standoff Cutting With Hand Torch and the pilot arc will shut off. NOTE! NOTE! For best performance and parts life, always use the The gas preflow and postflow are a characteristic of correct parts for the type of operation.
  • Page 30 ESAB CuTmASTEr 60 Shield Cup With Straight Edge The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand. Trigger WARNING The straight edge must be non - conductive. Trigger Release A-02986 6.
  • Page 31 ESAB CuTmASTEr 60 Cutting speed depends on material, thickness, and Piercing With Hand Torch the operator’s ability to accurately follow the desired 1. The torch can be comfortably held in one hand cut line. The following factors may have an impact or steadied with two hands.

  • Page 32: 05 Gouging

    ESAB CuTmASTEr 60 4T.05 Gouging Torch Head WARNING Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions at the front of this manual have 35° been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch is activated.

  • Page 33: 06 Mechanized Torch Operation

    ESAB CuTmASTEr 60 For optimum smooth surface quality, the travel 4T.06 Mechanized Torch Operation speed should be adjusted so that only the lead- ing edge of the arc column produces the cut. If Cutting With Mechanized Torch the travel speed is too slow, a rough cut will be...

  • Page 34: 07 Parts Selection For Manual And Mechanized Torch Cutting

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

  • Page 35: 08 Recommended Cutting Speeds For Mechanized Torch With Exposed Tip

    ESAB CuTmASTEr 60 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 Speed (Per Plasma Gas Pierce Thickness Output Amperage...
  • Page 36 ESAB CuTmASTEr 60 Type Torch: SL60 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Speed (Per Plasma Gas Pierce Thickness Output Amperage Standoff Flow (CFH) Pierce Minute) Press Height (Cat. Volts...

  • Page 37: 09 Recommended Cutting Speeds For Mechanized Torch With Shielded Tip

    ESAB CuTmASTEr 60 4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip Type Torch: SL60 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Speed (Per Plasma Gas Pierce Thickness Output Amperage...
  • Page 38 ESAB CuTmASTEr 60 Type Torch: SL60 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Speed (Per Plasma Gas Pierce Thickness Output Amperage Standoff Flow (CFH) Pierce Minute) Press Height Volts Delay Inches (Cat.

  • Page 39: Patent Information

    ESAB CuTmASTEr 60 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 9-8277 Cartridge US Pat No(s) 6903301; 6717096; 6936786;...
  • Page 40 ESAB CuTmASTEr 60 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...

  • Page 41: Section 5 System: Service

    ESAB CuTmASTEr 60 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.

  • Page 42: Maintenance Schedule

    4. Worn torch parts Daily Operational Checks or Every Six Cutting 5. Cutting current too low. Hours: 6. Non - Genuine ESAB parts used 1. Check torch consumable parts, replace if dam- 7. Incorrect gas pressure aged or worn. Main Arc 1.

  • Page 43: Fault Indicator

    ESAB CuTmASTEr 60 5.04 Fault Indicator At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7.

  • Page 44: Basic Troubleshooting Guide

    ESAB CuTmASTEr 60 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...
  • Page 45 ESAB CuTmASTEr 60 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 Gas flow is cycling cartridge missing.

  • Page 46: Power Supply Basic Parts Replacement

    ESAB CuTmASTEr 60 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 WARNING be checked per the Maintenance Schedule (Section Disconnect primary power to the system before 5.02), and either cleaned or replaced.
  • Page 47 ESAB CuTmASTEr 60 5. Remove the fitting from the filter element as- Optional Single-Stage Filter Element sembly by inserting a 6 mm hex wrench into Replacement the internal hex fitting and turning it counter These instructions apply to power supplies where the clock-wise (left).
  • Page 48 ESAB CuTmASTEr 60 Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replace- ment filter element catalog number.

  • Page 49: Section 5 Torch: Service

    ESAB CuTmASTEr 60 SECTION 5 TORCH: SERVICE Upper Groove 5T.01 General Maintenance with Vent Holes Must Remain Open NOTE! Refer to Previous "Section 5: System Service" for Upper O-Ring common and fault indicator descriptions. in Correct Groove Cleaning Torch Threads...

  • Page 50: 02 Inspection And Replacement Of Consumable Torch Parts

    ESAB CuTmASTEr 60 4. Remove the tip. Check for excessive wear 5T.02 Inspection and Replacement of (indicated by an elongated or oversized orifice). Consumable Torch Parts Clean or replace the tip if necessary. Good Tip Worn Tip WARNING Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 51: Parts Lists

    ESAB CuTmASTEr 60 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: 6.03 Power Supply Replacement 6.04 Replacement Power Supply Parts 6.05 Options and Accessories 6.06...

  • Page 52: Replacement Power Supply Parts

    ESAB CuTmASTEr 60 6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115 Filter Assembly Replacement Element 9-0116 Input Power Cord for 380/400 V Power Supply 9-0218 6.05 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter & Hose)

  • Page 53: Replacement Parts For Hand Torch

    ESAB CuTmASTEr 60 6.06 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 54: Replacement Parts - For Machine Torches With Unshielded Leads

    ESAB CuTmASTEr 60 6.07 Replacement Parts - for Machine Torches with Unshielded Leads Item No. Qty 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...
  • Page 55 ESAB CuTmASTEr 60 5 & 6 A-07994_AB Manual 0-5402 PARTS LIST...

  • Page 56: Replacement Shielded Machine Torch Leads Assemblies

    ESAB CuTmASTEr 60 6.08 Replacement Shielded Machine Torch Leads Assemblies Item No. Qty Description Catalog No. Mechanized Shielded Leads Assemblies with ATC Connectors 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847 25 - foot / 7.6 m Leads Assembly with ATC Connector...

  • Page 57: Torch Consumable Parts (Sl60)

    ESAB CuTmASTEr 60 6.09 Torch Consumable Parts (SL60) 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...

  • Page 58: Torch Consumable Parts (Sl100)

    ESAB CuTmASTEr 60 6.10 Torch Consumable Parts (SL100) Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243 9-8218...

  • Page 59: Appendix 1: Sequence Of Operation (Block Diagram

    ESAB CuTmASTEr 60 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...

  • Page 60: Appendix 2: Data Tag Information

    ESAB CuTmASTEr 60 APPENDIX 2: DATA TAG INFOrmATION Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Regulatory Standard Covering Type of Power This Type of Power Supply Supply (Note 1)

  • Page 61: Appendix 3: Torch Pin - Out Diagrams

    ESAB CuTmASTEr 60 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 - Ground 4 - Green /...

  • Page 62: Appendix 4: Torch Connection Diagrams

    ESAB CuTmASTEr 60 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 Receptacle Power Connector Torch Supply...
  • Page 63 ESAB CuTmASTEr 60 This Page Intentionally Blank Manual 0-5402 APPENDIX...

  • Page 64: Appendix 5: System Schematic, 380/400V Units

    ESAB CuTmASTEr 60 APPENDIX 5: SYSTEM SCHEMATIC, 380/400V 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...
  • Page 65 2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). 2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: Chk: Chk: App: App: App: Sheet Sheet Sheet Schematic ESAB Cutmaster 60/80 20'/50' SL60 400V/208-460V 3ph Size Size Size DWG No: DWG No: DWG No: TITLE: TITLE: TITLE: Last Modified:...

  • Page 66: Appendix 6: Publication History

    ESAB CuTmASTEr 60 APPENDIX 6: Publication History Cover Date rev. Change(s) Jan. 15, 2015 Manual released. APPENDIX Manual 0-5402...
  • Page 67 This Page Intentionally Blank...
  • Page 68 Bucharest SOUTH AFRICA ESAB Mexico S.A. Vamberk Tel: +40 316 900 600 ESAB Africa Welding & Cutting Ltd Monterrey Tel: +420 2 819 40 885 Fax: +40 316 900 601 Durbanvill 7570 - Cape Town Tel: +52 8 350 5959...

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