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CUTMASTER 60i

Manual 0-5436

INSTALLATION

3-3

3.05 Primary Input Power Connections, THREE 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

Three-Phase (3ø)

Art # A-13336_AB

Power

Cord

Power Switch

Three Phase Input Power Wiring

NOTE!

As long as the power supply is connected to
input power ranging from 208 VAC to 480
VAC, the system will automatically detect
this and run accordingly.

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Summary of Contents for CUTMASTER 60i

Page 1: ...60 208 480V esab com SL60QD OUTPUT MAX OUTPUT VOLTAGE INPUT POWER Art A 13285_AB INPUT POWER 3 Revision AB Issue Date April 3 2017 Manual No 0 5436 OPERATING MANUAL CUTMASTER 60i PLASMA CUTTING SYSTEM ...

Page 2: ...efore 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 competit...

Page 3: ...ny other cause For Material Print Specifications refer to document 47x1948 Original Publication Date December 12 2016 Revision Date April 3 2017 Record the following information for Warranty purposes Where Purchased __________________________________________________ Purchase Date _____________________________________________________ Power Supply Serial _____________________________________________...

Page 4: ...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 ...

Page 5: ...ormément 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 vérification 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 c...

Page 6: ...This Page Intentionally Blank ...

Page 7: ...Features 2 5 SECTION 2 TORCH INTRODUCTION 2T 1 2T 01 Scope of Manual 2T 1 2T 02 General Description 2T 1 2T 03 Specifications 2T 1 2T 04 Quick Connection Torch 2T 2 2T 05 Options And Accessories 2T 2 2T 06 Introduction to Plasma 2T 2 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...

Page 8: ...shooting Guide 5 4 5 06 Power Supply Basic Parts Replacement 5 8 SECTION 5 TORCH SERVICE 5T 1 5T 01 General Maintenance 5T 1 5T 02 Inspection and Replacement of Consumable Torch Parts 5T 2 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 Replacement Power Supply Parts 6 2 6 05 Options and Accessories 6 2 6 06 External Replacement ...

Page 9: ...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 ve...

Page 10: ...nformation on how to test for noise see item 1 in Section 1 03 Publications in this manual PLASMA ARC RAYS PlasmaArc 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...

Page 11: ...e 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 CONTAINERSAND 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 PROTECTIO...

Page 12: ...our des informations sur la manière de tester la fumée et les gaz de votre lieu de travail consultez l article 1 et les documents cités à la page 5 Utilisez un équipement spécial tel que des tables de coupe à débit d eau ou à courant descendant pour capter la fumée et les gaz N utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs...

Page 13: ...les étincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon état Remplacez toute lentille sale ou compor tant fissure ou rognure Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des écrans de protection Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANS...

Page 14: ...près de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Américaine pour la Protection contre les Incendies NFPA LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROCÉDÉS ASSOCIÉS disponible auprès de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL dispon...

Page 15: ...ld cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of ESAB 1 Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonab...

Page 16: ...CUTMASTER 60i GENERAL INFORMATION Manual 0 5436 1 8 This Page Intentionally Blank ...

Page 17: ...nformation 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 c...

Page 18: ...up 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...

Page 19: ... 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 alon...

Page 20: ...d 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 I1 eff 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 ...

Page 21: ...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 ...

Page 22: ...CUTMASTER 60i INTRODUCTION Manual 0 5436 2 6 This Page Intentionally Blank ...

Page 23: ...oth the plasma and secondary gas The air flow is divided inside the torch head Single gas operation provides a smaller sized torch and inexpensive operation CAUTION Torch Leads are flexible but in ternal wires can be broken Do not exceed a 2 radius bend and avoid repeated tight bends when possible NOTE Refer to Section 2T 05 Introduction to Plasma for a more detailed description of plasma torch op...

Page 24: ... following 1 Remove the torch handle assembly by grasping the torch handle in one hand and the coupler nut and leads in the other 2 Rotate the nut a minimum of one full turn to the left counter clockwise and pull the torch handle assembly out from the leads in a straight line 3 To reattach grasp both as before and carefully align the internal connecting parts 4 Carefully press the two together in ...

Page 25: ...ridge around the electrode and out through the tip orifice The secondary gas flows down around the outside of the torch starter cartridge and out between the tip and shield cup around the plasma arc C Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting or gouging tip This pilot arc creates a path for the main arc to transfer to the work D Main Cutting A...

Page 26: ...CUTMASTER 60i INTRODUCTION Manual 0 5436 2T 4 This Page Intentionally Blank ...

Page 27: ...l 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 ...

Page 28: ...nnect 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...

Page 29: ...e 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 Three Phase 3ø Art A 13336_AB Power Cord Power Switch Three Phase Input Power Wiring NOTE As long as the power supply is connected to input power ranging from 208 VAC to 480 VAC the...

Page 30: ...illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to manufac turer s instructions Do not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch 3 8 barb to 1 4 NPT 6mm Fitting Filter Assembly 1 4 NPT Inlet Port Hose Clamp Gas Supply Hose Art A 13262 Ai...

Page 31: ...se 3 Connect the air line to the Filter using the 1 4 NPT The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to manufac turer s instructions Do not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch Hose Clamp System Filter Assembly 1 4 NPT Inle...

Page 32: ...nufac turer s instructions Do not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch 2 Connect the two stage filter outlet hose to the inlet port of the Regulator Filter Assembly 3 Use customer supplied fittings to connect the air line to the Filter A5 16 8mm O D smooth tubing should be used with the press in fitting 5 16 8...

Page 33: ...regulator capable of outlet pressures up to 120 psi 8 3 bar maximum and flows of least 300 500 scfh 5 8 3 CFM 142 235 lpm 4 Connect supply hose to the cylinder NOTE Pressure should be set at 120 psi 8 3 bar at the high pressure cylinder regulator 3 07 Work Lead Connections Connect the Work Lead to the power supply and the work piece 1 Attache the Dinse type connection of the work lead to the power...

Page 34: ...CUTMASTER 60i INSTALLATION Manual 0 5436 3 8 This Page Intentionally Blank ...

Page 35: ...286 Connecting the Torch to the Power Supply 3 The system is ready for operation Check Air Quality To test the quality of air 1 Put the ON OFF switch in the ON Left position 2 Select SET mode 3 Place a welding filter lens in front of the torch and turn ON the air Do not start an arc Any oil or moisture in the air will be visible on the lens 3T 02 Setting Up Mechanical Torch WARNING Disconnect prim...

Page 36: ...CUTMASTER 60i INSTALLATION Manual 0 5436 3T 2 This Page Intentionally Blank ...

Page 37: ...plays software revision at start up Displays amperage values Factory default Displays error codes Displays pre set preview maintenance functions 2 AC Indicator Steady light indicates power supply is ready for operation Blinking light indicates the input voltage is outside of operating range or internal fault 3 DC Indicator Indicator is ON when DC output circuit is active 4 Latch Lock Indicator is ...

Page 38: ...lluminated Normal Cutting and Latch Mode Center indicator will be off RAR Rapid Auto Restart Cutting Every other indicator will be off Set Mode All indicators will be off 9 Fault Indicator Indicator is ON when unit is in fault condition See error codes appendix for fault light explanations Flashing when active Factory default Off 10 EOL End Of Life Indicator Indicator is normally off It is also of...

Page 39: ...LEDs will represent a value in between the two or 2 5 lb pressure change 13 Gas Pressure Selector Rotate the lower knob to set the gas pressure 14 Torch Type Indicator Used for selecting one of the three torch options and torch length for each SLV will be automatically detected Factory default On SL60 which includes SL60QD Quick Disconnect Press and release the lower knob without rotating it to st...

Page 40: ...e source before assembling or disassembling power supply torch parts or torch and leads as semblies Torch Parts Selection Check the torch for proper assembly and appropriate torch parts The torch parts must correspond with the type of operation and with the amperage output of this Power Supply 60 amps maximum Refer to Section 4T 07 and following for torch parts selection Torch Connection Check tha...

Page 41: ...mine if the firmware has been corrupted If there are no issues detected the output current setting will be displayed with the letter A to the right show ing the output current setting Should a problem be detected the fault code in the format Exxx will display and the A will not be illuminated Refer to Section 5 04 for fault code explanations Gas indicator turns ON if there is sufficient gas pressu...

Page 42: ...tem in one of the four cutting modes available by pressing and releasing the knob until you reach the desired mode RUN LATCH RAPID AUTO RESTART GOUGE SET PURGE gas flow only 2 After selecting the cutting mode set the output current by turning the knob Set Torch Parameters 1 Press and release the bottom knob without rotating to enter the torch type and leads length selections ...

Page 43: ...kpiece Use the Rapid Auto Restart mode when cutting expanded metal or gratings or trimming operations when an uninterrupted restart is desired With the system in the LATCH mode the main cutting arc will be maintained after the torch switch is released To exit or cancel the LATCH mode press and release the trigger again or lift the torch from the cutting surface so the arc goes out Typical Cutting ...

Page 44: ...CUTMASTER 60i OPERATION Manual 0 5436 4 8 This Page Intentionally Blank ...

Page 45: ... Electrode by pulling it straight out of the Torch Head A 03510_AB Electrode Start Cartridge Tip Shield Cup Torch Head Large O Ring Small O Ring Torch Parts 3 Install the replacement Electrode by pushing it straight into the torch head until it clicks 4 Install the start cartridge and desired tip for the operation into the torch head 5 Hand tighten the shield cup assembly until it is seated on the...

Page 46: ...al Cutting Information WARNING Disconnect primary power at the source before disassembling the power supply torch or torch leads Frequently review the Important Safety Precautions at the front of this manual Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s body comes into contact with the workpiece while the torch is activated ...

Page 47: ...imes useful to reduce the cutting speed to produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding 4T 04 Hand Torch Operation Standoff Cutting With Hand Torch NOTE For best performance and parts life always use the correct parts for the type of opera tion 1 The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Tr...

Page 48: ... from the work piece install the standoff guide by sliding it onto the torch shield cup Install the guide with the legs at the sides of the shield cup body to main tain good visibility of the cutting arc During operation position the legs of the standoff guide against the workpiece Shield Cup Workpiece Standoff Guide Art A 04034 Torch Tip Shield Cup With Straight Edge The drag shield cup can be us...

Page 49: ...talled there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage components Piercing With Hand Torch 1 The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the ...

Page 50: ... or power supply CAUTION Sparks from plasma gouging can cause damage to coated painted or other sur faces such as glass plastic and metal Check torch parts The torch parts must correspond with the type of operation Refer to Section 4T 07 Torch Parts Selection Gouging Parameters Gouging performance depends on parameters such as torch travel speed current level lead angle the angle between the torch...

Page 51: ...ected in the same direction as torch travel Afive degree leading arc is gener ally recommended for air plasma on mild steel 3 Trailing Arc The trailing arc is directed in the opposite direc tion as torch travel Standoff Distance Straight Arc Trailing Arc Leading Arc Direction of Torch Travel A 02586 Mechanized Torch Operation For optimum smooth surface quality the travel speed should be adjusted s...

Page 52: ... for Manual and Mechanized Torch Cutting Art A 13147_AC 9 8215 Std Life 9 8214 Ext Life 9 8213 9 8218 9 8281 9 8241 9 8237 9 8237 9 8243 9 8235 9 8252 60A 9 8210 60A 9 8226 B 60A 9 8218 8 3487 8 3486 Torch Head Replace Consumables Remplacer les consommables 23x6005 ...

Page 53: ...375 9 5 9 8208 124 40 21 0 53 0 19 4 8 55 170 NR NR NR 0 500 12 7 9 8208 123 40 11 0 28 0 19 4 8 55 170 NR NR NR 0 625 15 9 9 8208 137 40 7 0 18 0 19 4 8 55 170 NR NR NR CutMaster 60i With Exposed Tip Type Material Stainless Steel Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Tip Output Amperage Speed Per Minute Standoff Plasma Gas Pressure Flow SCFH Pierce Pierce Height Inches...

Page 54: ...Tip Type Material Mild Steel Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Tip Output Amperage Speed Per Minute Standoff Plasma Gas Pressure Flow SCFH Pierce Pierce Height Inches mm Cat No Volts VDC Amps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 060 1 5 9 8210 110 60 290 7 37 0 19 4 8 Set to the central region on the pressure dial This is illuminated gr...

Page 55: ...0i With Exposed Tip Type Material Aluminum Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Tip Output Amperage Speed Per Minute Standoff Plasma Gas Pressure Flow SCFH Pierce Pierce Height Inches mm Cat No Volts VDC Amps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 060 1 5 9 8210 110 60 440 11 18 0 25 6 4 Set to the central region on the pressure dial This is...

Page 56: ... psi bar Plasma Total Delay Sec Inches mm 0 036 0 9 9 8208 109 40 180 4 57 0 125 3 2 Set to the central region on the pressure dial This is illuminated green when selected 55 170 0 00 0 2 5 1 0 05 1 3 9 8208 105 40 165 4 19 0 125 3 2 55 170 0 00 0 2 5 1 0 06 1 5 9 8208 115 40 120 3 05 0 125 3 2 55 170 0 10 0 2 5 1 0 078 2 0 9 8208 120 40 65 1 65 0 187 4 8 55 170 0 30 0 2 5 1 0 135 3 4 9 8208 125 4...

Page 57: ...4 0 36 0 19 4 8 90 245 NR NR NR 0 750 19 1 9 8210 145 60 14 0 36 0 19 4 8 90 245 NR NR NR 1 000 25 4 9 8210 156 60 4 0 10 0 19 4 8 90 245 NR NR NR CutMaster 60i With Shielded Tip Type Material Stainless Steel Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Tip Output Amperage Speed Per Minute Standoff Plasma Gas Pressure Flow SCFH Pierce Pierce Height Inches mm Cat No Volts VDC A...

Page 58: ... 00 0 20 5 1 0 075 1 9 9 8210 110 60 350 8 89 0 13 3 2 90 245 0 10 0 20 5 1 0 120 3 0 9 8210 110 60 275 6 99 0 13 3 2 90 245 0 10 0 20 5 1 0 188 3 4 9 8210 122 60 140 3 56 0 13 3 2 90 245 0 20 0 20 5 1 0 250 6 4 9 8210 134 60 80 2 03 0 19 4 8 90 245 0 30 0 20 5 1 0 375 9 5 9 8210 140 60 45 1 14 0 19 4 8 90 245 0 50 0 20 5 1 0 500 12 7 9 8210 144 60 26 0 66 0 19 4 8 90 245 0 80 0 20 5 1 0 625 15 9 ...

Page 59: ...461 Other Pat s Pending 9 8211 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8212 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8253 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8225 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8226 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8227 Tip US Pat No s 6774336 7145099 69...

Page 60: ...d 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 ...

Page 61: ... before maintaining Each Use Visual check of torch tip and electrode Weekly Visually inspect the torch body consumables and Quick Connect Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supply Replace all broken parts Maintain more often if used under severe conditions Art A 13267 ...

Page 62: ...Weekly or Every 30 Cutting Hours 1 Check fan for proper operation and adequate air flow 2 Inspect torch for any cracks or exposed wires replace if necessary 3 Inspect input power cable for damage or exposed wires replace if necessary Six Months or Every 720 Cutting Hours 1 Check the in line air filter s clean or replace as required 2 Check cables and hoses for leaks or cracks replace if necessary ...

Page 63: ... cable disconnected 5 Worn torch parts 6 Non Genuine Thermal Dynamics parts used Excessive Dross Formation 1 Cutting speed too slow 2 Torch standoff too high from workpiece 3 Worn torch parts 4 Improper cutting current 5 Non Genuine Thermal Dynamics parts used 6 Incorrect gas pressure Short Torch Parts Life1 Oil or moisture in air source 2 Exceeding system capability material too thick 3 Excessive...

Page 64: ...B set wrong E004 PIP Fault Parts in Place fault Shield cup not in place or tight E005 PIC Fault Parts in Contact fault Missing or worn tip start cartridge or electrode Inlet pressure exceeds rating causing continuous gas flow E009 Fan Fault Fan failed or disconnected E010 Low Output Current Work Lead current less than output current setting Shorted pilot switch or defec tive current sensor possibl...

Page 65: ... Cup loose 2 Torch not properly connected to power supply 3 Problem in torch and leads PIP circuit 4 Failed components in unit 1 Hand tighten the shield cup until it is snug 2 Insure torch ATC is securely fastened to unit 3 Replace torch and leads or return to authorized service center for repair or replacement 4 Return to authorized service center for repair or replacement FAULT and indicators fl...

Page 66: ...zed service center for repair FAULT indicators flashing Error code E024 or E031 1 Internal Error 1 Turn the ON OFF switch OFF then back ON again If that does not clear the fault return to an authorized service center for repair Pilot arc is ON but cutting arc will not establish 1 Work cable not connected to work piece 2 Work cable connector broken 3 Failed components in unit 1 Connect work cable 2...

Page 67: ...ength Select SET PURGE mode to confirm the gas operation and purge the torch if needed ACTION Select desired Operating mode RUN LATCH Rapid Auto Restart RAR Gouge Set desired Operating Current Set the Gas pressure to the green nominal indicator ACTION Release Torch switch RESULT Main arc stops Gas flow stops after post flow Fans will continue to run for 5 minutes after the Torch switch START is re...

Page 68: ...ice Manual A Filter Element Assembly Replacement The Filter Element Assembly 9 0116 is in the rear panel For better system performance the filter element should be checked per the Maintenance Schedule Section 5 02 and either cleaned or replaced Regulator Filter Assembly Art A 13255 1 Remove power from the power supply turn OFF the gas supply and bleed down the system 2 Remove the clear filter bowl...

Page 69: ...eplace NOTE If replacing or cleaning just the filter ele ment refer to the following illustration for disassembly Art A 07990 Filter Element 4 Install the new or cleaned assembly by reversing these procedures 5 Turn ON the air supply and check for leaks before reinstalling the cover ...

Page 70: ...hut OFF air supply and bleed down system before disassembling Filter to change Filter Element 3 Disconnect gas supply hose 4 Turn the Filter Housing Cover counter clockwise and remove it The Filter Element is located inside the Housing Art A 02476 Filter Element Cat No 9 7741 Housing Cover Barbed Fitting Spring Assembled Filter O ring Cat No 9 7743 Optional Single Stage Filter Element Replacement ...

Page 71: ...op of the Filter Assembly enough to allow the Filter Elements to move freely 4 Note the location and orientation of the old Filter Elements 5 Slide out the old Filter Elements First Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Replacement 6 Slide the replacement Filter Elements into the Filter Assembly with the same orientation as noted in Step 4 above 7 Hand tighten the...

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Page 73: ...nd blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling O Ring Lubrication An O Ring on the Torch Head and ATC Male Con nector requires lubrication on a scheduled basis This will allow the O Rings to remain pliable and provide a proper seal The O Rings will dry out becoming hard and cracked if the lubricant is not used on a regular basis This can lead to pote...

Page 74: ...e may be an O Ring between the shield cup body and drag shield cap Do not lubricate the O Ring Drag Shield Cap Shield Cup Body O Ring No 8 3488 Art A 03878 4 Remove the tip Check for excessive wear indi cated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip A 03406 Example of Tip Wear 5 Remove the starter cartridge Check for excessive wear plugged gas ho...

Page 75: ...uct must be returned for service contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the power supply Address all inquiries to your authorized distrib...

Page 76: ...lacement Filter Body 9 7740 1 Replacement Filter Hose not shown 9 7742 2 Replacement Filter Element 9 7741 1 Two Stage Filter Kit includes Hose Mounting Screws 9 9387 1 Two Stage Air Filter Assembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Work Cable 8 with 50mm Dinse plug 9 9692 1 Multi Purpose Cart 7 8888 1 Filter Wrench Factory Filter 9 9675 Art A 02476 Filter Ele...

Page 77: ...Case Top 9 9702 2 1 Bezel Side Frame RH 9 9703 3 1 Handle CM60i 3 total 9 9665 4 1 Foot Case Front 9 9694 5 1 Bezel Side Frame LH 9 9704 6 1 Foot Case Rear 9 9693 Screws and nuts can be obtained at a local hardware store a M5x0 8x12mm screw b M5x0 8x16mm screw c M5x0 8 nut 1 2 3 4 5 6 3 a b c b b a a a a a a c c Art A 13343 ...

Page 78: ... Assembly Replacement 7 5680 2 Leads Assemblies with ATC connector and Quick Connectors 1 SL60QD 20 foot Leads Assembly with ATC and QD connectors 4 5604 1 SL60QD 50 foot Leads Assembly with ATC and QD connectors 4 5605 1 2 1 Torch and Leads Assembly 20 foot 7 5604 1 2 1 Torch and Leads Assembly 50 foot 7 5605 2 Art A 13248 1 ...

Page 79: ...orch Consumable Parts SL60 Art A 13147_AC 9 8215 Std Life 9 8214 Ext Life 9 8213 9 8218 9 8281 9 8241 9 8237 9 8237 9 8243 9 8235 9 8252 60A 9 8210 60A 9 8226 B 60A 9 8218 8 3487 8 3486 Torch Head Replace Consumables Remplacer les consommables 23x6005 ...

Page 80: ...ps Tip E 9 8254 60 120 Amps Shield Cup Gouging 9 8241 Shield Cup Body 9 8237 Tips 40 120A GOUGING Shield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Machine 50 60A 9 8238 Drag Shield Cap 9 8235 Art A 13148 CUTTING STANDOFF 20 40A Shield Cap Deflector 9 8243 50 60A CUTTING STANDOFF Heavy Duty Start Cartridge Non HF Only 9 8277 Shield Cap Deflector 9 8243 Shield Cap Machine 40A 9 8245 20A 9 8205 30...

Page 81: ...ng Second row Rated cutting current values Third row Conventional load voltage values 4 Sections of the Data Tag may be applied to separate areas of the power supply I Art A 13265_AB Date of Mfr Output Range Amperage Voltage Type of Power Supply Note 1 Output Current Type Rated No Load Voltage Plasma Cutting Symbol Manufacturer s Name and or Logo Location Model and Revision Level Serial Number and...

Page 82: ...ve Plasma 3 White Pendant Connector 4 Black Pendant Connector 2 Orange PIP 1 Black PIP Pilot 2 PIP 1 PIP 6 Open 7 Open 5 Open 8 Ground 8 Green Pendant Connector Ground 5 White Not Used 7 Green Not Used 6 Open UNSHIELDED MACHINE TORCH 3 Switch 4 Switch Art A 03799 Negative Plasma Pilot 1 2 3 4 5 6 7 8 5 6 8 1 2 3 4 7 C Automation SL100SV Torch Pin out Diagram ATC Female Receptacle Front View ATC Ma...

Page 83: ... 3 8 7 1 2 5 6 4 3 8 7 Torch Switch Green White To Power Supply Circuitry B Mechanized Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Remote Pendant Connector Power Supply with ATC Female Receptacle Pilot Negative Plasma Power Supply To Remote Control Remote Pendant Connector PIP Switch Not Used Male ATC Leads Connector ATC Female Recept...

Page 84: ... 6 G 1 2 0 7 K D300 INPUT BIAS SUPPLY PCB PFC PCB MULTIFUNCTION DISPLAY CONTROL PCB DISPLAY_7SEG_QUAD AC DC FAULT END OF LIFE OVERTEMP MODE KNOB Rotate to Set Current Press to Select Mode KNOB Rotate to Set Pressure Press to Select Torch Lead Lenght D101 15V under knob D135 HEARTBEAT under knob D159 PRI _OC behind PCB 1 2 3 J102 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 J103 GND J101 J103...

Page 85: ...608 GND 24V_PWM VIO BK OR J401 J602 50 PIN RIBBON CABLE FAN1 24V GND BASIC CNC OPTIONAL AUTOMATION INTERFACE A SERIES ONLY GND 5V 15V PRI GND PRI 24V 15V 15V GND PRI 50 PIN RIBBON CABLE SIGNALS all others are GND or unused PIN NAME Description means signal active low 1 3 GATE B GATE A Gate drive signals 5 6 15V 7 9 I_PRI_A I_PRI_B Primary Current Sense signals 12 PFC_OFF Disables PFC 13 V_SENSE Ou...

Page 86: ...IN 6 G 1 2 0 7 K D300 INPUT BIAS SUPPLY PCB PFC PCB MULTIFUNCTION DISPLAY CONTROL PCB DISPLAY_7SEG_QUAD AC DC FAULT END OF LIFE OVERTEMP MODE KNOB Rotate to Set Current Press to Select Mode KNOB Rotate to Set Pressure Press to Select Torch Lead Lenght D101 15V under knob D135 HEARTBEAT under knob D159 PRI _OC behind PCB 1 2 3 J102 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 J103 GND J101 J1...

Page 87: ...D625 PIC OK Q608 GND 24V_PWM VIO BK OR J401 J602 50 PIN RIBBON CABLE FAN1 24V GND BASIC CNC OPTIONAL AUTOMATION INTERFACE A SERIES ONLY GND 5V 15V PRI GND PRI 24V 15V 15V GND PRI 50 PIN RIBBON CABLE SIGNALS all others are GND or unused PIN NAME Description means signal active low 1 3 GATE B GATE A Gate drive signals 5 6 15V 7 9 I_PRI_A I_PRI_B Primary Current Sense signals 12 PFC_OFF Disables PFC ...

Page 88: ...CUTMASTER 60i APPENDIX Manual 0 5436 A 8 APPENDIX 6 Publication History Cover Date Rev Change s Dec 12 2016 AA Manual released Apr 3 2017 AB Updated Manual to include 3phase systems VCR 02204 ...

Page 89: ...This Page Intentionally Blank ...

Page 90: ... Care Ph 1 940 381 1212 Fax 1 940 483 8178 Miami FL USA Sales Office Latin America Ph 1 954 727 8371 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 ...

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