Thermal Dynamics CUTMASTER 60i Bedienungsanleitung

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Art # A-13291

60 208-

480V

SL60QD OUTPUT MAX OUTPUT VOLTAGE INPUT POWER INPUT POWER

Revision: AA Issue Date: April 3, 2017 Manual No.: 0-5475

SERVICE

MANUAL

CUTMASTER®60i

PLASMA CUTTING SYSTEM

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics 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 locate your nearest distributor

or service agency call 1-800-426-1888, or visit us on the web at www.esab.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your

Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate

concern. Therefore 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 competition through market-leading, dependable products that

have stood the test of time. We pride ourselves on technical innovation, competitive prices, excel-

lent delivery, superior customer service and technical support, together with excellence in sales and

marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer

working environment within the welding industry.

Plasma Cutting Power Supply

CutMaster™ 60i

SL60QD™ 1Torch™

Service Manual Number 0-5475

Published by:

ESAB Group Incorporated

2800 Airport Rd.

Denton, Texas 76207

www.esab.com

Thermal Dynamics an ESAB brand.

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.

Original Publication Date: April 3, 2017

Revision Date:

Record the following information for Warranty purposes:

Where Purchased:_______________________________ __________________

Purchase Date:____________________________________________________

Power Supply Serial #:______________________________________________

Torch Serial #:___________________________________ _________________

WARNING

Read and understand this entire Manual and your employer’s safety practices

before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s

best judgement, the Manufacturer assumes no liability for its use.

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,” Booklet 0-5407. Do NOT permit untrained persons to install,

operate, or maintain this equipment. Do NOT attempt to install or operate this equip-

ment until you have read and fully understand these instructions. If you do not fully

understand these instructions, contact your supplier for further information. Be sure

to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description 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

become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the

Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The

user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty main-

tenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by

the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

OPERATING.

PROTECT YOURSELF AND OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.

VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.

ATTENTION

Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.

Si vous n’avez pas une connaissance approfondie des principes de fonctionnement

et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous

vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Wel-

ding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux personnes non

qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez

PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces

instructions. Si vous ne comprenez pas bien les instructions, communiquez avec

votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de

Sécurité avant d’installer ou d’opérer cet équipement.

RESPONSABILITÉS DE L’UTILISATEUR

Cet équipement opérera conformément 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 vérication 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 contaminées doivent être remplacées immédiatement.

Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande

de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.

Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant. L’utilisa-

teur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des

dommages, une réparation incorrecte ou une modication par une personne autre que le fabricant ou un centre de service

désigné par le fabricant.

ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT

D’INSTALLER OU D’OPÉRER L’UNITÉ.

PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ........................................................................... 1-1

1.01 Notes, Cautions and Warnings........................................................................ 1-1

1.02 Important Safety Precautions ......................................................................... 1-1

1.03 Publications.................................................................................................... 1-2

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 ..................................................................................... 2-2

2.04 Power Supply Speciﬁcations .......................................................................... 2-2

2.05 Input Wiring Speciﬁcations............................................................................. 2-4

2.06 Power Supply Features ................................................................................... 2-5

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 ......................................... 3-2

3.05 Primary Input Power Connections, THREE Phase........................................... 3-3

3.06 Gas Connections............................................................................................. 3-4

3.07 Work Lead Connections.................................................................................. 3-7

SECTION 4 SYSTEM:

OPERATION .......................................................................................... 4-1

4.01 Front Panel Controls / Features....................................................................... 4-1

4.02 Preparations for Operation.............................................................................. 4-4

SECTION 5 SYSTEM:

SERVICE............................................................................................... 5-1

5.01 General Maintenance ...................................................................................... 5-1

5.02 Maintenance Schedule.................................................................................... 5-2

5.03 Common Faults............................................................................................... 5-3

5.04 Fault Indicator................................................................................................. 5-4

5.05 Basic Troubleshooting Guide .......................................................................... 5-5

5.06 Advanced Troubleshooting Guide Pre-Tests.................................................... 5-8

5.07 Power OFF Advanced Troubleshooting.......................................................... 5-10

5.08 Power ON Advanced Troubleshooting........................................................... 5-19

5.09 Fault Code..................................................................................................... 5-28

5.10 Advanced Features Menu.............................................................................. 5-33

5.11 Power Supply Basic Parts Replacement ....................................................... 5-34

5.12 Internal Parts Replacement........................................................................... 5-38

TABLE OF CONTENTS

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 Miscellaneous Replacement Power Supply Parts ........................................... 6-2

6.05 Options and Accessories ................................................................................ 6-2

6.06 External Replacement Parts (Plastic) ............................................................. 6-3

6.07 Internal Plastics Replacement Parts ............................................................... 6-4

6.08 Left Side Replacement Parts .......................................................................... 6-5

6.09 Right Side Replacement Parts ........................................................................ 6-6

6.10 Replacement Parts for Hand Torch ................................................................ 6-7

6.11 Torch Consumable Parts (SL60)..................................................................... 6-8

6.12 Torch Consumable Parts ................................................................................ 6-9

APPENDIX 1: DATA TAG INFORMATION ................................................................ A-1

APPENDIX 2: TORCH PIN - OUT DIAGRAMS........................................................... A-2

APPENDIX 3: TORCH CONNECTION DIAGRAMS ...................................................... A-3

APPENDIX 4: SYSTEM SCHEMATIC, 1PHASE 208/460V UNITS..................................... A-4

APPENDIX 5: SYSTEM SCHEMATIC, 3PHASE 208/460V UNITS..................................... A-6

APPENDIX 6: PUBLICATION HISTORY .................................................................. A-8

CUTMASTER 60i

Manual 0-5475 GENERAL INFORMATION 1-1

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 em-

phasis or is helpful in efﬁcient operation of

the system.

CAUTION

A procedure which, if not properly followed,

may cause damage to the equipment.

WARNING

A procedure which, if not properly followed,

may cause injury to the operator or others in

the operating area.

WARNING

Gives information regarding possible electri-

cal shock injury. Warnings will be enclosed

in a box such as this.

1.02 Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF

PLASMAARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric

and magnetic emissions that may interfere

with the proper function of cardiac pacemak-

ers, hearing aids, or other electronic health

equipment. Persons who work near plasma

arc cutting applications should consult their

medical health professional and the manufac-

turer of the health equipment to determine

whether a hazard exists.

To prevent possible injury, read, understand

and follow all warnings, safety precautions

and instructions before using the equipment.

Call 1-603-298-5711 or your local distributor

if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma 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 very careful when cutting or welding any metals

which may contain one or more of the following:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (SDS/

GHS) that should be supplied with the material

you are using. These SDS/GHSs will give you

the information regarding the kind and amount of

fumes and gases that may be dangerous to your

health.

• For information on how to test for fumes and

gases in your workplace, refer to item 1 in "1.03

Publications" on page 1-2 in this manual.

• Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

• WARNING: This product contains chemicals,

including lead, known to the State of California to

cause birth defects and other reproductive harm.

Wash hands after handling.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the

operator or others in the workplace.

CUTMASTER 60i

GENERAL INFORMATION Manual 0-5475

1-2

• Never touch any parts that are electrically “live”

or “hot.”

• Wear dry gloves and clothing. Insulate yourself

from the work piece or other parts of the welding

circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

code, refer to item 9 in Section "1.03 Publications"

on page 1-2.

• Disconnect power source before performing any

service or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or ﬂammable mate-

rial in the workplace. Any material that cannot be

removed must be protected.

• Ventilate all ﬂammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have

held combustibles.

• Provide a ﬁre watch when working in an area where

ﬁre hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut under-

water or while using a water table. DO NOT cut

aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dis-

sipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc

processes can cause noise levels to exceed safe limits.

You must protect your ears from loud noise to prevent

permanent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noise levels should be measured to be sure the

decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item

1 in Section "1.03 Publications", in this manual.

PLASMA ARC RAYS

Plasma Arc 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 wear safety glasses with side

shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protect

your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc

is clearly seen. Experience has shown that

lighter ﬁlters may be used when the arc is

hidden by the workpiece.

WARNING

WARNING: This product contains chemicals, includ-

ing lead, known to the State of California to cause birth

defects and other reproductive harm.

Wash hands after

handling.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETYAND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Docu-

ments, U.S. Government Printing Ofﬁce, Washington,

D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding

Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainable

from the Superintendent of Documents, U.S. Govern-

ment Printing Ofﬁce, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-

CUPATION AND EDUCATIONAL EYE AND FACE

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