Victor CUTMASTER Specifications

A120
CUTMASTER
™
Automated PLASMA
CUTTING SYSTEM
Art # A-08955_AB
Operating Manual
Rev. AO
Date: Dec. 7, 2012
Operating Features:
Manual # 0-4989
380400
460
600
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 1-800426-1888, or visit us on the web at www.thermal-dynamics.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 Victor Technologies International, Inc.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent 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.
!
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.
Plasma Cutting Power Supply
CutMaster™ A120
SL100 1Torch™
Operating Manual Number 0-4989
Published by:
Victor Technologies International, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2008, 2009, 2010, 2012 by
Victor Technologies International, Inc.
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 negligence, accident, or any other cause.
Original Publication Date: June 30, 2008
Revision Date: Dec. 7, 2012
Record the following information for Warranty purposes:
Where Purchased:__________________________________________________
Purchase Date:_____________________________________________________
Power Supply Serial #:_______________________________________________
Torch Serial #:_____________________________________________________
i
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
1.03Publications...................................................................................................................1-2
1.04
Note, Attention et Avertissement...................................................................................1-3
1.05
Precautions De Securite Importantes............................................................................1-3
1.06
Documents De Reference.............................................................................................1-5
1.07
Declaration of Conformity..............................................................................................1-6
1.08
Statement of Warranty...................................................................................................1-7
SECTION 2 SYSTEM: INTRODUCTION ...........................................................................................2-1
2.01
2.02
2.03
2.04
2.05
2.06
How To Use This Manual..............................................................................................2-1
Equipment Identification................................................................................................2-1
Receipt Of Equipment...................................................................................................2-1
Power Supply Specifications.........................................................................................2-2
Input Wiring Specifications............................................................................................2-3
Power Supply Features.................................................................................................2-4
SECTION 2 TORCH: INTRODUCTION ...........................................................................................2T-1
2T.01 Scope of Manual..........................................................................................................2T-1
2T.02 General Description.....................................................................................................2T-1
2T.03Specifications .............................................................................................................2T-1
2T.04 Options And Accessories............................................................................................2T-2
2T.05 Introduction to Plasma.................................................................................................2T-2
SECTION 3 SYSTEM: INSTALLATION .............................................................................................3-1
3.01Unpacking .....................................................................................................................3-1
3.02
Lifting Options................................................................................................................3-1
3.03
Power Supply location and Mounting............................................................................3-1
3.04
Opening the Contactor Cover........................................................................................3-1
3.05
Primary Input Power Connections.................................................................................3-2
3.06
Gas Connections...........................................................................................................3-4
SECTION 3 TORCH: INSTALLATION..............................................................................................3T-1
3T.01
3T.02
Torch Connections......................................................................................................3T-1
CNC Connection..........................................................................................................3T-1
SECTION 4 SYSTEM: OPERATION.................................................................................................4-1
4.01
4.02
Front Panel Controls / Features....................................................................................4-1
Preparations for Operation............................................................................................4-2
SECTION 4 TORCH: OPERATION..................................................................................................4T-1
4T.01
4T.02
4T.03
4T.04
4T.05
4T.06
4T.07
4T.08
4T.09
Machine and Automated Torch Operation...................................................................4T-1
Automation Torch Parts Selection...............................................................................4T-2
Machine and Hand Torch Parts Selection...................................................................4T-2
Cut Quality...................................................................................................................4T-3
General Cutting Information........................................................................................4T-4
Hand Torch Operation.................................................................................................4T-5
Gouging ..................................................................................................................4T-8
Recommended Cutting Speeds for Machine and Automated Torches
With Exposed Tip......................................................................................................4T-10
Recommended Cutting Speeds for Machine and Automated Torches
With Shielded Tip......................................................................................................4T-36
TABLE OF CONTENTS
PATENT INFORMATION................................................................................................................4T-58
SECTION 5 SYSTEM: SERVICE........................................................................................................5-1
5.01
5.02
5.03
5.04
5.05
5.06
General Maintenance....................................................................................................5-1
Maintenance Schedule..................................................................................................5-2
Common Faults.............................................................................................................5-2
Fault Indicator................................................................................................................5-3
Basic Troubleshooting Guide........................................................................................5-4
Power Supply Basic Parts Replacement.......................................................................5-6
SECTION 5 TORCH: SERVICE........................................................................................................5T-1
5T.01
5T.02
General Maintenance..................................................................................................5T-1
Inspection and Replacement of Consumable Torch Parts..........................................5T-2
SECTION 6: PARTS LISTS................................................................................................................6-1
6.01Introduction....................................................................................................................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
Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube).............6-4
6.07
Torch Consumable Parts (SL100).................................................................................6-6
6.08
Replacement Parts for Hand Torch ..............................................................................6-7
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, 400/600V UNITS................................................................. A-8
APPENDIX 7: RAW ARC VOLTAGE ............................................................................................. A-10
APPENDIX 8: PUBLICATION HISTORY........................................................................................ A-14
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION..............................................Rear Cover
CUTMASTER A120
SECTION 1:
GENERAL INFORMATION
• 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:
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
Antimony
Chromium
Mercury
ArsenicCobaltNickel
Barium
Copper
Selenium
BerylliumLeadSilver
Cadmium
Manganese
Vanadium
An operation, procedure, or background information
which requires additional emphasis or is helpful in efficient operation of the system.
• Always read the Material Safety Data Sheets (MSDS) that should
be supplied with the material you are using. These MSDSs
will give you the information regarding the kind and amount of
fumes and gases that may be dangerous to your health.
CAUTION
A procedure which, if not properly followed, may cause
damage to the equipment.
!
• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications in
this manual.
• Use special equipment, such as water or down draft cutting
tables, to capture fumes and gases.
WARNING
• Do not use the plasma torch in an area where combustible or
explosive gases or materials are located.
A procedure which, if not properly followed, may cause
injury to the operator or others in the operating area.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these
vapors.
WARNING
• This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)
Gives information regarding possible electrical shock
injury. Warnings will be enclosed in a box such as this.
1.02 Important Safety Precautions
!
ELECTRIC SHOCK
WARNING
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.
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.
• 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.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the proper
function of cardiac pacemakers, hearing aids, or other
electronic health equipment. Persons who work near
plasma arc cutting applications should consult their
medical health professional and the manufacturer of the
health equipment to determine whether a hazard exists.
• 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 Subsection 1.03, Publications.
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.
• Disconnect power source before performing any service or
repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
GASES AND FUMES
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
Gases and fumes produced during the plasma cutting process can be
dangerous and hazardous to your health.
Manual 0-4989 • Be sure there is no combustible or flammable material in the
workplace. Any material that cannot be removed must be
protected.
1-1
GENERAL INFORMATION
CUTMASTER A120
• 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 underwater 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 dissipated.
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 protective 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 Subsection 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:
Arc Current
Minimum Protective
Shade No.
Suggested
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.
LEAD WARNING
This product contains chemicals, including lead, or otherwise produces
chemicals known to the State of California to cause cancer, birth defects
and other reproductive harm. Wash hands after handling. (California
Health & Safety Code § 25249.5 et seq.)
GENERAL INFORMATION
1.03Publications
Refer to the following standards or their latest revisions for more
information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
obtainable from the Superintendent of Documents, 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. Government Printing Office, Washington,
D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable
from American National Standards Institute, 1430 Broadway,
New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY
10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
10.NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11.CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
12.CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
13.NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable
from the National Welding Supply Association, 1900 Arch
Street, Philadelphia, PA 19103
14.American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS AND 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 RESPIRATORY PROTECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018
1-2
Manual 0-4989
CUTMASTER A120
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont
utilisés pour mettre en relief des informations à caractère important.
Ces mises en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement général
sur lequel il importe d’insister davantage ou qui contribue
à l’efficacité de fonctionnement du système.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de plasma peuvent
présenter des risques et des dangers de santé.
•
Eloignez toute fumée et gaz de votre zone de respiration. Gardez
votre tête hors de la plume de fumée provenant du chalumeau.
•
Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.
•
Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le
métal et des différents procédés. Vous devez prendre soin lorsque
vous coupez ou soudez tout métal pouvant contenir un ou plusieurs
des éléments suivants:
ATTENTION
Toute procédure pouvant résulter l’endommagement
du matériel en cas de non-respect de la procédure en
question.
!
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures de
l’opérateur ou des autres personnes se trouvant dans
la zone de travail en cas de non-respect de la procédure
en question.
AVERTISSEMENT
Fournit l'information concernant des dommages possibles de choc électrique. Des avertissements seront
enfermés dans une boîte de ce type.
1.05 Precautions De Securite Importantes
!
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE
SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magnétique qui
peuvent interférer la fonction propre d’un “pacemaker”
cardiaque, les appareils auditif, ou autre matériel de santé
electronique. Ceux qui travail près d’une application à
l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel
de santé pour déterminer s’il existe des risques de santé.
Il faut communiquer aux opérateurs et au personnel
TOUS les dangers possibles. Afin d’éviter les blessures
possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes
les consignes avant d’utiliser le matériel. Composez le
+ 603-298-5711 ou votre distributeur local si vous avez
des questions.
Manual 0-4989 antimoinecadmiummercure
argentchromenickel
arseniccobaltplomb
baryumcuivresélénium
béryllium
manganèse
vanadium
•
Lisez toujours les fiches de données sur la sécurité des matières
(sigle américain “MSDS”); celles-ci devraient être fournies avec
le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
•
Pour 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.
•
Le phosgène, un gaz toxique, est généré par la fumée provenant
des solvants et des produits de nettoyage chlorés. Eliminez toute
source de telle fumée.
•
Ce produit, dans le procéder de soudage et de coupe, produit de
la fumée ou des gaz pouvant contenir des éléments reconnu dans
L’état de la Californie, qui peuvent causer des défauts de naissance
et le cancer. (La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet
de plasma requiert et produit de l’énergie électrique haute tension. Cette
énergie électrique peut produire des chocs graves, voire mortels, pour
l’opérateur et les autres personnes sur le lieu de travail.
•
Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
gants et des vêtements secs. Isolez-vous de la pièce de travail ou
des autres parties du circuit de soudage.
•
Réparez ou remplacez toute pièce usée ou endommagée.
•
Prenez des soins particuliers lorsque la zone de travail est humide
ou moite.
1-3
INFORMATIONS GÉNÉRALES
CUTMASTER A120
•
Montez et maintenez le matériel conformément au Code électrique
national des Etats-Unis. (Voir la page 5, article 9.)
Courant Arc
•
Débranchez l’alimentation électrique avant tout travail d’entretien
ou de réparation.
Lisez et respectez toutes les consignes du Manuel de consignes.
•
Nuance Minimum
Protective Numéro
Nuance Suggerée
Numéro
Moins de 300*
8
9
300 - 400*
9
12
400 - 800*
10
14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est caché
par moiceau de travail.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories chaudes,
des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma
produit du métal, des étincelles, des scories chaudes pouvant mettre
le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables. •
Soyez certain qu’aucune matière combustible ou inflammable ne
se trouve sur le lieu de travail. Protégez toute telle matière qu’il
est impossible de retirer de la zone de travail.
•
Procurez une bonne aération de toutes les fumées inflammables
ou explosives.
•
Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer
des matières combustibles.
•
Prévoyez une veille d’incendie lors de tout travail dans une zone
présentant des dangers d’incendie.
•
Le gas hydrogène peut se former ou s’accumuler sous les pièces
de travail en aluminium lorsqu’elles sont coupées sous l’eau ou
sur une table d’eau. NE PAS couper les alliages en aluminium sous
l’eau ou sur une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé explosera
si enflammé.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
supérieurs aux limites normalement acceptables. Vous dúez vous
protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également
les autres personnes se trouvant sur le lieu de travail.
•
Il faut mesurer les niveaux sonores afin d’assurer que les décibels
(le bruit) ne dépassent pas les niveaux sûrs.
•
Pour des renseignements sur la manière de tester le bruit, consultez
l’article 1, page 5.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques, comme le plomb,
ou engendre des produits chimiques, reconnus par l’état de
Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou d’autres problèmes de reproduction.
Il faut se laver les mains après toute manipulation.
(Code de Californie de la sécurité et santé, paragraphe 25249.5
et suivants)
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
•
Pour protéger vos yeux, portez toujours un casque ou un écran
de soudeur. Portez toujours des lunettes de sécurité munies de
parois latérales ou des lunettes de protection ou une autre sorte
de protection oculaire.
•
Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de l’arc.
•
Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant 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 ANSI/ASC Z49.1:
INFORMATIONS GÉNÉRALES
•
1-4
Manual 0-4989
CUTMASTER A120
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes ayant
été faites à celles-ci pour de plus amples renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION
DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd.,
Miami, FL 33126
14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À
LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT
RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de
la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE,
disponible auprès de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès
du Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (American
National Standards Institute), 1430 Broadway, New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible
auprès de l’American National Standards Institute, 1430 Broadway,
New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ
DES PRODUITS COMBUSTIBLES, disponible auprès 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, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12.Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE
ET LA COUPE, disponible auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE,
disponible auprès de l’Association Nationale de Fournitures de
Soudage (National Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
Manual 0-4989 1-5
INFORMATIONS GÉNÉRALES
CUTMASTER A120
1.07 Declaration of Conformity
Manufacturer:
Address:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive
73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/
EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 when used in
conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs
as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all
design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative:
GENERAL INFORMATION
Steve Ward
Operations Director
Victor Technologies International, Inc. Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
1-6
Manual 0-4989
CUTMASTER A120
1.08 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. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal Dynamics Corporation shall, upon
notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics’ specifications,
instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the
time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation
will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of
sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Product
Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
U.S.
Non U.S.
CUTMASTER™ A40
4 Years
3 Years
1 Year
CUTMASTER™ A60
4 Years
3 Years
1 Year
CUTMASTER™ A80
4 Years
3 Years
1 Year
CUTMASTER™ A120
4 Years
3 Years
1 Year
This warranty does not apply to:
1.
Consumable Parts, such as tips, electrodes, shield 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 Thermal Dynamics Corporation:
1.
Repair of the defective product.
2.
Replacement of the defective product.
3.
Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4.
Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Victor Technologies service station. Product
returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such
as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics with respect to any contract, or anything
done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered
by or furnished by Thermal Dynamics whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as
expressly provided herein, exceed the price of the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics
product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective September 4, 2007
Manual 0-4989 1-7
GENERAL INFORMATION
CUTMASTER A120
This Page Intentionally Blank
GENERAL INFORMATION
1-8
Manual 0-4989
CUTMASTER A120
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification
or part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay
particular attention to the information provided
under these headings. These special annotations
are easily recognized as
follows:
NOTE
An operation, procedure, or background information which requires additional emphasis 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
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.thermal-dynamics.com
2.02 Equipment Identification
The unit’s identification number (specification
or part number), model, and serial number
usually appear on a data tag attached to the
rear panel. Equipment which does not have a
data tag such as torch and cable assemblies are
identified only by the specification 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
immediately to file a claim. Furnish complete
information concerning damage claims or shipping errors to the location in your area listed in
the inside back cover of this manual.
Include all equipment identification numbers as
described above along with a full description of
the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging
the equipment when using bars, hammers, etc., to
un-crate the unit.
Gives information 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 Victor Technologies
at the address and phone number in your area
listed on the back cover of this manual. Include
the Owner’s Manual number and equipment
identification numbers.
Manual 0-4989 2-1INTRODUCTION
CUTMASTER A120
2.04 Power Supply Specifications
CutMaster A120 Power Supply Specifications
Input Power
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
400 VAC (360 - 440 VAC), Three Phase, 50 Hz
460 VAC (414 - 506 VAC), Single Phase, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (540 - 630), Three Phase, 60 Hz
Input Power Cable
Power Supply includes input cable.
Output Current
30 - 120 Amps, Continuously Adjustable
Power Supply Gas Filtering Ability
Particulates to 5 Microns
CutMaster A120 Power Supply Duty Cycle *
Ambient Temperature
Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
All Units
Duty Cycle
**60%
80%
100%
Current
120
120
100
IEC
IEC
IEC
DC Voltage
128
128
120
* 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.
** 60% at 208/230V 1-Phase Input ONLY
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications
include calculating an output voltage based upon power supply rated current. To facilitate comparison between
power supplies, all manufacturers use this output voltage to determine duty cycle.
Power Supply Dimensions & Weight
Ventilation Clearance Requirements
10"
254 mm
Art # A-08459
13.78"
350 mm
Art # A-07925_AB
6"
150 mm
63 lb / 28.6 kg
26.3"
0.668 m
24"
610 mm
6"
150 mm
INTRODUCTION2-2
6"
150 mm
Manual 0-4989
CUTMASTER A120
2.05 Input Wiring Specifications
CutMaster A120 Power Supply Input Cable Wiring Requirements
Input
Freq Power
Suggested Sizes
voltage
Input
Volts
Hz
kVA
I max
I eff
Fuse
Flexible Cord
Flexible Cord
(amps)
(Min. AWG)
(Min. mm2)
1 Phase 208
60
26.2
126
98
150
4 Type W
25 Type W
230
60
27.6
118
95
125
4 Type W
25 Type W
460
60
35
76
68
100
4
25
3 Phase 208
60
21.6
60
55
60
4
25
230
60
22.3
56
50
60
4
25
380
50
23
35
32
40
8
10
400
50
23.6
34
31
40
8
10
460
60
29.5
37
33
40
8
10
600
60
29.0
28
25
30
10
6
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTE
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.
I1max is taken at TDC rated minimum duty cycle.
I1eff is taken at TDC 100% rated duty cycle
Manual 0-4989 2-3INTRODUCTION
CUTMASTER A120
2.06 Power Supply Features
Art # A-08460
Control Panel
Torch Leads
Receptacle
Mounting Rails
Work Cable
and Clamp
Automation Interface
Cable Port
Input Power Selection
Filter Assembly
Gas Inlet Port
Input Power Cord
INTRODUCTION2-4
Art # A-08461
Manual 0-4989
CUTMASTER A120
SECTION 2 TORCH:
INTRODUCTION
2T.03Specifications
A. Torch Configurations
1. Automation Torch, Model
2T.01Scope of Manual
This manual contains descriptions, operating
instructions and maintenance procedures for the
1Torch Models SL100/Manual and SL100/Mechanized Plasma Cutting Torches. Service of this
equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned
against attempting repairs or adjustments not
covered in this manual, at the risk of voiding the
Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of
this equipment will assure the dependable operation for which it was designed.
The standard automation torch has a positioning tube with rack & pinch block assembly and
a solenoid valve.
18.875" / 479 mm
12.285" / 312 mm
2.875” /
73 mm
1.75" /
44.5 mm
0.625" /
16 mm
1.375" / 35 mm
4.95" / 126 mm 1.175" / 30 mm
Art # A-07402_AC
2. Machine Torch, Model
The standard machine torch has a positioning
tube with rack & pinch block assembly.
15.875" / 403 mm
9.285" / 236 mm
2T.02General Description
Plasma torches are similar in design to the automotive spark plug. They consist of negative and
positive sections separated by a center insulator.
Inside the torch, the pilot arc starts in the gap
between the negatively charged electrode and
the positively charged tip. Once the pilot arc has
ionized the plasma gas, the superheated column of
gas flows through the small orifice in the torch tip,
which is focused on the metal to be cut.
A single torch lead provides gas from a single
source to be used as both 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.
NOTE
Refer to Section "2T.05
Introduction
to Plasma" on page 2T-2, for a more detailed
description of plasma torch operation.
Refer to the Appendix Pages for additional specifications as related to the Power Supply used.
1.375" / 35 mm
1.75" /
44.5 mm
0.625" /
16 mm
1.175" / 30 mm
4.95" / 126 mm
Art # A-02998
3. Hand/Manual Torch, Models
The hand torch head is at 75° to the torch handle.
The hand torches include a torch handle and torch
trigger assembly.
10.125" (257 mm)
3.75"
(95 mm)
Art # A-03322_AB
1.17" (29 mm)
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 / Automation 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
Manual 0-4989
2T-1INTRODUCTION
CUTMASTER A120
C. Torch Parts
H. Direct Contact Hazard
Starter Cartridge, Electrode, Tip, Shield Cup
For standoff tip the recommended standoff is 3/16
inches / 4.7 mm.
D. Parts - In - Place (PIP)
Torch Head has built - in switch
2T.04Options And Accessories
12 VDC circuit rating
For options and accessories, see section 6.
2T.05Introduction to Plasma
E. Type Cooling
Combination of ambient air and gas stream through
torch.
A. Plasma Gas Flow
F. Torch Ratings
Automated / Machine Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle
100% @ 100 Amps @ 400 scfh
80% @ 120 Amps @ 400 scfh
Maximum Current
120 Amps
Voltage (Vpeak)
500V
Arc Striking Voltage
7kV
Manual Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle
100% @ 120 Amps @ 400 scfh
Maximum Current
120 Amps
Voltage (Vpeak)
500V
Arc Striking Voltage
7kV
Plasma is a gas which has been heated to an extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma to
transfer an electrical arc to the workpiece. The metal
to be cut or removed is melted by the heat of the arc
and then blown away.
While the goal of plasma arc cutting is separation of
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.
In a Plasma Cutting Torch a cool gas enters Zone B,
where a pilot arc between the electrode and the torch
tip heats and ionizes the gas. The main cutting arc
then transfers to the workpiece through the column
of plasma gas in Zone C.
G. Gas Requirements
Automated, Manual and Machine Torch Gas
Specifications
Gas (Plasma and Secondary) Compressed Air
Operating Pressure
Refer to NOTE
60 - 95 psi
4.1 - 6.5 bar
Maximum Input Pressure
125 psi / 8.6 bar
Gas Flow (Cutting and
Gouging)
300 - 500 scfh
142 - 235 lpm
!
A
_
Power
Supply
+
B
WARNING
This torch is not to be used with oxygen (O2).
NOTE
Operating pressure varies with torch model, operating amperage, and torch leads length. Refer
to gas pressure settings charts for each model.
INTRODUCTION2T-2
Workpiece
C
A-08331
Typical Torch Head Detail
Manual 0-4989
CUTMASTER A120
By forcing the plasma gas and electric arc through a
small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
arc is shown in Zone C. Direct current (DC) straight
polarity is used for plasma cutting, as shown in the
illustration.
E. Parts - In - Place (PIP)
The torch includes a 'Parts - In - Place' (PIP) circuit.
When the shield cup is properly installed, it closes
a switch. The torch will not operate if this switch
is open.
Remote Pendant
Zone A channels a secondary gas that cools the torch.
This gas also assists the high velocity plasma gas in
blowing the molten metal out of the cut allowing for
a fast, slag - free cut.
B. Gas Distribution
To ATC
PIP Switch
Shield Cup
The single gas used is internally split into plasma
and secondary gases.
The plasma gas flows into the torch through the
negative lead, through the starter cartridge, 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.
CNC Start
To ATC
PIP Switch
Shield Cup
C. Pilot Arc
Art # A-08168
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.
Automation Torch
D. Main Cutting Arc
DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
through the torch lead. The positive output is connected to the workpiece via the work cable and to
the torch through a pilot wire.
To ATC
PIP Switch
Shield Cup
Parts - In - Place Circuit Diagram for Machine Torch
To Control
Cable Wiring
Torch Switch
PIP Switch
A-02997
Torch Trigger
Shield Cup
Parts - In - Place Circuit Diagram for Hand Torch
Manual 0-4989
2T-3INTRODUCTION
CUTMASTER A120
This Page Intentionally Blank
INTRODUCTION2T-4
Manual 0-4989
CUTMASTER A120
SECTION 3 SYSTEM:
INSTALLATION
3.01Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping
damage. If damage is evident, contact
your distributor and / or shipping company
before proceeding with the installation.
3. Record Power Supply and Torch model
and serial numbers, purchase date and vendor name, in the information block at the
front of this manual.
3.02 Lifting Options
The Power Supply includes hand holds in the
front and rear panels 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 before moving
unit.
FALLING EQUIPMENT can cause serious personal
injury and can damage equipment.
• Only persons of adequate physical strength
should lift the unit.
• Lift unit by the handles, using two hands.
Do not use straps for lifting.
mounting the power supply. Choose one
that allows for free movement of torch
leads, complies with ventilation per section
2.04 and provides a safe firm surface where
the unit can be secured.
2. Place the unit in the desired position
and mark where the four keyway holes
in the mounting rails touch.
3. Remove the unit and using these markings,
prepare holes for mounting hardware.
4. Insert proper hardware. If using hardware
that screws into the mounting surface,
leave all four loose enough for the thickness of the rail to slide under the head and
washer if used.
5. Lower the power supply over the mounting
hardware and slide forward or backward
until the keyway stops against the mounting hardware.
6. Secure the hardware to the rail.
3.04 Opening the Contactor Cover
The input power cord is connected to the main
contactor, the contactor is located inside a box
with a snap on cover. The cover is held in place
with two or more snap lock tabs. To remove the
cover release the front latch and tilt the cover up
about ½ inch. Then squeeze both sides of the
cover and lift it straight up. See the Primary Input
Power Connections section for the necessary
changes to the Contactor. Remember to replace
the Contactor Cover when the changes are complete.
• Use optional cart or similar device of adequate capacity to move unit.
1
1
2
2
• Place unit on a proper skid and secure in
place before transporting with a fork lift or
other vehicle.
3.03 Power Supply location and
Mounting
NOTE
It is recommended that the unit be secured
to a suitable surface using the mounting
rails.
Art# A-11478
Contactor cover
1. First choose an appropriate location for
Manual 0-4989
3-1INSTALLATION
CUTMASTER A120
3.05 Primary Input Power
Connections
Upper
Screws
Lower
Screws
CAUTION
Check your power source for correct voltage
before plugging in or connecting the unit.
Check the Voltage Selector at the rear of the
unit for correct setting before plugging in
or connecting the unit. The primary power
source, fuse, and any extension cords used
must conform to local electrical code and
the recommended circuit protection and wiring requirements as specified in Section 2.
Slots
Lower
Screws
Most units are shipped from the factory with a
230 Volt input power cable wired to the input
contactor in the single - phase configuration.
The following illustrations and directions are for
changing that configuration to a different voltage
and or to three - phase operation or back again if a
change had already been made.
Art # A-08429
2. Carefully pull the Cover up and away from
the unit.
A. Cover Removal
1. Remove the upper and lower screws which
secure the cover to the main assembly. Do
not loosen the lower screws inside the cut
out slots in the bottom of the cover.
NOTE
The upper screws and lower screws are
not the same. Do not mix them. The upper
screws are for threading into the plastic of
the front and rear panels. DO NOT use the
finer threaded lower screws for this.
B. Cover Installation
1. Reverse previous procedures for cover
installation.
NOTE
When installing the upper screws, attempt to
reuse the original threads. The easiest way
to do this is by turning the screw counterclockwise until you feel the threads line up,
then begin to turn the screw clockwise to
tighten. Do not over tighten.
C. Input Power Selection
Set the Input Voltage Selection Switch at the rear
of the unit based on the primary input voltage it
is connected to. Low is 208/230 VAC and high is
460 VAC.
LO
HI
S
Art # A-08316
INSTALLATION3-2
Manual 0-4989
CUTMASTER A120
D. Quick Guide to Phase Wiring
The following illustration and directions are for
changing phase of the power supply.
CAUTION
The primary power source and power cable
must conform to local electrical code and the
recommended circuit protection and wiring
requirements (refer to table in Section 2).
Input Power Cable Connections
Three-Phase (3ø)
L1
L1
L2
L2
L3
L3
L4
Art # A-08493
Single-Phase (1ø) and Jumper Settings
Store copper jumpers on base plate
L4
GND
GND
Single and Three Phase Input Power Wiring
NOTE
There are two jumpers used for the single
phase 230V setting and none for three
phase.
E. Connections to Single Phase Input Power
WARNING
Disconnect input power from the power supply
and input cable before attempting this procedure.
These instructions are for changing the input
power and or cable on the 208/230, 400, 460 VAC
Power Supply to Single - Phase input power.
1. Remove the Power Supply cover. See "A.
Cover Removal".
2. Disconnect the original input power cable
from the main input contactor and the
chassis ground connection.
3. Loosen the through-hole protector on the
back panel of the power supply. Pull the
original power cable out of the power supply.
4. If the power cable being used is not the
factory - supplied cable, use a three - conductor input power cable for the voltage
desired and strip back the insulation on the
individual wires.
5. Pass the cable being used through the
access opening in the back panel of the
power supply. Refer to Section 2 for
power cable specifications.
Manual 0-4989
6. Connect the wires as follows.
• Connect Bus Bar Jumpers on the contactor as shown in prior illustration and
on label in the power supply.
• Green / Yellow wire to Ground.
7. With a little slack in the wires, tighten
the through - hole protector to secure the
power cable.
8. Reinstall the Power Supply cover. See "B.
Cover Installation".
9. Connect the opposite end of individual
wires to a customer supplied plug or main
disconnect.
10.Connect the input power cable (or close
the main disconnect switch) to supply
power.
F. Connections to Three Phase Input Power
WARNING
Disconnect input power from the power supply
and input cable before attempting this procedure.
These instructions are for changing the input
power and or cable on the 208/230, 400, 460 VAC
Power Supply to Three - Phase input power.
1. Remove the Power Supply cover. See "A.
Cover Removal".
2. Disconnect the original input power cable
from the main input contactor and the
chassis ground connection.
3. Loosen the through-hole protector on the
back panel of the power supply. Pull the
original power cable out of the power supply.
4. Using a customer supplied four - conductor
input power cable for the voltage desired,
strip back the insulation on the individual
wires.
5. Pass the cable being used through the
access opening in the back panel of the
power supply. Refer to Section 2 for
power cable specifications.
3-3INSTALLATION
CUTMASTER A120
Filter Assembly
CAUTION
Inlet Port
The primary power source and power cable
must conform to local electrical code and the
recommended circuit protection and wiring
requirements (refer to table in Section 2).
6. Connect the wires as follows.
• Wires to L1, L2 and L3 input. It does
not matter what order these wires are attached. See previous illustration and on
label in the power supply.
• Green / Yellow wire to Ground.
7. With a little slack in the wires, tighten
the through - hole protector to secure the
power cable.
8. Reinstall the Power Supply cover. See "B.
Cover Installation".
9. Connect the opposite end of individual
wires to a customer supplied plug or main
disconnect.
10.Connect the input power cable (or close
the main disconnect switch) to supply
power.
3.06 Gas Connections
Connecting Gas Supply to Unit
The connection is the same for compressed air or
high pressure cylinders. Refer to the following
subsections if an optional air line filter is to be
installed.
1. Connect the air line to the inlet port. The
illustration shows typical fittings as an
example.
Hose Clamp
Gas Supply
Hose
Art # A-08320
1/4 NPT or ISO-R
to 1/4” (6mm) Fitting
Air Connection to Inlet Port
Installing Optional Single - Stage Air Filter
An optional filter kit is recommended for improved filtering with compressed air, to keep
moisture and debris out of the torch.
1. Attach the Single - Stage Filter Hose to the
Inlet Port.
2. Attach the Filter Assembly to the filter
hose.
3. Connect the air line to the Filter. The
illustration shows typical fittings as an
example.
NOTE
NOTE
For a secure seal, apply thread sealant to the
fitting threads, according to the manufacturer'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. Connect as follows:
For a secure seal, apply thread sealant to the
fitting threads, according to manufacturer'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.
INSTALLATION3-4
Manual 0-4989
CUTMASTER A120
Installing Optional Two - Stage Air Filter Kit
Filter Assembly
Inlet Port
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:
Art # A-08319
1. Attach the Two Stage Filter bracket to the
back of the power supply per instructions
supplied with the filter assembly.
NOTE
Hose Clamp
1/4 NPT to 1/4"
(6mm) Fitting
Gas Supply
Hose
Optional Single - Stage Filter Installation
Using High Pressure Air Cylinders
When using high pressure air cylinders as the air
supply:
1. Refer to the manufacturer’s specifications
for installation and maintenance procedures for high pressure regulators.
2. Examine the cylinder valves to be sure
they are clean and free of oil, grease or any
foreign material. Briefly open each cylinder valve to blow out any dust which may
be present.
3. The cylinder must be equipped with an
adjustable high - pressure regulator capable
of outlet pressures up to 100 psi (6.9 bar)
maximum and flows of at least 300 scfh
(141.5 lpm).
4. Connect supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar)
at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6
mm) I.D.
For a secure seal, apply thread sealant to the
fitting threads, according to manufacturer'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.
Manual 0-4989
For a secure seal, apply thread sealant to the
fitting threads according to manufacturer'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. A 1/4 NPT to 1/4"
hose barbed fitting is shown as an example.
Regulator/Filter
Assembly
Regulator
Input
2-Stage Filter
Inlet Port (IN)
Outlet Port
(OUT)
Two Stage
Filter
Assembly
Hose Clamp
Gas Supply
Hose
1/4 NPT to 1/4”
(6mm) Fitting
Art # A-07945_AC
Optional Two - Stage Filter Installation
3-5INSTALLATION
CUTMASTER A120
Using High Pressure Air Cylinders
When using high pressure air cylinders as the air
supply:
1. Refer to the manufacturer’s specifications
for installation and maintenance procedures for high pressure regulators.
2. Examine the cylinder valves to be sure
they are clean and free of oil, grease or any
foreign material. Briefly open each cylinder valve to blow out any dust which may
be present.
3. The cylinder must be equipped with an
adjustable high - pressure regulator capable
of outlet pressures up to 100 psi (6.9 bar)
maximum and flows of at least 300 scfh
(141.5 lpm).
4. Connect supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar)
at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6
mm) I.D.
For a secure seal, apply thread sealant to the
fitting threads, according to manufacturer'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.
INSTALLATION3-6
Manual 0-4989
CUTMASTER A120
SECTION 3 TORCH:
INSTALLATION
3T.01Torch Connections
If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model
SL100SV / Automation, SL100 / Mechanical
or SL100 / Manual Torch to this power supply.
Maximum torch leads length is 100 feet / 30.5 m,
including extensions.
Check Air Quality
To test the quality of air:
1. Put the ON / OFF
switch in the ON
(up) position.
2. Put the Function Control switch in the SET
position.
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.02CNC Connection
WARNING
Disconnect primary power at the source before
connecting the torch.
1. Align the ATC male connector (on the
torch lead) with the female receptacle.
Push the male connector into the female
receptacle. The connectors should push
together with a small amount of pressure.
2. Secure the connection by turning the locking nut clockwise until it clicks. DO NOT
use the locking nut to pull the connection
together. Do not use tools to secure the
connection.
1. Locate the interface connection port on the
rear of the power supply.
Automation Interface
Cable Port
Art # A-08464
2. Note the pin-out of the connector and that
the customer supplied connector matches.
Plasma
Start / Stop
Signal
2
1
Art # A-07885
Connecting the Torch to the Power Supply
3. The system is now ready for operation.
Art # A-08323
Cutting Machine
OK to Move
3. Connect CNC to the power supply.
Manual 0-4989
3T-1INSTALLATION
CUTMASTER A120
3T.03
Setting Up Automation or
Machine Torch
NOTE
An adapter is required to be installed in the
power supply if converting a hand torch system
to operate a machine or automation torch.
WARNING
Disconnect primary power at the source before
disassembling the torch or torch leads.
The Automation and Machine torch include a
positioning tube with rack and pinch block assembly.
1. Mount the torch assembly on the cutting
table.
2. To obtain a clean vertical cut, use a square
to align the torch perpendicular to the surface of the workpiece.
Pinch Block
Assembly
Square
Workpiece
A-02585
Automated and Machine 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.08, Torch Parts Selection for details.
INSTALLATION3T-2
Manual 0-4989
CUTMASTER A120
SECTION 4 SYSTEM:
OPERATION
1
4.01 Front Panel Controls /
Features
MIN
2
A
MAX
3
PSI
BAR
MAX
MAX
MIN
MIN
4
+
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.
!
2. Function Control
Function Control Knob, Used to select between the
different operating modes.
RUN
LATCH
Used for longer hand held or
mechanical cuts. (Does not apply to automation).
Once a cutting arc is established, the torch switch
can be released. The cutting arc will remain ON
until the torch is lifted away from the work piece,
the torch leaves the edge of the work piece the torch
switch is activated again or if one of the system
interlocks is activated.
3. ON OFF Power Switch
ON / OFF
Switch controls input power to the
power supply. Up is ON, down is OFF.
4. Air/Gas Pressure Control
+ Control is used in the "SET"
The Pressure
mode to adjust the air/gas pressure. Pull the knob
out to adjust and push in to lock.
AC Indicator
Steady light indicates power supply is ready for
operation. Blinking light indicates unit is in protective interlock mode. Shut unit OFF, shut OFF or
disconnect input power, correct the fault, and restart
the unit. Refer to Section 5 for details.
Manual 0-4989
Temp Indicator
Indicator is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Let the
unit cool before continuing operation.
Used for general cutting operations
RAPID AUTO RESTART
Allows for faster
restarting of the Pilot Arc for uninterrupted cutting.
5.
6.
Art# A-07886
7.
Gas Indicator
Indicator is ON when minimum input gas pressure
for power supply operation is present. Minimum
pressure for power supply operation is not sufficient
for torch operation.
8.
DC Indicator
Indicator is ON when DC output circuit is active.
9.
!
Fault Error Indicator
Indicator is ON when Fault circuit is active. See section 5 for explanations of fault lights.
10.Pressure Indicators
PSI
BAR
MAX
MAX
90
6.3
85
5.9
80
5.5
75
5.2
70
4.8
65
4.5
MIN
MIN
Art # A-08170
SET
Used to purge the air through the unit
and torch and leads and to adjust gas pressure.
5 6 7 8 9 10
The Indicators will illuminate
according to the pressure set by the Pressure Control
Knob (number 4).
4-1OPERATION
CUTMASTER A120
4.02 Preparations for Operation
Power ON
Place the Power Supply ON / OFF switch to the
ON (up) position. AC indicator
turns ON.
At the start of each operating session:
WARNING
Gas indicator
turns ON if there is sufficient gas
pressure for power supply operation and the cooling fans turn ON.
Disconnect primary power at the source before
assembling or disassembling power supply,
torch parts, or torch and leads assemblies.
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 (120 amps maximum).
Refer to Section 4T.07 and following for torch parts
selection.
Torch Connection
Check that the torch is properly connected. Only
Thermal Dynamics model SL100 / Manual or SL100
/ Mechanical Torches may be connected to this
Power Supply. See Section 3T of this manual.
NOTE
Minimum pressure for power supply operation is lower than minimum for torch operation.
The cooling fans will turn ON as soon as the
unit is turned ON. After the unit is idle for
ten (10) minutes the fans will turn OFF. The
fans will come back ON as soon as the torch
switch (Start Signal) is activated or if the
unit is turned OFF, then turned ON again. If
an over temperature condition occurs, the
fans will continue to run while the condition
exists and for a ten (10) minute period once
the condition is cleared.
Set Operating Pressure
Check Primary Input Power Source
1. Check the power source for proper input
voltage. Make sure the input power source
meets the power requirements for the unit
per Section 2, Specifications.
2. Connect the input power cable (or close the
main disconnect switch) to supply power to
the system.
Air Source
Ensure source meets requirements (refer to Section
2). Check connections and turn air supply ON.
1. Place the Power Supply Function Control
knob to the SET
flow.
position. Gas will
2. For Standoff cutting, adjust gas pressure
from 70 - 85 psi / 4.8 - 5.9 bar (LED's
in center of control panel). Refer to the
Standoff chart for pressure setting details.
2
1
Connect Work Cable
Clamp the work cable to the workpiece or cutting
table. The area must be free from oil, paint and rust.
Connect only to the main part of the workpiece; do
not connect to the part to be cut off.
MIN
A
MAX
PSI
BAR
MAX
MAX
MIN
MIN
+
!
Art # A-04509
OPERATION4-2
Art# A-07946
Manual 0-4989
CUTMASTER A120
Cutting Operation
STANDOFF
CutMaster A120 Gas Pressure Settings
SL100
SL100
(Mechanized Torch)
SL100 SV
(Hand Torch)
(Automation Torch)
Leads
Length
Up to 50'
(7.6 m)
75 psi
5.2 bar
75 psi
5.2 bar
Each additional
25' (7.6 m)
Add 5 psi
0.4 bar
Add 5 psi
0.4 bar
3. For Drag cutting (60 Amps and below),
adjust gas pressure from 75 - 95 psi / 5.2 6.5 bar (LED's in center of control panel).
Refer to the Drag Cutting chart for pressure setting details.
DRAG (60 Amps or less)
CutMaster A120 Gas Pressure Settings
Leads
Length
SL100
(Hand Torch)
Up to 25'
(7.6 m)
80 psi
5.5 bar
Each additional
25' (7.6 m)
Add 5 psi
0.4 bar
Select Current Output Level
1. Place the Function Control Knob in one of
the three operating positions available:
RUN
,
RAPID AUTO RESTART
Gas flow stops.
2. Set the output current to desired amperage
with the Output Current Control Knob.
or LATCH
.
Pre-flow
When the torch leaves the workpiece during cutting
operations with the Function Control Knob in the
RUN position, there is a brief delay in restarting
the pilot arc. With the knob in the RAPID AUTO
RESTART position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting
arc restarts instantly when the pilot arc contacts the
workpiece. (Use the 'Rapid Auto Restart' position
when cutting expanded metal or gratings, or in
gouging or trimming operations when an uninterrupted restart is desired). And with the knob in the
LATCH position the main cutting arc will be maintained after the torch switch is released.
Typical Cutting Speeds
Cutting speeds vary according to torch output amperage, the type of material being cut, and operator
skill. Refer to Section 4T.08 and following for greater
details.
Output current setting or cutting speeds may be
reduced to allow slower cutting when following a
line, or using a template or cutting guide while still
producing cuts of excellent quality.
Postflow
Release the trigger to stop the cutting arc. Gas continues to flow for approximately 20 seconds. During
post - flow, if the user moves the trigger release to
the rear and presses the trigger, the pilot arc starts.
The main arc transfers to the workpiece if the torch
tip is within transfer distance to the workpiece.
Shutdown
Turn the ON / OFF
switch to OFF
(down).
All Power Supply indicators shut OFF. Unplug the
input power cord or disconnect input power. Power
is removed from the system.
With hand or mechanical torch, there will be a .5
second pre-flow of the gas. Pre-flow does not apply
to automation torch use.
Manual 0-4989
4-3OPERATION
CUTMASTER A120
This Page Intentionally Blank
OPERATION4-4
Manual 0-4989
CUTMASTER A120
SECTION 4 TORCH:
OPERATION
4T.01Machine and Automated Torch
Operation
Cutting With Machine or Automated Torch
These torches are activated by remote control
pendant or by a remote interface device such
as CNC.
1. To start a cut at the plate edge, position the
center of the torch along the edge of the
plate.
Travel Speed
Proper travel speed is indicated by the trail of
the arc which is seen below the plate. The arc
can be one of the following:
1. Straight Arc
A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cut using air plasma on
stainless or aluminum.
2. Leading Arc
The leading arc is directed in the same direction as torch travel. A five degree leading arc
is generally recommended for air plasma on
mild steel.
3. Trailing Arc
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.
Travel speed also affects the bevel angle of a
cut. When cutting in a circle or around a corner,
slowing down the travel speed will result in a
squarer cut. The power source output should
be reduced also. Refer to the appropriate Control Module Operating Manual for any Corner
Slowdown adjustments that may be required.
Piercing With Machine or Automated Torch
To pierce, the arc should be started with the
torch positioned as high as possible above the
plate while allowing the arc to transfer and
pierce. This standoff helps avoid having molten
metal blow back onto the front end of the torch.
When operating with a cutting machine, a
pierce or dwell time is required. Torch travel
should not be enabled until the arc penetrates
the bottom of the plate. As motion begins,
torch standoff should be reduced to the recommended 1/8 - 1/4 inch (3-6 mm) distance for
optimum speed and cut quality. Clean spatter
and scale from the shield cup and the tip as soon
as possible. Spraying or dipping the shield cup
in anti - spatter compound will minimize the
amount of scale which adheres to it.
The trailing arc is directed in the opposite
direction as torch travel.
Dir
ect
ion
of T
orc
hT
rav
el
Standoff Distance
Straight Arc
Trailing Arc
A-02586
Leading Arc
Automation and Machine Torch Operation
Manual 0-4989
4T-1OPERATION
CUTMASTER A120
4T.02Automation Torch Parts
Selection
Torch Head
Art # A-04173_AB
Electrode
Check the torch for proper consumable parts.
The parts supplied in the torch may not be correct for the operator’s chosen amperage level.
The torch parts must correspond with the type
of operation.
Start Cartridge
Tip
Torch parts:
Ohmic Clip
(If installed)
Shield Cup, Cutting Tip, Electrode and
Starter Cartridge
NOTE
Shield Cup Body
Refer to Sections 4T.08 and following for
additional information on torch parts.
Change the torch parts for a different operation as
follows:
Deflector
Shield Cap
WARNING
Automation Torch Parts
Disconnect primary power at the source before
assembling or disassembling torch parts, or
torch and leads assemblies.
3. Install the replacement Electrode by pushing it straight into the torch head until it
clicks.
4. Install the starter cartridge and desired tip
for the operation into the torch head.
5. Hand tighten the shield cup assembly until
it is seated on the torch head. If resistance
is felt when installing the cup, check the
threads before proceeding
6. If used, attach the ohmic clip to the shield
cup.
NOTE
The shield cup holds the tip and starter cartridge in place. Position the torch with the
shield cup facing upward to keep these parts
from falling out when the cup is removed.
1. If attached, remove the ohmic clip then
unscrew and remove the shield cup assembly from the torch head. Wipe it clean or
replace if damaged
2. Remove the Electrode by pulling it straight
out of the Torch Head.
4T.03Machine and Hand Torch Parts
Selection
Depending on the type of operation to be done
determines the torch parts to be used.
Type of operation:
Drag cutting, standoff cutting or gouging
Torch parts:
Shield Cup, Cutting Tip, Electrode and
Starter Cartridge
NOTE
Refer to Section 4T.08 and following for additional information on torch parts.
OPERATION4T-2
Manual 0-4989
CUTMASTER A120
Change the torch parts for a different operation as
follows:
WARNING
Disconnect primary power at the source before
assembling or disassembling torch parts, or
torch and leads assemblies.
NOTE
The shield cup holds the tip and starter cartridge in place. Position the torch with the
shield cup facing upward to keep these parts
from falling out when the cup is removed.
1. Unscrew and remove the shield cup assembly from the torch head.
2. Remove the Electrode by pulling it straight
out of the Torch Head.
4T.04Cut Quality
NOTE
Cut quality depends heavily on setup and
parameters such as torch standoff, alignment with the workpiece, cutting speed, gas
pressures, and operator ability.
Cut quality requirements differ depending on
application. For instance, nitride build - up and
bevel angle may be major factors when the surface will be welded after cutting. Dross - free cutting is important when finish cut quality is desired
to avoid a secondary cleaning operation. The
following cut quality characteristics are illustrated
in the following figure:
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
Torch Head
Top Edge
Rounding
Electrode
Dross
Build-Up
Start Cartridge
Tip
Shield Cup
A-03510_AB
Torch Parts (Drag Shield Cap & Shield Cup
Body Shown)
3. Install the replacement Electrode by pushing it straight into the torch head until it
clicks.
4. Install the starter cartridge and desired tip
for the operation into the torch head.
5. Hand tighten the shield cup assembly until
it is seated on the torch head. If resistance
is felt when installing the cup, check the
threads before proceeding.
Cut Surface
Drag Lines
A-00007
Cut Quality Characteristics
Cut Surface
The desired or specified condition (smooth or
rough) of the face of the cut.
Nitride Build - Up
Nitride deposits can be left on the surface of the
cut when nitrogen is present in the plasma gas
stream. These buildups may create difficulties
if the material is to be welded after the cutting
process.
Bevel Angle
The angle between the surface of the cut edge
and a plane perpendicular to the surface of
the plate. A perfectly perpendicular cut would
result in a 0° bevel angle.
Top - Edge Rounding
Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on
the workpiece.
Manual 0-4989
4T-3OPERATION
CUTMASTER A120
Bottom Dross Buildup
Edge Starting
Molten material which is not blown out of the
cut area and resolidifies on the plate. Excessive
dross may require secondary cleanup operations after cutting.
For edge starts, hold the torch perpendicular to
the workpiece with the front of the tip near (not
touching) the edge of the workpiece at the point
where the cut is to start. When starting at the
edge of the plate, do not pause at the edge and
force the arc to "reach" for the edge of the metal.
Establish the cutting arc as quickly as possible.
Kerf Width
The width of the cut (or the width of material
removed during the cut).
Top Spatter (Dross)
Direction of Cut
In the torches, the plasma gas stream swirls as
it leaves the torch to maintain a smooth column
of gas. This swirl effect results in one side of a
cut being more square than the other. Viewed
along the direction of travel, the right side of
the cut is more square than the left.
Top spatter or dross on the top of the cut caused
by slow travel speed, excess cutting height, or
cutting tip whose orifice has become elongated.
4T.05General Cutting Information
!
Left Side
Cut Angle
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.
A-00512
Side Characteristics Of Cut
To make a square - edged cut along an inside
diameter of a circle, the torch should move
counterclockwise around the circle. To keep
the square edge along an outside diameter cut,
the torch should travel in a clockwise direction.
CAUTION
Sparks from the cutting process can cause
damage to coated, painted, and other surfaces such as glass, plastic and metal.
NOTE
Right Side
Cut Angle
Dross
Handle torch leads with care and protect
them from damage.
Piloting
Piloting is harder on parts life than actual cutting because the pilot arc is directed from the
electrode to the tip rather than to a workpiece.
Whenever possible, avoid excessive pilot arc
time to improve parts life.
Torch Standoff
Improper standoff (the distance between the
torch tip and workpiece) can adversely affect
tip life as well as shield cup life. Standoff may
also significantly affect the bevel angle. Reducing standoff will generally result in a more
square cut.
OPERATION4T-4
When dross is present on carbon steel, it is commonly referred to as either “high speed, slow
speed, or top dross”. Dross present on top of
the plate is normally caused by too great a torch
to plate distance. "Top dross" is normally very
easy to remove and can often be wiped off with
a welding glove. "Slow speed dross" is normally
present on the bottom edge of the plate. It can
vary from a light to heavy bead, but does not
adhere tightly to the cut edge, and can be easily
scraped off. "High speed dross" usually forms
a narrow bead along the bottom of the cut edge
and is very difficult to remove. When cutting
a troublesome steel, it is sometimes useful to
reduce the cutting speed to produce "slow speed
dross". Any resultant cleanup can be accomplished by scraping, not grinding.
Manual 0-4989
CUTMASTER A120
4T.06Hand Torch Operation
Standoff Cutting With Hand Torch
NOTE
For best performance and parts life, always
use the correct parts for the type of operation.
1. The torch can be comfortably held in one
hand or steadied with two hands. Position
the hand to press the Trigger on the torch
handle. With the hand torch, the hand may
be positioned close to the torch head for
maximum control or near the back end for
maximum heat protection. Choose the
holding technique that feels most comfortable and allows good control and movement.
NOTE
The tip should never come in contact with
the workpiece except during drag cutting
operations.
2. Depending on the cutting operation, do one
of the following:
a)For edge starts, hold the torch perpendicular to the workpiece with the front
of the tip on the edge of the workpiece
at the point where the cut is to start.
b) For standoff cutting, hold the torch 1/8
- 3/8 in (3-9 mm) from the workpiece as
shown below.
3. Hold the torch away from your body.
4. Slide the trigger release toward the back
of the torch handle while simultaneously
squeezing the trigger. The pilot arc will
start.
Trigger
Trigger Release
A-02986
5. Bring the torch within transfer distance to
the work. The main arc will transfer to the
work, and the pilot arc will shut OFF.
NOTE
The gas preflow and postflow are a characteristic of the power supply and not a function of the torch.
Trigger
1
2
Trigger Release
3
4
Torch
Art # A-03383
6. Cut as usual. Simply release the trigger
assembly to stop cutting.
7. Follow normal recommended cutting
practices as provided in the power supply
operator's manual.
Shield Cup
Standoff Distance
1/8" - 3/8" (3 - 9mm)
A-00024_AB
Standoff Distance
Manual 0-4989
NOTE
When the shield cup is properly installed,
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.
4T-5OPERATION
CUTMASTER A120
8. For a consistent standoff height from the
workpiece, 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 maintain good visibility
of the cutting arc. During operation, position the legs of the standoff guide against
the workpiece.
Shield Cup
Standoff Guide
Torch Tip
Workpiece
Art # A-04034
Shield Cup With Straight Edge
2. The torch can be comfortably held in one
hand or steadied with two hands. Position
the hand to press the Trigger on the torch
handle. With the hand torch, the hand may
be positioned close to the torch head for
maximum control or near the back end for
maximum heat protection. Choose the
holding technique that feels most comfortable and allows good control and movement.
4. Keep the torch in contact with the workpiece during the cutting cycle.
5. Hold the torch away from your body.
6. Slide the trigger release toward the back
of the torch handle while simultaneously
squeezing the trigger. The pilot arc will
start.
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.
Non-Conductive
Straight Edge
Cutting Guide
Trigger Release
A-02986
7. Bring the torch within transfer distance to
the work. The main arc will transfer to the
work, and the pilot arc will shut OFF.
NOTE
The gas preflow and postflow are a characteristic of the power supply and not a function of the torch.
Trigger
A-03539
Using Drag Shield Cup With Straight Edge
The crown shield cup functions best when
cutting 3/16 inch (4.7 mm) solid metal with
relatively smooth surface.
1
2
Trigger Release
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.
1. Install the drag cutting tip and set the output current.
OPERATION4T-6
3
4
Art # A-03383
8. Cut as usual. Simply release the trigger
assembly to stop cutting.
Manual 0-4989
CUTMASTER A120
9. Follow normal recommended cutting
practices as provided in the power supply
operator's manual.
6. Bring the torch within transfer distance to
the work. The main arc will transfer to the
work, and the pilot arc will shut OFF.
NOTE
NOTE
When the shield cup is properly installed,
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 Trigger on the torch
handle. With the hand torch, the hand may
be positioned close to the torch head for
maximum control or near the back end for
maximum heat protection. Choose the
technique that feels most comfortable and
allows good control and movement.
NOTE
The tip should never come in contact with
the workpiece except during drag cutting
operations.
2. Angle the torch slightly to direct blowback
particles away from the torch tip (and operator) rather than directly back into it until
the pierce is complete.
3. In a portion of the unwanted metal start the
pierce off the cutting line and then continue
the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce
is complete.
4. Hold the torch away from your body.
5. Slide the trigger release toward the back
of the torch handle while simultaneously
squeezing the trigger. The pilot arc will
start.
The gas preflow and postflow are a characteristic of the power supply and not a function of the torch.
When the shield cup is properly installed,
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.
7. Clean spatter and scale from the shield cup
and the tip as soon as possible. Spraying
the shield cup in anti - spatter compound
will minimize the amount of scale which
adheres to it.
Cutting speed depends on material, thickness,
and the operator’s ability to accurately follow the
desired cut line. The following factors may have
an impact on system performance:
• Torch parts wear
• Air quality
• Line voltage fluctuations
• Torch standoff height
• Proper work cable connection
Trigger
Trigger Release
A-02986
Manual 0-4989
4T-7OPERATION
CUTMASTER A120
4T.07Gouging
!
Lead Angle
The angle between the torch and workpiece
depends on the output current setting and torch
travel speed. The recommended lead angle is
35°. At a lead angle greater than 45° the molten
metal will not be blown out of the gouge and
may be blown back onto the torch. If the lead
angle is too small (less than 35°), less material
may be removed, requiring more passes. In
some applications, such as removing welds or
working with light metal, this may be desirable.
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 been followed. Make sure no
part of the operator’s body comes in contact with the workpiece when the torch is
activated.
Disconnect primary power to the system before disassembling the torch, leads, or power
supply.
Torch Head
35°
CAUTION
Sparks from plasma gouging can cause
damage to coated, painted or other surfaces
such as glass, plastic, and metal.
Check torch parts. The torch parts must correspond with the type of operation. Refer to
Section 4T.09, Torch Parts Selection.
Gouging Parameters
Standoff Height
Workpiece
A-00941_AB
Gouging Angle and Standoff Distance
Standoff Distance
Gouging performance depends on parameters
such as torch travel speed, current level, lead
angle (the angle between the torch and workpiece), and the distance between the torch tip
and workpiece (standoff).
The tip to work distance affects gouge quality and depth. Standoff distance of 1/8 - 1/4
inch (3 - 6 mm) allows for smooth, consistent
metal removal. Smaller standoff distances may
result in a severance cut rather than a gouge.
Standoff distances greater than 1/4 inch (6 mm)
may result in minimal metal removal or loss of
transferred main arc.
CAUTION
Touching the torch tip or shield cup to the
work surface will cause excessive parts
wear.
Torch Travel Speed
Slag Buildup
NOTE
Refer to Appendix Pages for additional information as related to the Power Supply used.
Optimum torch travel speed is dependent on
current setting, lead angle, and mode of operation (hand or machine torch).
Current Setting
Slag generated by gouging on materials such as
carbon and stainless steels, nickels, and alloyed
steels, can be removed easily in most cases.
Slag does not obstruct the gouging process if it
accumulates to the side of the gouge path. However, slag build - up can cause inconsistencies
and irregular metal removal if large amounts of
material build up in front of the arc. The build
- up is most often a result of improper travel
speed, lead angle, or standoff height.
Current settings depend on torch travel speed,
mode of operation (hand or machine torch), and
the amount of material to be removed.
OPERATION4T-8
Manual 0-4989
CUTMASTER A120
This Page Intentionally Blank
Manual 0-4989
4T-9OPERATION
CutMaster A120
4T.08Recommended Cutting Speeds for Machine and Automated Torches
With Exposed Tip
Mild Steel
40A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8208
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
20
0.036
101
0.14
160
0.18
0.0
0.05
16
0.060
103
0.14
140
0.18
0.0
0.05
14
0.075
105
0.14
120
0.18
0.1
0.06
12
0.105
108
0.14
80
0.18
0.2
0.06
10
0.135
110
0.14
60
0.18
0.3
0.06
111
0.14
55
0.18
0.4
0.06
70 (25')
75 (50')
3/16
0.188
1/4
0.250
117
0.14
40
0.18
0.5
0.07
3/8
0.375
119
0.14
25
0.18
1.2
0.07
1/2
0.500
120
0.14
15
0.2
2.0
0.07
OPERATION4T-10
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
101
3.6
3990
4.6
0.0
1.1
2
105
3.6
2920
4.6
0.1
1.4
3
109
3.6
1810
4.6
0.3
1.5
4
110
3.6
1470
4.6
0.3
1.6
112
3.6
1345
4.6
0.4
1.6
116
3.6
1100
4.6
0.5
1.7
8
118
3.6
815
4.6
1.0
1.7
10
119
3.6
595
4.6
1.5
1.8
12
120
3.6
435
5.1
2.0
1.8
5
6
4.8 (7.6m)
5.2 (15.2m)
BOLD TYPE indicates maximum piercing parameters.
Manual 0-4989
4T-11OPERATION
CutMaster A120
Stainless Steel
40A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8208
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
18
0.050
110
0.19
60
0.20
0.00
0.07
16
0.063
100
0.19
50
0.20
0.00
0.07
14
0.078
105
0.19
45
0.20
0.10
0.07
12
0.109
110
0.19
40
0.20
0.20
0.07
10
0.141
108
0.19
35
0.20
0.30
0.07
110
0.19
30
0.20
0.40
0.07
75 (25')
80 (50')
3/16
0.188
1/4
0.250
120
0.19
18
0.20
0.50
0.08
3/8
0.375
126
0.19
10
0.20
2.00
0.08
1/2
0.500
118
0.19
8
OPERATION4T-12
Edge start
0.09
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
112
4.8
1670
4.8
0.0
1.7
2
105
4.8
1140
5.1
0.1
1.8
3
109
4.8
980
5.1
0.2
1.8
4
109
4.8
845
5.1
0.3
1.8
111
4.8
715
5.1
0.4
1.8
118
4.8
525
5.1
0.5
2.0
8
123
4.8
350
5.1
1.5
2.0
10
125
4.8
245
5.1
2.0
2.0
12
120
4.8
215
5.2 (7.6)
5
5.5 (15.2)
6
Edge Start
2.2
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-13OPERATION
CutMaster A120
Aluminum
40A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8208
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
20
0.040
95
0.16
300
0.16
0.0
0.06
16
0.063
97
0.16
170
0.16
0.0
0.06
12
0.097
113
0.16
100
0.16
0.2
0.07
11
0.125
70 (25')
115
0.16
90
0.18
0.3
0.07
9
0.160
75 (50')
113
0.18
85
0.18
0.4
0.07
3/16
0.188
116
0.18
75
0.18
0.5
0.07
1/4
0.250
128
0.18
30
0.18
1.0
0.08
3/8
0.375
150
0.18
10
OPERATION4T-14
Edge Start
0.09
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1.0
95
4.1
7620
4.1
0.0
1.5
2.0
104
4.1
3500
4.1
0.2
1.6
3.0
115
4.1
2350
4.6
0.3
1.7
4.0
4.8 (7.6m)
113
4.6
2170
4.6
0.4
1.7
5.0
5.2 (15.2m)
118
4.6
1740
4.6
0.5
1.8
125
4.6
1015
4.6
0.8
1.9
8.0
139
4.6
500
Edge Start
2.0
10.0
153
4.6
180
Edge Start
2.2
6.0
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-15OPERATION
CutMaster A120
Mild Steel
60A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8210
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.060
118
0.19
290
0.19
0.00
0.08
14
0.075
120
0.19
285
0.19
0.10
0.08
11
0.120
118
0.19
180
0.19
0.10
0.08
10
0.135
119
0.19
176
0.19
0.10
0.07
121
0.19
100
0.19
0.20
0.08
122
0.19
80
0.19
0.30
0.08
124
0.19
50
0.19
0.50
0.09
0.19
0.75
0.10
3/16
0.188
1/4
0.250
3/8
0.375
1/2
0.500
132
0.19
26
5/8
0.625
135
0.19
19
Edge Start
0.10
3/4
0.750
136
0.19
14
Edge Start
0.08
1
1.000
150
0.19
6
Edge Start
0.11
85 (25')
90 (50')
OPERATION4T-16
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
115
4.8
7540
4.8
0
2.1
2
120
4.8
7015
4.0
0.10
1.9
3
118
4.8
4570
4.8
0.10
0.1
4
120
4.8
3650
4.8
0.20
1.9
5
121
4.8
2465
4.8
0.20
2.1
5.9 (7.6m)
122
4.8
2145
4.8
0.30
2.0
6.2 (15.2m)
123
4.8
1635
4.8
0.40
2.2
125
4.8
1180
4.8
0.60
2.4
12
130
4.8
795
4.8
0.75
2.4
15
134
4.8
530
Edge Start
2.4
20
138
4.8
325
Edge Start
2.2
25
149
4.8
165
Edge Start
2.7
6
8
10
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-17OPERATION
CutMaster A120
Stainless Steel
60A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8210
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.063
119
0.19
350
0.20
0.00
0.05
14
0.078
116
0.19
300
0.20
0.10
0.07
11
0.125
123
0.19
150
0.20
0.10
0.07
10
0.141
118
0.19
125
0.20
0.10
0.08
3/16
0.188
85 (25')
122
0.19
90
0.20
0.20
0.08
1/4
0.250
90 (50')
123
0.19
65
0.20
0.30
0.09
3/8
0.375
130
0.19
30
0.20
0.50
0.09
1/2
0.500
132
0.19
21
0.20
0.90
0.08
5/8
0.625
132
0.19
14
Edge Start
0.11
3/4
0.750
135
0.19
10
Edge Start
0.10
OPERATION4T-18
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
124
4.8
10890
5.1
0.00
0.8
2
116
4.8
7560
5.1
0.10
1.7
3
122
4.8
4365
5.1
0.10
1.7
4
119
4.8
2865
5.1
0.20
2.1
122
4.8
2195
5.1
0.20
2.1
123
4.8
1790
5.1
0.30
2.2
127
4.8
1190
5.1
0.40
2.2
10
130
4.8
725
5.1
0.50
2.2
12
132
4.8
580
5.1
0.90
2.1
15
132
4.8
405
Edge Start
2.6
20
136
4.8
230
Edge Start
2.5
5
5.9 (7.6m)
6
6.2 (15.2m)
8
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-19OPERATION
CutMaster A120
Aluminum
60A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8210
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.064
123
0.25
440
0.25
0.00
0.08
14
0.079
126
0.25
300
0.25
0.10
0.09
11
0.120
128
0.25
250
0.25
0.10
0.09
132
0.25
170
0.25
0.20
0.09
132
0.25
85
0.25
0.30
0.09
141
0.25
45
0.25
0.50
0.10
0.25
0.80
0.09
3/16
0.188
1/4
0.250
3/8
0.375
1/2
0.500
148
0.25
30
5/8
0.625
145
0.19
18
Edge Start
0.08
3/4
0.750
147
0.19
12
Edge Start
0.10
85 (25')
90 (50')
OPERATION4T-20
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
118
6.4
17010
6.4
0.00
1.8
2
126
6.4
7680
6.4
0.10
2.3
3
128
6.4
6410
6.4
0.10
2.3
4
130
6.4
5230
6.4
0.20
2.3
132
6.4
4010
6.4
0.20
2.4
132
6.4
2640
6.4
0.30
2.4
137
6.4
1630
6.4
0.40
2.4
10
142
6.4
1085
6.4
0.60
2.4
12
146
6.4
845
6.4
0.70
2.3
15
146
4.8
540
Edge Start
2.1
20
148
4.8
260
Edge Start
2.5
5
5.9 (7.6m)
6
6.2 (15.2m)
8
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-21OPERATION
CutMaster A120
Mild Steel
80A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8211
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.060
110
0.19
320
0.20
0.00
0.06
11
0.120
113
0.19
230
0.20
0.10
0.07
10
0.135
110
0.19
180
0.20
0.20
0.07
3/16
0.188
110
0.19
136
0.20
0.30
0.07
1/4
0.250
115
0.19
100
0.20
0.40
0.09
3/8
0.375
125
0.19
42
0.20
0.50
0.09
1/2
0.500
123
0.19
40
0.20
0.60
0.09
0.19
18
0.20
0.75
0.10
85 (25')
90 (50')
5/8
0.625
133
3/4
0.750
140
0.25
18
Edge Start
0.11
7/8
0.875
150
0.25
10
Edge Start
0.11
1
1.000
152
0.25
8
Edge Start
0.13
OPERATION4T-22
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
109
4.8
8915
5.1
0.00
1.5
2
111
4.8
7415
5.1
0.10
1.7
3
113
4.8
5915
5.1
0.10
1.8
4
110
4.8
4095
5.1
0.30
1.7
5
111
4.8
3325
5.1
0.30
1.8
114
4.8
2745
5.1
0.40
2.2
120
4.8
1775
5.1
0.50
2.3
125
4.8
1060
5.1
0.50
2.3
12
123
4.8
1025
5.1
0.60
2.3
15
130
4.8
610
5.1
0.75
2.5
20
143
6.4
395
Edge Start
2.7
25
152
6.4
210
Edge Start
3.2
5.9 (7.6m)
6
8
6.2 (15.2m)
10
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-23OPERATION
CutMaster A120
Stainless Steel
80A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8211
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.063
110
0.19
340
0.25
0.00
0.06
11
0.125
115
.0.19
300
0.25
0.10
0.06
10
0.141
115
0.19
280
0.25
0.10
0.06
115
0.19
140
0.25
0.20
0.07
118
0.19
100
0.25
0.30
0.08
119
0.19
45
0.25
0.40
0.08
0.25
0.80
0.10
3/16
0.188
1/4
0.250
3/8
0.375
1/2
0.500
124
0.19
26
5/8
0.625
133
0.19
16
Edge Start
0.10
3/4
0.750
136
0.19
10
Edge Start
0.11
85 (25')
90 (50')
OPERATION4T-24
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
108
4.8
9020
6.4
0.00
1.5
2
111
4.8
8380
6.4
0.00
1.5
3
114
4.8
7730
6.4
0.10
1.5
4
115
4.8
5865
6.4
0.20
1.6
115
4.8
3410
6.4
0.20
1.8
117
4.8
2765
6.4
0.30
1.9
119
4.8
1815
6.4
0.40
2.0
10
120
4.8
1070
6.4
0.60
2.1
12
123
4.8
765
6.4
0.80
2.3
15
131
4.8
475
Edge Start
2.5
20
137
4.8
205
Edge Start
3.0
5
5.9 (7.6m)
6
6.2 (15.2m)
8
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-25OPERATION
CutMaster A120
Aluminum
80A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8211
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.064
116
0.25
350
0.25
0.00
0.10
11
0.120
120
0.25
280
0.25
0.10
0.10
3/16
0.188
124
0.25
180
0.25
0.20
0.10
1/4
0.250
130
0.25
110
0.25
0.30
0.09
3/8
0.375
136
0.25
55
0.25
0.40
0.11
1/2
0.500
139
0.25
38
0.25
0.60
0.11
5/8
0.625
136
0.19
26
0.25
0.75
0.10
3/4
0.750
150
0.19
14
Edge Start
0.12
7/8
0.875
153
0.19
10
Edge Start
0.11
85 (25')
90 (50')
OPERATION4T-26
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
114
6.4
8890
6.4
0.00
2.4
2
117
6.4
8420
6.4
0.00
2.5
3
120
6.4
7170
6.4
0.10
2.5
4
122
6.4
5710
6.4
0.20
2.5
125
6.4
4315
6.4
0.20
2.5
129
6.4
3190
6.4
0.30
2.4
133
6.4
2070
6.4
0.40
2.5
136
6.4
1330
6.4
0.50
2.7
2.9
2.5
5
5.9 (7.6m)
6
6.2 (15.2m)
8
10
12
138
6.4
1060
6.4
0.50
15
137
4.8
745
6.4
0.75
20
151
4.8
325
Edge Start
3.0
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-27OPERATION
CutMaster A120
Mild Steel
100A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
9-8243
9-8218
9-8237
9-8212
Material
Thickness
(GA)
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8213
9-8232
9-8277
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
110
0.18
85
0.20
0.10
0.09
3/8
0.375
112
0.18
75
0.20
0.20
0.09
1/2
0.500
115
0.18
45
0.20
0.40
0.10
5/8
0.625
118
0.18
30
0.20
0.60
0.11
3/4
0.750
120
0.18
20
0.20
1.20
0.12
1
1.000
123
0.18
15
Edge Start
0.12
1-1/4
1.250
128
0.18
8
Edge Start
0.13
75 (25')
75 (50')
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
110
4.6
2200
5.1
0.10
2.3
8
111
4.6
2030
5.1
0.10
2.3
112
4.6
1790
5.1
0.20
2.3
114
4.6
1310
5.1
0.40
2.5
117
4.6
870
5.1
0.60
2.7
20
120
4.6
490
5.0
1.20
3.0
25
123
4.6
390
Edge Start
3.0
30
127
4.6
250
Edge Start
3.2
10
12
15
5.2 (7.6m)
5.2 (15.2m)
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
OPERATION4T-28
Manual 0-4989
cutmaster A120
Stainless Steel
100A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8212
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
102
0.16
100
0.00
0.09
106
0.16
65
0.18
0.10
0.10
109
0.16
45
0.18
0.30
0.10
123
0.19
20
0.23
2.00
0.11
(in)
inch
1/4
0.250
3/8
0.375
1/2
0.500
5/8
0.625
3/4
0.750
128
0.19
15
Edge Start
0.12
1
1.000
135
0.19
10
Edge Start
0.13
75 (25')
75 (50')
0.18
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
102
4.1
2630
4.6
0.00
2.3
8
104
4.1
2080
4.6
0.10
2.4
106
4.1
1575
4.6
0.20
2.4
108
4.1
1255
4.6
0.30
2.4
119
4.6
685
5.7
2.00
2.7
20
129
4.8
360
Edge Start
3.1
25
135
4.8
260
Edge Start
3.2
10
5.2 (7.6m)
12
5.2 (15.2m)
15
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-29OPERATION
CutMaster A120
Aluminum
100A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8212
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
110
0.19
100
0.20
0.00
0.09
3/8
0.375
124
0.19
65
0.20
0.20
0.10
1/2
0.500
75 (25')
128
0.19
45
0.20
0.30
0.11
5/8
0.625
75 (50')
132
0.19
35
0.20
0.50
0.11
3/4
0.750
135
0.19
20
0.20
2.00
0.13
1
1.000
140
0.19
10
Edge Start
0.13
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
109
4.8
2630
5.1
0.00
2.3
8
117
4.8
2080
5.1
0.10
2.5
125
4.8
1575
5.1
0.20
2.7
127
4.8
1255
5.1
0.30
2.7
131
4.8
960
5.1
0.50
2.8
20
136
4.8
470
6.0
2.00
3.3
25
140
4.8
270
10
12
15
5.2 (7.6m)
5.2 (15.2m)
Edge Start
3.4
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
OPERATION4T-30
Manual 0-4989
cutmaster A120
This Page Intentionally Blank
Manual 0-4989
4T-31OPERATION
CutMaster A120
Mild Steel
120A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8233
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
134
0.19
150
0.25
0.10
0.11
3/8
0.375
141
0.19
85
0.25
0.30
0.11
1/2
0.500
141
0.19
70
0.25
0.80
0.12
5/8
0.625
146
0.19
45
0.25
1.00
0.12
3/4
0.750
150
0.19
30
0.25
1.20
0.12
7/8
0.875
160
0.25
25
Edge Start
0.14
1
1.000
163
0.25
19
Edge Start
0.14
1-1/4
1.250
168
0.25
12
Edge Start
0.15
1-1/2
1.500
172
0.25
8
Edge Start
0.16
80 (25')
80 (50')
OPERATION4T-32
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6.0
133
4.8
3990
6.4
0.1
2.5
8.0
138
4.8
2950
6.4
0.2
2.7
10.0
141
4.8
2100
6.4
0.4
2.8
12.0
141
4.8
1860
6.4
0.6
2.9
145
4.8
1320
6.4
1.0
3.0
153
4.8
720
6.4
1.2
3.2
163
6.4
500
Edge Start
3.6
30.0
167
6.4
355
Edge Start
3.8
35.0
170
6.4
255
Edge Start
4.0
40.0
173
6.4
175
Edge Start
4.2
5.5 (7.6m)
15.0
20.0
5.5 (15.2m)
25.0
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-33OPERATION
CutMaster A120
Stainless Steel
120A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8233
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
133
0.19
180
0.25
0.20
0.10
3/8
0.375
136
0.19
100
0.25
0.40
0.11
1/2
0.500
140
0.19
60
0.25
0.80
0.11
5/8
0.625
152
0.25
40
0.30
1.20
0.13
3/4
0.750
154
0.25
26
Edge Start
0.14
1
1.000
159
0.25
16
Edge Start
0.14
1-1/4
1.250
167
0.25
8
Edge Start
0.14
80 (25')
80 (50')
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
133
4.8
4800
6.4
0.2
2.6
8
135
4.8
3520
6.4
0.2
2.7
10
137
4.8
2390
6.4
0.5
2.8
12
5.5 (7.6m)
139
4.8
1750
6.4
0.8
2.9
15
5.5 (15.2m)
149
6.4
1160
7.6
1.2
3.4
20
155
6.4
625
Edge Start
3.6
25
159
6.4
425
Edge Start
3.6
30
165
6.4
260
Edge Start
3.6
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
OPERATION4T-34
Manual 0-4989
cutmaster A120
Aluminum
120A
Air Plasma / Air Shield
Deflector
Standard Shield Cup
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8243
9-8218
9-8237
9-8233
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
139
0.19
180
0.25
0.30
0.11
3/8
0.375
140
0.19
110
0.25
0.50
0.11
1/2
0.500
80 (25')
143
0.19
75
0.25
0.80
0.11
5/8
0.625
80 (50')
156
0.25
50
0.30
1.00
0.12
3/4
0.750
161
0.25
34
Edge Start
0.13
1
1.000
167
0.25
23
Edge Start
0.14
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
139
4.8
4770
6.4
0.2
2.8
8
140
4.8
3650
6.4
0.2
2.8
140
4.8
2660
6.4
0.5
2.8
142
4.8
2100
6.4
0.8
2.8
152
6.4
1445
7.6
1.2
3.0
20
162
6.4
820
Edge Start
3.4
25
167
6.4
600
Edge Start
3.4
10
5.5 (7.6m)
12
5.5 (15.2m)
15
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-35OPERATION
CutMaster A120
4T.09Recommended Cutting Speeds for Machine and Automated Torches
With Shielded Tip
Mild Steel
40A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8245
9-8237
9-8208
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
20
0.036
107
0.16
130
0.16
0.0
0.06
16
0.060
113
0.16
120
0.16
0.0
0.06
14
0.075
108
0.16
90
0.16
0.1
0.06
12
0.105
111
0.16
75
0.16
0.2
0.06
10
0.135
114
0.16
65
0.16
0.3
0.07
115
0.16
65
0.16
0.4
0.07
75 (25')
80 (50')
3/16
0.188
1/4
0.250
118
0.16
45
0.16
0.5
0.07
3/8
0.375
123
0.16
23
0.16
1.2
0.08
1/2
0.500
128
0.16
18
0.16
2.0
0.08
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
108
4.1
3266
4.1
0.0
1.4
2
108
4.1
2239
4.1
0.0
1.5
3
112
4.1
1794
4.1
0.1
1.7
114
4.1
1651
4.1
0.2
1.7
4
5
5.2 (7.6)
115
4.1
1578
4.1
0.3
1.7
117
4.1
1256
4.1
0.4
1.7
8
121
4.1
853
4.1
0.5
1.7
10
124
4.1
565
4.1
1.2
1.8
127
4.1
485
4.1
2.0
1.9
6
12
5.5 (15.2)
BOLD TYPE indicates maximum piercing parameters.
OPERATION4T-36
Manual 0-4989
cutmaster A120
Stainless Steel
40A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8245
9-8237
9-8208
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
18
0.050
110
0.16
60
4.1
0.0
0.06
16
0.063
108
0.16
50
4.1
0.1
0.07
14
0.078
114
0.16
45
4.1
0.1
0.07
12
0.109
113
0.16
40
4.1
0.2
0.07
10
0.141
116
0.16
35
4.1
0.3
0.07
115
0.16
30
4.1
0.4
0.07
75 (25')
80 (50')
3/16
0.188
1/4
0.250
118
0.16
20
4.1
1.2
0.07
3/8
0.375
125
0.16
15
4.1
1.8
0.08
1/2
0.500
127
0.16
10
4.1
2.0
0.08
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
109
4.1
1670
4.1
0.0
1.7
2
114
4.1
1140
4.1
0.1
1.8
3
114
4.1
980
4.1
0.2
1.8
4
116
4.1
845
4.1
0.3
1.8
115
4.1
725
4.1
0.4
1.8
117
4.1
565
4.1
0.5
2.0
8
122
4.1
440
4.1
1.5
2.0
10
125
4.1
360
4.1
1.8
2.0
127
4.1
280
4.1
2.0
2.2
5
6
12
5.2 (7.6)
5.5 (15.2)
BOLD TYPE indicates maximum piercing parameters.
Manual 0-4989
4T-37OPERATION
CutMaster A120
Aluminum
40A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8245
9-8237
9-8208
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
20
0.040
110
0.19
300
0.20
0.0
0.06
16
0.063
113
0.19
170
0.20
0.1
0.07
12
0.097
120
0.19
100
0.20
0.2
0.07
11
0.125
75 (25')
125
0.19
90
0.20
0.3
0.07
9
0.160
80 (50')
126
0.19
85
0.20
0.4
0.07
3/16
0.188
128
0.19
70
0.20
0.5
0.07
1/4
0.250
137
0.19
30
0.20
1.0
0.08
3/8
0.375
145
0.19
10
0.20
2.0
0.09
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1.0
110
4.8
7660
5.1
0.0
1.6
2.0
116
4.8
3490
5.1
0.2
1.8
124
4.8
2350
5.1
0.3
1.8
4.0
5.2 (7.6)
126
4.8
2170
5.1
0.4
1.8
5.0
5.5 (15.2)
129
4.8
1630
5.1
0.6
1.8
6.0
135
4.8
990
5.1
1.0
1.9
8.0
141
4.8
500
5.1
1.6
2.0
10.0
146
4.8
180
5.1
2.1
2.3
3.0
BOLD TYPE indicates maximum piercing parameters.
OPERATION4T-38
Manual 0-4989
cutmaster A120
This Page Intentionally Blank
Manual 0-4989
4T-39OPERATION
CutMaster A120
Mild Steel
60A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8238
9-8237
9-8210
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.060
128
0.19
250
0.20
0.00
0.09
14
0.075
129
0.19
237
0.20
0.10
0.09
11
0.120
126
0.19
200
0.20
0.10
0.08
10
0.135
128
0.19
142
0.20
0.10
0.09
132
0.19
115
0.20
0.20
0.09
134
0.19
80
0.20
0.30
0.08
132
0.19
34
0.20
0.70
0.10
0.20
0.75
0.10
3/16
0.188
1/4
0.250
3/8
0.375
1/2
0.500
144
0.19
23
5/8
0.625
150
0.19
14
Edge Start
0.10
3/4
0.750
145
0.19
14
Edge Start
0.10
1
1.000
160
0.19
4
Edge Start
0.12
85 (25')
90 (50')
OPERATION4T-40
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
127
4.8
6804
5.1
0
2.2
2
129
4.8
5942
5.1
0.10
2.2
3
126
4.8
5080
5.1
0.10
0.1
4
130
4.8
3316
5.1
0.20
2.3
132
4.8
2794
5.1
0.20
2.2
134
4.8
2230
5.1
0.30
2.1
5
5.9 (7.6m)
6
6.2 (15.2m)
8
133
4.8
1425
5.1
0.40
2.3
10
134
4.8
822
5.1
0.60
2.5
12
141
4.8
646
5.1
0.75
2.5
15
148
4.8
419
Edge Start
2.6
20
147
4.8
318
Edge Start
2.7
159
4.8
118
Edge Start
3.0
25
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-41OPERATION
CutMaster A120
Stainless Steel
60A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8238
9-8237
9-8210
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.063
110
0.13
165
0.20
0.00
0.06
14
0.078
116
0.13
155
0.20
0.10
0.07
11
0.125
118
0.13
125
0.20
0.10
0.07
10
0.141
126
0.13
80
0.20
0.10
0.09
3/16
0.188
85 (25')
125
0.13
75
0.20
0.20
0.09
1/4
0.250
90 (50')
127
0.13
60
0.20
0.30
0.08
3/8
0.375
134
0.13
28
0.20
0.50
0.08
1/2
0.500
136
0.19
17
0.25
0.75
0.09
5/8
0.625
131
0.13
14
Edge Start
0.08
3/4
0.750
142
0.19
10
Edge Start
0.11
OPERATION4T-42
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
101
3.3
4590
5.1
0.00
1.2
2
116
3.3
3925
5.1
0.10
1.7
3
118
3.3
3285
5.1
0.10
1.7
4
126
3.3
1985
5.1
0.20
2.2
125
3.3
1850
5.1
0.20
2.1
127
3.3
1605
5.1
0.30
2.1
5
5.9 (7.6m)
6
6.2 (15.2m)
8
131
3.3
1100
5.1
0.40
2.1
10
134
3.3
670
5.1
0.50
2.1
12
136
4.8
490
6.4
0.90
2.2
15
132
3.3
375
Edge Start
2.6
20
144
4.8
230
Edge Start
2.5
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-43OPERATION
CutMaster A120
Aluminum
60A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8238
9-8237
9-8210
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.064
118
0.13
350
0.20
0.00
0.07
14
0.079
118
0.13
350
0.20
0.10
0.08
11
0.120
123
0.13
275
0.20
0.10
0.08
125
0.13
140
0.20
0.20
0.08
132
0.13
80
0.20
0.30
0.08
135
0.13
45
0.20
0.50
0.08
0.20
0.80
0.08
3/16
0.188
1/4
0.250
3/8
0.375
1/2
0.500
140
0.13
26
5/8
0.625
148
0.19
18
Edge start
0.10
3/4
0.750
155
0.19
12
Edge start
0.11
85 (25')
90 (50')
OPERATION4T-44
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
118
6.4
8890
6.4
0.00
2
2
118
6.4
8890
6.4
0.10
2.0
3
123
6.4
7070
6.4
0.10
2.1
4
124
6.4
5095
6.4
0.20
2.0
126
6.4
3335
6.4
0.20
2.0
130
6.4
2370
6.4
0.30
2.0
134
6.4
1570
6.4
0.40
2.0
10
136
6.4
1070
6.4
0.60
2.0
12
139
6.4
765
6.4
0.70
2.0
15
146
4.8
515
Edge start
2.4
20
157
4.8
260
Edge start
2.7
5
5.9 (7.6m)
6
6.2 (15.2m)
8
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-45OPERATION
CutMaster A120
Mild Steel
80A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8239
9-8237
9-8211
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
Initial Piercing
Pierce Delay
Height
Kerf Width
@ Rec.
Speed
16
0.060
115
0.13
280
0.20
0.00
0.06
11
0.120
112
0.13
190
0.20
0.10
0.06
10
0.135
110
0.13
176
0.20
0.20
0.06
3/16
0.188
122
0.19
135
0.20
0.30
0.08
1/4
0.250
127
0.19
100
0.20
0.40
0.09
3/8
0.375
134
0.19
40
0.20
0.50
0.10
1/2
0.500
136
0.19
36
0.20
0.60
0.10
5/8
0.625
145
0.19
18
Edge Start
0.11
3/4
0.750
147
0.19
14
Edge Start
0.11
7/8
0.875
146
0.19
10
Edge Start
0.12
1.000
1.000
152
0.187
8
Edge Start
0.13
85 (25')
90 (50')
OPERATION4T-46
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
116
3.3
7895
5.1
0.00
1.6
2
114
3.3
6395
5.1
0.10
1.6
3
112
3.3
4895
5.1
0.10
1.5
4
115
4.8
4025
5.1
0.30
1.7
123
4.8
3300
5.1
0.30
2.0
126
4.8
2735
5.1
0.40
2.2
131
4.8
1745
5.1
0.50
2.5
5
5.9 (7.6m)
6
6.2 (15.2m)
8
Initial Piercing
Pierce Delay
Height
Kerf Width
@ Rec.
Speed
10
134
4.8
1000
5.1
0.50
2.6
12
136
4.8
935
5.1
0.60
2.6
15
143
4.8
580
5.1
0.80
2.8
20
147
4.8
325
Edge Start
2.9
151
4.8
210
Edge Start
3.2
25
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-47OPERATION
CutMaster A120
Stainless Steel
80A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8239
9-8237
9-8211
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
Initial Piercing
Pierce Delay
Height
Kerf Width
@ Rec.
Speed
16
0.063
114
0.125
340
0.2
0.00
0.06
11
0.125
115
0.125
260
0.2
0.10
0.06
10
0.141
116
0.125
250
0.2
0.10
0.06
115
0.125
170
0.2
0.20
0.07
118
0.125
85
0.2
0.30
0.08
127
0.19
45
0.25
0.40
0.09
0.25
0.75
0.11
3/16
0.188
1/4
0.250
3/8
0.375
1/2
0.500
136
0.19
16
5/8
0.625
143
0.19
10
Edge Start
0.12
3/4
0.750
146
0.19
8
Edge Start
0.11
85 (25')
90 (50')
OPERATION4T-48
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
114
3.2
9410
5.1
0.00
1.5
2
114
3.2
8120
5.1
0.00
1.4
3
115
3.2
6830
5.1
0.10
1.4
4
116
3.2
5635
5.1
0.20
1.5
115
3.2
4010
5.1
0.20
1.8
117
3.2
2640
5.1
0.30
2.0
123
4.8
1630
6.4
0.40
2.1
10
128
4.8
1030
6.4
0.60
2.2
12
134
4.8
565
6.4
0.75
2.6
15
141
4.8
295
Edge Start
3.0
20
147
4.8
185
Edge Start
2.8
5
5.9 (7.6m)
6
6.2 (15.2m)
8
Initial Piercing
Pierce Delay
Height
Kerf Width
@ Rec.
Speed
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-49OPERATION
CutMaster A120
Aluminum
80A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8239
9-8237
9-8211
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
16
0.064
115
0.13
320
0.2
0.00
0.09
11
0.120
120
0.13
240
0.2
0.10
0.08
3/16
0.188
122
0.13
165
0.2
0.20
0.08
124
0.13
100
0.2
0.30
0.10
140
0.19
60
0.2
0.40
0.09
1/4
0.250
85 (25')
3/8
0.375
90 (50')
1/2
0.500
142
0.19
36
0.2
0.60
0.11
5/8
0.625
148
0.19
26
0.2
0.75
0.11
3/4
0.750
155
0.19
16
OPERATION4T-50
Edge Start
0.12
Manual 0-4989
cutmaster A120
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
1
113
3.3
9020
5.1
0.00
2.4
2
116
3.3
7595
5.1
0.00
2.2
3
120
3.3
6165
5.1
0.10
2.0
4
121
3.3
5045
5.1
0.20
2.1
122
3.3
3955
5.1
0.20
2.2
124
3.3
2905
5.1
0.30
2.3
132
4.8
2010
5.1
0.40
2.3
10
140
4.8
1430
5.1
0.50
2.3
12
142
4.8
1045
5.1
0.60
2.6
15
146
4.8
730
5.1
0.75
2.7
20
157
4.8
330
5
5.9 (7.6m)
6
6.2 (15.2m)
8
Edge Start
3.2
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-51OPERATION
CutMaster A120
Mild Steel
100A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8239
9-8237
9-8233
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
114
0.16
85
0.18
0.00
0.08
3/8
0.375
112
0.16
70
0.18
0.20
0.09
1/2
0.500
115
0.16
40
0.18
0.30
0.10
5/8
0.625
123
0.16
30
0.18
0.40
0.10
3/4
0.750
127
0.16
20
0.18
0.80
0.11
1
1.000
133
0.16
12
Edge Start
0.12
1-1/4
1.250
135
0.16
8
Edge Start
0.12
75 (25')
75 (50')
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
114
4.1
2210
4.6
0.00
2.0
8
113
4.1
1960
4.6
0.10
2.2
10
112
4.1
1665
4.6
0.20
2.3
12
114
4.1
1185
4.6
0.30
2.4
15
121
4.1
830
4.6
0.40
2.5
20
128
4.1
475
5.0
0.80
2.8
25
133
4.1
315
Edge Start
2.9
134
4.1
230
Edge Start
3.1
30
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
OPERATION4T-52
Manual 0-4989
cutmaster A120
Stainless Steel
100A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8239
9-8237
9-8212
9-8213
9-8277
9-8232
Material
Thickness
(GA)
(in)
inch
1/4
0.250
3/8
0.375
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
114
0.16
110
0.18
0.00
0.08
116
0.16
70
0.18
0.10
0.09
119
0.16
45
0.18
0.30
0.10
130
0.19
20
0.23
2.00
0.11
0.23
2.80
0.11
1/2
0.500
75 (25')
5/8
0.625
75 (50')
3/4
0.750
135
0.19
15
1
1.000
140
0.19
10
Edge Start
0.11
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
114
4.1
2900
4.6
0.00
2.0
8
115
4.1
2265
4.6
0.10
2.2
5.2 (7.6m)
116
4.1
1685
4.6
0.20
2.4
5.2 (15.2m)
118
4.1
1285
4.6
0.30
2.4
127
4.6
685
5.7
2.00
2.7
20
136
4.8
360
5.7
2.80
2.8
25
140
4.8
260
10
12
15
Edge Start
2.8
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-53OPERATION
CutMaster A120
Aluminum
100A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8239
9-8237
9-8212
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
121
0.18
110
0.19
0.00
0.10
3/8
0.375
129
0.18
60
0.19
0.20
0.10
1/2
0.500
75 (25')
135
0.18
45
0.19
0.30
0.11
5/8
0.625
75 (50')
133
0.18
32
0.19
0.60
0.11
3/4
0.750
138
0.18
25
0.19
2.00
0.11
1
1.000
143
0.18
15
Edge Start
0.14
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
120
4.6
2920
4.8
0.00
2.5
8
125
4.6
2135
4.8
0.10
2.5
5.2 (7.6m)
130
4.6
1470
4.8
0.20
2.6
5.2 (15.2m)
134
4.6
1230
4.8
0.30
2.7
134
4.6
905
4.8
0.60
2.9
139
4.6
595
6.0
2.00
3.0
143
4.6
395
10
12
15
20
25
Edge Start
3.6
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
OPERATION4T-54
Manual 0-4989
cutmaster A120
Mild Steel
120A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8256
9-8237
9-8233
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
139
0.125
160
0.20
0.20
0.11
3/8
0.375
140
0.125
85
0.20
0.20
0.11
1/2
0.500
142
0.125
75
0.20
0.50
0.10
5/8
0.625
144
0.125
45
0.20
0.70
0.11
3/4
0.750
150
0.125
30
0.25
1.50
0.12
7/8
0.875
158
0.175
25
Edge Start
0.13
1
1.000
160
0.175
22
Edge Start
0.14
1-1/4
1.250
165
0.175
15
Edge Start
0.17
1-1/2
1.500
171
0.175
8
Edge Start
0.15
80 (25')
80 (50')
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
139
4.8
4270
5.08
0.20
2.8
8
140
4.8
3070
5.1
0.2
2.8
10
140
6.4
2120
5.08
0.30
2.8
142
6.4
1960
5.08
0.50
2.8
143
4.8
1355
5.08
0.70
2.8
152
4.8
725
6.4
1.6
3.1
25
160
4.8
570
Edge Start
3.6
30
164
4.8
430
Edge Start
4.0
35
168
4.8
290
Edge Start
4.3
173
4.45
150
Edge Start
4.4
12
5.5 (7.6m)
15
20
5.5 (15.2m)
40
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-55OPERATION
CutMaster A120
Stainless Steel
120A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8256
9-8237
9-8233
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
140
0.13
180
0.20
0.30
0.11
3/8
0.375
140
0.13
100
0.20
0.40
0.12
1/2
0.500
142
0.15
65
0.25
0.80
0.12
5/8
0.625
152
0.15
40
0.25
1.00
0.12
150
0.15
26
Edge Start
0.13
80 (25')
80 (50')
3/4
0.750
1
1.000
155
0.15
16
Edge Start
0.13
1-1/4
1.250
165
0.15
8
Edge Start
0.13
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
6
140
4.8
4800
5.1
0.3
2.8
8
140
4.8
3520
5.1
0.4
2.7
140
4.8
2410
5.1
0.6
3.0
142
4.8
1850
6.4
0.8
3.1
6.4
1.0
3.1
10
12
5.5 (7.6m)
149
6.4
1190
20
151
6.4
620
Edge Start
3.3
25
155
6.4
420
Edge Start
3.3
30
162
6.4
260
Edge Start
3.3
15
5.5 (15.2m)
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
OPERATION4T-56
Manual 0-4989
cutmaster A120
Aluminum
120A
Air Plasma / Air Shield
Shield Cap
Maximum Life Shield Cup
Tip
Starter Cartridge
Heavy Duty Starter
Cartridge
Electrode
9-8256
9-8237
9-8233
9-8213
9-8277
9-8232
Material
Thickness
(GA)
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
PSI
(torch lead
length)
Volts
(in)
(ipm)
(in)
(sec)
(in)
(in)
inch
1/4
0.250
140
0.13
180
0.20
0.20
0.10
3/8
0.375
142
0.13
110
0.20
0.30
0.11
1/2
0.500
80 (25')
148
0.13
75
0.20
0.50
0.11
5/8
0.625
80 (50')
156
0.15
45
0.25
0.80
0.11
3/4
0.750
158
0.15
35
Edge Start
0.11
1
1.000
164
0.15
23
Edge Start
0.12
Material
Thickness
Gas Pressure
(Air)
Arc Voltage
Torch
Working
Height
Travel Speed
Initial
Piercing
Height
Pierce Delay
Kerf Width
@ Rec.
Speed
(mm)
Bar
(torch lead
length)
Volts
(mm)
(mm/min)
(mm)
(sec)
(mm)
140
4.8
4770
5.1
0.2
2.6
8
141
4.8
3650
5.1
0.3
2.6
10
143
4.8
2660
5.1
0.4
2.7
147
4.8
2100
5.1
0.5
2.8
154
4.8
1355
6.4
0.8
2.8
20
159
4.8
845
Edge Start
2.9
25
164
4.8
605
Edge Start
3.0
6
5.5 (7.6m)
12
5.5 (15.2m)
15
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.
Manual 0-4989
4T-57OPERATION
CUTMASTER A120
PATENT INFORMATION
Plasma Cutting Torch Patents
The following parts are covered under U.S. and Foreign Patents as follows:
Catalog #
Description
9-8215
Electrode
9-8232
Electrode
9-8213
Cartridge
9-8205
Tip
9-8206
Tip
9-8207
Tip
9-8252
Tip
9-8208
Tip
9-8209
Tip
9-8210
Tip
9-8231
Tip
9-8211
Tip
9-8212
Tip
9-8253
Tip
9-8233
Tip
9-8225
Tip
9-8226
Tip
9-8227
Tip
9-8228
Tip
9-8241
Shield Cap
9-8243
Shield Cap
9-8235
Shield Cap
9-8236
Shield Cap
9-8237
Shield Cup
9-8238
Shield Cap
OPERATION4T-58
Patent(s)
US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
US Pat No(s) 6903301; 6717096; 6936786; 6703581; D496842; D511280; D492709; D499620; D504142 Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
US Pat No(s) 6914211; D505309
Other Pat(s) Pending
US Pat No(s) 6914211; D493183
Other Pat(s) Pending
US Pat No(s) 6914211; D505309
Other Pat(s) Pending
US Pat No(s) 6914211; D505309
Other Pat(s) Pending
US Pat No(s) 6914211; D501632; D511633
Other Pat(s) Pending
US Pat No(s) 6914211; D496951
Other Pat(s) Pending
Manual 0-4989
CUTMASTER A120
Catalog #
Description
9-8239
Shield Cap
9-8244
Shield Cap
9-8245
Shield Cap
Patent(s)
US Pat No(s) 6914211; D496951
Other Pat(s) Pending
US Pat No(s) 6914211; D505309
Other Pat(s) Pending
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
9-8236
9-8237
9-8238
9-8239
9-8244
9-8245
Shield Cap
Shield Cap
Shield Cup
Shield Cap
Shield Cap
Shield Cap
Shield Cap
Manual 0-4989
4T-59OPERATION
CUTMASTER A120
This Page Intentionally Blank
OPERATION4T-60
Manual 0-4989
CUTMASTER A120
SECTION 5 SYSTEM:
SERVICE
5.01 General Maintenance
Warning!
Disconnect input power before maintaining.
Maintain more often
if used under severe
conditions
Each Use
Visual check of
torch tip and electrode
Weekly
Visually inspect the torch body tip,
electrode, start cartridge and shield cup
Visually inspect the
cables and leads.
Replace as needed
3 Months
Replace all
broken parts
Clean
exterior
of power supply
6 Months
Visually check and
Carefully clean the
interior
Art # A-07938_AB
Manual 0-4989
5-1
SERVICE
CUTMASTER A120
5.02 Maintenance Schedule
NOTE
5.03 Common Faults
Problem - Symptom
The actual frequency of maintenance may need to
be adjusted according to the operating environment.
Insufficient
Penetration
1. Cutting speed too fast.
2. Torch tilted too much.
3. Metal too thick.
4. Worn torch parts
5. Cutting current too low.
6. Non - Genuine Thermal Dynamics
parts used
7. Incorrect gas pressure
Main Arc
Extinguishes
1. Cutting speed too slow.
2. Torch standoff too high from
workpiece.
3. Cutting current too high.
4. Work 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 Life
1. Oil or moisture in air source.
2. Exceeding system capability
(material too thick).
3. Excessive pilot arc time
4. Gas pressure too low.
5. Improperly assembled torch.
6. Non - Genuine Thermal Dynamics
parts used
Difficult Starting
1. Worn torch parts.
2. Non - Genuine Thermal Dynamics
parts used.
3. Incorrect gas pressure.
Daily Operational Checks or Every Six Cutting
Hours:
1. Check torch consumable parts, replace if damaged
or worn.
2. Check plasma and secondary supply and pressure/flow.
3. Purge plasma gas line to remove any moisture
build-up.
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.
3. Check all contactor points for severe arcing or
pits, replace if necessary.
4. Vacuum dust and dirt out of the entire machine.
CAUTION
Common Cause
Do not blow air into the power supply during
cleaning. Blowing air into the unit can cause metal
particles to interfere with sensitive electrical components and cause damage to the unit.
SERVICE
5-2
Manual 0-4989
CUTMASTER A120
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. In the example below the Temp indicator and 76 psi indicators are ON indicating the version
would be 2.3.
7
6
5
4
3
2
1
MIN
0
A
MAX
PSI
BAR
MAX
MAX
MIN
MIN
+
!
1
2 3 4
5
Art# A-07988
When the ! "Fault" indicator is ON or blinking it
will be accompanied by one of the pressure indicator
lights depending on what the Fault is. The following
table explains each of those Faults.
Pressure
Indicator
Max
90
85
80
75
70
65
Min
Fault
Over Pressure
Internal Error
Shorted Torch
Consumables Missing
Start Error
Parts in Place
Input Power
Under Pressure
NOTE
Fault explanations are covered in the following
tables.
Manual 0-4989
5-3
SERVICE
CUTMASTER A120
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
is ON but the A/C
Indicator does not
light
1. Primary power disconnect is in 1. Turn primary power disconnect switch to ON position.
OFF position.
2. Primary fuses / breakers are
2. a) Have qualified person check primary fuses / breakers.
blown or tripped.
b) Connect unit to known good primary power receptacle
3. Units internal fuse blown.
3. a) Replace fuse.
b) If fuse blows again, return to authorized service center for
repair or replacement.
4. Faulty components in unit.
4. Return to authorized service center for repair or replacement.
Fault indicator
flashing, 65 PSI
indicator flashing
1. INPUT VOLTAGE SELECTION
1. Set INPUT VOLTAGE SELECTION SWITCH to match primary
SWITCH set for incorrect voltage. input voltage.
2. Primary input voltage problem. 2. Have qualified person check primary voltage to insure it
meets unit requirements see section 2.05.
3. Faulty components in unit.
3. Return to authorized service center for repair or replacement.
TEMPERATURE
1. Air flow through or around the 1. Refer to clearance information – section 2.04
indicator ON. FAULT unit is obstructed.
indicator flashing.
2. Duty cycle of the unit has been 2. Allow unit to cool.
exceeded
3. Failed components in unit
3. Return to authorized service center for repair or replacement.
GAS LED OFF, FAULT 1. Gas supply not connected to
and MIN pressure
unit.
indicators flashing. 2. Gas supply not turned ON.
3. Gas supply pressure too low.
4. AIR PRESSURE CONTROL
regulator set too low.
5. Failed components in unit.
1. Connect gas supply to unit.
FAULT and 70 PSI
indicators flashing.
1. Shield 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.
1. Start signal is active when ON/
OFF SWITCH is turned to ON
position.
1. Start can be active for one of the following:
• Hand torch switch held closed
• Hand pendant switch held closed
• CNC START signal is active low
Release the START signal source
2. Replace torch and leads or return to authorized service center
for repair or replacement.
3. Return to authorized service center for repair or replacement.
FAULT and 75 PSI
indicators flashing.
2. Problem in the torch and leads
switch circuit.
3. Failed components in unit.
SERVICE
2. Turn gas supply ON.
3. Set air supply inlet pressure to unit to 120 psi.
4. Adjust regulator to set air pressure - see section 4.02.
5. Return to authorized service center for repair or replacement.
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.
5-4
Manual 0-4989
CUTMASTER A120
Problem - Symptom
FAULT & 80 PSI
indicators flashing. Gas flow is cycling
ON and OFF.
Possible Cause
1. Torch shield cup is loose.
2. Torch tip, electrode or starter
cartridge missing.
3. Torch start cartridge is stuck.
4. Open conductor in torch leads.
Recommended Action
1. Tighten shield cup by hand. Do not overtighten.
2. Turn OFF power supply. Remove shield cup. Install
missing parts.
3. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and start cartridge. Check start
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
4. Replace torch and leads or return to authorized service
center for repair or replacement.
5. Problem in the torch and leads
switch circuit.
6. Failed components in unit.
5. Replace torch and leads or return to authorized service
center for repair or replacement.
6. Return to authorized service center for repair or
replacement.
Nothing happens
when torch switch
or remote switch
is closed (Or CNC
START signal is
active) No gas flow,
DC LED OFF.
1. Problem in the torch and leads
switch circuit (Remote pendant
switch circuit).
2. CNC Contoller device not
providing Start signal.
3. Failed components in unit.
1. Take Torch and Leads (Remote Pendant) to Authorized
Repair Facility.
FAULT and 85 PSI
indicators flashing.
1. Upper O-Ring on torch head is in 1. Remove shield cup from torch; check upper O-Ring
wrong position.
position; correct if necessary.
2. Torch starter cartridge is stuck. 2. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
3. Worn or faulty torch parts.
3. Inspect torch consumable parts. Replace if necessary.
4. Shorted Torch.
4. Replace torch and leads or return to an authorized service
center for repair.
5. Temporary Short indicated by 5 5. Release torch switch and reactivate.
blinks per second.
6. Power Supply Failure (Standard 6. Return to authorized service center for repair or
rate of blinking)
replacement.
2. Contact Controller manufacturer.
3. Return to authorized service center for repair or
replacement.
No Fault lights ON, no 1. Failed components in unit.
arc in torch.
1. Return to an authorized service center for repair.
FAULT and 85 PSI
indicators flashing
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.
Torch cutting is
diminished
1. Incorrect current setting.
2. Worn torch consumables.
3. Poor work cable connection to
work piece.
4. Torch being moved too fast.
5. Excessive oil or water in torch.
6. Failed components in unit.
1. Check and adjust to proper setting.
2. Check torch consumables and replace as needed.
3. Check the connection of the Work Lead to the work piece.
Manual 0-4989
2. Replace work cable.
3. Return to an authorized service center for repair.
4. Reduce cutting speed.
5. Refer to "Check air quality" in section 3 Torch.
6. Return to an authorized service center for repair.
5-5
SERVICE
CUTMASTER A120
5.06 Power Supply Basic Parts
Replacement
WARNING
C. Filter Element Assembly Replacement
The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should be
checked per the Maintenance Schedule (Subsection 5.02),
and either cleaned or replaced.
1. Remove power from the power supply; turn OFF
the gas supply and bleed down the system.
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
2. Remove the system cover. See "A Cover Removal" in this section.
This section describes procedures for basic parts replacement. For more detailed parts replacement procedures,
refer to the Power Supply Service Manual.
3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
illustration.
A. Cover Removal
4. Hold a wrench or similar tool against the locking ring on the filter assembly fitting, then pull
on the hose to release it. (Numbers 2 and 3 in the
following illustration).
1. Remove the upper and lower screws which secure
the cover to the main assembly. Do not loosen the
lower screws inside the cut out slots in the bottom
of the cover.
Upper
Screws
1
Lower
Screws
Slots
Lower
Screws
Art # A-07989
2
Art # A-08429
2. Carefully pull the Cover up and away from the
unit.
3
B. Cover Installation
4
5
1. Reconnect the ground wire, if necessary.
2. Place the cover onto the power supply so that
slots in the bottom edges of the cover engage the
lower screws.
6mm
3. Tighten lower screws.
4. Reinstall and tighten the upper screws.
SERVICE
5-6
Manual 0-4989
CUTMASTER A120
5. Remove the fitting from the filter element assembly by inserting a 6 mm hex wrench into
the internal hex fitting and turning it counter
clock-wise (left). Numbers 4 and 5 in the previous
illustration.
Optional Single-Stage Filter Element
Replacement
6. Disconnect the input line from the filter element
assembly.
The Power Supply shuts down automatically when
the Filter Element becomes completely saturated. The
Filter Element can be removed from its housing, dried,
and reused. Allow 24 hours for Element to dry. Refer
to Section 6, Parts List, for replacement filter element
catalog number.
7. Remove the filter element assembly through the
rear opening.
These instructions apply to power supplies where the
optional Single-Stage Filter has been installed.
NOTE
1. Remove power from power supply.
If replacing or cleaning just the filter element refer
to the following illustration for disassembly.
2. Shut 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.
Filter Element
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
Art # A-07990
8. Install the new or cleaned assembly by reversing
these procedures.
O-ring
(Cat. No. 9-7743)
9. Turn ON the air supply and check for leaks before
reinstalling the cover.
Cover
Assembled Filter
Barbed
Fitting
Art # A-02476
Optional Single-Stage Filter Element Replacement
5. Remove the Filter Element from the Housing and
set Element aside to dry.
6. Wipe inside of housing clean, then insert the
replacement Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply.
NOTE
If unit leaks between housing and cover, inspect
the O-Ring for cuts or other damage.
Manual 0-4989
5-7
SERVICE
CUTMASTER A120
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 replacement
filter element catalog number.
1. Shut OFF primary input power.
2. Shut OFF air supply and bleed down system.
WARNING
Always turn OFF the air supply and bleed the system
before disassembling the Filter Assembly as injury
could result.
3. Loosen the two bolts on the top 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 two bolts evenly, then torque
each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper
torque may damage the gasket.
8. Slowly apply air pressure to the assembly, checking for leaks.
NOTE
A small amount of air leakage from the bottom
fitting is normal.
This completes the parts replacement procedures.
SERVICE
5-8
Manual 0-4989
CUTMASTER A120
SECTION 5 TORCH:
SERVICE
Upper Groove
with Vent Holes
Must Remain Open
5T.01General Maintenance
NOTE
Upper O-Ring
in Correct Groove
Refer to Previous "Section 5 System" for common and fault indicator descriptions.
Threads
Lower O-Ring
Cleaning Torch
Art # A-03725
Torch Head O-Ring
Even if precautions are taken to use only clean air
with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect
the pilot arc initiation and the overall cut quality of
the torch.
ATC Male Connector
WARNING
Disconnect primary power to the system before disassembling the torch or torch leads.
DO NOT touch any internal torch parts while
the AC indicator light of the Power Supply is
ON.
Gas Fitting
The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet
rag. In severe cases, the torch can be removed from
the leads and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and blowing
it through with compressed air.
O-Ring
Art #A-03791
CAUTION
ATC O-Ring
Dry the torch thoroughly before reinstalling.
NOTE
O-Ring Lubrication
DO NOT use other lubricants or grease, they
may not be designed to operate within high
temperatures or may contain “unknown elements” that may react with the atmosphere.
This reaction can leave contaminants inside
the torch. Either of these conditions can lead
to inconsistent performance or poor parts life.
An o-ring on the Torch Head and ATC Male Connector 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 potential performance
problems.
It is recommended to apply a very light film of oring lubricant (Catalog # 8-4025) to the o-rings on a
weekly basis.
Manual 0-4989
5T-1
SERVICE
CUTMASTER A120
5T.02Inspection and Replacement
of Consumable Torch Parts
4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean
or replace the tip if necessary.
Worn Tip
Good Tip
WARNING
Disconnect primary power to the system before disassembling the torch or torch leads.
DO NOT touch any internal torch parts while
the AC indicator light of the Power Supply is
ON.
A-03406
Example of Tip Wear
5. Remove the starter cartridge. Check for excessive
wear, plugged gas holes, or discoloration. Check
the lower end fitting for free motion. Replace if
necessary.
Remove the consumable torch parts as follows:
Spring-Loaded
Lower End Fitting
Full Compression
NOTE
The shield cup holds the tip and starter cartridge in place. Position the torch with the
shield cup facing upward to prevent these
parts from falling out when the cup is removed.
Spring-Loaded
Lower End Fitting at Reset /
Full Extension
1. Unscrew and remove the shield cup from the
torch.
Art # A-08064_AC
NOTE
6. Pull the Electrode straight out of the Torch Head.
Check the face of the electrode for excessive wear.
Refer to the following figure.
Slag built up on the shield cup that cannot be
removed may effect the performance of the
system.
2. Inspect the cup for damage. Wipe it clean or
replace if damaged.
New Electrode
Art # A-03284
Art # A-08067
Electrode Wear
Shield Cups
7. Reinstall the Electrode by pushing it straight into
the torch head until it clicks.
3. On torches with a shield cup body and a shield
cap or deflector, ensure that the cap or deflector is
threaded snugly against the shield cup body. In
shielded drag cutting operations (only), there may
be an O-ring between the shield cup body and
drag shield cap. Do not lubricate the O-ring.
8. Reinstall the desired starter cartridge and tip into
the torch head.
9. Hand tighten the shield cup until it is seated on
the torch head. If resistance is felt when installing
the cup, check the threads before proceeding.
Drag Shield Cap
Shield
Cup Body
Worn Electrode
This completes the parts replacement procedures.
O-Ring No. 8-3488
Art # A-03878
SERVICE
5T-2
Manual 0-4989
CUTMASTER A120
SECTION 6:
PARTS LISTS
6.01Introduction
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 Replacement Power Supply Parts"
Section "6.05 Options and Accessories"
Section "6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)"
Section "6.07 Torch Consumable Parts (SL100)"
Section "6.08 Replacement Parts for Hand Torch"
NOTE
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.
B.Returns
If a product 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 distributor.
6.03 Power Supply Replacement
The following items are included with the replacement power supply: work cable & clamp, input power cable, gas
pressure regulator / filter, and operating manual.
Qty Description
Catalog #
1 CutMaster A120 Power Supply 208/230 - 460VAC, Single or 3 Phase, 60Hz,
with 208/230 single phase input power cable and plug
3-1734-1
With 460 single phase input power cable
3-1734-2
1
400VAC, Non CE Power Supply
With 400V, 3 Phase input power cable
3-1734-3
1
400VAC, CE Power Supply
With 400V, 3 Phase input power cable
3-1734-4
1
600VAC, Power Supply
With 600V, 3 Phase input power cable
3-1734-5
Manual 0-4989
6-1
PARTS LIST
CUTMASTER A120
6.04 Replacement Power Supply Parts
Qty Description
1 Regulator 1
Filter Assembly Replacement Element
1
Input Power Cord for 208 / 230 V Power Supply
1
Input Power Cord for 400 V Power Supply
Catalog #
9-0115
9-0116
9-0191
9-0216
6.05 Options and Accessories
Qty Description
1
Single - Stage Filter Kit (includes Filter & Hose) 1
Replacement Filter Body 1
Replacement Filter Hose (not shown)
2
Replacement Filter Element 1
Two - Stage Filter Kit (includes Hose & Mounting Screws)
1
Two - Stage Air Filter Assembly
1
First Stage Cartridge
1
Second Stage Cartridge
1
Extended Work Cable (50 ft / 15.2 m) with Clamp
1
Multi - Purpose Cart
1
Automation Interface Kit
for Start/Stop, OK to move and Divided Arc Voltage)
1
Automation Harness for Start/Stop and OK to move
1
25' / 7.6 m CNC Cable for Automation Interface Kit
1
35' / 10.7 m CNC Cable for Automation Interface Kit
1
50' /15.2 m CNC Cable for Automation Interface Kit
1
Nylon Dust Cover
Catalog #
7-7507
9-7740
9-7742
9-7741
9-9387
9-7527
9-1021
9-1022
9-8529
7-8888
9-8311
9-9385
9-1008
9-1010
9-1011
9-7071
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Assembled Filter
Cover
Barbed
Fitting
Art # A-02476
Art # A-02942
Optional Single - Stage Filter Kit
PARTS LIST
First & Second
Stage
Cartridges
(as marked)
Optional Two - Stage Filter Kit
6-2
Manual 0-4989
CUTMASTER A120
This Page Intentionally Blank
Manual 0-4989
6-3
PARTS LIST
CUTMASTER A120
6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting
Tube)
Item No. Qty
Description
Catalog No.
1
1
Torch Head Assembly without leads (includes items 2, 3, and 14)
9-8220
21Large O-Ring 8-3487
31Small O-Ring 8-3486
4
1
PIP Switch Kit
9-7036
5
1
PIP Plunger and Return Spring Kit
9-7045
6
Automated Leads Assemblies with ATC connectors
1
25 - foot / 7.6m Leads Assembly with ATC connector
4-3058
1
35 - foot / 10.6m Leads Assembly with ATC connector
4-3059
1
50 - foot / 15.2m Leads Assembly with ATC connector
4-3060
71Rack 9-9448
81Mounting Tube 9-9445
91End Cap Assembly 9-7044
10
2
Body, Mounting, Pinch Block 9-4513
11
1
Pin, Mounting, Pinch Block
9-4521
12
1
Torch Holder Sleeve
7-2896
13
1
Pinion Assembly (does not include positioning tube)
7-2827
14
1
Torch Holder Sleeve
7-2896
15
1
Pinion Gear-Short
8-6074
16
1
Handwheel (Torch Holder)
9-4514
17
1
Low Profile Torch Holder (1 3/8 Dia) w/o Hardware
9-4515
18
1
Calibrated Torch Holder Bushing
9-4366
19
1
5/32 Dia x 5/8 Lg Slotted Spring Pin
See Note 1
20
1
3/8-24 x 3/8 Soc Hd Set Screw, Cup Point
See Note 1
21
2
1/4-20 x 5/8 Hex Socket Head Screw
See Note 1
22
1
#10-24 x 3/8 Hex Socket Set Screw, Cup Point
See Note 1
23
1
Solenoid Assembly
9-9447
24
1
Solenoid Cover
9-9446
NOTE
Purchase these parts locally.
PARTS LIST
6-4
Manual 0-4989
CUTMASTER A120
23
24
9
10
7
8
13
19
21
16
10
1
21
20
11
2
3
4
12
17
5
15
22
18
14
6
Art # A-07113
Manual 0-4989
6-5
PARTS LIST
CUTMASTER A120
6.07 Torch Consumable Parts (SL100)
Ohmic Clip
Automation Torch
9-8224
Ohmic Clip
Manual Torch
9-8259
20-40A
Tip:
STANDOFF
CUTTING
20A
30A
40A
9-8205
9-8206
9-8208
Shield
Cup Body,
9-8237
Shield Cap, Machine
40A 9-8245
Shield Cup
9-8218
Shield Cap, Deflector
9-8243
Drag Shield Cup
9-8235
50-60A
Tips:
STANDOFF
CUTTING
50-55A
60A
Electrode
Auto 9-8232
Manual 9-8215
Starter
Heavy Duty
Cartridge
Starter Cartridge
9-8213 Non HF Only 9-8277
70-120A
STANDOFF
CUTTING
9-8209
9-8210
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Shield Cap, Machine
50-60A 9-8238
Shield Cap, Deflector
9-8243
Drag Shield Cup
70-100A 9-8236
Tips:
70A 9-8231
80A 9-8211
90/100A 9-8212
120A Auto 9-8233
120A Manual 9-8253
Shield
Cup Body,
9-8237
Drag Shield Cup
120A 9-8258
Shield Cap, Machine
70-100A 9-8239
Shield Cup
9-8218
Shield Cap, Machine
120A 9-8256
Shield Cap, Deflector
9-8243
40-120A
GOUGING
Shield
Cup Body,
9-8237
Tips:
Tip A 9-8225 (40 Amps Max.)
Tip B 9-8226 (50 - 120 Amps)
Shield Cup, Gouging
9-8241
Tip C 9-8227 (60 - 120 Amps)
Tip D 9-8228 (60 - 120 Amps)
Art # A-08066_AG
PARTS LIST
Tip E 9-8254 (60 - 120 Amps)
6-6
Manual 0-4989
CUTMASTER A120
6.08 Replacement Parts for Hand Torch
Item #
Qty
Description
Catalog #
1
1
Torch Handle Replacement Kit (includes items No. 2 & 3)
2
1
Trigger Assembly Replacement Kit 3
1
Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench)
4
1
Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 51Large O-Ring
61Small O-Ring
7
Leads Assemblies with ATC connectors (includes switch assemblies)
1
SL100, 20 - foot Leads Assembly with ATC connector
1
SL100, 50 - foot Leads Assembly with ATC connector
81Switch Kit
10
1
Torch Control Cable Adapter (includes item # 11)
11
1
Through - Hole Protector
9-7030
9-7034
9-8062
9-8219
8-3487
8-3486
4-7836
4-7837
9-7031
7-3447
9-8103
1
8
2
4
5
6
3
7
Art # A-07993_AB
Manual 0-4989
6-7
PARTS LIST
CUTMASTER A120
This Page Intentionally Blank
PARTS LIST
6-8
Manual 0-4989
CUTMASTER A120
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION:
ACTION:
Close external
disconnect switch.
RESULT:
Power to system.
ACTION:
ON / OFF switch to ON
RESULT:
AC indicator
ON.
GAS indicator
ON
when input
pressure is adequate
for power supply operation.
Power circuit ready.
RUN /
Rapid Auto Restart /
SET / LATCH switch
to SET
RESULT:
Gas flows to set
pressure.
ACTION:
RUN / Rapid Auto Restart /
SET / LATCH
switch to RUN
(for most applications)
or to
Rapid Auto Restart
(for gouging, trimming,
or expanded metal
applications)
or to
LATCH
is used for specific applications
(torch switch can be released
after main arc transfer).
RESULT:
ACTION:
Connect work cable to workpiece.
Set output amperage.
ACTION:
RESULT:
Torch moved away from work (while
still activated).
System is ready
for operation.
RESULT:
Main arc stops.
Pilot arc automatically
restarts.
ACTION:
Protect eyes and activate
Torch switch (START)
Gas flow stops.
PILOT ARC
RESULT:
Fans turn on. Gas flows briefly,
then stops.Gas restarts.
ACTION:
Torch moved within
transfer distance of workpiece.
DC indicator
ON
Pilot arc established.
RESULT:
Main arc transfers.
Pilot arc off.
ACTION:
Release Torch switch.
RESULT:
Main arc stops.
Gas flow stops after post - flow.
ACTION:
ON / OFF switch
to OFF
(Fans will continue to run for
10 minutes after the Torch switch
[START] is removed)
RESULT:
All indicators off.
Power supply fans shut off.
ACTION:
Unplug input
power cord or
open external
disconnect.
RESULT:
No power to system.
Art #A-07979_AB
Manual 0-4989
A-1
APPENDIX
CUTMASTER A120
APPENDIX 2: DATA TAG INFORMATION
West Lebanon, NH USA 03784
Model :
Dat e of Mf r :
Type of Power
Supply (Note 1)
1/ 3
f1
S/N
Made in USA
Regulatory Standard Covering
This Type of Power Supply
f2
Output Current Type
Duty Cycle Factor
Output Range (Amperage/
Voltage)
Plasma Cutting
Symbol
X
U0 =
Rated NoLoad Voltage
Duty Cycle Data (Note 3)
I
U2
Conventional
Load Voltage
Rated Maximum
Supply Current
Input Power
Symbol
U1
I 1max 3Ø
1
1Ø
1
1Ø
I 1eff
3Ø
Input Power
Specifications
(Phase, AC or DC
Hertz Rating)
Degree of Protection
Maximum Effective
Supply Current
Manufacturer's Electrical
Schematic File Number
and Revision Level
Rated Supply
Voltage (Note 2)
NOTES:
1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission.
TDC duty cycle value is determined under the power supply
manufacturer's test procedures.
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.
APPENDIX
Manufacturer's Name and/or
Logo, Location, Model and
Revision Level, Serial Number
and Production Code
A-2
Standard Symbols
AC
DC
Ø
Phase
Art # A-03288
Manual 0-4989
CUTMASTER A120
APPENDIX 3: TORCH PIN - OUT DIAGRAMS
A. Hand Torch Pin - Out Diagram
8 - Open
4 - Green /
Switch
3 - White /
Switch
Negative /
Plasma
8 - Ground
4 - Switch
4
3
2- Orange /
PIP
1 - Black /
PIP
ATC Female Receptacle
Front View
ATC Male Connector
Front View
Negative /
Plasma
6
5
2
1
8
7
7 - Open
7 - Open
6 - Open
6 - Open
5 - Open
8
7
6
5
2
1
3 - Switch
4
3
2 - PIP
5 - Open
1 - PIP
Pilot
Pilot
A-03701
B. Mechanized (Machine) Torch Pin - Out Diagram
Negative / Plasma
8 - Green Pendant
Connector
Ground
4- Black Pendant
Connector
3 - White Pendant
Connector
2 - Orange /
PIP
4
3
2
1
ATC Female Receptacle
Front View
UNSHIELDED MACHINE TORCH
ATC Male Connector
Front View
6
5
8
7
7 - Green /
Not Used
Negative / Plasma
7 - Open
6 - Open
6 - Open
5 - White /
Not Used
1 - Black /
PIP
4 - Switch
8 - Ground
8
7
6
5
2
1
3 - Switch
2 - PIP
1 - PIP
5 - Open
Pilot
4
3
Pilot
Art # A-03799
Manual 0-4989
A-3
APPENDIX
CUTMASTER A120
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
Torch
Head
Male
ATC Leads
Connector
ATC Female
Receptacle
Power
Supply
Torch
Leads
Black
PIP
Switch
Orange
Green
Torch
Switch
White
1
1
2
2
5
5
6
6
4
4
3
3
8
8
7
7
Negative / Plasma
To Power Supply
Circuitry
To Power Supply
Circuitry
Negative / Plasma
Pilot
Pilot
Art # A-03797
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
Male
ATC Leads
Connector
Torch
Head
To Remote Control
Remote
Pendant
Connector
ATC Female
Receptacle
Power
Supply
Torch
Leads
PIP
Switch
Black
1
1
Orange
2
2
White
5
5
6
6
Black 4
White 3
Green 8
4
7
7
Not
Used
Green
Negative / Plasma Lead
Pilot Lead
3
To Power Supply
Circuitry
To Power Supply
Circuitry
8
Negative / Plasma
Pilot
Art # A-03798
APPENDIX
A-4
Manual 0-4989
CUTMASTER A120
This Page Intentionally Blank
Manual 0-4989
A-5
APPENDIX
CUTMASTER A120
APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS
T1
3
C
1
2
3
4
5
4
2
PRI 4
PRI 3
J1
SW1
1
BIAS
SUPPLY
PRI 2
INRUSH
RESISTORS
+12VDC
PRI 1
+
TP2
MTH1
B
A
D
PRI 2
PRI 1
+
MTH2 TP1
K1
Q1
/INRUSH
+12VDC
BIAS
SUPPLY
D1
+
TP8
PRIMARY
AC INPUT
_
W1
L1
L2
L3
GND
L1
T1
L2
T2
L3
T3
L4
T4
AC1
80A_AC1
AC2
80A_AC2
AC3
80A_AC3
MTH4 TP5
7
8
9
K1
K2
K3
K4
K5
K6
7A
SW2
J3
*
460_IN
1
2
BUSS BARS/JUMPERS
*PRIMARY POWER
C3,C4,C7,C8*
* CM102 & A80
C7 & C10 not installed
MTH7
MTH8 TP4
INPUT VOLTAGE SELECTOR
(Closed for 230VAC input)
CONNECTIONS:
FOR 3 PH:
REMOVE BUSS BARS/JUMPERS
BETWEEN L1 TO L4 & L2 TO L3
CONNECT PRIMARY INPUT CABLE
TO L1,L2,L3 & GND
FOR 1PH:
INSTALL BUSS BARS/JUMPERS
BETWEEN L1 TO L4 & L2 TO L3
CONNECT PRIMARY INPUT CABLE
TO BUSS BARS (L1/L4) & (L2/L3)
MOT1
+
+12VDC
J7
FAN
-
MTH6
1
2
Q2
+
J5
SOL 1
1
2
3
5
C5,C6,C9,C10*
/SOLENOID
24VAC
J6
1
2
W1
TP3
/FAN
24VAC RET
_
6
J14
J4
SYNC
J13
/OVERTEMP
/FAN_ON
/CSR
CUR_SET
MAIN_PCB_ID
COMMON
+12VDC
/230
/460
1
2
3
4
5
6
D
J12
PCB1
K1,K2
MAIN PCB ASSY
K5,K6
3
2
1
3.3VDC
TXD
RXD
1
2
3
4
5
6
SERIAL PORT
1
2
3
4
5
T2
K3,K4
J1
1
2
3
FERRITE
FILTER
J2
+12VDC
J1
FAN
1
2
+12VDC
J2
FAN
1
2
PRI 3
PRI 2
A
B
J9
/FAN
C
PRI 4
D
+
SYNC
-
+
MOT3
PRI 1
+12VDC
-
+
MOT2
J3
1
2
3
4
5
6
7
8
9
10
J4
1
2
1
2
AC1
40A_AC1
AC2
40A_AC2
AC3
40A_AC3
Q1
PMTH1 PMTH1
+
C16-17
+
D1
PCB2
PMTH2
PMTH2
PMTH3
PMTH3
INPUT CAPACITOR PCB
Q2
C12-13
PMTH4
+
PMTH4
_
PCB5
40/50 AMP PCB
_
A-09132_AB
APPENDIX
A-6
Manual 0-4989
CUTMASTER A120
A120 ONLY
1TORCH
TS1
PIP SWITCH
L1
TORCH SWITCH
1
2
J11
SEC1
SEC2
+12VDC
CHOKE1
ATC CONNECTOR
J1
TEMP
CIRCUIT
1
2
3
4
5
6
7
8
/OVERTEMP
NTC
-V OUT 1
1
2
3
4
5
6
7
8
E64
-
E35
+
AUTOMATION
TORCH SOLENOID
ELECTRODE1
D3
TIP1
Q5
PILOT IGBT
WORK1
WORK
J9
/PIP
1
2
3
4
5
6
7
/START
24VAC RETURN
24VAC SUPPLY
78
79
80
81
82
CNC INTERFACE STANDARD ON A80 & A120 UNITS
CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS
83
J2
J10
1
2
3
4
5
6
7
8
OK-TO-MOVE
(5A @ 250VAC / 30VDC)
+12VDC
P10
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
} OK TO MOVE
CNC PINOUT
1
3
7
4
11
14
8
12
} /START / STOP
J2
40 PIN RIBBON CABLE SIGNALS
D78 CSR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
29
34
35
36
37
38
39
TEST POINTS
GND1
GND2
+12V1
48V1
I_DMD_1
TIP_SEN
COMMON
COMMON
+12 VDC SUPPLY
+48 VDC SUPPLY
CURRENT DEMAND
TIP DRAG SENSE
FERRITE
FILTER
-V_OUT_SIGNAL
/TIP_VOLTS
/TIP_SENSE
/460V_IN
/230V_IN
CUR_SET
/RAR (RAPID AUTO RESTART)
/INRUSH
/W1_ON
SHDN
/TORCH_SOLENOID
/SOLENOID_ON
/OK_TO_MOVE
/FAN_ON
/LATCH_ACTIVE
/TORCH_SWITCH
/PIP
AC_ON
CSR
/TORCH_SOLENOID_DETECT
/OVERTEMP
V_IN
+12VDC
+12VDC
COMMON
COMMON
MAIN_PCB_ID
460_IN
+3.3VDC
TXD
RXD
COMMON
D
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
M-L
M-L
M-L
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
L-M
M-L
M-L
L-M
M-L
*
To -V OUT 1
on PCB1
P1
*
1
2
3
D59 PCR
To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS / 16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
J1
E1
P2
P10
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
+12VDC
K1
PCB4
AUTOMATION
INTERFACE PCB
K1
} /START / STOP
} (+) *DIVIDED
(-)
(-)
} (+)
ARC VOLTS
ARC VOLTS
(W/ 100K IN SERIES (2))
} OK-TO-MOVE
L2
J1
SEC1
SEC2
CHOKE1
AC
OVERTEMP
GAS
DC
ERROR
D2
NTC
TEMP
CIRCUIT
Current Control
/OVERTEMP
LATCH
ERROR IND
FAULT
MAX
90
85
80
75
70
65
MIN
OVER PRESSURE
INTERNAL ERROR
SHORTED TORCH
CONSUMABLES MISSING
START ERROR
PARTS IN PLACE
INPUT POWER
UNDER PRESSURE
MAX
90
85
TEST POINTS
TP1
TP2
TP3
TP4
TP5
TP6
TP7
80
GND
+12 VDC
+5 VDC
3.3 VDC
0.v - 5.0 VDC / 0-100PSI
1.8 VDC
CURRENT DEMAND
GAS CONTROL
75
REGULATOR
70
D1
SOLENOID
VALVE
FILTER
65
+12VDC
MIN
PRESSURE
TRANSDUCER
SET
+OUT_1
+5VDC
RAR
0-100PSI / 0-4.5VDC
PCB3
LOGIC PCB
J3
1
2
3
RUN
ATC
AIR
INLET
3
2
1
A-09132_AB
Rev
Revisions
AA
AB
AC
AD
AD
INTRO ECO-B935
ECO B1116
ECO B1192
By
Date
MNC
05/21/08
MNC
09/11/08
MNC
11/01/08
ECO B1357
RWH 03/31/09
ECO B1611
RWH
12/11/09
THERMADYNE
16052 Swingley Ridge Road
Suite 300
St Louis, MO 63017 USA
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE:
TITLE:
Last Modified: Friday, December 11, 2009
Manual 0-4989
A-7
09:02:19
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)
SCHEMATIC,
PCB No:
Assy No:
Scale
Supersedes
Date:
JANUARY 31, 2008
Drawn:
MNC
References
Chk:
App:
Size
DWG No:
CUTMASTER 102/152/A80/A120 230/460V D
1
Sheet
of 1
42X1315
APPENDIX
CUTMASTER A120
APPENDIX 6: SYSTEM SCHEMATIC, 400/600V UNITS
5
4
T1
3
2
C
1
2
3
4
5
4
PRI 4
PRI 3
J1
SW1
1
BIAS
SUPPLY
PRI 2
D
INRUSH
RESISTORS
+12VDC
PRI 1
+
TP2
MTH1
B
A
D
PRI 2
PRI 1
+
MTH2 TP1
K1
Q1
EMI
*CHOKE
/INRUSH
+12VDC
BIAS
SUPPLY
D1
+ C3,C4,C7,C8*
UNITS
* CEONLY
TP8
EMI
*FILTER
L1
1
1
L2
2
2
L3
3
3
GND
4
4
_
W1
MTH7
AC1
80A_AC1
AC2
80A_AC2
AC3
80A_AC3
MTH4 TP5
7
L1
T1
L2
T2
8
9
L3
T3
L4
T4
7A
380/400/415V
OR 600V
3 PH AC INPUT
PRIMARY POWER CONNECTIONS:
USE L1, L2, L3 & GND
MTH8 TP4
MOT1
C
+
+12VDC
J7
FAN
MTH6
1
2
-
Q2
+
J5
SOL 1
1
2
3
5
C5,C6,C9,C10*
/SOLENOID
24VAC
J6
1
2
W1
TP3
/FAN
24VAC RET
_
6
J14
J4
SERIAL PORT
SYNC
3.3VDC
TXD
RXD
1
2
3
4
5
6
D
J13
/OVERTEMP
/FAN_ON
/CSR
CUR_SET
MAIN_PCB_ID
COMMON
PCB1
MAIN PCB ASSY
1
2
3
4
5
6
1
2
3
4
5
T2
FERRITE
FILTER
J2
B
+12VDC
J1
FAN
1
2
+12VDC
J2
FAN
1
2
PRI 3
PRI 2
A
B
J9
/FAN
C
PRI 4
D
+
SYNC
-
+
MOT3
PRI 1
+12VDC
-
+
MOT2
J3
1
2
3
4
5
6
7
8
9
10
J4
1
2
1
2
AC1
40A_AC1
AC2
40A_AC2
AC3
40A_AC3
PMTH1
+
Q1
PMTH1
C16-17
+
D1
PCB2
PMTH2
PMTH2
PMTH3
PMTH3
INPUT CAPACITOR PCB
Q2
*CM102/35mm/A80
C7 & C10 may not be installed
C12-13
+
A
PMTH4
PMTH4
_
PCB5
40/50 AMP PCB
_
A-09130_AC
5
APPENDIX
4
A-8
Manual 0-4989
CUTMASTER A120
3
2
1
1TORCH
TS1
PIP SWITCH
L1
TORCH SWITCH
1
2
J11
SEC1
SEC2
+12VDC
CHOKE1
ATC CONNECTOR
J1
TEMP
CIRCUIT
1
2
3
4
5
6
7
8
/OVERTEMP
NTC
-V OUT 1
1
2
3
4
5
6
7
8
E64
-
E35
+
AUTOMATION
TORCH SOLENOID
D
ELECTRODE1
D3
TIP1
Q5
PILOT IGBT
WORK1
WORK
J9
/PIP
1
2
3
4
5
6
7
/START
24VAC RETURN
24VAC SUPPLY
78
79
80
81
82
CNC INTERFACE STANDARD ON A80 & A120 UNITS
CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS
83
J2
J10
1
2
3
4
5
6
7
8
OK-TO-MOVE
(5A @ 250VAC / 30VDC)
+12VDC
P10
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
} OK TO MOVE
CNC PINOUT
3
1
7
4
11
14
8
12
} /START / STOP
J2
C
40 PIN RIBBON CABLE SIGNALS
D78 CSR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
29
34
35
36
37
38
39
TEST POINTS
GND1
GND2
+12V1
48V1
I_DMD_1
TIP_SEN
COMMON
COMMON
+12 VDC SUPPLY
+48 VDC SUPPLY
CURRENT DEMAND
TIP DRAG SENSE
FERRITE
FILTER
-V_OUT_SIGNAL
/TIP_VOLTS
/TIP_SENSE
/460V_IN
/230V_IN
CUR_SET
/RAR (RAPID AUTO RESTART)
/INRUSH
/W1_ON
SHDN
/TORCH_SOLENOID
/SOLENOID_ON
/OK_TO_MOVE
/FAN_ON
/LATCH_ACTIVE
/TORCH_SWITCH
/PIP
AC_ON
CSR
/TORCH_SOLENOID_DETECT
/OVERTEMP
V_IN
+12VDC
+12VDC
COMMON
COMMON
MAIN_PCB_ID
460_IN
+3.3VDC
TXD
RXD
COMMON
D
M-L
M-L
M-L
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
L-M
M-L
M-L
L-M
M-L
*
To -V OUT 1
on PCB1
P1
*
1
2
3
D59 PCR
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
J1
E1
P10
P2
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS / 16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
1
2
3
4
5
6
7
8
9
10
11
12
13
14
+12VDC
K1
PCB4
AUTOMATION
INTERFACE PCB
K1
} /START / STOP
} (+) *DIVIDED
(-)
(-)
} (+)
ARC VOLTS
ARC VOLTS
(W/ 100K IN SERIES (2))
} OK-TO-MOVE
L2
B
J1
SEC1
SEC2
CHOKE1
AC
OVERTEMP
GAS
DC
ERROR
D2
NTC
TEMP
CIRCUIT
Current Control
/OVERTEMP
LATCH
ERROR IND
FAULT
MAX
90
85
80
75
70
65
MIN
OVER PRESSURE
INTERNAL ERROR
SHORTED TORCH
CONSUMABLES MISSING
START ERROR
PARTS IN PLACE
INPUT POWER
UNDER PRESSURE
MAX
90
85
TEST POINTS
TP1
TP2
TP3
TP4
TP5
TP6
TP7
80
GND
+12 VDC
+5 VDC
3.3 VDC
0.v - 5.0 VDC / 0-100PSI
1.8 VDC
CURRENT DEMAND
GAS CONTROL
75
REGULATOR
70
+12VDC
D1
SOLENOID
VALVE
FILTER
65
MIN
PRESSURE
TRANSDUCER
SET
+OUT_1
+5VDC
RAR
3
2
1
0-100PSI / 0-4.5VDC
PCB3
J3
1
2
3
RUN
ATC
AIR
INLET
LOGIC PCB
A
A-09130_AC
Rev
AA
AB
AB
By
Date
INTRO ECO B1357
RWH
03/31/09
ECO B1399
RWH
05/05/09
ECO B1611
Revisions
RWH
05/05/09
THERMADYNE
16052 Swingley Ridge Road
Suite 300
St Louis MO 63017 USA
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE:
TITLE:
Last Modified: Friday, December 11, 2009
3
2
Manual 0-4989
09:02:19
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)
SCHEMATIC,
PCB No:
Assy No:
Scale
Supersedes
Date:
MARCH 30, 2009
Drawn:
RWH
References
Chk:
App:
Size
DWG No:
CM102/152/35mm/40mm/A80/A120 380/400/415/600V
D
1
Sheet
of 1
42X1330
1
A-9
APPENDIX
CUTMASTER A120
APPENDIX 7: RAW ARC VOLTAGE
If raw arc voltage is necessary for the torch height control, the customer must supply an 18 AWG (1.0 mm2), single
pair, unshielded cable rated for 300V or greater. All work must be performed following applicable local and national
codes.
1. Disconnect the power from the power supply.
2. Remove the screws that attach the power supply cover to the chassis. Remove the cover.
3. Route the cable through the customer supplied strain relief at the rear of the power supply.
Cut out for cable
Art # A-10286
4. On the main board use insulated type 1/4-inch ring lug terminal ends to connect to –Vout1 (- polarity) and
WORK 1 (+ polarity).
!
WARNING
The raw arc voltage can exceed 350VDC !!!!
-V OUT 1
WORK 1
WORK 1
-V OUT 1
J10
Art # A-10287
APPENDIX
A-10
Manual 0-4989
CUTMASTER A120
Art # A-10288
Work1 (+) Polarity
-V out (-) Polarity
5. Tighten the strain relief.
6. Replace the cover.
7. Connect the cable to negative and positive of Torch Height Control .
Manual 0-4989
A-11
APPENDIX
CUTMASTER A120
This Page Intentionally Blank
APPENDIX
A-12
Manual 0-4989
CUTMASTER A120
This Page Intentionally Blank
Manual 0-4989
A-13
APPENDIX
CutMaster A120
APPENDIX 8: PUBLICATION HISTORY
Cover Date Rev. Change(s)
June 30, 2008
AA Manual released.
Sept. 19, 2008
AB
Added CE information Per ECOB.
Jan. 27, 2009
AC
Updated art in section 3 to show all the information for the two stage filter per ECOB1248. Updated power supply and input wiring specs per ECOB1197
Apr. 1, 2009
AD
Updated Cover, system specs and input wiring specs in section 2, system catalog number in section 6 and Appendix with 600V schematic info per ECOB1346.
May 29, 2009
AE
Updated 400V/600V schematic in appendix per ECOB1399 and updated 230/460V schematic per ECOB1357. Corrected part numbers in section 6 per ECOB1201.
Oct. 20, 2009
AF
Updated Electrode and Tip part numbers per ECOB1494 changing 9-8215 to 9-8232 and 9-8253 to 9-8233.
Jan. 7, 2010
AG
Updated "Power Supply Input Cable Wiring Requirements" with metric power cable sizes in Section 2. Updated torch consumables art section 4T and 6. Updated automation interface and harness descriptions and part numbers per ECOB1282.
Feb. 25, 2010
AH
Updated CNC cable part numbers in section 6 per ECOB1637.
Mar. 14, 2011
AI
Updated power cord part number in section 6 per ECOB1234.
June 22, 2011
AJ
Added Appendix 7: Raw Arc Voltage
Oct. 18, 2011
AK
Corrected CutMaster 230V power cord number in section 6 per ECOB2128.
Mar. 20, 2012
AL
Updated ART A-08066 and changed COO text, per ECOB2149.
June 11, 2012
AM
Corrected warranty chart in section 1 to show US and None US terms per ECOB2252
Aug. 20, 2012
AN
Added Opening the Contactor Cover text per ECOB2122. Inserted Victor Technologies branding text.
Dec. 7, 2012
Add Heavy Duty Start Cartridge 80×144(9-8277) to automated 1Torch per ECO-B2305.
APPENDIX
AO
A-14
Manual 0-4989
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