ESAB Cutmaster® 120

Plasma Cutting System

SL100 1TorchTM

Operating
Manual Art # A-12786

120 380/400V

Revision: AC Issue Date: July 6, 2015 Manual No.: 0-5405

esab.com.cn
 WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer
and will strive to provide you with the best service and reliability in the industry. This
product is backed by our extensive warranty and world-wide service network. To lo-
cate your nearest distributor or service agency, visit us on the web at www.esab.com.cn.

This Operating Manual has been designed to instruct you on the correct use and op-
eration of your ESAB product. Your satisfaction with this product and its safe opera-
tion 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.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.

We distinguish ourselves from our competition through market-leading, dependable

products that have stood the test of time. We pride ourselves on technical innovation,
competitive prices, 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 install-
ing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judge-
ment, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply

ESAB Cutmaster® 120 with SL100 1Torch™
Operating Manual Number 0-5405

Published by:
ESAB
2800 Airport Rd.
Denton, Texas 76207

www.esab.com.cn

Copyright © 2015 by
ESAB

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: January 15, 2015

Revision Date: July 6, 2015

Record the following information for Warranty purposes:

Where Purchased:__________________________________________

Purchase Date:_____________________________________________

Power Supply Serial #:______________________________________

Torch Serial #:______________________________________________

i
 Be sure this information reaches the operator.
You can get extra copies through your supplier.

CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully
familiar with the principles of operation and safe practices for arc welding
and cutting equipment, we urge you to read our booklet, “Precautions and
Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do
NOT permit untrained persons to install, operate, or maintain this equip-
ment. Do NOT attempt to install or operate this equipment until you have
read and fully understand these instructions. If you do not fully understand
these instructions, contact your supplier for further information. Be sure to
read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance
with the instructions provided. This equipment must be checked periodically. Malfunctioning or
poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted
or contaminated should be replaced immediately. Should such repair or replacement become
necessary, the manufacturer recommends that a telephone or written request for service advice
be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the
manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which
results from improper use, faulty maintenance, damage, improper repair or alteration by anyone
other than the manufacturer or a service facility designated by the manufacturer.

!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!
 TABLE OF CONTENTS

SECTION 1: SAFETY............................................................................................................................. 1-1

1.0 Safety Precautions........................................................................................... 1-1
SECTION 2 SYSTEM:
INTRODUCTION .......................................................................................................................... 2-1
2.01 How To Use This Manual................................................................................. 2-1
2.02 Equipment Identification.................................................................................. 2-1
2.03 Receipt Of Equipment...................................................................................... 2-1
2.04 Power Supply Specifications........................................................................... 2-2
2.05 Input Wiring Specifications.............................................................................. 2-3
2.06 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.03 Specifications ................................................................................................2T-1
2T.04 Options And Accessories................................................................................2T-2
2T.05 Introduction to Plasma...................................................................................2T-2
SECTION 3 SYSTEM:
INSTALLATION ........................................................................................................................... 3-1
3.01 Unpacking........................................................................................................ 3-1
3.02 Lifting Options................................................................................................. 3-1
3.03 Primary Input Power Connections................................................................... 3-1
3.04 Gas Connections.............................................................................................. 3-2
SECTION 3 TORCH:
INSTALLATION...........................................................................................................................3T-1
3T.01 Torch Connections..........................................................................................3T-1
3T.02 Setting Up Mechanical Torch..........................................................................3T-1
SECTION 4 SYSTEM:
OPERATION................................................................................................................................ 4-1
4.01 Front Panel Controls / Features........................................................................ 4-1
4.02 Preparations for Operation............................................................................... 4-2
SECTION 4 TORCH:
OPERATION................................................................................................................................4T-1
4T.01 Torch Parts Selection......................................................................................4T-1
4T.02 Cut Quality......................................................................................................4T-2
4T.03 General Cutting Information............................................................................4T-3
4T.04 Hand Torch Operation.....................................................................................4T-4
4T.05 Gouging..........................................................................................................4T-7
4T.06 Mechanized Torch Operation...........................................................................4T-8
4T.07 Parts Selection for SL100 Torch Cutting.........................................................4T-9
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip.....4T-10
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip.....4T-15
PATENT INFORMATION.....................................................................................................................4T-20
 TABLE OF CONTENTS

SECTION 5 SYSTEM:
SERVICE...................................................................................................................................... 5-1
5.01 General Maintenance....................................................................................... 5-1
5.02 Maintenance Schedule..................................................................................... 5-2
5.03 Common Faults................................................................................................ 5-2
5.04 Fault Indicator.................................................................................................. 5-3
5.05 Basic Troubleshooting Guide........................................................................... 5-4
5.06 Power Supply Basic Parts Replacement.......................................................... 5-6
SECTION 5 TORCH:
SERVICE.....................................................................................................................................5T-1
5T.01 General Maintenance......................................................................................5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts...............................5T-2
SECTION 6:
PARTS LISTS............................................................................................................................... 6-1
6.01 Introduction..................................................................................................... 6-1
6.02 Ordering Information....................................................................................... 6-1
6.03 Power Supply Replacement............................................................................. 6-1
6.04 Replacement Power Supply Parts.................................................................... 6-2
6.05 Options and Accessories................................................................................. 6-2
6.06 Replacement Parts for Hand Torch ................................................................. 6-3
6.07 Replacement Parts - for Machine Torches with Unshielded Leads................... 6-4
6.08 Replacement Shielded Machine Torch Leads Assemblies ............................... 6-6
6.09 Torch Consumable Parts (SL100).................................................................... 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, 380/400V UNITS........................................................................ A-6
APPENDIX 6: PUBLICATION HISTORY................................................................................................. A-8
 ESAB CUTMASTER 120

SECTION 1: SAFETY
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding or plasma cutting equipment. The following
recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or
plasma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which
can result in injury to the operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, flame proof
clothing, safety gloves.
- Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualified electrician.
- Appropriate fire extinguishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in
accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of
at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.
For further information contact the nearest ESAB dealer.

ESAB can provide you with all necessary cutting protection and accessories.

Manual 0-5405 SAFETY 1-1

ESAB CUTMASTER 120
Arc welding and cutting can be injurious to yourself and others.

WARNING Take precautions when welding and cutting. Ask for your employer's
safety practices which should be based on manufacturers' hazard
data.

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and filter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmuffs or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING Do not use the power source for thawing frozen pipes.

Class A equipment is not intended for use in residential

CAUTION locations where the electrical power is provided by the
public low-voltage supply system. There may be poten-
tial difficulties in ensuring electromagnetic compat-
ibility of class A equipment in those locations, due to
conducted as well as radiated disturbances.

CAUTION This product is solely intended for plasma cutting. Any other use may
result in personal injury and / or equipment damage.

CAUTION Read and understand the instruction manual before

installing or operating. !

1-2 SAFETY Manual 0-5405
 ESAB CUTMASTER 120
SECTION 2 SYSTEM: 2.03 Receipt Of Equipment
INTRODUCTION 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
2.01 How To Use This Manual there is any damage, notify the carrier immediately to
This Owner’s Manual applies to just specification or file a claim. Furnish complete information concerning
part numbers listed on page i. damage claims or shipping errors to the location in
your area listed in the inside back cover of this manual.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and Include all equipment identification numbers as
warnings. described above along with a full description of the
parts in error.
Throughout this manual, the words WARNING, CAU-
TION, and NOTE may appear. Pay particular attention Move the equipment to the installation site before
to the information provided under these headings. un-crating the unit. Use care to avoid damaging the
These special annotations are easily recognized as equipment when using bars, hammers, etc., to un-
follows: crate the unit.

NOTE!
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful 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 operat-
ing area.
WARNING
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 ESAB at the address and phone num-
ber in your area listed on back cover of this manual.
Include the Owner’s Manual number and equipment
identification numbers.
Electronic copies of this manual can also be down-
loaded at no charge in Acrobat PDF format by going
to the ESAB web site listed below
http://www.esab.com.cn

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 specifica-
tion or part number printed on loosely attached card
or the shipping container. Record these numbers on
the bottom of page i for future reference.

Manual 0-5405 INTRODUCTION 2-1

ESAB CUTMASTER 120
2.04 Power Supply Specifications
ESAB Cutmaster® 120 Power Supply Specifications
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power
400 VAC (360 - 440 VAC), Three Phase, 50 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 120 Amps, Continuously Adjustable
Power Supply Gas
Particulates to 5 Microns
Filtering Ability
ESAB Cutmaster® 120 Power Supply Duty Cycle *
Duty Cycle Ratings @ 40° C (104° F)
Ambient Temperature
Operating Range 0° - 50° C
Duty Cycle 80% 100%
Rating IEC IEC
All Units
Current 120A 110A
DC Voltage 128 124

* 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.

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

10.75"
273 mm

Art # A-08358_AB

Art # A-07925_AB
16.375"
416 mm

6"
150 mm

24"
610 mm
30.5"
63 lb / 28.6 kg 774.7 mm
6" 6"
150 mm 150 mm

2-2 INTRODUCTION Manual 0-5405
 ESAB CUTMASTER 120
2.05 Input Wiring Specifications

ESAB Cutmaster® 120 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Flexible Cord Flexible Cord

Volts Hz kVA I 1max I1eff Fuse (amps) (Min. AWG) (Min. mm2)
380 50 23 35 32 40 10# 6
3 phase
400 50 23.6 34 31 40 10# 6

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on US Electric Code and Canadian Electric Code

NOTE!
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
I1max is taken at rated minimum duty cycle.
I1eff is taken at 100% rated duty cycle.

Manual 0-5405 INTRODUCTION 2-3

ESAB CUTMASTER 120
2.06 Power Supply Features
Handle and Leads Wrap

Control Panel

Torch Leads Receptacle

Art # A-08359

Work Cable
and Clamp

Port for Optional Automation

Interface Cable

Filter Assembly

Gas Inlet Port

Art # A-08547
Input Power Cord

2-4 INTRODUCTION Manual 0-5405
 ESAB CUTMASTER 120
SECTION 2 TORCH: 2T.03 Specifications
INTRODUCTION A. Torch Configurations
1. Hand/Manual Torch, Models
2T.01 Scope of Manual The hand torch head is at 75° to the torch
This manual contains descriptions, operating instruc- handle. The hand torches include a torch
tions and maintenance procedures for the 1Torch handle and torch trigger assembly.
Models SL100/Manual and SL100/Mechanized 10.125" (257 mm)
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. 3.75"
Read this manual thoroughly. A complete under- (95 mm)
Art # A-03322_AB
standing of the characteristics and capabilities of this
1.17" (29 mm)
equipment will assure the dependable operation for
which it was designed. 2. Mechanized Torch, Model

2T.02 General Description The standard machine torch has a positioning

tube with rack & pinch block assembly.
Plasma torches are similar in design to the automotive 15.875" / 403 mm
spark plug. They consist of negative and positive sec- 9.285" / 236 mm
tions 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.
1.175" / 30 mm
Once the pilot arc has ionized the plasma gas, the 1.375" / 35 mm
superheated column of gas flows through the small 4.95" / 126 mm
1.75" / 0.625" /
orifice in the torch tip, which is focused on the metal 44.5 mm 16 mm Art # A-02998
to be cut.
B. Torch Leads Lengths
A single torch lead provides gas from a single source
to be used as both the plasma and secondary gas. Hand Torches are available as follows:
The air flow is divided inside the torch head. Single • 20 ft / 6.1 m, with ATC connectors
- gas operation provides a smaller sized torch and
inexpensive operation. • 50 ft / 15.2 m, with ATC connectors
Machine Torches are available as follows:
NOTE!
An operation,Refer to Section "2T.05 Introduction to • 5 foot / 1.5 m, with ATC connectors
Plasma", for a more detailed description of plasma • 10 foot / 3.05 m, with ATC connectors
torch operation. • 25 foot / 7.6 m, with ATC connectors
Refer to the Appendix Pages for additional specifi- • 50 foot / 15.2 m, with ATC connectors
cations as related to the Power Supply used.
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch Head has built - in switch
12 VDC circuit rating
E. Type Cooling
Combination of ambient air and gas stream
through torch.

Manual 0-5405 INTRODUCTION 2T-1

ESAB CUTMASTER 120
F. Torch Ratings
2T.05 Introduction to Plasma
Manual Torch Ratings
A. Plasma Gas Flow
Ambient 104° F
Temperature 40° C Plasma is a gas which has been heated to an
Duty Cycle 100% @ 100 Amps @ 400 scfh extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
Maximum Current 120 Amps
cutting and gouging processes use this plasma
Voltage (Vpeak) 500V to transfer an electrical arc to the workpiece. The
Arc Striking Voltage 7kV metal to be cut or removed is melted by the heat
of the arc and then blown away.
Mechanized Torch Ratings While the goal of plasma arc cutting is separation
Ambient 104° F of the material, plasma arc gouging is used to
Temperature 40° C remove metals to a controlled depth and width.
Duty Cycle 100% @ 100 Amps @ 400 scfh In a Plasma Cutting Torch a cool gas enters Zone
Maximum Current 120 Amps B, where a pilot arc between the electrode and
Voltage (Vpeak) 500V the torch tip heats and ionizes the gas. The main
cutting arc then transfers to the workpiece through
Arc Striking Voltage 7kV
the column of plasma gas in Zone C.

G. Gas Requirements
Manual and Mechanized Torch Gas Specifications
Gas (Plasma and Secondary) Compressed Air
Operating Pressure 60 - 95 psi
Refer to NOTE 4.1 - 6.5 bar _
Maximum Input Pressure 125 psi / 8.6 bar Power
300 - 500 scfh Supply A
Gas Flow (Cutting and Gouging)
142 - 235 lpm +

WARNING B
! This torch is not to be used with oxygen (O2).

NOTE! Workpiece
Operating pressure varies with torch model, oper- C A-00002
ating amperage, and torch leads length. Refer to
Typical Torch Head Detail
gas pressure settings charts for each model.
H. Direct Contact Hazard
By forcing the plasma gas and electric arc through
For standoff tip the recommended standoff is 3/16 a small orifice, the torch delivers a high concentra-
inches / 4.7 mm. tion of heat to a small area. The stiff, constricted
plasma arc is shown in Zone C. Direct current
2T.04 Options And Accessories (DC) straight polarity is used for plasma cutting,
as shown in the illustration.
For options and accessories, see Section 6.
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.

2T-2 INTRODUCTION Manual 0-5405
 ESAB CUTMASTER 120
B. Gas Distribution E. Parts - In - Place (PIP)
The single gas used is internally split into plasma The torch includes a 'Parts - In - Place' (PIP) cir-
and secondary gases. cuit. When the shield cup is properly installed, it
closes a switch. The torch will not operate if this
The plasma gas flows into the torch through switch is open.
the negative lead, through the starter cartridge,
around the electrode, and out through the tip Torch Trigger
Torch Switch
orifice. To Control
Cable Wiring
The secondary gas flows down around the outside
of the torch starter cartridge, and out between the PIP Switch Shield Cup
A-02997
tip and shield cup around the plasma arc.
Parts - In - Place Circuit Diagram for Hand Torch
C. Pilot Arc
Remote Pendant
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.
D. Main Cutting Arc To ATC PIP Switch Shield Cup

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 CNC Start
cable and to the torch through a pilot wire.

To ATC PIP Switch Shield Cup

Art # A-08168
Automation Torch

To ATC PIP Switch Shield Cup

Parts - In - Place Circuit Diagram for Machine Torch

Manual 0-5405 INTRODUCTION 2T-3

ESAB CUTMASTER 120

This Page Intentionally Blank

2T-4 INTRODUCTION Manual 0-5405
 ESAB CUTMASTER 120
SECTION 3 SYSTEM: 3.03 Primary Input Power Connections
INSTALLATION CAUTION
! Check your power source for correct voltage before
plugging in or connecting the unit. The primary
3.01 Unpacking
power source, fuse, and any extension cords used
1. Use the packing lists to identify and account must conform to local electrical code and the
for each item. recommended circuit protection and wiring require-
2. Inspect each item for possible shipping
ments as specified in Section 2..
damage. If damage is evident, contact your Connect three-phase input power cable as shown in
distributor and / or shipping company before the illustration below.
proceeding with the installation.
Input Power Cable Connections
3. Record Power Supply and Torch model and Three-Phase (3ø)
serial numbers, purchase date and vendor
name, in the information block at the front of
this manual. L1

3.02 Lifting Options L2

Art # A-08548
The Power Supply includes a handle for hand lifting L3
only. Be sure unit is lifted and transported safely and
L4
securely.
GND
WARNING
Do not touch live electrical parts. Three Phase Input Power Wiring
Disconnect input power cord before moving unit.
WARNING
WARNING Disconnect input power from the power supply and
! FALLING EQUIPMENT can cause serious personal
injury and can damage equipment.
input cable before attempting this procedure.
These instructions are for changing the input power
HANDLE is not for mechanical lifting.
and or cable on the 400 VAC Power Supply to Three
• Only persons of adequate physical strength - Phase input power.
should lift the unit.
1. Remove the Power Supply cover per instruc-
• Lift unit by the handles, using two hands. Do tions found in Section 5.
not use straps for lifting.
• Use optional cart or similar device of adequate 2. Disconnect the original input power cable
capacity to move unit. from the main input contactor and the chassis
ground connection.
• Place unit on a proper skid and secure in place
before transporting with a fork lift or other ve- 3. Loosen the through - hole protector on the
hicle. 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 specifica-
tions.

CAUTION
! The primary power source and power cable must
conform to local electrical code and the recom-
mended circuit protection and wiring requirements
(refer to table in Section 2).

Manual 0-5405 INSTALLATION 3-1

 ESAB CUTMASTER 120
6. Connect the wires as follows. Installing Optional Single - Stage Air Filter
• Wiring to L1, L2 and L3 input. See the previ- An optional filter kit is recommended for improved
ous illustration and power label. It does not filtering with compressed air, to keep moisture and
matter what order these wires are attached. debris out of the torch.
• Green / Yellow wire to Ground. 1. Attach the Single - Stage Filter Hose to the
Inlet Port.
7. With a little slack in the wires, tighten the
through - hole protector to secure the power 2. Attach the Filter Assembly to the filter hose.
cable.
3. Connect the air line to the Filter. The illustra-
8. Reinstall the Power Supply cover per instruc- tion shows typical fittings as an example.
tions found in Section 5.
NOTE!
9. Connect the opposite end of individual wires to For a secure seal, apply thread sealant to the fitting
a customer supplied plug or main disconnect. threads, according to manufacturer's instructions.
10. Connect the input power cable (or close the Do not use Teflon tape as a thread sealer, as small
main disconnect switch) to supply power. particles of the tape may break off and block the
small air passages in the torch.
3.04 Gas Connections
Connecting Gas Supply to Unit Regulator/Filter
Assembly
The connection is the same for compressed air or
high pressure cylinders. Refer to the following two
subsections if an optional air line filter is to be installed.
Inlet Port
1. Connect the air line to the inlet port. The il-
lustration shows typical fittings as an example.

NOTE!
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 Art # A-07944
particles of the tape may break off and block the
small air passages in the torch.
Regulator/Filter
Assembly Hose Clamp

Gas Supply 1/4 NPT to 1/4"

Hose (6mm) Fitting
Inlet Port
Optional Single - Stage Filter Installation

Hose Clamp
1/4 NPT or ISO-R
to 1/4” (6mm) Fitting
Gas Supply
Hose

Art # A-07943

Air Connection to Inlet Port

3-2 INSTALLATION Manual 0-5405
 ESAB CUTMASTER 120
Installing Optional Two - Stage Air Filter Kit
This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture
and contaminants to at least 5 microns.
Connect the air supply as follows:
1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the
filter assembly.

NOTE!
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
2-Stage Filter
Regulator Inlet Port (IN)
Input
Outlet Port
(OUT)

Two Stage
Filter
Hose Clamp Assembly
Gas Supply
Hose

1/4 NPT to 1/4”

(6mm) Fitting

Art # A-07945_AC

Optional Two - 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 pres-
sure 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 0-5405 INSTALLATION 3-3

ESAB CUTMASTER 120

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3-4 INSTALLATION Manual 0-5405
 ESAB CUTMASTER 120
SECTION 3 TORCH: 3T.02 Setting Up Mechanical Torch
INSTALLATION NOTE!
When converting a hand torch to a mechanical
torch, one adaptor will be required inside the
3T.01 Torch Connections
power source.
If necessary, connect the torch to the Power Sup-
ply. Connect only the ESAB model SL100/ Manual WARNING
or SL100 / Mechanical Torch to this power supply. Disconnect primary power at the source before
Maximum torch leads length is 100 feet / 30.5 m, disassembling the torch or torch leads.
including extensions. The mechanical torch includes a positioning tube with
rack and pinch block assembly.
WARNING
Disconnect primary power at the source before con- 1. Mount the torch assembly on the cutting table.
necting the torch. 2. To obtain a clean vertical cut, use a square to
1. Align the ATC male connector (on the torch align the torch perpendicular to the surface of
lead) with the female receptacle. Push the the workpiece.
male connector into the female receptacle.
The connectors should push together with a
small amount of pressure. Pinch Block
2. Secure the connection by turning the locking Assembly
nut clockwise until it clicks. DO NOT use the
locking nut to pull the connection together.
Do not use tools to secure the connection.

Square

Workpiece
A-02585
2

1
Art # A-07885

Mechanical Torch Set - Up

Connecting the Torch to the Power Supply
3. The system is ready for operation. 3. The proper torch parts (shield cup, tip, start
cartridge, and electrode) must be installed for
Check Air Quality the type of operation. Refer to Section 4T.07
for the selection of torch parts.
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.

Manual 0-5405 INSTALLATION 3T-1

ESAB CUTMASTER 120

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3T-2 INSTALLATION Manual 0-5405
 ESAB CUTMASTER 120
SECTION 4 SYSTEM: 1 2 3 4

OPERATION
4.01 Front Panel Controls / Features
A
MIN MAX
PSI BAR
MAX MAX

See Illustration for numbering Identification +

1. Output Current Control

Sets the desired output current. Output settings MIN MIN

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. Art# A-07886

5 6 7 8 9 10
SET Used to purge the air through the unit
and torch and leads and to adjust gas pressure.
6. Temp Indicator
RUN Used for general cutting operations
Indicator is normally OFF. Indicator is ON when
RAPID AUTO RESTART Allows for faster internal temperature exceeds normal limits. Let
restarting of the Pilot Arc for uninterrupted cutting. the unit cool before continuing operation.

LATCH Used for longer hand held 7. Gas Indicator

cuts. Once a cutting arc is established, the torch
Indicator is ON when minimum input gas pressure
switch can be released. The cutting arc will remain
for power supply operation is present. Minimum
ON until the torch is lifted away from the work
pressure for power supply operation is not suf-
piece, the torch leaves the edge of the work piece
ficient for torch operation.
the torch switch is activated again or if one of the
system interlocks is activated. 8. DC Indicator
3. ON OFF Power Switch Indicator is ON when DC output circuit is active.

ON / OFF Switch controls input power to 9. ! Fault Error Indicator

the power supply. Up is ON, down is OFF. Indicator is ON when Fault circuit is active. See
4. Air/Gas Pressure Control Section 5 for explanations of fault lights.
10. Pressure Indicators
The Pressure + Control is used in the
"SET" mode to adjust the air/gas pressure. Pull PSI BAR
MAX MAX
the knob OUT to adjust and push IN to lock.
90 6.3

5. AC Indicator 85 5.9
80 5.5
Steady light indicates power supply is ready for
operation. Blinking light indicates unit is in pro- 75 5.2
Art # A-08170

tective interlock mode. Shut unit OFF, shut OFF 70 4.8

or disconnect input power, correct the fault, and 65 4.5
restart the unit. Refer to Section 5 for details.
MIN MIN

The Indicators will illuminate according to the

pressure set by the Pressure Control Knob (num-
ber 4).

Manual 0-5405 OPERATION 4-1

ESAB CUTMASTER 120
4.02 Preparations for Operation Power ON

At the start of each operating session: Place the Power Supply ON / OFF switch to the
ON (up) position. AC indicator turns ON.
WARNING
Disconnect primary power at the source before Gas indicator turns ON if there is sufficient
assembling or disassembling power supply, torch gas pressure for power supply operation and the
parts, or torch and leads assemblies.. cooling fans turn ON.

NOTE!
Torch Parts Selection Minimum pressure for power supply operation is
lower than minimum for torch operation.
Check the torch for proper assembly and ap- The cooling fans will turn ON as soon as the unit is
propriate torch parts. The torch parts must cor- turned ON. After the unit is idle for ten (10) minutes
respond with the type of operation, and with the
the fans will turn OFF. The fans will come back ON as
amperage output of this Power Supply (120 amps
maximum). Refer to Section 4T.07 and following
soon as the torch switch (Start Signal) is activated
for torch parts selection. or if the unit is turned off, then turned ON again.
If an over temperature condition occurs, the fans
Torch Connection will continue to run while the condition exists and
Check that the torch is properly connected. Only for a ten (10) minute period once the condition is
ESAB model SL100 / Manual or SL100 / Mechani- cleared.
cal Torches may be connected to this Power Sup-
ply. See Section 3T of this manual. Set Operating Pressure
Check Primary Input Power Source 1. Place the Power Supply Function Control knob
1. Check the power source for proper input volt- to the SET position. Gas will flow.
age. Make sure the input power source meets
the power requirements for the unit per Section
2, Specifications. 2. For Standoff cutting, adjust gas pressure from
70 - 85 psi / 4.8 - 5.9 bar (LED's in center of
2. Connect the input power cable (or close the control panel). Refer to the Standoff chart for
main disconnect switch) to supply power to pressure setting details.
the system.
Air Source 1 2
Ensure source meets requirements (refer to Sec-
tion 2). Check connections and turn air supply
ON.
Connect Work Cable MIN
A MAX
PSI BAR
MAX MAX

+
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 work-
piece; do not connect to the part to be cut off.
MIN MIN

Art# A-07946

Art # A-04509

4-2 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
STANDOFF Typical Cutting Speeds
ESAB Cutmaster® 120 Gas Pressure Settings Cutting speeds vary according to torch output
SL100 amperage, the type of material being cut, and
Leads SL100 (Mechanized Torch) operator skill. Refer to Section "4T.08
Length (Hand Torch) SL 100 SV Recommended Cutting Speeds for Mechanized
(Automation Torch) Torch With Exposed Tip" and following for greater
details.
Up to 25' 75 psi 75 psi
(7.6 m) 5.2 bar 5.2 bar Output current setting or cutting speeds may be
Each reduced to allow slower cutting when following a
additional Add 5 psi Add 5 psi line, or using a template or cutting guide while still
25' 0.4 bar 0.4 bar producing cuts of excellent quality.
(7.6 m)
Postflow

3. For Drag cutting, adjust gas pressure from Release the trigger to stop the cutting arc. Gas
75 - 95 psi / 5.2 - 6.5 bar (LED's in center of continues to flow for approximately 20 seconds.
control panel). Refer to the Drag Cutting chart During post - flow, if the user moves the trigger
for pressure setting details. release to the rear and presses the trigger, the
pilot arc starts. The main arc transfers to the
DRAG (Up to 60A) workpiece if the torch tip is within transfer distance
ESAB Cutmaster® 120 Gas Pressure Settings to the workpiece.

SL100 Shutdown
Leads Length
(Hand Torch)
Up to 25' 80 psi Turn the ON / OFF switch to OFF
(7.6 m) 5.5 bar (down). All Power Supply indicators shut OFF.
Unplug the input power cord or disconnect input
Each additional 25' Add 5 psi power. Power is removed from the system.
(7.6 m) 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

or LATCH . Gas flow stops.

2. Set the output current to desired amperage
with the Output Current Control Knob.
Cutting Operation
When the torch leaves the workpiece during cut-
ting 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 cut-
ting arc will be maintained after the torch switch
is released.

Manual 0-5405 OPERATION 4-3

ESAB CUTMASTER 120

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4-4 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
SECTION 4 TORCH: 3. Install the replacement Electrode by pushing
it straight into the torch head until it clicks.
OPERATION 4. Install the starter cartridge and desired tip for
the operation into the torch head.
4T.01 Torch Parts Selection 5. Hand tighten the shield cup assembly until it
is seated on the torch head. If resistance is
Depending on the type of operation to be done deter-
felt when installing the cup, check the threads
mines the torch parts to be used.
before proceeding.
Type of operation:
Drag cutting, standoff cutting or gouging
Torch parts:
Shield Cup, Cutting Tip, Electrode and Starter
Cartridge

NOTE!
Refer to Section 4T.07 and following for additional
information on torch parts.
Change the torch parts for a different operation as
follows:

WARNING
Disconnect primary power at the source before as-
sembling 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.

Torch Head

Electrode

Start Cartridge

Tip

Shield Cup

A-03510_AB

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

Manual 0-5405 OPERATION 4T-1

ESAB CUTMASTER 120
Kerf Width
4T.02 Cut Quality
The width of the cut (or the width of material re-
NOTE! moved during the cut).
Cut quality depends heavily on setup and pa- Top Spatter (Dross)
rameters such as torch standoff, alignment with
the workpiece, cutting speed, gas pressures, and Top spatter or dross on the top of the cut caused
operator ability. by slow travel speed, excess cutting height, or
cutting tip whose orifice has become elongated.
Cut quality requirements differ depending on applica-
tion. 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 clean-
ing operation. The following cut quality characteristics
are illustrated in the following figure:
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter

Top Edge
Rounding

Dross
Build-Up
Cut Surface A-00007
Drag Lines
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.
Bottom Dross Buildup
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.

4T-2 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
4T.03 General Cutting Information Left Side
Cut Angle
Right Side
WARNING Cut Angle

! Disconnect primary power at the source before dis-

assembling 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 A-00512
body comes into contact with the workpiece while
Side Characteristics Of Cut
the torch is activated.
CAUTION To make a square - edged cut along an inside
! Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
diameter of a circle, the torch should move
counterclockwise around the circle. To keep the
plastic and metal. square edge along an outside diameter cut, the
torch should travel in a clockwise direction.
NOTE! Dross
Handle torch leads with care and protect them from
damage. When dross is present on carbon steel, it is com-
monly referred to as either “high speed, slow
Piloting
speed, or top dross”. Dross present on top of
Piloting is harder on parts life than actual cutting the plate is normally caused by too great a torch
because the pilot arc is directed from the electrode to plate distance. "Top dross" is normally very
to the tip rather than to a workpiece. Whenever easy to remove and can often be wiped off with
possible, avoid excessive pilot arc time to improve a welding glove. "Slow speed dross" is normally
parts life. present on the bottom edge of the plate. It can
vary from a light to heavy bead, but does not
Torch Standoff adhere tightly to the cut edge, and can be easily
Improper standoff (the distance between the torch scraped off. "High speed dross" usually forms
tip and workpiece) can adversely affect tip life as a narrow bead along the bottom of the cut edge
well as shield cup life. Standoff may also signifi- and is very difficult to remove. When cutting a
cantly affect the bevel angle. Reducing standoff troublesome steel, it is sometimes useful to reduce
will generally result in a more square cut. the cutting speed to produce "slow speed dross".
Any resultant cleanup can be accomplished by
Edge Starting scraping, not grinding.
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.
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.

Manual 0-5405 OPERATION 4T-3

ESAB CUTMASTER 120
4T.04 Hand Torch Operation
Standoff Cutting With Hand Torch

NOTE!
For best performance and parts life, always use the Trigger
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 Trigger Release
A-02986
to press the Trigger on the torch handle. With
the hand torch, the hand may be positioned 5. Bring the torch within transfer distance to the
close to the torch head for maximum control or work. The main arc will transfer to the work,
near the back end for maximum heat protec- and the pilot arc will shut off.
tion. Choose the holding technique that feels
most comfortable and allows good control and NOTE!
movement. The gas preflow and postflow are a characteristic of
the power supply and not a function of the torch.
NOTE!
The tip should never come in contact with the Trigger
workpiece except during drag cutting operations.
2. Depending on the cutting operation, do one of
the following: 1
a. For edge starts, hold the torch perpendicu- 2
lar to the workpiece with the front of the tip
Trigger Release
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
Torch

Art # A-11504

6. Cut as usual. Simply release the trigger as-

sembly to stop cutting.
7. Follow normal recommended cutting practices
Shield Cup Standoff Distance as provided in the power supply operator's
1/8" - 3/8" (3 - 9mm)
manual.

NOTE!
When the shield cup is properly installed, there
A-00024_AB
is a slight gap between the shield cup and the
Standoff Distance torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
3. Hold the torch away from your body.
shield cup to close this gap. Forcing the shield cup
against the torch head or torch handle can damage
4. Slide the trigger release toward the back of the components.
torch handle while simultaneously squeezing
8. For a consistent standoff height from the
the trigger. The pilot arc will start.
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.

4T-4 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
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.

Shield Cup
Standoff Guide
Torch Tip
Workpiece Art # A-04034 Trigger

Shield Cup With Straight Edge

Trigger Release
The drag shield cup can be used with a non
A-02986
conductive straight edge to make straight cuts
by hand. 6. Bring the torch within transfer distance to the
work. The main arc will transfer to the work,
WARNING and the pilot arc will shut off.
The straight edge must be non - conductive.
NOTE!
The gas preflow and postflow are a characteristic of
the power supply and not a function of the torch.
Trigger

Non-Conductive
Straight Edge
1
Cutting Guide
2

Trigger Release
A-03539

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when cut- 3

ting 3/16 inch (4.7 mm) solid metal with relatively
smooth surface.
Drag Cutting With a Hand Torch 4

Drag cutting works best on metal 1/4" (6 mm)

Art # A-03383
thick or less.
7. Cut as usual. Simply release the trigger as-
NOTE!
sembly to stop cutting.
For best parts performance and life, always use the
correct parts for the type of operation. 8. Follow normal recommended cutting practices
1. Install the drag cutting tip and set the output as provided in the power supply operator's
current. manual.

2. The torch can be comfortably held in one hand NOTE!

or steadied with two hands. Position the hand When the shield cup is properly installed, there is
to press the Trigger on the torch handle. With a slight gap between the shield cup and the torch
the hand torch, the hand may be positioned handle. Gas vents through this gap as part of normal
close to the torch head for maximum control or operation. Do not attempt to force the shield cup
near the back end for maximum heat protec- to close this gap. Forcing the shield cup against the
tion. Choose the holding technique that feels torch head or torch handle can damage components.
most comfortable and allows good control and
movement.
3. Keep the torch in contact with the workpiece
during the cutting cycle.

Manual 0-5405 OPERATION 4T-5

ESAB CUTMASTER 120
Piercing With Hand Torch Cutting speed depends on material, thickness, and
1. The torch can be comfortably held in one hand the operator’s ability to accurately follow the desired
or steadied with two hands. Position the hand cut line. The following factors may have an impact
to press the Trigger on the torch handle. With on system performance:
the hand torch, the hand may be positioned
• Torch parts wear
close to the torch head for maximum con-
trol or near the back end for maximum heat • Air quality
protection. Choose the technique that feels • Line voltage fluctuations
most comfortable and allows good control and
• Torch standoff height
movement.
• Proper work cable connection
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.

Trigger

Trigger Release
A-02986

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!
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.

4T-6 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
4T.05 Gouging
Torch Head
WARNING
! Be sure the operator is equipped with proper
gloves, clothing, eye and ear protection and that all
safety precautions at the front of this manual have 35°
been followed. Make sure no part of the operator’s
body comes in contact with the workpiece when
the torch is activated. Standoff Height
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
Workpiece
CAUTION
!
A-00941_AB
Sparks from plasma gouging can cause damage Gouging Angle and Standoff Distance
to coated, painted or other surfaces such as glass,
plastic, and metal. Standoff Distance
Check torch parts. The torch parts must correspond
with the type of operation. Refer to Section 4T.07, The tip to work distance affects gouge quality and
depth. Standoff distance of 1/8 - 1/4 inch (3 - 6
Torch Parts Selection.
mm) allows for smooth, consistent metal removal.
Gouging Parameters Smaller standoff distances may result in a sever-
Gouging performance depends on parameters ance cut rather than a gouge. Standoff distances
such as torch travel speed, current level, lead greater than 1/4 inch (6 mm) may result in minimal
angle (the angle between the torch and work- metal removal or loss of transferred main arc.
piece), and the distance between the torch tip Slag Buildup
and workpiece (standoff).
Slag generated by gouging on materials such as
CAUTION carbon and stainless steels, nickels, and alloyed
! Touching the torch tip or shield cup to the work
surface will cause excessive parts wear.
steels, can be removed easily in most cases. Slag
does not obstruct the gouging process if it accu-
Torch Travel Speed mulates to the side of the gouge path. However,
slag build - up can cause inconsistencies and
NOTE! irregular metal removal if large amounts of mate-
Refer to Appendix Pages for additional information rial build up in front of the arc. The build - up is
as related to the Power Supply used. most often a result of improper travel speed, lead
angle, or standoff height.
Optimum torch travel speed is dependent on cur-
rent setting, lead angle, and mode of operation
(hand or machine torch).
Current Setting
Current settings depend on torch travel speed,
mode of operation (hand or machine torch), and
the amount of material to be removed.
Pressure Setting
Even though the setting is within the specified
range, if the torch does not pilot well the pressure
may need to be reduced
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 appli-
cations, such as removing welds or working with
light metal, this may be desirable.
Manual 0-5405 OPERATION 4T-7
ESAB CUTMASTER 120
4T.06 Mechanized Torch Operation For optimum smooth surface quality, the travel
speed should be adjusted so that only the lead-
Cutting With Mechanized Torch ing edge of the arc column produces the cut. If
the travel speed is too slow, a rough cut will be
The mechanized torch can be activated by remote produced as the arc moves from side to side in
control pendant or by a remote interface device search of metal for transfer.
such as CNC.
Travel speed also affects the bevel angle of a cut.
1. To start a cut at the plate edge, position the
When cutting in a circle or around a corner, slow-
center of the torch along the edge of the plate.
ing down the travel speed will result in a squarer
Travel Speed cut. The power source output should be reduced
also. Refer to the appropriate Control Module
Proper travel speed is indicated by the trail of the Operating Manual for any Corner Slowdown ad-
arc which is seen below the plate. The arc can be justments that may be required.
one of the following:
Piercing With Machine Torch
1. Straight Arc
To pierce with a machine torch, the arc should
A straight arc is perpendicular to the workpiece be started with the torch positioned as high as
surface. This arc is generally recommended possible above the plate while allowing the arc
for the best cut using air plasma on stainless to transfer and pierce. This standoff helps avoid
or aluminum. having molten metal blow back onto the front end
2. Leading Arc of the torch.

The leading arc is directed in the same direc- When operating with a cutting machine, a pierce or
tion as torch travel. A five degree leading arc dwell time is required. Torch travel should not be
is generally recommended for air plasma on enabled until the arc penetrates the bottom of the
mild steel. plate. As motion begins, torch standoff should be
reduced to the recommended 1/8 - 1/4 inch (3-6
3. Trailing Arc mm) distance for optimum speed and cut quality.
Clean spatter and scale from the shield cup and
The trailing arc is directed in the opposite direc-
the tip as soon as possible. Spraying or dipping
tion as torch travel.
the shield cup in anti - spatter compound will
minimize the amount of scale which adheres to it.

Dir
ect
ion
of T
orc
hT
rav Standoff Distance
el

Straight Arc

Trailing Arc

A-02586

Leading Arc

Mechanized Torch Operation

4T-8 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
4T.07 Parts Selection for SL100 Torch Cutting

Ohmic Clip
Automation Torch
Ohmic Clip 9-8224
Manual Torch
9-8259

20-40A Tip:
Shield
Cup Body, Shield Cap, Machine
STANDOFF 40A 9-8245
9-8237
CUTTING

20A 9-8205 Shield Cup Shield Cap, Deflector

30A 9-8206 9-8218 9-8243
40A 9-8208

Drag Shield Cup

9-8235

50-60A Tips:
Shield
Cup Body,
STANDOFF Shield Cap, Machine
CUTTING 9-8237
50-60A 9-8238

50-55A 9-8209 Shield Cup

60A 9-8210 9-8218 Shield Cap, Deflector
9-8243

Drag Shield Cup

70-100A 9-8236
Electrode Starter
Auto 9-8232 Cartridge Tips: Shield Drag Shield Cup
Manual 9-8215 9-8277 Cup Body, 120A 9-8258
9-8237
Shield Cap, Machine
70-100A 9-8239
70-120A 70A 9-8231
STANDOFF 80A 9-8211 Shield Cup Shield Cap, Machine
CUTTING 90/100A 9-8212 9-8218 120A 9-8256
120A Auto 9-8233
120A Manual 9-8253
Shield Cap, Deflector
9-8243

40-120A
GOUGING Shield
Cup Body,
9-8237
Tips:

Tip A 9-8225 (40 Amps Max.) Shield Cup, Gouging

9-8241
Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Art # A-11506 Tip E 9-8254 (60 - 120 Amps)

Manual 0-5405 OPERATION 4T-9

ESAB CUTMASTER 120
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip
Type Torch: SL100 With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.036 0.9 9-8208 104 40 340 8.64 0.19 4.8 65 4.5 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 108 40 250 6.35 0.19 4.8 65 4.5 55 170 0.10 0.2 5.1
0.075 1.9 9-8208 108 40 190 4.83 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 110 40 105 2.67 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 113 40 60 1.52 0.19 4.8 65 4.5 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 111 40 40 1.02 0.19 4.8 65 4.5 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 124 40 21 0.53 0.19 4.8 65 4.5 55 170 NR NR NR
0.500 12.7 9-8208 123 40 11 0.28 0.19 4.8 65 4.5 55 170 NR NR NR
0.625 15.9 9-8208 137 40 7 0.18 0.19 4.8 65 4.5 55 170 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.036 0.9 9-8208 103 40 355 9.02 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1
0.05 1.3 9-8208 98 40 310 7.87 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 98 40 240 6.10 0.125 3.2 65 4.5 55 170 0.10 0.2 5.1
0.078 2.0 9-8208 100 40 125 3.18 0.125 3.2 65 4.5 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 65 4.5 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 124 40 20 0.51 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 122 40 15 0.38 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 126 40 10 0.25 0.187 4.8 65 4.5 55 170 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.032 0.8 9-8208 110 40 440 11.18 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1
0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1
0.064 1.6 9-8208 112 40 250 6.35 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1
0.079 2.0 9-8208 112 40 200 5.08 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1
0.125 3.2 9-8208 118 40 100 2.54 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 120 40 98 2.49 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1
0.250 6.4 9-8208 123 40 50 1.27 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 134 40 16 0.41 0.187 4.8 65 4.5 55 170 NR NR NR

4T-10 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
Type Torch: SL100 With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8 70 4.8 90 245 0.00 0.19 4.8
0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8
0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8
0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8
0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 70 4.8 90 245 0.20 0.19 4.8
0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.19 4.8
0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 70 4.8 90 245 0.50 0.19 4.8
0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 70 4.8 90 245 0.75 0.19 4.8
0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR
0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR
1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8 70 4.8 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1
0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1
0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 70 4.8 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1
0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR
0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 70 4.8 90 245 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.00 0.25 6.4
0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4
0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4
0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 70 4.8 90 245 0.20 0.25 6.4
0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 70 4.8 90 245 0.30 0.25 6.4
0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 70 4.8 90 245 0.50 0.25 6.4
0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 70 4.8 90 245 0.80 0.25 6.4
0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 70 4.8 90 245 NR NR NR
0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 70 4.8 90 245 NR NR NR

Manual 0-5405 OPERATION 4T-11

ESAB CUTMASTER 120
Type Torch: SL100 With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8211 113 80 320 8.13 0.19 4.8 65 4.5 115 340 0.00 0.19 4.8
0.120 3.0 9-8211 113 80 230 5.84 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8
0.135 3.4 9-8211 115 80 180 4.57 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8
0.188 4.8 9-8211 114 80 140 3.56 0.19 4.8 65 4.5 115 340 0.20 0.19 4.8
0.250 6.4 9-8211 114 80 100 2.54 0.19 4.8 65 4.5 115 340 0.30 0.19 4.8
0.375 9.5 9-8211 117 80 42 1.07 0.19 4.8 65 4.5 115 340 0.40 0.19 4.8
0.500 12.7 9-8211 120 80 33 0.84 0.19 4.8 65 4.5 115 340 0.60 0.19 4.8
0.625 15.9 9-8211 133 80 22 0.56 0.19 4.8 65 4.5 115 340 0.75 0.19 4.8
0.750 19.1 9-8211 128 80 18 0.46 0.19 4.8 65 4.5 115 340 NR NR NR
0.875 22.2 9-8211 133 80 10 0.25 0.19 4.8 65 4.5 115 340 NR NR NR
1.000 25.4 9-8211 132 80 9 0.23 0.19 4.8 65 4.5 115 340 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8211 120 80 340 8.64 0.25 6.4 65 4.5 115 340 0.00 0.25 6.4
0.120 3.0 9-8211 120 80 300 7.62 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4
0.135 3.4 9-8211 120 80 280 7.11 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4
0.188 4.8 9-8211 120 80 140 3.56 0.25 6.4 65 4.5 115 340 0.20 0.25 6.4
0.250 6.4 9-8211 120 80 100 2.54 0.25 6.4 65 4.5 115 340 0.30 0.25 6.4
0.375 9.5 9-8211 126 80 50 1.27 0.25 6.4 65 4.5 115 340 0.40 0.25 6.4
0.500 12.7 9-8211 129 80 28 0.71 0.25 6.4 65 4.5 115 340 0.80 0.25 6.4
0.625 15.9 9-8211 135 80 20 0.51 0.25 6.4 65 4.5 115 340 1.00 0.25 6.4
0.750 19.1 9-8211 143 80 10 0.25 0.25 6.4 65 4.5 115 340 NR NR NR
0.875 22.2 9-8211 143 80 9 0.23 0.25 6.4 65 4.5 115 340 NR NR NR
1.000 25.4 9-8211 146 80 8 0.20 0.25 6.4 65 4.5 115 340 NR NR NR

Type Torch: SL100 with Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.06 1.5 9-8211 120 80 350 8.89 0.25 6.4 65 4.5 115 340 0.00 0.25 6.4
0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4
0.188 4.8 9-8211 124 80 180 4.57 0.25 6.4 65 4.5 115 340 0.20 0.25 6.4
0.250 6.4 9-8211 128 80 110 2.79 0.25 6.4 65 4.5 115 340 0.30 0.25 6.4
0.375 9.5 9-8211 136 80 55 1.40 0.25 6.4 65 4.5 115 340 0.40 0.25 6.4
0.500 12.7 9-8211 139 80 38 0.97 0.25 6.4 65 4.5 115 340 0.60 0.25 6.4
0.625 15.9 9-8211 142 80 26 0.66 0.25 6.4 65 4.5 115 340 0.75 0.25 6.4
0.750 19.1 9-8211 145 80 24 0.61 0.25 6.4 65 4.5 115 340 NR NR NR
0.875 22.2 9-8211 153 80 10 0.25 0.25 6.4 65 4.5 115 340 NR NR NR
1.000 25.4 9-8211 162 80 6 0.15 0.25 6.4 65 4.5 115 340 NR NR NR

4T-12 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
Type Torch: SL100 With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8212 110 100 105 2.65 0.190 4.8 75 5.2 130 390 0.4 0.200 5.1
0.375 9.5 9-8212 117 100 70 1.75 0.190 4.8 75 5.2 130 390 0.5 0.200 5.1
0.500 12.7 9-8212 120 100 50 1.25 0.190 4.8 75 5.2 130 390 0.6 0.200 5.1
0.625 15.9 9-8212 125 100 35 0.90 0.190 4.8 75 5.2 130 390 1.0 0.200 5.1
0.750 19.0 9-8212 131 100 18 0.45 0.190 4.8 75 5.2 130 390 2.0 0.250 6.4
1.000 25.4 9-8212 135 100 10 0.25 0.190 4.8 75 5.2 130 390 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8212 118 100 90 2.30 0.190 4.8 75 5.2 130 390 0.5 0.250 6.4
0.375 9.5 9-8212 122 100 55 1.40 0.190 4.8 75 5.2 130 390 0.8 0.250 6.4
0.500 12.7 9-8212 126 100 30 0.75 0.190 4.8 75 5.2 130 390 1.0 0.250 6.4
0.625 15.9 9-8212 133 100 20 0.50 0.190 4.8 75 5.2 130 390 1.5 0.250 6.4
0.750 19.0 9-8212 138 100 15 0.40 0.190 4.8 75 5.2 130 390 NR NR NR
1.000 25.4 9-8212 139 100 10 0.25 0.190 4.8 75 5.2 130 390 NR NR NR

Type Torch: SL100 with Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8212 108 100 120 3.05 0.190 4.8 65 4.5 120 360 0.2 0.225 5.7
0.375 9.5 9-8212 117 100 65 1.65 0.190 4.8 65 4.5 120 360 0.4 0.225 5.7
0.500 12.7 9-8212 120 100 45 1.15 0.190 4.8 65 4.5 120 360 0.5 0.225 5.7
0.625 15.9 9-8212 125 100 30 0.75 0.190 4.8 65 4.5 120 360 0.8 0.225 5.7
0.750 19.0 9-8212 131 100 25 0.65 0.190 4.8 65 4.5 120 360 1.0 0.225 5.7
1.000 25.4 9-8212 140 100 10 0.25 0.190 4.8 65 4.5 120 360 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8253 138 120 150 3.81 0.19 4.8 75 5.2 180 360 0.10 0.25 6.4
0.375 9.5 9-8253 140 120 85 2.16 0.19 4.8 75 5.2 180 360 0.30 0.25 6.4
0.500 12.7 9-8253 144 120 70 1.78 0.19 4.8 75 5.2 180 360 0.50 0.25 6.4
0.625 15.9 9-8253 152 120 45 1.14 0.19 4.8 75 5.2 180 360 0.70 0.25 6.4
0.750 19.0 9-8253 155 120 30 0.76 0.19 4.8 75 5.2 180 360 0.90 0.25 6.4
0.875 22.2 9-8253 160 120 25 0.64 0.25 6.4 75 5.2 180 360 NR NR NR
1.000 25.4 9-8253 164 120 20 0.51 0.25 6.4 75 5.2 180 360 NR NR NR
1.250 31.8 9-8253 170 120 12 0.30 0.25 6.4 75 5.2 180 360 NR NR NR
1.500 38.1 9-8253 180 120 8 0.20 0.25 6.4 75 5.2 180 360 NR NR NR

Manual 0-5405 OPERATION 4T-13

ESAB CUTMASTER 120
Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8253 135 120 180 4.57 0.19 4.8 75 5.2 180 360 0.20 0.25 6.4
0.375 9.5 9-8253 144 120 100 2.54 0.19 4.8 75 5.2 180 360 0.40 0.25 6.4
0.500 12.7 9-8253 146 120 60 1.52 0.19 4.8 75 5.2 180 360 0.80 0.25 6.4
0.625 15.9 9-8253 155 120 40 1.02 0.25 6.4 75 5.2 180 360 1.20 0.28 7.0
0.750 19.0 9-8253 164 120 26 0.66 0.25 6.4 75 5.2 180 360 NR NR NR
1.000 25.4 9-8253 164 120 18 0.46 0.25 6.4 75 5.2 180 360 NR NR NR
1.250 31.8 9-8253 170 120 9 0.23 0.25 6.4 75 5.2 180 360 NR NR NR

Type Torch: SL100 with Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8253 142 120 190 4.83 0.19 4.8 75 5.2 180 360 0.30 0.25 6.4
0.375 9.5 9-8253 145 120 120 3.05 0.19 4.8 75 5.2 180 360 0.50 0.25 6.4
0.500 12.7 9-8253 151 120 70 1.78 0.19 4.8 75 5.2 180 360 0.80 0.25 6.4
0.625 15.9 9-8253 162 120 50 1.27 0.25 6.4 75 5.2 180 360 1.00 0.28 7.0
0.750 19.0 9-8253 164 120 34 0.86 0.25 6.4 75 5.2 180 360 NR NR NR
1.000 25.4 9-8253 170 120 20 0.51 0.25 6.4 75 5.2 180 360 NR NR NR

NOTE!
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads,refer to section 4.02
"Operating Pressure".
** Total flow rate includes plasma and secondary gas flow.

4T-14 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip
Type Torch: SL100 With Shielded Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.036 0.9 9-8208 114 40 170 4.32 0.19 4.8 65 4.5 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 120 40 90 2.29 0.19 4.8 65 4.5 55 170 0.10 0.2 5.1
0.075 1.9 9-8208 121 40 80 2.03 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 122 40 75 1.91 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 123 40 30 0.76 0.19 4.8 65 4.5 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 125 40 25 0.64 0.19 4.8 65 4.5 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 138 40 11 0.28 0.19 4.8 65 4.5 55 170 NR NR NR
0.500 12.7 9-8208 142 40 7 0.18 0.19 4.8 65 4.5 55 170 NR NR NR
0.625 15.9 9-8208 152 40 3 0.08 0.19 4.8 65 4.5 55 170 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.036 0.9 9-8208 109 40 180 4.57 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1
0.05 1.3 9-8208 105 40 165 4.19 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 115 40 120 3.05 0.125 3.2 65 4.5 55 170 0.10 0.2 5.1
0.078 2.0 9-8208 120 40 65 1.65 0.187 4.8 65 4.5 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 125 40 25 0.64 0.187 4.8 65 4.5 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 132 40 20 0.51 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 130 40 15 0.38 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 130 40 10 0.25 0.187 4.8 65 4.5 55 170 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.032 0.8 9-8208 116 40 220 5.59 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1
0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1
0.064 1.6 9-8208 118 40 180 4.57 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1
0.079 2.0 9-8208 116 40 150 3.81 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1
0.125 3.2 9-8208 130 40 75 1.91 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 132 40 60 1.52 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1
0.250 6.4 9-8208 134 40 28 0.71 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 143 40 11 0.28 0.187 4.8 65 4.5 55 170 NR NR NR

Manual 0-5405 OPERATION 4T-15

ESAB CUTMASTER 120
Type Torch: SL100 With Shielded Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 70 4.8 90 245 0.00 0.2 5.1
0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1
0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1
0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1
0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 70 4.8 90 245 0.20 0.2 5.1
0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.2 5.1
0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 70 4.8 90 245 0.50 0.2 5.1
0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 70 4.8 90 245 0.75 0.2 5.1
0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR
0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR
1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.06 1.5 9-8210 110 60 165 4.19 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 116 60 155 3.94 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 115 60 125 3.18 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1
0.135 3.4 9-8210 118 60 80 2.03 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1
0.188 4.8 9-8210 120 60 75 1.91 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 121 60 60 1.52 0.13 3.2 70 4.8 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 129 60 28 0.71 0.13 3.2 70 4.8 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 135 60 17 0.43 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1
0.625 15.9 9-8210 135 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR
0.750 19.1 9-8210 142 60 10 0.25 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1
0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 70 4.8 90 245 0.80 0.20 5.1
0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR
0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR

4T-16 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
Type Torch: SL100 With Shielded Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8211 128 80 280 7.11 0.19 4.8 65 4.5 115 340 0.00 0.2 5.1
0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1
0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1
0.188 4.8 9-8211 128 80 137 3.48 0.19 4.8 65 4.5 115 340 0.20 0.2 5.1
0.250 6.4 9-8211 131 80 100 2.54 0.19 4.8 65 4.5 115 340 0.30 0.2 5.1
0.375 9.5 9-8211 134 80 40 1.02 0.19 4.8 65 4.5 115 340 0.50 0.2 5.1
0.500 12.7 9-8211 136 80 36 0.91 0.19 4.8 65 4.5 115 340 0.60 0.2 5.1
0.625 15.9 9-8211 145 80 21 0.53 0.19 4.8 65 4.5 115 340 0.75 0.2 5.1
0.750 19.1 9-8211 144 80 14 0.36 0.19 4.8 65 4.5 115 340 NR NR NR
0.875 22.2 9-8211 149 80 11 0.28 0.19 4.8 65 4.5 115 340 NR NR NR
1.000 25.4 9-8211 162 80 8 0.20 0.19 4.8 65 4.5 115 340 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8211 110 80 340 8.50 0.125 3.2 65 4.5 115 340 0.00 0.2 5.1
0.120 3.0 9-8211 115 80 260 6.50 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1
0.135 3.4 9-8211 113 80 250 6.25 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1
0.188 4.8 9-8211 114 80 170 4.25 0.125 3.2 65 4.5 115 340 0.20 0.2 5.1
0.250 6.4 9-8211 116 80 85 2.13 0.125 3.2 65 4.5 115 340 0.30 0.2 5.1
0.375 9.5 9-8211 123 80 45 1.13 0.125 3.2 65 4.5 115 340 0.40 0.25 6.4
0.500 12.7 9-8211 133 80 18 0.45 0.125 3.2 65 4.5 115 340 0.75 0.25 6.4
0.625 15.9 9-8211 135 80 16 0.40 0.125 3.2 65 4.5 115 340 1.00 0.25 6.4
0.750 19.1 9-8211 144 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR
0.875 22.2 9-8211 137 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR
1.000 25.4 9-8211 140 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.06 1.5 9-8211 115 80 320 8.13 0.13 3.2 65 4.5 115 340 0.00 0.25 6.4
0.12 3.0 9-8211 120 80 240 6.10 0.13 3.2 65 4.5 115 340 0.10 0.25 6.4
0.188 4.8 9-8211 120 80 165 4.19 0.13 3.2 65 4.5 115 340 0.20 0.25 6.4
0.250 6.4 9-8211 124 80 100 2.54 0.13 3.2 65 4.5 115 340 0.30 0.25 6.4
0.375 9.5 9-8211 138 80 60 1.52 0.19 4.8 65 4.5 115 340 0.40 0.25 6.4
0.500 12.7 9-8211 141 80 36 0.91 0.19 4.8 65 4.5 115 340 0.60 0.25 6.4
0.625 15.9 9-8211 142 80 26 0.66 0.19 4.8 65 4.5 115 340 0.75 0.25 6.4
0.750 19.1 9-8211 150 80 18 0.46 0.19 4.8 65 4.5 115 340 NR NR NR
0.875 22.2 9-8211 156 80 8 0.20 0.19 4.8 65 4.5 115 340 NR NR NR
1.000 25.4 9-8211 164 80 6 0.15 0.19 4.8 65 4.5 115 340 NR NR NR

Manual 0-5405 OPERATION 4T-17

ESAB CUTMASTER 120
Type Torch: SL100 With Shielded Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8212 124 100 110 2.80 0.180 4.6 75 5.2 130 390 0.4 0.200 5.1
0.375 9.5 9-8212 127 100 75 1.90 0.180 4.6 75 5.2 130 390 0.5 0.200 5.1
0.500 12.7 9-8212 132 100 50 1.30 0.180 4.6 75 5.2 130 390 0.6 0.200 5.1
0.625 15.9 9-8212 136 100 30 0.75 0.180 4.6 75 5.2 130 390 0.8 0.200 5.1
0.750 19.0 9-8212 140 100 18 0.45 0.190 4.8 75 5.2 130 390 2.0 0.225 5.7
1.000 25.4 9-8212 147 100 10 0.25 0.190 4.8 75 5.2 130 390 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8212 121 100 110 2.80 0.125 3.2 75 5.2 130 390 0.5 0.200 5.1
0.375 9.5 9-8212 125 100 60 1.50 0.150 3.8 75 5.2 130 390 0.8 0.200 5.1
0.500 12.7 9-8212 132 100 35 0.90 0.150 3.8 75 5.2 130 390 1.0 0.200 5.1
0.625 15.9 9-8212 137 100 20 0.50 0.150 3.8 75 5.2 130 390 2.0 0.225 5.7
0.750 19.0 9-8212 144 100 15 0.40 0.190 4.8 75 5.2 130 390 NR NR NR
1.000 25.4 9-8212 154 100 8 0.20 0.190 4.8 75 5.2 130 390 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250 6.4 9-8212 120 100 120 3.05 0.180 65 4.5 105 360 0.2 0.225 5.7

0.375 9.5 9-8212 128 100 65 1.65 0.180 65 4.5 105 360 0.4 0.225 5.7

0.500 12.7 9-8212 130 100 45 1.15 0.180 65 4.5 105 360 0.5 0.225 5.7

0.625 15.9 9-8212 135 100 30 0.75 0.180 65 4.5 105 360 0.8 0.225 5.7

0.750 19.0 9-8212 140 100 25 0.65 0.180 65 4.5 105 360 1.0 0.225 5.7

1.000 25.4 9-8212 148 100 10 0.25 0.190 65 4.5 105 360 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8253 140 120 165 4.19 0.125 3.2 75 5.2 180 360 0.20 0.20 5.1
0.375 9.5 9-8253 142 120 85 2.16 0.125 3.2 75 5.2 180 360 0.50 0.20 5.1
0.500 12.7 9-8253 144 120 75 1.91 0.125 3.2 75 5.2 180 360 0.70 0.20 5.1
0.625 15.9 9-8253 150 120 50 1.27 0.125 3.2 75 5.2 180 360 0.80 0.20 5.1
0.750 19.0 9-8253 154 120 30 0.76 0.150 3.8 75 5.2 180 360 1.50 0.20 5.1
0.875 22.2 9-8253 158 120 25 0.64 0.150 3.8 75 5.2 180 360 NR NR NR
1.000 25.4 9-8253 160 120 20 0.51 0.150 3.8 75 5.2 180 360 NR NR NR
1.250 31.8 9-8253 170 120 13 0.33 0.175 4.4 75 5.2 180 360 NR NR NR
1.500 38.1 9-8253 176 120 8 0.20 0.175 4.4 75 5.2 180 360 NR NR NR

4T-18 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8253 136 120 180 4.57 0.13 3.2 75 5.2 180 360 0.20 0.20 5.1
0.375 9.5 9-8253 144 120 100 2.54 0.13 3.2 75 5.2 180 360 0.40 0.20 5.1
0.500 12.7 9-8253 149 120 60 1.52 0.13 3.2 75 5.2 180 360 0.80 0.20 5.1
0.625 15.9 9-8253 153 120 40 1.02 0.15 3.8 75 5.2 180 360 1.20 0.20 5.1
0.750 19.1 9-8253 157 120 30 0.76 0.15 3.8 75 5.2 180 360 NR NR NR
1.000 25.4 9-8253 162 120 20 0.51 0.15 3.8 75 5.2 180 360 NR NR NR
1.250 31.8 9-8253 165 120 10 0.25 0.15 3.8 75 5.2 180 360 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.250 6.4 9-8253 144 120 190 4.83 0.13 3.2 75 5.2 180 360 0.20 0.20 5.1
0.375 9.5 9-8253 148 120 120 3.05 0.13 3.2 75 5.2 180 360 0.50 0.20 5.1
0.500 12.7 9-8253 152 120 75 1.91 0.15 3.8 75 5.2 180 360 0.70 0.20 5.1
0.625 15.9 9-8253 162 120 45 1.14 0.15 3.8 75 5.2 180 360 1.00 0.20 5.1
0.750 19.1 9-8253 163 120 35 0.89 0.15 3.8 75 5.2 180 360 NR NR NR
1.000 25.4 9-8253 168 120 20 0.51 0.15 3.8 75 5.2 180 360 NR NR NR

NOTE!
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads,refer to section 4.02
"Operating Pressure".
** Total flow rate includes plasma and secondary gas flow.

Manual 0-5405 OPERATION 4T-19

ESAB CUTMASTER 120
PATENT INFORMATION
Plasma Cutting Torch Patents
The following parts are covered under U.S. and Foreign Patents as follows:
Catalog # Description Patent(s)
9-8215 Electrode US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
9-8277 Cartridge US Pat No(s) 6903301; 6717096; 6936786;
6703581; D496842; D511280; D492709;
D499620; D504142 Other Pat(s) Pending
9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8241 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8243 Shield Cap US Pat No(s) 6914211; D493183
Other Pat(s) Pending
9-8235 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8236 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633
Other Pat(s) Pending
9-8238 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
9-8239 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
9-8244 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending

4T-20 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
Catalog # Description Patent(s)
9-8245 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending

The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:

Catalog # Description
9-8235 Shield Cap
9-8236 Shield Cap
9-8237 Shield Cup
9-8238 Shield Cap
9-8239 Shield Cap
9-8244 Shield Cap
9-8245 Shield Cap

Manual 0-5405 OPERATION 4T-21

ESAB CUTMASTER 120

This Page Intentionally Blank

4T-22 OPERATION Manual 0-5405
 ESAB CUTMASTER 120
SECTION 5 SYSTEM:
SERVICE
5.01 General Maintenance
Maintain more often
Warning! if used under severe
Disconnect input power before maintaining. conditions

Each Use

Visual check of
torch tip and electrode

Weekly

Visually inspect the

cables and leads.
Visually inspect the torch body tip, Replace as needed
electrode, start cartridge and shield cup

3 Months

Replace all
Clean
broken parts
exterior
of power supply

6 Months

Visually check and

Carefully clean the
interior

Art # A-07938_AB

Manual 0-5405 SERVICE 5-1

ESAB CUTMASTER 120
5.02 Maintenance Schedule 5.03 Common Faults
NOTE! Problem - Symptom Common Cause
The actual frequency of maintenance may need to Insufficient 1. Cutting speed too fast.
be adjusted according to the operating environ- Penetration 2. Torch tilted too much.
ment. 3. Metal too thick.
Daily Operational Checks or Every Six Cutting 4. Worn torch parts
Hours: 5. Cutting current too low.
6. Non - Genuine ESAB parts used
1. Check torch consumable parts, replace if dam- 7. Incorrect gas pressure
aged or worn.
Main Arc 1. Cutting speed too slow.
2. Check plasma and secondary supply and Extinguishes 2. Torch standoff too high from
pressure/flow. workpiece.
3. Cutting current too high.
3. Purge plasma gas line to remove any moisture 4. Work cable disconnected.
build-up. 5. Worn torch parts.
Weekly or Every 30 Cutting Hours: 6. Non - Genuine ESAB parts used
Excessive Dross 1. Cutting speed too slow.
1. Check fan for proper operation and adequate
Formation 2. Torch standoff too high from
air flow.
workpiece.
2. Inspect torch for any cracks or exposed wires, 3. Worn torch parts.
replace if necessary. 4. Improper cutting current.
5. Non - Genuine ESAB parts used
3. Inspect input power cable for damage or ex- 6. Incorrect gas pressure
posed wires, replace if necessary.
Short Torch Parts Life 1. Oil or moisture in air source.
Six Months or Every 720 Cutting Hours: 2. Exceeding system capability
(material too thick).
1. Check the in-line air filter(s), clean or replace
3. Excessive pilot arc time
as required.
4. Gas pressure too low.
2. Check cables and hoses for leaks or cracks, 5. Improperly assembled torch.
replace if necessary. 6. Non - Genuine ESAB parts used

3. Check all contactor points for severe arcing or Difficult Starting 1. Worn torch parts.
pits, replace if necessary. 2. Non - Genuine ESAB parts used.
3. Incorrect gas pressure.
4. Vacuum dust and dirt out of the entire machine.

CAUTION
! Do not blow air into the power supply during
cleaning. Blowing air into the unit can cause metal
particles to interfere with sensitive electrical com-
ponents and cause damage to the unit.

5-2 SERVICE Manual 0-5405
 ESAB CUTMASTER 120
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 75 psi indicators are ON indicating the version would be 2.3.

7
6
5 MIN
A
MAX
PSI
MAX
BAR
MAX

+
4
3
2
1 MIN MIN

0
!

Art# A-07988
1 2 3 4 5

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 Fault
Indicator
Max Over Pressure
90 Internal Error
85 Shorted Torch
80 Consumables Missing
75 Start Error
70 Parts in Place
65 Input Power
Min Under Pressure

NOTE!
Fault explanations are covered in the following tables.

Manual 0-5405 SERVICE 5-3

ESAB CUTMASTER 120
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 1. Primary fuses / breakers are 1. a) Have qualified person check primary fuses / breakers.
is ON but the A/C blown or tripped. b) Connect unit to known good primary power receptacle
Indicator does not 2. Units internal fuse blown. 2. a) Replace fuse.
light b) If fuse blows again, return to authorized service center for
repair or replacement.
3. Faulty components in unit. 3. Return to authorized service center for repair or replacement.

Fault indicator 1. INPUT VOLTAGE SELECTION 1. Set INPUT VOLTAGE SELECTION SWITCH to match primary
flashing, 65 PSI SWITCH set for incorrect voltage. input voltage.
indicator flashing 2. Primary input voltage problem. 2. Have qualified person check primary voltage to insure it
meets unit requirements see Section "2.05 Input Wiring
3. Faulty components in unit. Specifications" on page 2-3.
3. Return to authorized service center for repair or replacement.
TEMPERATURE 1. Air flow through or around the 1. Refer to clearance information – see Section "2.04 Power
indicator ON. unit is obstructed. Supply Specifications" on page 2-2
FAULT indicator 2. Duty cycle of the unit has been 2. Allow unit to cool.
flashing. exceeded.
3. Failed components in unit. 3. Return to authorized service center for repair or replacement.
GAS LED OFF, 1. Gas supply not connected to 1. Connect gas supply to unit.
FAULT and MIN unit.
pressure indicators 2. Gas supply not turned ON. 2. Turn gas supply ON.
flashing. 3. Gas supply pressure too low. 3. Set air supply inlet pressure to unit to 120 psi.
4. AIR PRESSURE CONTROL 4. Adjust regulator to set air pressure - see Section "4. Air/Gas
regulator set too low. Pressure Control" on page 4-1
5. Failed components in unit. 5. Return to authorized service center for repair or replacement.

FAULT and 70 PSI 1. Shield Cup loose. 1. Hand tighten the shield cup until it is snug.
indicators flashing. 2. Torch not properly connected to 2. Insure torch ATC is securely fastened to unit.
power supply.
3. Problem in torch and leads PIP 3. Replace torch and leads or return to authorized service center
circuit. for repair or replacement.
4. Failed components in unit. 4. Return to authorized service center for repair or replacement.
FAULT and 75 PSI 1. Start signal is active when ON/ 1. Start can be active for one of the following:
indicators flashing. OFF SWITCH is turned to ON • Hand torch switch held closed
position. • Hand pendant switch held closed
• CNC START signal is active low
Release the START signal source
2. Problem in the torch and leads 2. Replace torch and leads or return to authorized service center
switch circuit. for repair or replacement.
3. Failed components in unit. 3. Return to authorized service center for repair or replacement.

5-4 SERVICE Manual 0-5405
 ESAB CUTMASTER 120
Problem - Symptom Possible Cause Recommended Action
FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten.
indicators flashing. 2. Torch tip, electrode or starter 2. Turn OFF power supply. Remove shield cup. Install
Gas flow is cycling cartridge missing. missing parts.
ON and OFF. 3. Torch start cartridge is stuck. 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. Open conductor in torch leads. 4. Replace torch and leads or return to authorized service
center for repair or replacement.

5. Problem in the torch and leads 5. Replace torch and leads or return to authorized service
switch circuit. center for repair or replacement.
6. Failed components in unit. 6. Return to authorized service center for repair or
replacement.

Nothing happens 1. Problem in the torch and leads 1. Take Torch and Leads (Remote Pendant) to Authorized
when torch switch switch circuit (Remote pendant Repair Facility.
or remote switch switch circuit).
is closed (Or CNC 2. CNC Controller device not 2. Contact Controller manufacturer.
START signal is providing Start signal.
active) No gas flow, 3. Failed components in unit. 3. Return to authorized service center for repair or
DC LED OFF. replacement.
FAULT and 85 PSI 1. Upper O-ring on torch head is in 1. Remove shield cup from torch; check upper O-ring position;
indicators flashing. wrong 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. 6. Return to authorized service center for repair or
replacement.

No Fault lights ON, no 1. Failed components in unit. 1. Return to an authorized service center for repair.
arc in torch.
FAULT and 85 PSI 1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that
indicators flashing does not clear the fault, return to an authorized service center
for repair.
Pilot arc is ON but 1. Work cable not connected to 1. Connect work cable.
cutting arc will not work piece.
establish 2. Work cable/connector broken. 2. Replace work cable.
3. Failed components in unit. 3. Return to an authorized service center for repair.

Torch cutting is 1. Incorrect current setting. 1. Check and adjust to proper setting.
diminished 2. Worn torch consumables. 2. Check torch consumables and replace as needed.
3. Poor work cable connection to 3. Check the connection of the Work Lead to the work piece.
work piece.
4. Torch being moved too fast. 4. Reduce cutting speed.
5. Excessive oil or water in torch. 5. Refer to "Check air quality" in Section 3 Torch.
6. Failed components in unit. 6. Return to an authorized service center for repair.

Manual 0-5405 SERVICE 5-5

ESAB CUTMASTER 120
5.06 Power Supply Basic Parts C. Filter Element Assembly Replacement
Replacement The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should
WARNING be checked per the Maintenance Schedule (Section
Disconnect primary power to the system before 5.02), and either cleaned or replaced.
disassembling the torch, leads, or power supply.
1. Remove power from the power supply; turn
This section describes procedures for basic parts OFF the gas supply and bleed down the sys-
replacement. For more detailed parts replacement tem.
procedures, refer to the Power Supply Service Manual.
2. Remove the system cover. See "A Cover
A. Cover Removal Removal" in this section.
1. Remove the upper and lower screws which 3. Locate the internal air line and the fitting from
secure the cover to the main assembly. Do the filter assembly. Number 1 in the following
not loosen the lower screws inside the cut out illustration.
slots in the bottom of the cover.
4. Hold a wrench or similar tool against the lock-
Upper ing ring on the filter assembly fitting, then pull
Screws on the hose to release it. (Numbers 2 and 3 in
the following illustration).
Lower
Screws

Slots

Lower 1
Screws

Art # A-07989

Art # A-08429

2. Carefully pull the Cover up and away from the

unit.
B. Cover Installation 2
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.
3. Tighten lower screws. 4
3 5
4. Reinstall and tighten the upper screws.

6mm

5-6 SERVICE Manual 0-5405
 ESAB CUTMASTER 120
5. Remove the fitting from the filter element as- Optional Single-Stage Filter Element
sembly by inserting a 6 mm hex wrench into Replacement
the internal hex fitting and turning it counter
clock-wise (left). Numbers 4 and 5 in the previ- These instructions apply to power supplies where the
ous illustration. optional Single-Stage Filter has been installed.

6. Disconnect the input line from the filter element The Power Supply shuts down automatically when the
assembly. Filter Element becomes completely saturated. The
Filter Element can be removed from its housing, dried,
7. Remove the filter element assembly through and reused. Allow 24 hours for Element to dry. Refer
the rear opening. to Section 6, Parts List, for replacement filter element
catalog number.
NOTE!
If replacing or cleaning just the filter element refer 1. Remove power from power supply.
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-clock-
wise and remove it. The Filter Element is
Filter Element located inside the Housing.

Housing

Filter
Element
(Cat. No. 9-7741)
Art # A-07990
Spring
8. Install the new or cleaned assembly by revers-
ing these procedures. O-ring
(Cat. No. 9-7743) Assembled Filter
9. Turn ON the air supply and check for leaks
before reinstalling the cover. Cover

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 0-5405 SERVICE 5-7

ESAB CUTMASTER 120
Optional Two-Stage Filter Element Replacement
The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply
will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replace-
ment filter element catalog number.
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.

5-8 SERVICE Manual 0-5405
 ESAB CUTMASTER 120
SECTION 5 TORCH:
SERVICE
Upper Groove
5T.01 General Maintenance with Vent Holes
Must Remain Open
NOTE!
Refer to Previous "Section 5: System Service" for Upper O-Ring
common and fault indicator descriptions. in Correct Groove
Cleaning Torch Threads
Even if precautions are taken to use only clean Lower O-Ring Art # A-03725
air with a torch, eventually the inside of the torch Torch Head O-Ring
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..
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 com-
pressed air. Gas Fitting

CAUTION
! Dry the torch thoroughly before reinstalling.
O-Ring Lubrication
An O-Ring on the Torch Head and ATC Male Con-
nector requires lubrication on a scheduled basis.
This will allow the O-Rings to remain pliable and Art #A-03791 O-Ring
provide a proper seal. The O-Rings will dry out,
ATC O-Ring
becoming hard and cracked if the lubricant is not
used on a regular basis. This can lead to potential
performance problems. NOTE!
DO NOT use other lubricants or grease, they may not
It is recommended to apply a very light film of O-
be designed to operate within high temperatures
Ring lubricant (Catalog # 8-4025) to the O-Rings
on a weekly basis. 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.

Manual 0-5405 SERVICE 5T-1

ESAB CUTMASTER 120
5T.02 Inspection and Replacement of 4. Remove the tip. Check for excessive wear
(indicated by an elongated or oversized orifice).
Consumable Torch Parts Clean or replace the tip if necessary.
WARNING Good Tip Worn Tip
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..
Remove the consumable torch parts as follows: A-03406

Example of Tip Wear

NOTE!
The shield cup holds the tip and starter cartridge in 5. Remove the starter cartridge. Check for ex-
place. Position the torch with the shield cup facing cessive wear, plugged gas holes, or discol-
upward to prevent these parts from falling out oration. Check the lower end fitting for free
when the cup is removed. motion. Replace if necessary.
1. Unscrew and remove the shield cup from the Spring-Loaded Spring-Loaded
torch. Lower End Fitting Lower End Fitting at Reset /
Full Compression Full Extension
NOTE!
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.
Art # A-08064_AC

6. Pull the Electrode straight out of the Torch

Head. Check the face of the electrode for
Art # A-08067 excessive wear. Refer to the following figure.
Shield Cups

3. On torches with a shield cup body and a New Electrode

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
Worn Electrode
shield cup body and drag shield cap. Do not Art # A-03284

lubricate the O-Ring. Electrode Wear

Drag Shield Cap
7. Reinstall the Electrode by pushing it straight
Shield into the torch head until it clicks.
Cup Body
8. Reinstall the desired starter cartridge and tip
into the torch head.
9. Hand tighten the shield cup until it is seated
O-Ring No. 8-3488 on the torch head. If resistance is felt when
installing the cup, check the threads before
proceeding.

Art # A-03878 This completes the parts replacement procedures.

5T-2 SERVICE Manual 0-5405
 ESAB CUTMASTER 120
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:

6.03 Power Supply Replacement

6.04 Replacement Power Supply Parts
6.05 Options and Accessories
6.06 Replacement Parts for Hand Torch
6.07 Replacement Parts - for Machine Torches with Unshielded Leads
6.08 Replacement Shielded Machine Torch Leads Assemblies
6.09 Torch Consumable Parts (SL100)

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 authoriza-
tion 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 ESAB CutMaster 120 Power Supply, CCC version
®

with 400VAC 3 Phase input power cable C559319303

Manual 0-5405 PARTS LIST 6-1

ESAB CUTMASTER 120
6.04 Replacement Power Supply Parts
Qty Description Catalog #
1 Regulator 9-0115
1 Filter Assembly Replacement Element 9-0116
1 Input Power Cord for 380/400 V Power Supply 9-0216

6.05 Options and Accessories

Qty Description Catalog #
1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two - Stage Filter Kit (includes Hose & Mounting Screws) 9-9387
1 Two - Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Extended Work Cable (50 ft / 15.2 m) with Clamp 9-8529
1 Automation Interface Kit,
Controls Start/ Stop, OK to Move and divided arc voltage 9-8311
1 Automation Interface Harness
Controls Start/ Stop, OK to Move 9-9385
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008
1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011

Housing

Filter
Element
(Cat. No. 9-7741)

Spring

O-ring
(Cat. No. 9-7743) Assembled Filter First & Second
Stage
Cover Cartridges
(as marked)
Barbed
Fitting Art # A-02476 Art # A-02942

Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

6-2 PARTS LIST Manual 0-5405
 ESAB CUTMASTER 120
6.06 Replacement Parts for Hand Torch
Item # Qty Description Catalog #
1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
2 1 Trigger Assembly Replacement Kit 9-7034
3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O-Ring 8-3487
6 1 Small O-Ring 8-3486
7 Leads Assemblies with ATC connectors (includes switch assemblies)
1 SL100, 20 - foot / 6.1m Leads Assembly with ATC connector 4-7836
1 SL100, 50 - foot / 15.2m Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031
10 1 Adaptor for Torch Control Cable (including Item 11)(not shown) 7-3447
11 1 Through-hole Protector (not shown) 9-8103

5
6
3

Art # A-07993_AB

Manual 0-5405 PARTS LIST 6-3

ESAB CUTMASTER 120
6.07 Replacement Parts - for Machine Torches with Unshielded Leads
Item No. Qty Description Catalog No.
1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O-Ring 8-3487
3 1 Small O-Ring 8-3486
4 1 PIP Switch Kit 9-7036
5 Unshielded Automated Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853
6 Unshielded Mechanized Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Le-ads Assembly with ATC connector 4-7842
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845
7 1 11” / 279 mm Rack 9-7041
8 1 11” / 279 mm Mounting Tube 9-7043
9 1 End 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 PIP Plunger and Return Spring Kit 9-7045
1 Pinion Assembly (Not shown) 7-2827
1 5” / 126 mm Positioning Tube (Not shown) 9-7042

NOTE!
* Control cable adaptor or through-hole protector is not included.
Refer to Section 6.08 "Replacement Shielded Machine Torch Leads Assemblies".

6-4 PARTS LIST Manual 0-5405
 ESAB CUTMASTER 120

10

10

1
2 11
3
12
4

13

5&6

A-07994_AB

Manual 0-5405 PARTS LIST 6-5

ESAB CUTMASTER 120
6.08 Replacement Shielded Machine Torch Leads Assemblies
Item No. Qty Description Catalog No.
1 Mechanized Shielded Leads Assemblies with ATC Connectors
1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846
1 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847
1 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848
1 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849

Remote Pendant Adapter is Torch Continuity

present on Mechanized leads only. ('PIP') Switch

A-03684

6-6 PARTS LIST Manual 0-5405
 ESAB CUTMASTER 120
6.09 Torch Consumable Parts (SL100)

Ohmic Clip
Automation Torch
Ohmic Clip 9-8224
Manual Torch
9-8259

20-40A Tip:
Shield
Cup Body, Shield Cap, Machine
STANDOFF 40A 9-8245
9-8237
CUTTING

20A 9-8205 Shield Cup Shield Cap, Deflector

30A 9-8206 9-8218 9-8243
40A 9-8208

Drag Shield Cup

9-8235

50-60A Tips:
Shield
Cup Body,
STANDOFF Shield Cap, Machine
CUTTING 9-8237
50-60A 9-8238

50-55A 9-8209 Shield Cup

60A 9-8210 9-8218 Shield Cap, Deflector
9-8243

Drag Shield Cup

70-100A 9-8236
Electrode Starter
Auto 9-8232 Cartridge Tips: Shield Drag Shield Cup
Manual 9-8215 9-8277 Cup Body, 120A 9-8258
9-8237
Shield Cap, Machine
70-100A 9-8239
70-120A 70A 9-8231
STANDOFF 80A 9-8211 Shield Cup Shield Cap, Machine
CUTTING 90/100A 9-8212 9-8218 120A 9-8256
120A Auto 9-8233
120A Manual 9-8253
Shield Cap, Deflector
9-8243

40-120A
GOUGING Shield
Cup Body,
9-8237
Tips:

Tip A 9-8225 (40 Amps Max.) Shield Cup, Gouging

9-8241
Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Art # A-11506 Tip E 9-8254 (60 - 120 Amps)

Manual 0-5405 PARTS LIST 6-7

ESAB CUTMASTER 120

This Page Intentionally Blank

6-8 PARTS LIST Manual 0-5405
 ESAB CUTMASTER 120
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION: ACTION: ACTION: ACTION:
ON / OFF switch to ON RUN / Rapid Auto Restart /
Close external RUN / SET / LATCH
disconnect switch. Rapid Auto Restart /
RESULT: switch to RUN
RESULT: SET / LATCH switch
AC indicator ON. to SET (for most applications)
Power to system. or to
GAS indicator ON Rapid Auto Restart
when input RESULT:
pressure is adequate (for gouging, trimming,
for power supply operation. Gas flows to set or expanded metal
pressure. applications)
Power circuit ready.
or to
LATCH

is used for specific applications

(torch switch can be released
after main arc transfer).

ACTION: RESULT: Gas flow stops.

Connect work cable to workpiece.

Set output amperage. ACTION:
RESULT:
Torch moved away from work (while
System is ready still activated).
for operation.
RESULT:

Main arc stops.

Pilot arc automatically
ACTION:
restarts.
Protect eyes and activate
Torch switch (START) PILOT ARC
RESULT:

Fans turn on. Gas flows briefly, ACTION:

then stops.Gas restarts.
Torch moved within
DC indicator ON transfer distance of workpiece.
Pilot arc established.
RESULT:

Main arc transfers.

Pilot arc off.
ACTION:
Release Torch switch.
RESULT: ACTION:
ACTION:
Main arc stops. Unplug input
Gas flow stops after post - flow. ON / OFF switch power cord or
to OFF open external
(Fans will continue to run for disconnect.
10 minutes after the Torch switch RESULT:
[START] is removed) RESULT:
All indicators off. No power to system.
Power supply fans shut off.
Art #A-07979_AB

Manual 0-5405 APPENDIX A-1

ESAB CUTMASTER 120
APPENDIX 2: DATA TAG INFORMATION
Manufacturer's Name and/or
Logo, Location, Model and
Model: Revision Level, Serial Number
S/N and Production Code
Date of Mfr:
3~ f1 Regulatory Standard Covering
Type of Power f2
This Type of Power Supply
Supply (Note 1)
Duty Cycle Factor
Output Current Type Output Range (Amperage/
Plasma Cutting Voltage)
Symbol X
I Duty Cycle Data (Note 3)
U 0=
S U2

Rated No- Conventional Rated Maximum

Load Voltage Load Voltage Supply Current
Input Power
Symbol U1 I1max I1eff Maximum Effective
3ø 3ø
Supply Current
Input Power
Specifications
(Phase, AC or DC Manufacturer's Electrical
Hertz Rating) Schematic File Number
and Revision Level
Degree of Rated Supply
Protection Voltage (Note 2)

NOTES:
1. Symbol shown indicates three-phase AC input, static
Standard Symbols
frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power AC
supplies carry a label at the input power cord showing input DC
voltage requirements for the power supply as built.
3. Top row: Duty cycle values. Ø Phase
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission.
Duty cycle value is determined under the power supply
Art # A-12784_AA
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.

A-2 APPENDIX Manual 0-5405
 ESAB CUTMASTER 120
APPENDIX 3: TORCH PIN - OUT DIAGRAMS
A. Hand Torch Pin - Out Diagram

ATC Male Connector ATC Female Receptacle

Negative / Front View Front View Negative /
Plasma Plasma

4 - Green / 8 - Open 8 - Ground

Switch 4 - Switch

7 - Open 7 - Open 3 - Switch

3 - White / 4 8 8 4
Switch 3 7 7 3
2 6 6 - Open 6 2
2- Orange / 6 - Open
1 5 5 1 2 - PIP
PIP
5 - Open 5 - Open
1 - PIP
1 - Black /
PIP Pilot
Pilot A-03701

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector UNSHIELDED MACHINE TORCH ATC Female Receptacle
Front View Front View
Negative / Plasma
Negative / Plasma
8 - Green -
4- Black -
Pendant
Pendant
Connector 8 - Ground 4 - Switch
Connector
Ground
3 - White -
4 8 7 - Green / 3 - Switch
Pendant 7 - Open 8 4
3 7 Not Used
Connector 7 3
2 6 6 2
6 - Open
2 - Orange / 1 5 5 1
6 - Open 2 - PIP
PIP

5 - White / 1 - PIP
1 - Black / 5 - Open
Not Used
PIP
Pilot Pilot

Art # A-03799

Manual 0-5405 APPENDIX A-3

 ESAB CUTMASTER 120
APPENDIX 4: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram

Torch: SL60 / SL100 Hand Torch

Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle Male
ATC Leads ATC Female
Connector Receptacle Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
5 5
6 6
Torch Green 4 4 To Power Supply
Switch White 3 3 Circuitry
8 8
7 7
Negative / Plasma 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 To Remote Control
Power Supply: with ATC Female Receptacle
Remote
Male ATC Female
Pendant
ATC Leads Receptacle
Connector
Connector
Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
White 5 5
6 6
Not Black 4 4 To Power Supply
Used
White 3 3 Circuitry
Green 8 8
Green 7 7
Negative / Plasma Lead Negative / Plasma
Pilot Lead
Pilot

Art # A-03798

A-4 APPENDIX Manual 0-5405
 ESAB CUTMASTER 120

This Page Intentionally Blank

Manual 0-5405 APPENDIX A-5

ESAB CUTMASTER 120
APPENDIX 5: SYSTEM SCHEMATIC, 380/400V UNITS
5 4

T1

SW1 J1 PRI 3 PRI 4

1 3 1 C D
2 BIAS
3 SUPPLY
2 4
4 B
5 PRI 2 PRI 2

D
INRUSH A
+12VDC RESISTORS PRI 1 PRI 1

+ TP2 MTH1 MTH2 TP1 +

K1

Q1

*CHOKE
EMI
/INRUSH
+12VDC
D1 BIAS
SUPPLY
+ C3,C4,C7,C8*

* CE UNITS
ONLY

TP8 MTH7
MTH4 TP5

*FILTER
EMI
W1
_ AC1 80A_AC1
7
L1 1 1
L1 T1
AC2 80A_AC2
L2 2 2
L2 T2
8

9
L3 3 3
L3 T3
AC3 80A_AC3

GND 4 4 L4 T4
7A

380/400/415V
OR 600V
3 PH AC INPUT
PRIMARY POWER CONNECTIONS:
USE L1, L2, L3 & GND MTH8 TP4

+12VDC
MOT1 J7 TP3
C MTH6
1
+ FAN - 2 /FAN
Q2

C5,C6,C9,C10*
+
J5

SOL 1 1
2
3 /SOLENOID

5 24VAC
J6

W1 1
2 24VAC RET
_
6
J14
J4
SYNC
1 3.3VDC
2 TXD
SERIAL PORT 3 RXD
1 /OVERTEMP
4 2 /FAN_ON
5 D
3 /CSR
4 CUR_SET
5 MAIN_PCB_ID PCB1 MAIN PCB ASSY
6 COMMON

J13
1
2
3
4
5
6

T2

FERRITE
FILTER +12VDC
J2
B
1
2

J4 J3
1
2
3
4
5
6
7
8
9
10

1
2

PRI 1 PRI 2 PRI 3 PRI 4

+12VDC
MOT2 +12VDC A B C D
+

J1
FAN 1 J9
2 /FAN
SYNC +
-

AC1 40A_AC1
MOT3 Q1
+

J2
FAN AC2 40A_AC2
1
2
AC3 40A_AC3
-

PMTH1 PMTH1
+
C16-17 +

D1
PMTH2 PMTH2

PMTH3 PMTH3

PCB2 INPUT CAPACITOR PCB

Q2
C7 & C10 may not be installed C12-13
+

PMTH4 PMTH4

PCB5 40/50 AMP PCB

A-12770_AA
5 4

A-6 APPENDIX Manual 0-5405
 ESAB CUTMASTER 120

3 2 1

1TORCH
TS1
PIP SWITCH

L1
TORCH SWITCH
J11
1
2

SEC1 SEC2 CHOKE1

+12VDC

ATC CONNECTOR
J1
1 1 AUTOMATION
TEMP /OVERTEMP 2 2
CIRCUIT TORCH SOLENOID
3 3
4 4 D
5 5
6 6
NTC 7 7
8 8
-V OUT 1

-
E64
ELECTRODE1

+
D3 TIP1 E35
Q5

PILOT IGBT

WORK1
WORK

J9
78
/PIP 1
79
2 80
/START 3
81
4
24VAC RETURN 82
5
6 83
24VAC SUPPLY 7

J2

J10 P10 14

1 1
13
12
} OK TO MOVE
CNC PINOUT
OK-TO-MOVE 2 2 11
(5A @ 250VAC / 30VDC) 3 3 10 3 1
4 4 9
5 5 8 7 4
+12VDC
6 6 7 11 8
7 7 6 14 12
8 8 5
4
3
} /START / STOP
2
1

J2
C

40 PIN RIBBON CABLE SIGNALS FULL FEATURED AUTOMATION INTERFACE PCB OPTION
TEST POINTS 1 -V_OUT_SIGNAL M-L
D59 PCR 2 /TIP_VOLTS M-L *
GND1 COMMON 3 /TIP_SENSE M-L * To configure DIVIDED ARC VOLTS signal output
GND2 COMMON 4 /460V_IN L-M No jumper installed for ARC VOLTS / 16.67
+12V1 +12 VDC SUPPLY 5 /230V_IN L-M Jumper pins 1 & 2 for ARC VOLTS / 30
48V1 +48 VDC SUPPLY 6 CUR_SET L-M Jumper pins 2 & 3 for ARC VOLTS / 50

1
2
3
D78 CSR I_DMD_1 CURRENT DEMAND To -V OUT 1 P1
7 /RAR (RAPID AUTO RESTART) L-M
TIP_SEN TIP DRAG SENSE on PCB1
8 /INRUSH L-M
E1 J1
9 /W1_ON L-M
10 SHDN L-M 1
11 /TORCH_SOLENOID L-M 2
12 /SOLENOID_ON L-M 3
13 /OK_TO_MOVE L-M
P10 P2 +12VDC
4
} /START / STOP
} (+) *DIVIDED
14 /FAN_ON L-M 1 1 1 5 (-)
15 /LATCH_ACTIVE ARC VOLTS
L-M 2 2 2 6
16 /TORCH_SWITCH M-L 3 3 3 K1 7 (-)
17
18
/PIP
AC_ON
M-L
M-L
4
5
4
5
4
5
8
9
} (+) ARC VOLTS
(W/ 100K IN SERIES (2))
19 CSR M-L 6 6 6 10
FERRITE
FILTER
20 /TORCH_SOLENOID_DETECT M-L 7 7 7 PCB4 11
21 /OVERTEMP M-L 8 8 8 12
22 V_IN M-L AUTOMATION K1 13 } OK-TO-MOVE
23 +12VDC M-L INTERFACE PCB 14
24 +12VDC M-L
25 COMMON M-L
26 COMMON M-L
29 MAIN_PCB_ID M-L
34 460_IN M-L
35 +3.3VDC L-M
36 TXD M-L
37 RXD M-L
38 COMMON L-M
39 D M-L

L2

J1

SEC1 SEC2 CHOKE1

ERROR IND FAULT

AC MAX
MAX OVER PRESSURE
90 INTERNAL ERROR
85 SHORTED TORCH
OVERTEMP 80 CONSUMABLES MISSING 90
75 START ERROR
70 PARTS IN PLACE
65 INPUT POWER
GAS MIN UNDER PRESSURE 85

TEST POINTS
DC 80
TP1 GND
TP2 +12 VDC
TP3 +5 VDC
D2 ERROR TP4 3.3 VDC 75 GAS CONTROL
TP5 0.v - 5.0 VDC / 0-100PSI
TP6 1.8 VDC
REGULATOR
TP7 CURRENT DEMAND
70
SOLENOID
VALVE ATC
Current Control
NTC TEMP +12VDC 65 FILTER
/OVERTEMP
CIRCUIT AIR
INLET
LATCH D1
MIN PRESSURE
SET TRANSDUCER

RUN J3
+5VDC
1
2
3

+OUT_1 RAR 3
0-100PSI / 0-4.5VDC 2
1
PCB3 LOGIC PCB

A-12770_AA
Rev Revisions By Date PCB No:
SEE

AA INTRO ECO B1357 RWH 03/31/09 Assy No:

Scale Supersedes
AB ECO B1399 RWH 05/05/09
AB ECO B1611 RWH 05/05/09
Date:
MARCH 30, 2009

Drawn: References
A-09130

NOTE: RWH
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF) Chk: App: Sheet
1 of 1
TITLE: SCHEMATIC, ESAB Cutmaster 100/120 20'/50' SL100 400V/208-460V Size DWG No:
Last Modified: Friday, December 11, 2009 09:02:19 3ph CE/Non-CE CCC/ 1/3ph CSA (Configured for 460V 3ph) D 42X1330
3 2 1

Manual 0-5405 APPENDIX A-7

ESAB CUTMASTER 120
APPENDIX 6: Publication History
Cover Date Rev. Change(s)

Jan. 15, 2015 AA Manual released.

April 8, 2015 AB Updated per ECO-B2708. Changed "SL60/ Manual" pg. 2T-1 to "SL100/ Manual".
July 6, 2015 AC Corrected Duty Cycle in Section 2.04 and suggested flexible cord size in Section 2.05 per
VCN-00920.

A-8 APPENDIX Manual 0-5405
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