®

120 208- 380-

230V 400V 460V 600V

CUTMASTER® A120
AUTOMATED PLASMA
CUTTING SYSTEM

Operating
Manual
Art # A-08955_AD

Revision: AU Issue Date: November 16,2023 Manual No.: 0-4989

Thermal-Dynamics.com
 ®

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are proud to have you as our
customer and will strive to provide you with the best service and reliability in the industry.
This product is backed by our extensive warranty and world-wide service network. To locate
your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at www.
thermal-dynamics.com.

This Operating Manual has been designed to instruct you on the correct use and operation of
your Thermal Dynamics product. Your satisfaction with this product and its safe operation is
our ultimate concern. Therefore please take the time to read the entire manual, especially the
Safety Precautions. They will help you to avoid potential hazards that may exist when working
with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for
Thermal Dynamics Corporation.

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 installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply

CutMaster® A120
SL100 1Torch™
Operating Manual Number 0-4989

Published by:
Thermal Dynamics Corporation
2800 Airport Rd.
Denton,Texas 76207

www.thermal-dynamics.com

Copyright 2008, 2009, 2010, 2012, 2013, 2014, 2016 by

Thermal Dynamics Corporation

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 dam-
age caused by any error or omission in this Manual, whether such error results from negligence,
accident, or any other cause.

Original Publication Date: June 30, 2008

Revision Date: November 16, 2023

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,” Booklet 0-5407. Do NOT permit untrained persons to install, operate, or main-
tain this equipment. 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 instruc-
tions, 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 ac-
companying 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 main-
tained 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 manu-
facturer. 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 AN D OTHERS!
 ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.
VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.

MISE EN GARDE
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualifiés seulement. Si vous
n’avez pas une connaissance approfondie des principes de fonctionnement et des règles
de sécurité pour le soudage à l’arc et l’équipement de coupage, nous vous suggérons de
lire notre brochure « Precautions and Safe Practices for Arc Welding, Cutting and Gouging,
» Brochure 0-5407. Ne permettez PAS aux personnes non qualifiées d’installer, d’opérer
ou de faire l’entretien de cet équipement. Ne tentez PAS d’installer ou d’opérer cet équi-
pement avant de lire et de bien comprendre ces instructions. Si vous ne comprenez pas
bien les instructions, communiquez avec votre fournisseur pour plus de renseignements.
Assurez-vous de lire les Règles de Sécurité avant d’installer ou d’opérer cet équipement.

RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’ac-
compagnement et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé
selon les instructions fournies. Vous devez faire une vérification périodique de l’équipement. Ne jamais
utiliser un équipement qui ne fonctionne pas bien ou n’est pas bien entretenu. Les pièces qui sont brisées,
usées, déformées ou contaminées doivent être remplacées immédiatement. Dans le cas où une réparation
ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande de conseil
de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modifiés sans permission préalable écrite par le fabri-
cant. L’utilisateur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation
incorrecte, un entretien fautif, des dommages, une réparation incorrecte ou une modification par une
personne autre que le fabricant ou un centre de service désigné par le fabricant.

!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT
D’INSTALLER OU D’OPÉRER L’UNITÉ.

PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank
 DECLARATION OF CONFORMITY

According to
The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016
The EMC Directive 2014/30/EU, entering into force 20 April 2016
The RoHS Directive 2011/65/EC, entering into force 2 January 2013

Type of equipment
PLASMA CUTTING SYSTEM

Type designation etc.

A120, from serial number MX1518XXXXXX

Brand name or trade mark

Thermal Dynamics

Manufacturer or his authorised representative

Name, address, telephone No:
Thermal Dynamics
2800 Airport Rd
Denton TX 76207
Phone: +01 800 426 1888, FAX +01 603 298 7402

The following harmonised standard in force within the EEA has been used in the design:

IEC/EN 60974-1:2017 / AMD 1:2019 - Arc Welding Equipment - Part 1: Welding power sources. IEC/EN 60974-10:2014 +
AMD 1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC) requirements

Additional Information: Restrictive use, Class A equipment, intended for use in location other than residential.

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative, that the equipment in question complies with the safety requirements stated above.

Date Signature Position

March 1, 2019 Vice President

John Boisvert Global Cutting
Mechanized Cutting

2019
This page intentionally blank.
 TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION.......................................................................................................1-11
1.01 Notes, Cautions and Warnings.......................................................................................................................1-11
1.02 Important Safety Precautions........................................................................................................................1-11
1.03 Publications..........................................................................................................................................................1-12
1.04 Note, Attention et Avertissement.................................................................................................................1-13
1.05 Precautions De Securite Importantes.........................................................................................................1-13
1.06 Documents De Reference................................................................................................................................1-15
1.08 Statement of Warranty.....................................................................................................................................1-16

SECTION 2 SYSTEM: INTRODUCTION .......................................................................................................2-19

2.01 How To Use This Manual..................................................................................................................................2-19
2.02 Equipment Identification.................................................................................................................................2-19
2.03 Receipt Of Equipment......................................................................................................................................2-19
2.04 Power Supply Specifications..........................................................................................................................2-20
2.05 Input Wiring Specifications.............................................................................................................................2-21
2.06 Power Supply Features.....................................................................................................................................2-22

SECTION 2 TORCH: INTRODUCTION ....................................................................................................... 2T-23

2T.01 Scope of Manual...............................................................................................................................................2T-23
2T.02 General Description.........................................................................................................................................2T-23
2T.03 Specifications ....................................................................................................................................................2T-23
2T.04 Options And Accessories...............................................................................................................................2T-24
2T.05 Introduction to Plasma...................................................................................................................................2T-24

SECTION 3 SYSTEM: INSTALLATION .........................................................................................................3-27

3.01 Unpacking 3-27
3.02 Lifting Options.....................................................................................................................................................3-27
3.03 Power Supply location and Mounting........................................................................................................3-27
3.04 Opening the Contactor Cover........................................................................................................................3-27
3.05 Primary Input Power Connections...............................................................................................................3-27
3.06 Gas Connections.................................................................................................................................................3-29

SECTION 3 TORCH: INSTALLATION.......................................................................................................... 3T-33

3T.01 Torch Connections...........................................................................................................................................3T-33
3T.02 CNC Connection...............................................................................................................................................3T-33
3T.03 Setting Up Automation or Machine Torch...............................................................................................3T-35

SECTION 4 SYSTEM: OPERATION..............................................................................................................4-37

4.01 Front Panel Controls / Features.....................................................................................................................4-37
4.02 Preparations for Operation.............................................................................................................................4-38

SECTION 4 TORCH: OPERATION.............................................................................................................. 4T-41

4T.01 Machine and Automated Torch Operation.............................................................................................4T-41
4T.02 Automation Torch Parts Selection..............................................................................................................4T-41
4T.03 Machine and Hand Torch Parts Selection................................................................................................4T-42
4T.04 Cut Quality .........................................................................................................................................................4T-43
4T.05 General Cutting Information........................................................................................................................4T-43
4T.06 Hand Torch Operation....................................................................................................................................4T-44
4T.07 Gouging .........................................................................................................................................................4T-47
4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip.....4T-48
4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip....4T-72
 TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE....................................................................................................................5-91
5.01 General Maintenance........................................................................................................................................5-91
5.02 Maintenance Schedule.....................................................................................................................................5-92
5.03 Common Faults...................................................................................................................................................5-92
5.04 Fault Indicator......................................................................................................................................................5-93
5.05 Basic Troubleshooting Guide.........................................................................................................................5-94
5.06 Power Supply Basic Parts Replacement.....................................................................................................5-96

SECTION 5 TORCH: SERVICE.................................................................................................................... 5T-99

5T.01 General Maintenance......................................................................................................................................5T-99
5T.02 Inspection and Replacement of Consumable Torch Parts (40A-80A)......................................... 5T-100
5T.03 Inspection and Replacement of Consumable Torch Parts (110 A)............................................... 5T-101

SECTION 6: PARTS LISTS..........................................................................................................................6-103

6.01 Introduction...................................................................................................................................................... 6-103
6.02 Ordering Information..................................................................................................................................... 6-103
6.03 Power Supply Replacement......................................................................................................................... 6-103
6.04 Replacement Power Supply Parts.............................................................................................................. 6-104
6.05 Options and Accessories............................................................................................................................... 6-104
6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube).......................... 6-106
6.07 Torch Consumable Parts (SL100)............................................................................................................... 6-108
6.08 Replacement Parts for Hand Torch ........................................................................................................... 6-109

APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM).............................................................. A-111

APPENDIX 2: DATA TAG INFORMATION................................................................................................ A-112

APPENDIX 3: TORCH PIN - OUT DIAGRAMS.......................................................................................... A-113

APPENDIX 4: TORCH CONNECTION DIAGRAMS................................................................................... A-115

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS.......................................................................... A-118

APPENDIX 6: SYSTEM SCHEMATIC, 400/600V UNITS.......................................................................... A-120

APPENDIX 7: RAW ARC VOLTAGE .......................................................................................................... A-122

APPENDIX 8 : MOD BUSS HARNESS CONNECTION(OPTIONAL)...................................................... A-124

APPENDIX 9: PUBLICATION HISTORY................................................................................................... A-126

 CUTMASTER A120
SECTION 1:
GENERAL INFORMATION GASES AND FUMES
Gases and fumes produced during the plasma cutting process can
be dangerous and hazardous to your health.
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used • Keep all fumes and gases from the breathing area. Keep
to highlight important information. These highlights are catego- your head out of the welding fume plume.
rized as follows: • Use an air-supplied respirator if ventilation is not adequate
NOTE to remove all fumes and gases.
An operation, procedure, or background information • The kinds of fumes and gases from the plasma arc depend
which requires additional emphasis or is helpful in on the kind of metal being used, coatings on the metal, and
efficient operation of the system. the different processes. You must be very careful when cut-
ting or welding any metals which may contain one or more
of the following:
Antimony Chromium Mercury
CAUTION Arsenic Cobalt Nickel
A procedure which, if not properly followed, may Barium Copper Selenium Beryl-
cause damage to the equipment. lium Lead Silver
Cadmium Manganese Vanadium

!
• Always read the Material Safety Data Sheets (MSDS) that
should be supplied with the material you are using. These
WARNING MSDSs will give you the information regarding the kind and
A procedure which, if not properly followed, may amount of fumes and gases that may be dangerous to your
cause injury to the operator or others in the operat- health.
ing area. • For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications
in this manual.
• Use special equipment, such as water or down draft cutting
WARNING tables, to capture fumes and gases.
Gives information regarding possible electrical shock • Do not use the plasma torch in an area where combustible
injury. Warnings will be enclosed in a box such as this. or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlo-
rinated solvents and cleansers. Remove all sources of these
1.02 Important Safety Precautions vapors.
• WARNING: This product contains chemicals, including lead,

!
known to the State of California to cause birth defects and
other reproductive harm. Wash hands after handling.
WARNING
OPERATION AND MAINTENANCE OF PLASMA ARC ELECTRIC SHOCK
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH. Electric Shock can injure or kill. The plasma arc process uses and
produces high voltage electrical energy. This electric energy
Plasma arc cutting produces intense electric and can cause severe or fatal shock to the operator or others in the
magnetic emissions that may interfere with the workplace.
proper function of cardiac pacemakers, hearing aids,
or other electronic health equipment. Persons who • Never touch any parts that are electrically “live” or “hot.”
work near plasma arc cutting applications should
• Wear dry gloves and clothing. Insulate yourself from the
consult their medical health professional and the
work piece or other parts of the welding circuit.
manufacturer of the health equipment to determine
whether a hazard exists. • Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or
To prevent possible injury, read, understand and fol-
damp.
low all warnings, safety precautions and instructions
before using the equipment. Call 1-603-298-5711 or • Install and maintain equipment according to NEC code, refer
your local distributor if you have any questions. to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or
repairs.
• Read and follow all the instructions in the Operating Manual.

Manual 0-4989 GENERAL INFORMATION 1-11

CUTMASTER A120
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters may
FIRE AND EXPLOSION be used when the arc is hidden by the workpiece.

Fire and explosion can be caused by hot slag, sparks, or the plasma
arc. ! WARNING
• Be sure there is no combustible or flammable material in
WARNING: This product contains chemicals, including lead, known
the workplace. Any material that cannot be removed must
to the State of California to cause birth defects and other reproduc-
be protected.
tive harm. Wash hands after handling.
• Ventilate all flammable or explosive vapors from the work-
place.
• Do not cut or weld on containers that may have held com- 1.03 Publications
bustibles.
• Provide a fire watch when working in an area where fire Refer to the following standards or their latest revisions for more
hazards may exist. information:
• Hydrogen gas may be formed and trapped under aluminum 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
workpieces when they are cut underwater or while using a obtainable from the Superintendent of Documents, U.S.
water table. DO NOT cut aluminum alloys underwater or on Government Printing Office, Washington, D.C. 20402
a water table unless the hydrogen gas can be eliminated or 2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,
dissipated. Trapped hydrogen gas that is ignited will cause obtainable from the American Welding Society, 550 N.W.
an explosion. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superin-
NOISE tendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
Noise can cause permanent hearing loss. Plasma arc processes can
cause noise levels to exceed safe limits. You must protect your ears 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
from loud noise to prevent permanent loss of hearing. AND EDUCATIONAL EYE AND FACE PROTECTION, obtain-
able from American National Standards Institute, 1430
• To protect your hearing from loud noise, wear protective Broadway, New York, NY 10018
ear plugs and/or ear muffs. Protect others in the workplace.
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
• Noise levels should be measured to be sure the decibels FOOTWEAR, obtainable from the American National Stan-
(sound) do not exceed safe levels. dards Institute, 1430 Broadway, New York, NY 10018
• For information on how to test for noise, see item 1 in Sub- 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF
section 1.03, Publications, in this manual. CUTTING AND WELDING PROCESSES, obtainable from
American National Standards Institute, 1430 Broadway,
New York, NY 10018
PLASMA ARC RAYS 7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
Plasma Arc Rays can injure your eyes and burn your skin. The ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
plasma arc process produces very bright ultra violet and infra red American Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126
light. These arc rays will damage your eyes and burn your skin if
you are not properly protected. 8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
• To protect your eyes, always wear a welding helmet or shield. from the National Fire Protection Association, Battery-
Also always wear safety glasses with side shields, goggles march Park, Quincy, MA 02269
or other protective eye wear.
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtain-
• Wear welding gloves and suitable clothing to protect your able from the National Fire Protection Association, Bat-
skin from the arc rays and sparks. terymarch Park, Quincy, MA 02269
• Keep helmet and safety glasses in good condition. Replace 10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
lenses when cracked, chipped or dirty. obtainable from the National Fire Protection Association,
• Protect others in the work area from the arc rays. Use protec- Batterymarch Park, Quincy, MA 02269
tive booths, screens or shields. 11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
• Use the shade of lens as suggested in the following per ANSI/ GASES IN CYLINDERS, obtainable from the Compressed
ASC Z49.1: Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
Minimum Protective Suggested
Arc Current Shade No. Shade No. 12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards
Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

1-12 GENERAL INFORMATION Manual 0-4989

 CUTMASTER A120
Association, Standards Sales, 178 Rexdale Boulevard, Rex- 1.05 Precautions De Securite Importantes
dale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable
from the National Welding Supply Association, 1900 Arch
Street, Philadelphia, PA 19103 ! AVERTISSEMENTS
14. American Welding Society Standard AWSF4.1, RECOM- L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL
MENDED SAFE PRACTICES FOR THE PREPARATION FOR DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT
WELDING AND CUTTING OF CONTAINERS AND PIPING THAT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.
HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL Coupant à l’arc au jet de plasma produit de l’énergie
33126 électrique haute tension et des émissions magné-
tique qui peuvent interférer la fonction propre d’un
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO-
“pacemaker” cardiaque, les appareils auditif, ou autre
TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018 matériel de santé electronique. Ceux qui travail près
d’une application à l’arc au jet de plasma devrait
consulter leur membre professionel de médication et
le manufacturier de matériel de santé pour déterminer
1.04 Note, Attention et Avertissement s’il existe des risques de santé.

Dans ce manuel, les mots “note,”“attention,” et “avertissement” sont Il faut communiquer aux opérateurs et au personnel
utilisés pour mettre en relief des informations à caractère important. TOUS les dangers possibles. Afin d’éviter les blessures
Ces mises en relief sont classifiées comme suit : possibles, lisez, comprenez et suivez tous les avertis-
sements, toutes les précautions de sécurité et toutes
NOTE les consignes avant d’utiliser le matériel. Composez
le + 603-298-5711 ou votre distributeur local si vous
Toute opération, procédure ou renseignement géné-
avez des questions.
ral sur lequel il importe d’insister davantage ou qui
contribue à l’efficacité de fonctionnement du système.

FUMÉE et GAZ
ATTENTION
La fumée et les gaz produits par le procédé de jet de plasma peuvent
Toute procédure pouvant résulter l’endomma-
présenter des risques et des dangers de santé.
gement du matériel en cas de non-respect de la
procédure en question. • Eloignez toute fumée et gaz de votre zone de respiration.
Gardez votre tête hors de la plume de fumée provenant du

!
chalumeau.

AVERTISSEMENT • Utilisez un appareil respiratoire à alimentation en air si l’aération

fournie ne permet pas d’éliminer la fumée et les gaz.
Toute procédure pouvant provoquer des blessures de
l’opérateur ou des autres personnes se trouvant dans la • Les sortes de gaz et de fumée provenant de l’arc de plasma
zone de travail en cas de non-respect de la procédure dépendent du genre de métal utilisé, des revêtements se
en question. trouvant sur le métal et des différents procédés. Vous devez
prendre soin lorsque vous coupez ou soudez tout métal pou-
vant contenir un ou plusieurs des éléments suivants:
AVERTISSEMENT
antimoine cadmium mercure
Fournit l'information concernant des dommages pos- argent chrome nickel
sibles de choc électrique. Des avertissements seront arsenic cobalt plomb
enfermés dans une boîte de ce type. baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité des matières
(sigle américain “MSDS”); celles-ci devraient être fournies avec
le matériel que vous utilisez. Les MSDS contiennent des ren-
seignements quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la fumée et les
gaz de votre lieu de travail, consultez l’article 1 et les documents
cités à la page 5.
• Utilisez un équipement spécial tel que des tables de coupe à
débit d’eau ou à courant descendant pour capter la fumée et
les gaz.

Manuel 0-4989 INFORMATIONS GÉNÉRALES 1-13

CUTMASTER A120
• N’utilisez pas le chalumeau au jet de plasma dans une zone où sous l’eau ou sur une table d’eau à moins que le gas hydrogène
se trouvent des matières ou des gaz combustibles ou explosifs. peut s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.
• Le phosgène, un gaz toxique, est généré par la fumée provenant
des solvants et des produits de nettoyage chlorés. Eliminez
toute source de telle fumée.
RAYONS D’ARC DE PLASMA
• AVERTISSEMENT: Ce produit contient des produits chimiques,
notamment du plomb, reconnu par l'État de la Californie pour Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
causer des malformations congénitales et d'autres dommages brûler votre peau. Le procédé à l’arc de plasma produit une lumière
touchant le système reproductif. Se laver les mains après infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
manipulation. nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou un écran
CHOC ELECTRIQUE
de soudeur. Portez toujours des lunettes de sécurité munies
Les chocs électriques peuvent blesser ou même tuer. Le procédé de parois latérales ou des lunettes de protection ou une autre
au jet de plasma requiert et produit de l’énergie électrique haute sorte de protection oculaire.
tension. Cette énergie électrique peut produire des chocs graves,
• Portez des gants de soudeur et un vêtement protecteur appro-
voire mortels, pour l’opérateur et les autres personnes sur le lieu
prié pour protéger votre peau contre les étincelles et les rayons
de travail.
de l’arc.
• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
• Maintenez votre casque et vos lunettes de protection en bon
gants et des vêtements secs. Isolez-vous de la pièce de travail
état. Remplacez toute lentille sale ou comportant fissure ou
ou des autres parties du circuit de soudage.
rognure.
• Réparez ou remplacez toute pièce usée ou endommagée.
• Protégez les autres personnes se trouvant sur la zone de travail
• Prenez des soins particuliers lorsque la zone de travail est contre les rayons de l’arc en fournissant des cabines ou des
humide ou moite. écrans de protection.

• Montez et maintenez le matériel conformément au Code élec- • Utilisez la nuance de lentille qui est suggèrée dans le recom-
trique national des Etats-Unis. (Voir la page 5, article 9.) mendation qui suivent ANSI/ASC Z49.1:

• Débranchez l’alimentation électrique avant tout travail d’entre- Nuance Minimum Nuance Suggerée
tien ou de réparation. Courant Arc Protective Numéro Numéro

Moins de 300* 8 9
• Lisez et respectez toutes les consignes du Manuel de consignes.
300 - 400* 9 12

400 - 800* 10 14
INCENDIE ET EXPLOSION * Ces valeurs s’appliquent ou l’arc actuel est observé
Les incendies et les explosions peuvent résulter des scories chaudes, clairement. L’experience a démontrer que les filtres
des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma moins foncés peuvent être utilisés quand l’arc est
produit du métal, des étincelles, des scories chaudes pouvant caché par moiceau de travail.
mettre le feu aux matières combustibles ou provoquer l’explosion
de fumées inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable BRUIT
ne se trouve sur le lieu de travail. Protégez toute telle matière Le bruit peut provoquer une perte permanente de l’ouïe. Les pro-
qu’il est impossible de retirer de la zone de travail. cédés de soudage à l’arc de plasma peuvent provoquer des niveaux
• Procurez une bonne aération de toutes les fumées inflammables sonores supérieurs aux limites normalement acceptables. Vous
ou explosives. dúez vous protéger les oreilles contre les bruits forts afin d’éviter
une perte permanente de l’ouïe.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu ren-
fermer des matières combustibles. • Pour protéger votre ouïe contre les bruits forts, portez des tam-
pons protecteurs et/ou des protections auriculaires. Protégez
• Prévoyez une veille d’incendie lors de tout travail dans une zone également les autres personnes se trouvant sur le lieu de travail.
présentant des dangers d’incendie.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels
• Le gas hydrogène peut se former ou s’accumuler sous les pièces (le bruit) ne dépassent pas les niveaux sûrs.
de travail en aluminium lorsqu’elles sont coupées sous l’eau ou
sur une table d’eau. NE PAS couper les alliages en aluminium • Pour des renseignements sur la manière de tester le bruit,
consultez l’article 1, page 5.

1-14 INFORMATIONS GÉNÉRALES Manuel 0-4989

 CUTMASTER A120
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOU-
! AVERTISSEMENT
DAGE, disponible auprès de la National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
AVERTISSEMENT : Ce produit contient des produits chimiques, 11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
notamment du plomb, reconnu par l'État de la Californie pour causer COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des malformations congénitales et d'autres dommages touchant des Gaz Comprimés (Compressed Gas Association), 1235 Jef-
le système reproductif. Se laver les mains après manipulation. ferson Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE
ET LA COUPE, disponible auprès de l’Association des Normes
1.06 Documents De Reference
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
Consultez les normes suivantes ou les révisions les plus récentes
ayant été faites à celles-ci pour de plus amples renseignements : 13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE,
disponible auprès de l’Association Nationale de Fournitures
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE
de Soudage (National Welding Supply Association), 1900 Arch
LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of
Street, Philadelphia, PA 19103
Documents, U.S. Government Printing Office, Washington, D.C.
20402 14. Norme AWSF4.1 de l’Association Américaine de Soudage,
RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARA-
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
TION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX
ET DE SOUDAGE, disponible auprès de la Société Américaine
AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible
de Soudage (American Welding Society), 550 N.W. LeJeune Rd.,
auprès de la American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE,
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès
disponible auprès de l’American National Standards Institute,
du Superintendent of Documents, U.S. Government Printing
1430 Broadway, New York, NY 10018
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (Ame-
rican National Standards Institute), 1430 Broadway, New York,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTEC-
TRICES, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible
auprès de l’American National Standards Institute, 1430 Broad-
way, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre
les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION
EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS
ASSOCIÉS, disponible auprès de la National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

Manuel 0-4989 INFORMATIONS GÉNÉRALES 1-15

CUTMASTER A120
1.08 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to
the original retail purchaser that new Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of
this warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within
the applicable period stated below, Thermal Dynamics Corporation shall, upon notification thereof and substantiation that
the product has been stored operated and maintained in accordance with Thermal Dynamics’ specifications, instructions,
recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in
material or workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within
30 days of any failure, at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures
to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty
periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal
Dynamics Distributor.
LIMITED WARRANTY PERIOD

Power Supply Components Torch and Leads

Product
(Parts and Labor) (Parts and Labor)
U.S. Non U.S.
CUTMASTER® A80 4 Years 3 Years 1 Year
CUTMASTER® A120 4 Years 3 Years 1 Year

This warranty does not apply to:

1. Consumable Parts, such as tips, electrodes, shield cups, o-rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused
based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Technologies
service station. Product returned for service is at the owner’s expense and no reimbursement of travel or transportation
is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or
consequential damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer

1-16 GENERAL INFORMATION Manual 0-4989

 CUTMASTER A120
of distributors (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive
and the liability of Thermal Dynamics with respect to any contract, or anything done in connection therewith such as the
performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered by or furnished
by Thermal Dynamics whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not,
except as expressly provided herein, exceed the price of the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or
performance of any Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective September 4, 2007

Manual 0-4989 GENERAL INFORMATION 1-17

CUTMASTER A120

This Page Intentionally Blank

1-18 GENERAL INFORMATION Manual 0-4989

 CUTMASTER A120
SECTION 2 SYSTEM: 2.02 Equipment Identification

INTRODUCTION 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
2.01 How To Use This Manual not have a data tag such as torch and cable assemblies are
identified only by the specification or part number printed
This Owner’s Manual applies to just specification or part on loosely attached card or the shipping container. Record
numbers listed on page i. these numbers on the bottom of page i for future reference.
To ensure safe operation, read the entire manual, including
2.03 Receipt Of Equipment
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, When you receive the equipment, check it against the invoice
and NOTE may appear. Pay particular attention to to make sure it is complete and inspect the equipment for
the information provided under these headings. possible damage due to shipping. If there is any damage,
These special annotations are easily recognized as notify the carrier immediately to file a claim. Furnish com-
follows: plete information concerning damage claims or shipping
errors to the location in your area listed in the inside back
NOTE cover of this manual.
An operation, procedure, or background infor- Include all equipment identification numbers as described
mation which requires additional emphasis or above along with a full description of the parts in error.
is helpful in efficient operation of the system.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when
using bars, hammers, etc., to un-crate the unit.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.

! WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others in
the operating area.

WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a box
such as this.

Additional copies of this manual may be purchased by

contacting Thermal Dynamics at the address and phone
number in your area listed on the back cover of this manual.
Include the Owner’s Manual number and equipment
identification numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Dynamics web site listed below and clicking on
Thermal Dynamics and then on the Literature link:
http://www.thermal-dynamics.com

Manual 0-4989 INTRODUCTION 2-19

CUTMASTER A120
2.04 Power Supply Specifications
CutMaster A120 Power Supply Specifications
Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz
230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50 Hz
460 VAC (414 - 506 VAC), Single Phase, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (540 - 630), Three Phase, 60 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 120 Amps, Continuously Adjustable
Power Supply Gas Filtering Ability Particulates to 5 Microns
CutMaster A120 Power Supply Duty Cycle *
Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
All Units Duty Cycle **60% 80% 100%
Current 120 120 100
IEC IEC IEC
DC Voltage 128 128 120
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output voltage (DC) is
higher than shown in this chart.
** 60% at 208/230V 1-Phase Input ONLY

NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications
include calculating an output voltage based upon power supply rated current. To facilitate comparison between
power supplies, all manufacturers use this output voltage to determine duty cycle.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

10"
254 mm

Art # A-08459

13.78"
350 mm Art # A-07925_AB

6"
150 mm

26.3" 24"
0.668 m 610 mm
63 lb / 28.6 kg

6" 6"
150 mm 150 mm

2-20 INTRODUCTION Manual 0-4989

 CUTMASTER A120
2.05 Input Wiring Specifications
CutMaster A120 Power Supply Input Cable Wiring Requirements
Input Freq Power Suggested Sizes
voltage Input
Volts Hz kVA I max I eff Fuse (amps) Flexible Cord (Min. Flexible Cord
AWG) (Min. mm2)
1 Phase 208 60 26.2 126 98 150 4 Type W 25 Type W
230 60 27.6 118 95 125 4 Type W 25 Type W
460 60 35 76 68 100 4 25
3 Phase 208 60 21.6 60 55 60 4 25
230 60 22.3 56 50 60 4 25
380 50 23 35 32 40 8 10
400 50 23.6 34 31 40 8 10
460 60 29.5 37 33 40 8 10
600 60 29.0 28 25 30 10 6
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code

NOTE
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installa-
tions refer to local or national codes.
I1max is taken at TDC rated minimum duty cycle.
I1eff is taken at TDC 100% rated duty cycle.

Manual 0-4989 INTRODUCTION 2-21

CUTMASTER A120
2.06 Power Supply Features

Art # A-08460
Control Panel

Torch Leads
Receptacle

Mounting Rails

Work Cable
and Clamp

Automation Interface
Cable Port
Input Power Selection

Filter Assembly

Gas Inlet Port

Input Power Cord Art # A-08461

2-22 INTRODUCTION Manual 0-4989

 CUTMASTER A120
SECTION 2 TORCH: 18.875" / 479 mm

INTRODUCTION
12.285" / 312 mm
2.875” /
73 mm

2T.01 Scope of Manual 1.375" / 35 mm

1.75" / 4.95" / 126 mm 1.175" / 30 mm
This manual contains descriptions, operating instructions 0.625" /
44.5 mm 16 mm Art # A-07402_AC
and maintenance procedures for the 1Torch Models SL100/
Manual and SL100/Mechanized Plasma Cutting Torches. 2. Machine Torch, Model
Service of this equipment is restricted to properly trained The standard machine torch has a positioning tube
personnel; unqualified personnel are strictly cautioned with rack & pinch block assembly.
against attempting repairs or adjustments not covered in
15.875" / 403 mm
this manual, at the risk of voiding the Warranty. 9.285" / 236 mm
Read this manual thoroughly. A complete understanding
of the characteristics and capabilities of this equipment will
assure the dependable operation for which it was designed. 1.175" / 30 mm
1.375" / 35 mm
4.95" / 126 mm
2T.02 General Description 1.75" / 0.625" /
44.5 mm 16 mm Art # A-02998

Plasma torches are similar in design to the automotive spark

3. Hand/Manual Torch, Models
plug. They consist of negative and positive sections sepa-
rated by a center insulator. Inside the torch, the pilot arc The hand torch head is at 75° to the torch handle.
starts in the gap between the negatively charged electrode The hand torches include a torch handle and torch
and the positively charged tip. Once the pilot arc has ion- trigger assembly.
ized the plasma gas, the superheated column of gas flows 10.125" (257 mm)
through the small orifice in the torch tip, which is focused
on the metal to be cut.
A single torch lead provides gas from a single source to be
used as both the plasma and secondary gas. The air flow
is divided inside the torch head. Single - gas operation 3.75"
provides a smaller sized torch and inexpensive operation. (95 mm)
Art # A-03322_AB

NOTE 1.17" (29 mm)

Refer to Section "2T.05 Introduction to
Plasma" on page 2T-24, for a more detailed de- B. Torch Leads Lengths
scription of plasma torch operation. Hand Torches are available as follows:
Refer to the Appendix Pages for additional speci- • 20 ft / 6.1 m, with ATC connectors
fications as related to the Power Supply used. • 50 ft / 15.2 m, with ATC connectors
Machine / Automation Torches are available as
follows:
2T.03 Specifications
• 5 foot / 1.5 m, with ATC connectors

A. Torch Configurations • 10 foot / 3.05 m, with ATC connectors

• 25 foot / 7.6 m, with ATC connectors
1. Automation Torch, Model
• 50 foot / 15.2 m, with ATC connectors
The standard automation torch has a positioning
tube with rack & pinch block assembly and a sole- C. Torch Parts
noid valve.
Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch
12 VDC circuit rating

Manual 0-4989 INTRODUCTION 2T-23

CUTMASTER A120
E. Type Cooling
2T.05 Introduction to Plasma
Combination of ambient air and gas stream through
torch. A. Plasma Gas Flow

F. Torch Ratings Plasma is a gas which has been heated to an extremely

high temperature and ionized so that it becomes electri-
Automated / Machine Torch Ratings cally conductive. The plasma arc cutting and gouging
Ambient 104° F processes use this plasma to transfer an electrical arc to
Temperature 40° C the workpiece. The metal to be cut or removed is melted
by the heat of the arc and then blown away.
100% @ 100 Amps @ 400 scfh
Duty Cycle While the goal of plasma arc cutting is separation of the
80% @ 120 Amps @ 400 scfh
material, plasma arc gouging is used to remove metals
Maximum Current 120 Amps to a controlled depth and width.
Voltage (Vpeak) 500V
In a Plasma Cutting Torch a cool gas enters Zone B,
Arc Striking Voltage 7kV where a pilot arc between the electrode and the torch
Manual Torch Ratings tip heats and ionizes the gas. The main cutting arc
then transfers to the workpiece through the column of
Ambient 104° F plasma gas in Zone C.
Temperature 40° C
Duty Cycle 100% @ 120 Amps @ 400 scfh
Maximum Current 120 Amps
Voltage (Vpeak) 500V
Arc Striking Voltage 7kV

G. Gas Requirements

Automated, Manual and Machine Torch Gas

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

! WARNING
Workpiece
This torch is not to be used with oxygen (O2).
C A-08331

NOTE Typical Torch Head Detail

Operating pressure varies with torch model, op-
erating amperage, and torch leads length. Refer By forcing the plasma gas and electric arc through a
to gas pressure settings charts for each model. small orifice, the torch delivers a high concentration of
heat to a small area. The stiff, constricted plasma arc is
H. Direct Contact Hazard shown in Zone C. Direct current (DC) straight polarity
is used for plasma cutting, as shown in the illustration.
For standoff tip the recommended standoff is 3/16
inches / 4.7 mm. Zone A channels a secondary gas that cools the torch.
This gas also assists the high velocity plasma gas in
2T.04 Options And Accessories blowing the molten metal out of the cut allowing for a
fast, slag - free cut.
For options and accessories, see section 6.

2T-24 INTRODUCTION Manual 0-4989

 CUTMASTER A120
B. Gas Distribution Remote Pendant

The single gas used is internally split into plasma and

secondary gases.
The plasma gas flows into the torch through the nega-
tive lead, through the starter cartridge, around the elec- To ATC PIP Switch Shield Cup
trode, and out through the tip orifice.
The secondary gas flows down around the outside of
the torch starter cartridge, and out between the tip and
shield cup around the plasma arc. CNC Start

C. Pilot Arc
When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot arc
To ATC PIP Switch Shield Cup
creates a path for the main arc to transfer to the work.

D. Main Cutting Arc

Art # A-08168
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 con-
nected to the workpiece via the work cable and to the Automation Torch
torch through a pilot wire.

E. Parts - In - Place (PIP) To ATC PIP Switch Shield Cup

The torch includes a 'Parts - In - Place' (PIP) circuit. When

the shield cup is properly installed, it closes a switch. The
Parts - In - Place Circuit Diagram for Machine Torch
torch will not operate if this switch is open.

Torch Switch Torch Trigger

To Control
Cable Wiring
PIP Switch Shield Cup
A-02997

Parts - In - Place Circuit Diagram for Hand Torch

Manual 0-4989 INTRODUCTION 2T-25

CUTMASTER A120

This Page Intentionally Blank

2T-26 INTRODUCTION Manual 0-4989

 CUTMASTER A120
SECTION 3 SYSTEM: 2. Place the unit in the desired position and mark

INSTALLATION where the four keyway holes in the

mounting rails touch.
3.01 Unpacking 3. Remove the unit and using these markings, prepare
holes for mounting hardware.
1. Use the packing lists to identify and account for each
item. 4. Insert proper hardware. If using hardware that
screws into the mounting surface, leave all four loose
2. Inspect each item for possible shipping damage. If enough for the thickness of the rail to slide under
damage is evident, contact your distributor and / the head and washer if used.
or shipping company before proceeding with the
installation. 5. Lower the power supply over the mounting hard-
ware and slide forward or backward until the keyway
3. Record Power Supply and Torch model and serial stops against the mounting hardware.
numbers, purchase date and vendor name, in the
information block at the front of this manual. 6. Secure the hardware to the rail.

3.02 Lifting Options 3.04 Opening the Contactor Cover

The Power Supply includes hand holds in the front and The input power cord is connected to the main contactor,
rear panels for hand lifting only. Be sure unit is lifted and the contactor is located inside a box with a snap on cover.
transported safely and securely. The cover is held in place with two or more snap lock tabs.
To remove the cover release the front latch and tilt the cover
up about ½ inch. Then squeeze both sides of the cover and
! WARNING
lift it straight up. See the Primary Input Power Connections
section for the necessary changes to the Contactor. Remem-
ber to replace the Contactor Cover when the changes are
Do not touch live electrical parts.
complete.
Disconnect input power cord before moving
unit.
FALLING EQUIPMENT can cause serious per-
sonal injury and can damage equipment.
1
2

• Only persons of adequate physical strength should lift

1
2

the unit.
• Lift unit by the handles, using two hands. Do not use
straps for lifting.
• Use optional cart or similar device of adequate capac-
ity to move unit.
• Place unit on a proper skid and secure in place before Art# A-11478

transporting with a fork lift or other vehicle.

Contactor cover
3.03 Power Supply location and Mounting
3.05 Primary Input Power Connections
NOTE
It is recommended that the unit be secured to a
suitable surface using the mounting rails. CAUTION
1. First choose an appropriate location for mounting Check your power source for correct voltage be-
the power supply. Choose one that allows for free fore plugging in or connecting the unit. Check
movement of torch leads, complies with ventilation the Voltage Selector at the rear of the unit for
per section 2.04 and provides a safe firm surface correct setting before plugging in or connect-
where the unit can be secured. ing the unit. The primary power source, fuse,
and any extension cords used must conform
to local electrical code and the recommended

Manual 0-4989 INSTALLATION 3-27

CUTMASTER A120
circuit protection and wiring requirements as do this is by turning the screw counter-clockwise
specified in Section 2. until you feel the threads line up, then begin
to turn the screw clockwise to tighten. Do not
Most units are shipped from the factory with a 230 Volt over tighten.
input power cable wired to the input contactor in the
single - phase configuration. The following illustrations and
C. Input Power Selection
directions are for changing that configuration to a different
voltage and or to three - phase operation or back again if a Set the Input Voltage Selection Switch at the rear of the unit
change had already been made. based on the primary input voltage it is connected to. Low
is 208/230 VAC and high is 460 VAC.
A. Cover Removal
LO
1. Remove the upper and lower screws which secure
the cover to the main assembly. Do not loosen the

HI
lower screws inside the cut out slots in the bottom
of the cover.
S
NOTE Art # A-08316

The upper screws and lower screws are not the

D. Quick Guide to Phase Wiring
same. Do not mix them. The upper screws are for
threading into the plastic of the front and rear The following illustration and directions are for changing
panels. DO NOT use the finer threaded lower phase of the power supply.
screws for this.
Input Power Cable Connections
Single-Phase (1ø) and Jumper Settings Three-Phase (3ø)
Store copper jumpers on base plate
Upper
Screws L1 L1
L2 L2

Art # A-08493
Lower L3 L3
Screws
L4 L4
GND GND
Slots
Single and Three Phase Input Power Wiring
Lower
Screws NOTE
There are two jumpers used for the single phase
230V setting and none for three phase.

E. Connections to Single Phase Input Power

WARNING
Disconnect input power from the power sup-
ply and input cable before attempting this
Art # A-08429
procedure.

2. Carefully pull the Cover up and away from the unit.

These instructions are for changing the input power and or
B. Cover Installation cable on the 208/230, 400, 460 VAC Power Supply to Single
- Phase input power.
1. Reverse previous procedures for cover installation.
1. Remove the Power Supply cover.
NOTE See "A. Cover Removal".
When installing the upper screws, attempt to
reuse the original threads. The easiest way to

3-28 INSTALLATION Manual 0-4989

 CUTMASTER A120
2. Disconnect the original input power cable from the 3. Loosen the through-hole protector on the back
main input contactor and the chassis ground con- panel of the power supply. Pull the original power
nection. cable out of the power supply.
3. Loosen the through-hole protector on the back 4. Using a customer supplied four - conductor input
panel of the power supply. Pull the original power power cable for the voltage desired, strip back the
cable out of the power supply. insulation on the individual wires.
4. If the power cable being used is not the factory - 5. Pass the cable being used through the access open-
supplied cable, use a three - conductor input power ing in the back panel of the power supply. Refer to
cable for the voltage desired and strip back the Section 2 for power cable specifications.
insulation on the individual wires.
5. Pass the cable being used through the access open-
ing in the back panel of the power supply. Refer to CAUTION
Section 2 for power cable specifications. The primary power source and power cable
must conform to local electrical code and the
recommended circuit protection and wiring
CAUTION requirements (refer to table in Section 2).
The primary power source and power cable 6. Connect the wires as follows.
must conform to local electrical code and the
• Wires to L1, L2 and L3 input. It does not matter
recommended circuit protection and wiring
what order these wires are attached. See previ-
requirements (refer to table in Section 2).
ous illustration and on label in the power supply.
6. Connect the wires as follows.
• Green / Yellow wire to Ground.
• Connect Bus Bar Jumpers on the contactor as
shown in prior illustration and on label in the 7. With a little slack in the wires, tighten the through
power supply. - hole protector to secure the power cable.

• Green / Yellow wire to Ground. 8. Reinstall the Power Supply cover. See "B. Cover
Installation".
7. With a little slack in the wires, tighten the through
- hole protector to secure the power cable. 9. Connect the opposite end of individual wires to a
customer supplied plug or main disconnect.
8. Reinstall the Power Supply cover.
See "B. Cover Installation". 10. Connect the input power cable (or close the main
disconnect switch) to supply power.
9. Connect the opposite end of individual wires to a
customer supplied plug or main disconnect. 3.06 Gas Connections
10. Connect the input power cable (or close the main
disconnect switch) to supply power. Connecting Gas Supply to Unit
The connection is the same for compressed air or high
F. Connections to Three Phase Input Power
pressure cylinders. Refer to the following subsections if an
optional air line filter is to be installed.
WARNING 1. Connect the air line to the inlet port. The illustration
shows typical fittings as an example.
Disconnect input power from the power sup-
ply and input cable before attempting this NOTE
procedure.
For a secure seal, apply thread sealant to the
fitting threads, according to manufacturer's
These instructions are for changing the input power and or instructions. Do not use Teflon tape as a thread
cable on the 208/230, 400, 460 VAC Power Supply to Three sealer, as small particles of the tape may break
- Phase input power. off and block the small air passages in the torch.
1. Remove the Power Supply cover.
See "A. Cover Removal".
2. Disconnect the original input power cable from the
main input contactor and the chassis ground con-
nection.
Manual 0-4989 INSTALLATION 3-29
CUTMASTER A120
Filter Assembly
Filter Assembly

Inlet Port
Inlet Port

Hose Clamp

Gas Supply
Hose
Art # A-08319

Art # A-08320

1/4 NPT or ISO-R Hose Clamp

to 1/4” (6mm) Fitting
Air Connection to Inlet Port Gas Supply 1/4 NPT to 1/4"
Hose (6mm) Fitting

Installing Optional Single - Stage Air Filter Optional Single - Stage Filter Installation
An optional filter kit is recommended for improved filter-
ing with compressed air, to keep moisture and debris out Using High Pressure Air Cylinders
of the torch.
When using high pressure air cylinders as the air supply:
1. Attach the Single - Stage Filter Hose to the Inlet Port.
1. Refer to the manufacturer’s specifications for instal-
2. Attach the Filter Assembly to the filter hose. lation and maintenance procedures for high pres-
sure regulators.
3. Connect the air line to the Filter. The illustration
shows typical fittings as an example. 2. Examine the cylinder valves to be sure they are clean
and free of oil, grease or any foreign material. Briefly
NOTE
open each cylinder valve to blow out any dust which
For a secure seal, apply thread sealant to the may be present.
fitting threads, according to the manufacturer's
3. The cylinder must be equipped with an adjustable
instructions. Do Not use Teflon tape as a thread
high - pressure regulator capable of outlet pressures
sealer, as small particles of the tape may break
up to 100 psi (6.9 bar) maximum and flows of at least
off and block the small air passages in the torch.
300 scfh (141.5 lpm).
Connect as follows:
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.

3-30 INSTALLATION Manual 0-4989

 CUTMASTER A120
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 con-
taminants 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 pressure regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open
each cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100
psi (6.9 bar) maximum and flows of at least 300 scfh (141.5 lpm).
4. Connect supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not
use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages
in the torch.

Manual 0-4989 INSTALLATION 3-31

CUTMASTER A120

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3-32 INSTALLATION Manual 0-4989

 CUTMASTER A120
SECTION 3 TORCH: 3. Place a welding filter lens in front of the torch and
turn ON the air. Do not start an arc!
INSTALLATION Any oil or moisture in the air will be visible on the lens.

3T.01 Torch Connections 3T.02 CNC Connection

If necessary, connect the torch to the Power Supply. Connect 1. Locate the interface connection port on the rear of
only the Thermal Dynamics model SL100SV / Automation, the power supply.
SL100 / Mechanical or SL100 / Manual Torch to this power Automation Interface
supply. Maximum torch leads length is 100 feet / 30.5 m, Cable Port
including extensions.

WARNING
Disconnect primary power at the source before
connecting the torch.

Art # A-08464
1. Align the ATC male connector (on the torch lead)
with the female receptacle. Push the male con-
2. Note the pin-out of the connector and that the
nector into the female receptacle. The connectors
customer supplied connector matches.
should push together with a small amount of pres-
sure. Plasma
Start / Stop
2. Secure the connection by turning the locking nut Signal
clockwise until it clicks. DO NOT use the locking nut Divided
Arc
to pull the connection together. Do not use tools to Voltage
secure the connection.

Plate Contact Common

Cutting Machine
Art # A-08323_AC
OK to Move

1
Art # A-07885

Connecting the Torch to the Power Supply

3. The system is now ready for operation.

Check Air Quality

To test the quality of air:

1. Put the ON / OFF switch in the ON (up) posi-

tion.
2. Put the Function Control switch in the

SET position.

Manual 0-4989 INSTALLATION 3T-33

CUTMASTER A120
DIVIDE RATIO SET BY DIP SW DIV1
DIV1-1 ON = 16.7:1 for SC11 DIV1-4 ON = 40:1 for Inova
DIV1-2 ON = 20:1 for ESAB DIV1-5 ON = 50:1 for IHT:
DIV1-3 ON = 30:1 SC3000 & 3100; Hypertherm®
DIV1-6 ON = 80:1 for TD iHC
DIV1
To -V OUT 1
on PCB1 -V0_1 J1
VOLTAGE

6 5 4 3 2 1
1 DIVIDER
1
CIRCUITS ISO GND
+ - 2

P10 J2 SW1 3 START / STOP (com)

*
+12V
1 1
4 START / STOP

2 2
5 DIVIDED ARC VOLTAGE (-)

3 3
6 DIVIDED ARC VOLTAGE (+)

4 4 OK TO MOVE
PCB4 7
AUTOMATION
5 5 INTERFACE PCB 8 COMMON
(w / OHMIC) 9
6 6 ISO GND

7 7
10 PLATE CONTACT COM
CONTACT PLATE CONTACT OUT
11
8 8 START / STOP
12 OK TO MOVE
TIP OHMIC 13
SENSE OK TO MOVE
1
CIRCUITS 14 OK TO MOVE
To TIP1 OHMIC
on PCB1 CONTACT M-ARC START

OK to MOVE Art # A-09819_AC

Part # 9-8309

WARNING
This divided arc voltage output signal is positive. Its common (-) is referenced to the work lead (ground). Using
this on a height control expecting a negative signal and whose positive input is grounded may damage the
divided arc voltage circuit.

3. Connect CNC to the power supply.

3T-34 INSTALLATION Manual 0-4989

 CUTMASTER A120
3T.03 Setting Up Automation or Machine Torch
NOTE
An adapter is required to be installed in the power supply if converting a hand torch system to operate a ma-
chine or automation torch.

WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.

The Automation and Machine torch include a positioning tube with rack and pinch block assembly.
1. Mount the torch assembly on the cutting table.
2. To obtain a clean vertical cut, use a square to align the torch perpendicular to the surface of the workpiece.

Pinch Block
Assembly

Square

Workpiece
A-02585

Automated and Machine Torch Set - Up

3. The proper torch parts (shield cup, tip, start cartridge, and electrode) must be installed for the type of operation.
Refer to Section 4T.08, Torch Parts Selection for details.

Manual 0-4989 INSTALLATION 3T-35

CUTMASTER A120

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3T-36 INSTALLATION Manual 0-4989

 CUTMASTER A120
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

MIN MIN

Sets the desired output current. Output settings up to

60 Amps may be used for drag cutting (with the torch tip !

contacting the workpiece) or higher for standoff cutting.

2. Function Control
Function Control Knob, Used to select between the
different operating modes. 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 internal
temperature exceeds normal limits. Let the unit cool
RAPID AUTO RESTART Allows for faster re- before continuing operation.
starting of the Pilot Arc for uninterrupted cutting.

LATCH Used for longer hand held or 7. Gas Indicator

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

9. ! Fault Error Indicator

ON / OFF Switch controls input power to the
power supply. Up is ON, down is OFF. Indicator is ON when Fault circuit is active. See section
5 for explanations of fault lights.
4. Air/Gas Pressure Control

The Pressure + Control is used in the "SET"

mode to adjust the air/gas pressure. Pull the knob out
to adjust and push in to lock.

5. AC Indicator
Steady light indicates power supply is ready for opera-
tion. Blinking light indicates unit is in protective inter-
lock mode. Shut unit OFF, shut OFF or disconnect input
power, correct the fault, and restart the unit. Refer to
Section 5 for details.

Manual 0-4989 OPERATION 4-37

CUTMASTER A120
10. Pressure Indicators Connect Work Cable

PSI BAR
Clamp the work cable to the workpiece or cutting table.
MAX MAX
The area must be free from oil, paint and rust. Connect
only to the main part of the workpiece; do not connect
90 6.3 to the part to be cut off.
85 5.9
80 5.5
75 5.2
Art # A-08170

70 4.8
65 4.5
MIN MIN

The Indicators will illuminate according to the pressure Art # A-04509

set by the Pressure Control Knob (number 4). Power ON

Place the Power Supply ON / OFF switch to the ON (up)
4.02 Preparations for Operation position. AC indicator turns ON. Gas indicator
At the start of each operating session:
turns ON if there is sufficient gas pressure for power
supply operation and the cooling fans turn ON.
WARNING NOTE
Disconnect primary power at the source before Minimum pressure for power supply operation is
assembling or disassembling power supply, lower than minimum for torch operation.
torch parts, or torch and leads assemblies.
The cooling fans will turn ON as soon as the
unit is turned ON. After the unit is idle for ten
(10) minutes the fans will turn OFF. The fans will
come back ON as soon as the torch switch (Start
Torch Parts Selection Signal) is activated or if the unit is turned OFF,
Check the torch for proper assembly and appropriate then turned ON again. If an over temperature
torch parts. The torch parts must correspond with the condition occurs, the fans will continue to run
type of operation, and with the amperage output of this while the condition exists and for a ten (10)
Power Supply (120 amps maximum). Refer to Section minute period once the condition is cleared.
4T.07 and following for torch parts selection.

Torch Connection
Check that the torch is properly connected. Only
Thermal Dynamics model SL100 / Manual or SL100 /
Mechanical Torches may be connected to this Power
Supply. See Section 3T of this manual.

Check Primary Input Power Source

1. Check the power source for proper input voltage.
Make sure the input power source meets the power
requirements for the unit per Section 2, Specifica-
tions.
2. Connect the input power cable (or close the main
disconnect switch) to supply power to the system.

Air Source
Ensure source meets requirements (refer to Section 2).
Check connections and turn air supply ON.

4-38 OPERATION Manual 0-4989

 CUTMASTER A120
Set Operating Pressure Select Current Output Level
1. Place the Power Supply Function Control knob to 1. Place the Function Control Knob in one of the
three operating positions available:
the SET position. Gas will flow.
RUN ,

2. For Standoff cutting, adjust gas pressure from 70 - 85 RAPID AUTO RESTART
psi / 4.8 - 5.9 bar (LED's in center of control panel).
Refer to the Standoff chart for pressure setting de- or LATCH . Gas flow stops.
tails.
2. Set the output current to desired amperage with
the Output Current Control Knob.
1 2
Pre-flow
With hand or mechanical torch, there will be a .5 second
pre-flow of the gas. Pre-flow does not apply to automa-
tion torch use.
MIN
A MAX
PSI
MAX
BAR
MAX
Cutting Operation
+
When the torch leaves the workpiece during cutting
operations with the Function Control Knob in the RUN
position, there is a brief delay in restarting the pilot
MIN MIN

arc. With the knob in the RAPID AUTO RESTART posi-

tion, 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
Art# A-07946 knob in the LATCH position the main cutting arc will be
maintained after the torch switch is released.
STANDOFF
CutMaster A120 Gas Pressure Settings Typical Cutting Speeds
SL100 Cutting speeds vary according to torch output amper-
Leads SL100 (Mechanized Torch) age, the type of material being cut, and operator skill.
Length (Hand Torch) SL100 SV Refer to Section 4T.08 and following for greater details.
(Automation Torch)
Up to 50' 75 psi 75 psi Output current setting or cutting speeds may be re-
(7.6 m) 5.2 bar 5.2 bar duced to allow slower cutting when following a line, or
using a template or cutting guide while still producing
Each additional Add 5 psi Add 5 psi cuts of excellent quality.
25' (7.6 m) 0.4 bar 0.4 bar
Postflow
3. For Drag cutting (60 Amps and below), adjust gas
pressure from 75 - 95 psi / 5.2 - 6.5 bar (LED's in Release the trigger to stop the cutting arc. Gas contin-
center of control panel). Refer to the Drag Cutting ues to flow for approximately 20 seconds. During post
chart for pressure setting details. - flow, if the user moves the trigger release to the rear
and presses the trigger, the pilot arc starts. The main
DRAG (60 Amps or less) arc transfers to the workpiece if the torch tip is within
transfer distance to the workpiece.
CutMaster A120 Gas Pressure Settings
Leads SL100 Shutdown
Length (Hand Torch)
Up to 25' 80 psi Turn the ON / OFF switch to OFF (down).
(7.6 m) 5.5 bar All Power Supply indicators shut OFF. Unplug the
Each additional Add 5 psi input power cord or disconnect input power. Power is
25' (7.6 m) 0.4 bar removed from the system.

Manual 0-4989 OPERATION 4-39

CUTMASTER A120

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4-40 OPERATION Manual 0-4989

 CUTMASTER A120
SECTION 4 TORCH: For optimum smooth surface quality, the travel speed
should be adjusted so that only the leading edge of the
OPERATION arc column produces the cut. If the travel speed is too
slow, a rough cut will be produced as the arc moves from
side to side in search of metal for transfer.
4T.01 Machine and Automated Torch
Operation Travel speed also affects the bevel angle of a cut. When
cutting in a circle or around a corner, slowing down
Cutting With Machine or Automated Torch the travel speed will result in a squarer cut. The power
source output should be reduced also. Refer to the
These torches are activated by remote control pendant
appropriate Control Module Operating Manual for any
or by a remote interface device such as CNC.
Corner Slowdown adjustments that may be required.
1. To start a cut at the plate edge, position the center
of the torch along the edge of the plate. Piercing With Machine or Automated Torch

Travel Speed To pierce, the arc should be started with the torch
positioned as high as possible above the plate while
Proper travel speed is indicated by the trail of the arc allowing the arc to transfer and pierce. This standoff
which is seen below the plate. The arc can be one of helps avoid having molten metal blow back onto the
the following: front end of the torch.
1. Straight Arc When operating with a cutting machine, a pierce or
dwell time is required. Torch travel should not be en-
A straight arc is perpendicular to the workpiece
abled until the arc penetrates the bottom of the plate.
surface. This arc is generally recommended for the
As motion begins, torch standoff should be reduced
best cut using air plasma on stainless or aluminum.
to the recommended 1/8 - 1/4 inch (3-6 mm) distance
2. Leading Arc for optimum speed and cut quality. Clean spatter and
scale from the shield cup and the tip as soon as pos-
The leading arc is directed in the same direction as sible. Spraying or dipping the shield cup in anti - spatter
torch travel. A five degree leading arc is generally compound will minimize the amount of scale which
recommended for air plasma on mild steel. adheres to it.
3. Trailing Arc
4T.02 Automation Torch Parts Selection
The trailing arc is directed in the opposite direction
as torch travel. Check the torch for proper consumable parts. The
parts supplied in the torch may not be correct for the
operator’s chosen amperage level. The torch parts must
correspond with the type of operation.

Torch parts:
Dir
ect Shield Cup, Cutting Tip, Electrode and Starter Cartridge
ion
of T
orc
hT NOTE
rav Standoff Distance
el
Refer to Sections 4T.08 and following for addi-
tional information on torch parts.
Change the torch parts for a different operation as follows:
Straight Arc

Trailing Arc WARNING

Disconnect primary power at the source before
A-02586
assembling or disassembling torch parts, or
Leading Arc
torch and leads assemblies.

Automation and Machine Torch Operation

Manual 0-4989 OPERATION 4T-41

CUTMASTER A120
NOTE Torch parts:
The shield cup holds the tip and starter cartridge Shield Cup, Cutting Tip, Electrode and Starter Car-
in place. Position the torch with the shield cup tridge
facing upward to keep these parts from falling
out when the cup is removed. NOTE

1. If attached, remove the ohmic clip then unscrew Refer to Section 4T.08 and following for addi-
and remove the shield cup assembly from the torch tional information on torch parts.
head. Wipe it clean or replace if damaged Change the torch parts for a different operation as follows:
2. Remove the Electrode by pulling it straight out of
the Torch Head.
WARNING
Torch Head
Art # A-04173_AB Disconnect primary power at the source before
assembling or disassembling torch parts, or
Electrode torch and leads assemblies.

NOTE
Start Cartridge
The shield cup holds the tip and starter cartridge
Tip in place. Position the torch with the shield cup
facing upward to keep these parts from falling
Ohmic Clip out when the cup is removed.
(If installed)
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.
Shield Cup Body

Torch Head
Deflector
Shield Cap Electrode

Automation Torch Parts

Start Cartridge

3. Install the replacement Electrode by pushing it

straight into the torch head until it clicks.
Tip
4. Install the starter cartridge and desired tip for the
operation into the torch head.
Shield Cup
5. Hand tighten the shield cup assembly until it is
seated on the torch head. If resistance is felt when A-03510_AB

installing the cup, check the threads before proceed-

ing Torch Parts (Drag Shield Cap & Shield Cup Body Shown)
6. If used, attach the ohmic clip to the shield cup.
3. Install the replacement Electrode by pushing it
straight into the torch head until it clicks.
4T.03 Machine and Hand Torch Parts
Selection 4. Install the starter cartridge and desired tip for the
operation into the torch head.
Depending on the type of operation to be done determines
the torch parts to be used. 5. Hand tighten the shield cup assembly until it is
seated on the torch head. If resistance is felt when
Type of operation: installing the cup, check the threads before proceed-
Drag cutting, standoff cutting or gouging ing.

4T-42 OPERATION Manual 0-4989

 CUTMASTER A120
4T.04 Cut Quality Kerf Width
The width of the cut (or the width of material removed
NOTE during the cut).
Cut quality depends heavily on setup and pa-
rameters such as torch standoff, alignment with Top Spatter (Dross)
the workpiece, cutting speed, gas pressures, and Top spatter or dross on the top of the cut caused by
operator ability. slow travel speed, excess cutting height, or cutting tip
whose orifice has become elongated.
Cut quality requirements differ depending on application.
For instance, nitride build - up and bevel angle may be major 4T.05 General Cutting Information
factors when the surface will be welded after cutting. Dross

!
- free cutting is important when finish cut quality is desired
to avoid a secondary cleaning operation. The following cut
quality characteristics are illustrated in the following figure: WARNING
Disconnect primary power at the source before
Kerf Width disassembling the power supply, torch, or torch
Cut Surface leads.
Bevel Angle
Top
Frequently review the Important Safety Pre-
Spatter cautions at the front of this manual. Be sure
the operator is equipped with proper gloves,
clothing, eye and ear protection. Make sure no
Top Edge part of the operator’s body comes into contact
Rounding with the workpiece while the torch is activated.

Dross
Build-Up
Cut Surface A-00007
Drag Lines CAUTION
Cut Quality Characteristics Sparks from the cutting process can cause dam-
age to coated, painted, and other surfaces such
Cut Surface as glass, plastic and metal.
The desired or specified condition (smooth or rough) NOTE
of the face of the cut.
Handle torch leads with care and protect them
from damage.
Nitride Build - Up
Nitride deposits can be left on the surface of the cut Piloting
when nitrogen is present in the plasma gas stream. Piloting is harder on parts life than actual cutting be-
These buildups may create difficulties if the material is cause the pilot arc is directed from the electrode to the
to be welded after the cutting process. tip rather than to a workpiece. Whenever possible, avoid
excessive pilot arc time to improve parts life.
Bevel Angle
Torch Standoff
The angle between the surface of the cut edge and a
plane perpendicular to the surface of the plate. A per- Improper standoff (the distance between the torch tip
fectly perpendicular cut would result in a 0° bevel angle. and workpiece) can adversely affect tip life as well as
shield cup life. Standoff may also significantly affect the
Top - Edge Rounding bevel angle. Reducing standoff will generally result in
a more square cut.
Rounding on the top edge of a cut due to wearing from
the initial contact of the plasma arc on the workpiece. Edge Starting

Bottom Dross Buildup For edge starts, hold the torch perpendicular to the
workpiece with the front of the tip near (not touching)
Molten material which is not blown out of the cut area the edge of the workpiece at the point where the cut is
and resolidifies on the plate. Excessive dross may re- to start. When starting at the edge of the plate, do not
quire secondary cleanup operations after cutting. pause at the edge and force the arc to "reach" for the
edge of the metal. Establish the cutting arc as quickly
as possible.
Manual 0-4989 OPERATION 4T-43
CUTMASTER A120
Direction of Cut technique that feels most comfortable and allows
good control and movement.
In the torches, the plasma gas stream swirls as it leaves
the torch to maintain a smooth column of gas. This swirl NOTE
effect results in one side of a cut being more square than
The tip should never come in contact with the
the other. Viewed along the direction of travel, the right
workpiece except during drag cutting opera-
side of the cut is more square than the left.
tions.
Left Side 2. Depending on the cutting operation, do one of the
Cut Angle
Right Side following:
Cut Angle
a) For edge starts, hold the torch perpendicular
to the workpiece with the front of the tip on the
edge of the workpiece at the point where the cut
is to start.
b) For standoff cutting, hold the torch 1/8 - 3/8 in
A-00512 (3-9 mm) from the workpiece as shown below.
Side Characteristics Of Cut
Torch
To make a square - edged cut along an inside diameter
of a circle, the torch should move counterclockwise
around the circle. To keep the square edge along an
outside diameter cut, the torch should travel in a clock-
wise direction.

Dross
When dross is present on carbon steel, it is commonly re-
ferred to as either “high speed, slow speed, or top dross”. Shield Cup Standoff Distance
Dross present on top of the plate is normally caused 1/8" - 3/8" (3 - 9mm)
by too great a torch to plate distance. "Top dross" is
normally very easy to remove and can often be wiped
off with a welding glove. "Slow speed dross" is normally
present on the bottom edge of the plate. It can vary
from a light to heavy bead, but does not adhere tightly A-00024_AB

to the cut edge, and can be easily scraped off. "High

speed dross" usually forms a narrow bead along the Standoff Distance
bottom of the cut edge and is very difficult to remove. 3. Hold the torch away from your body.
When cutting a troublesome steel, it is sometimes use-
ful to reduce the cutting speed to produce "slow speed 4. Slide the trigger release toward the back of the torch
dross". Any resultant cleanup can be accomplished by handle while simultaneously squeezing the trigger.
scraping, not grinding. The pilot arc will start.

4T.06 Hand Torch Operation

Standoff Cutting With Hand Torch

NOTE Trigger

For best performance and parts life, always use

the correct parts for the type of operation. Trigger Release
A-02986
1. The torch can be comfortably held in one hand or
steadied with two hands. Position the hand to press 5. Bring the torch within transfer distance to the work.
the Trigger on the torch handle. With the hand The main arc will transfer to the work, and the pilot
torch, the hand may be positioned close to the torch arc will shut OFF.
head for maximum control or near the back end
for maximum heat protection. Choose the holding

4T-44 OPERATION Manual 0-4989

 CUTMASTER A120
NOTE
The gas preflow and postflow are a characteristic
WARNING
of the power supply and not a function of the
torch. The straight edge must be non - conductive.
Trigger

2 Non-Conductive
Trigger Release Straight Edge
Cutting Guide

A-03539
3
Using Drag Shield Cup With Straight Edge
The crown shield cup functions best when cutting 3/16
4 inch (4.7 mm) solid metal with relatively smooth surface.
Art # A-03383
Drag Cutting With a Hand Torch
6. Cut as usual. Simply release the trigger assembly to
stop cutting. Drag cutting works best on metal 1/4" (6 mm) thick or
less.
7. Follow normal recommended cutting practices as
provided in the power supply operator's manual. NOTE

NOTE For best parts performance and life, always use

the correct parts for the type of operation.
When the shield cup is properly installed, there
is a slight gap between the shield cup and the 1. Install the drag cutting tip and set the output cur-
torch handle. Gas vents through this gap as part rent.
of normal operation. Do not attempt to force the 2. The torch can be comfortably held in one hand or
shield cup to close this gap. Forcing the shield steadied with two hands. Position the hand to press
cup against the torch head or torch handle can the Trigger on the torch handle. With the hand
damage components. torch, the hand may be positioned close to the torch
8. For a consistent standoff height from the workpiece, head for maximum control or near the back end
install the standoff guide by sliding it onto the torch for maximum heat protection. Choose the holding
shield cup. Install the guide with the legs at the sides technique that feels most comfortable and allows
of the shield cup body to maintain good visibility of good control and movement.
the cutting arc. During operation, position the legs 4. Keep the torch in contact with the workpiece during
of the standoff guide against the workpiece. the cutting cycle.
5. Hold the torch away from your body.
6. Slide the trigger release toward the back of the torch
handle while simultaneously squeezing the trigger.
The pilot arc will start.
Shield Cup
Standoff Guide
Torch Tip
Workpiece Art # A-04034

Trigger
Shield Cup With Straight Edge
The drag shield cup can be used with a non conductive Trigger Release
straight edge to make straight cuts by hand. A-02986

Manual 0-4989 OPERATION 4T-45

CUTMASTER A120
7. Bring the torch within transfer distance to the work. 2. Angle the torch slightly to direct blowback particles
The main arc will transfer to the work, and the pilot away from the torch tip (and operator) rather than
arc will shut OFF. directly back into it until the pierce is complete.
NOTE 3. In a portion of the unwanted metal start the pierce
off the cutting line and then continue the cut onto
The gas preflow and postflow are a characteristic
the line. Hold the torch perpendicular to the work-
of the power supply and not a function of the
piece after the pierce is complete.
torch.
Trigger 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.
1
The pilot arc will start.
2
Trigger Release

Trigger
3
Trigger Release
A-02986

4 6. Bring the torch within transfer distance to the work.

The main arc will transfer to the work, and the pilot
Art # A-03383
arc will shut OFF.
8. Cut as usual. Simply release the trigger assembly to
stop cutting. NOTE

9. Follow normal recommended cutting practices as The gas preflow and postflow are a characteristic
provided in the power supply operator's manual. of the power supply and not a function of the
torch.
NOTE
When the shield cup is properly installed, there
When the shield cup is properly installed, there is a slight gap between the shield cup and the
is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part
torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the
of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield
shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can
cup against the torch head or torch handle can damage components.
damage components.
7. Clean spatter and scale from the shield cup and the
Piercing With Hand Torch tip as soon as possible. Spraying the shield cup in
anti - spatter compound will minimize the amount
1. The torch can be comfortably held in one hand or of scale which adheres to it.
steadied with two hands. Position the hand to press
the Trigger on the torch handle. With the hand Cutting speed depends on material, thickness, and the
torch, the hand may be positioned close to the torch operator’s ability to accurately follow the desired cut line.
head for maximum control or near the back end for The following factors may have an impact on system per-
maximum heat protection. Choose the technique formance:
that feels most comfortable and allows good control • Torch parts wear
and movement.
• Air quality
NOTE • Line voltage fluctuations
The tip should never come in contact with the • Torch standoff height
workpiece except during drag cutting opera-
• Proper work cable connection
tions.

4T-46 OPERATION Manual 0-4989

 CUTMASTER A120
4T.07 Gouging Lead Angle
The angle between the torch and workpiece depends

! WARNING
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
Be sure the operator is equipped with proper of the gouge and may be blown back onto the torch.
gloves, clothing, eye and ear protection and If the lead angle is too small (less than 35°), less mate-
that all safety precautions at the front of this rial may be removed, requiring more passes. In some
manual have been followed. Make sure no part applications, such as removing welds or working with
of the operator’s body comes in contact with the light metal, this may be desirable.
workpiece when the torch is activated.
Torch Head
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.

CAUTION 35°

Sparks from plasma gouging can cause dam-

age to coated, painted or other surfaces such Standoff Height
as glass, plastic, and metal.
Check torch parts. The torch parts must cor-
Workpiece
respond with the type of operation. Refer to
Section 4T.09, Torch Parts Selection. A-00941_AB

Gouging Angle and Standoff Distance

Gouging Parameters
Gouging performance depends on parameters such as Standoff Distance
torch travel speed, current level, lead angle (the angle
between the torch and workpiece), and the distance The tip to work distance affects gouge quality and
between the torch tip and workpiece (standoff ). depth. Standoff distance of 1/8 - 1/4 inch (3 - 6 mm)
allows for smooth, consistent metal removal. Smaller
standoff distances may result in a severance cut rather
than a gouge. Standoff distances greater than 1/4 inch
CAUTION (6 mm) may result in minimal metal removal or loss of
Touching the torch tip or shield cup to the work transferred main arc.
surface will cause excessive parts wear.
Slag Buildup
Torch Travel Speed Slag generated by gouging on materials such as carbon
NOTE and stainless steels, nickels, and alloyed steels, can be
removed easily in most cases. Slag does not obstruct
Refer to Appendix Pages for additional informa- the gouging process if it accumulates to the side of the
tion as related to the Power Supply used. gouge path. However, slag build - up can cause incon-
Optimum torch travel speed is dependent on current sistencies and irregular metal removal if large amounts
setting, lead angle, and mode of operation (hand or of material build up in front of the arc. The build - up is
machine torch). most often a result of improper travel speed, lead angle,
or standoff height.
Current Setting
Current settings depend on torch travel speed, mode
of operation (hand or machine torch), and the amount
of material to be removed.

Manual 0-4989 OPERATION 4T-47

CUTMASTER A120
4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip

Mild Steel
40A
Air Plasma / Air Shield

Starter Cartridge
Standard Shield Cup
Deflector Tip Heavy Duty Starter Electrode
Maximum Life Shield Cup
Cartridge
9-8218 9-8213
9-8243 9-8208 9-8232
9-8237 9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
20 0.036 101 0.14 160 0.18 0.0 0.05
16 0.060 103 0.14 140 0.18 0.0 0.05
14 0.075 105 0.14 120 0.18 0.1 0.06
12 0.105 108 0.14 80 0.18 0.2 0.06
70 (25')
10 0.135 110 0.14 60 0.18 0.3 0.06
75 (50')
3/16 0.188 111 0.14 55 0.18 0.4 0.06
1/4 0.250 117 0.14 40 0.18 0.5 0.07
3/8 0.375 119 0.14 25 0.18 1.2 0.07
1/2 0.500 120 0.14 15 0.2 2.0 0.07

4T-48 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 101 3.6 3990 4.6 0.0 1.1
2 105 3.6 2920 4.6 0.1 1.4
3 109 3.6 1810 4.6 0.3 1.5
4 110 3.6 1470 4.6 0.3 1.6
4.8 (7.6m)
5 112 3.6 1345 4.6 0.4 1.6
6 5.2 (15.2m) 116 3.6 1100 4.6 0.5 1.7
8 118 3.6 815 4.6 1.0 1.7
10 119 3.6 595 4.6 1.5 1.8
12 120 3.6 435 5.1 2.0 1.8
BOLD TYPE indicates maximum piercing parameters.

Manual 0-4989 OPERATION 4T-49

CUTMASTER A120
Stainless Steel
40A
Air Plasma / Air Shield

Starter Cartridge
Standard Shield Cup
Deflector Tip Heavy Duty Starter Electrode
Maximum Life Shield Cup
Cartridge
9-8218 9-8213
9-8243 9-8208 9-8232
9-8237 9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
18 0.050 110 0.19 60 0.20 0.00 0.07
16 0.063 100 0.19 50 0.20 0.00 0.07
14 0.078 105 0.19 45 0.20 0.10 0.07
12 0.109 110 0.19 40 0.20 0.20 0.07
75 (25')
10 0.141 108 0.19 35 0.20 0.30 0.07
80 (50')
3/16 0.188 110 0.19 30 0.20 0.40 0.07
1/4 0.250 120 0.19 18 0.20 0.50 0.08
3/8 0.375 126 0.19 10 0.20 2.00 0.08
1/2 0.500 118 0.19 8 Edge start 0.09

4T-50 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 112 4.8 1670 4.8 0.0 1.7
2 105 4.8 1140 5.1 0.1 1.8
3 109 4.8 980 5.1 0.2 1.8
4 109 4.8 845 5.1 0.3 1.8
5.2 (7.6)
5 111 4.8 715 5.1 0.4 1.8
6 5.5 (15.2) 118 4.8 525 5.1 0.5 2.0
8 123 4.8 350 5.1 1.5 2.0
10 125 4.8 245 5.1 2.0 2.0
12 120 4.8 215 Edge Start 2.2
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-51

CUTMASTER A120
Aluminum
40A
Air Plasma / Air Shield

Starter Cartridge
Standard Shield Cup
Deflector Tip Heavy Duty Starter Electrode
Maximum Life Shield Cup
Cartridge
9-8218 9-8213
9-8243 9-8208 9-8232
9-8237 9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)

20 0.040 95 0.16 300 0.16 0.0 0.06

16 0.063 97 0.16 170 0.16 0.0 0.06
12 0.097 113 0.16 100 0.16 0.2 0.07
11 0.125 70 (25') 115 0.16 90 0.18 0.3 0.07
9 0.160 75 (50') 113 0.18 85 0.18 0.4 0.07
3/16 0.188 116 0.18 75 0.18 0.5 0.07
1/4 0.250 128 0.18 30 0.18 1.0 0.08
3/8 0.375 150 0.18 10 Edge Start 0.09

4T-52 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1.0 95 4.1 7620 4.1 0.0 1.5
2.0 104 4.1 3500 4.1 0.2 1.6
3.0 115 4.1 2350 4.6 0.3 1.7
4.0 4.8 (7.6m) 113 4.6 2170 4.6 0.4 1.7
5.0 5.2 (15.2m) 118 4.6 1740 4.6 0.5 1.8
6.0 125 4.6 1015 4.6 0.8 1.9
8.0 139 4.6 500 Edge Start 2.0
10.0 153 4.6 180 Edge Start 2.2
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-53

CUTMASTER A120
Mild Steel
60A
Air Plasma / Air Shield

Starter Cartridge
Standard Shield Cup
Deflector Tip Heavy Duty Starter Electrode
Maximum Life Shield Cup
Cartridge
9-8218 9-8213
9-8243 9-8210 9-8232
9-8237 9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.060 118 0.19 290 0.19 0.00 0.08
14 0.075 120 0.19 285 0.19 0.10 0.08
11 0.120 118 0.19 180 0.19 0.10 0.08
10 0.135 119 0.19 176 0.19 0.10 0.07
3/16 0.188 121 0.19 100 0.19 0.20 0.08
85 (25')
1/4 0.250 122 0.19 80 0.19 0.30 0.08
90 (50')
3/8 0.375 124 0.19 50 0.19 0.50 0.09
1/2 0.500 132 0.19 26 0.19 0.75 0.10
5/8 0.625 135 0.19 19 Edge Start 0.10
3/4 0.750 136 0.19 14 Edge Start 0.08
1 1.000 150 0.19 6 Edge Start 0.11

4T-54 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 115 4.8 7540 4.8 0 2.1
2 120 4.8 7015 4.0 0.10 1.9
3 118 4.8 4570 4.8 0.10 0.1
4 120 4.8 3650 4.8 0.20 1.9
5 121 4.8 2465 4.8 0.20 2.1
6 5.9 (7.6m) 122 4.8 2145 4.8 0.30 2.0
8 123 4.8 1635 4.8 0.40 2.2
6.2 (15.2m)
10 125 4.8 1180 4.8 0.60 2.4
12 130 4.8 795 4.8 0.75 2.4
15 134 4.8 530 Edge Start 2.4
20 138 4.8 325 Edge Start 2.2
25 149 4.8 165 Edge Start 2.7
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-55

CUTMASTER A120
Stainless Steel
60A
Air Plasma / Air Shield

Starter Cartridge
Standard Shield Cup
Deflector Tip Heavy Duty Starter Electrode
Maximum Life Shield Cup
Cartridge
9-8218 9-8213
9-8243 9-8210 9-8232
9-8237 9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.063 119 0.19 350 0.20 0.00 0.05
14 0.078 116 0.19 300 0.20 0.10 0.07
11 0.125 123 0.19 150 0.20 0.10 0.07
10 0.141 118 0.19 125 0.20 0.10 0.08
3/16 0.188 85 (25') 122 0.19 90 0.20 0.20 0.08
1/4 0.250 90 (50') 123 0.19 65 0.20 0.30 0.09
3/8 0.375 130 0.19 30 0.20 0.50 0.09
1/2 0.500 132 0.19 21 0.20 0.90 0.08
5/8 0.625 132 0.19 14 Edge Start 0.11
3/4 0.750 135 0.19 10 Edge Start 0.10

4T-56 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 124 4.8 10890 5.1 0.00 0.8
2 116 4.8 7560 5.1 0.10 1.7
3 122 4.8 4365 5.1 0.10 1.7
4 119 4.8 2865 5.1 0.20 2.1
5 122 4.8 2195 5.1 0.20 2.1
5.9 (7.6m)
6 123 4.8 1790 5.1 0.30 2.2
8 6.2 (15.2m) 127 4.8 1190 5.1 0.40 2.2
10 130 4.8 725 5.1 0.50 2.2
12 132 4.8 580 5.1 0.90 2.1
15 132 4.8 405 Edge Start 2.6
20 136 4.8 230 Edge Start 2.5
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-57

CUTMASTER A120
Aluminum
60A
Air Plasma / Air Shield

Starter Cartridge
Standard Shield Cup
Deflector Tip Heavy Duty Starter Electrode
Maximum Life Shield Cup
Cartridge
9-8218 9-8213
9-8243 9-8210 9-8232
9-8237 9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.064 123 0.25 440 0.25 0.00 0.08
14 0.079 126 0.25 300 0.25 0.10 0.09
11 0.120 128 0.25 250 0.25 0.10 0.09
3/16 0.188 132 0.25 170 0.25 0.20 0.09
85 (25')
1/4 0.250 132 0.25 85 0.25 0.30 0.09
90 (50')
3/8 0.375 141 0.25 45 0.25 0.50 0.10
1/2 0.500 148 0.25 30 0.25 0.80 0.09
5/8 0.625 145 0.19 18 Edge Start 0.08
3/4 0.750 147 0.19 12 Edge Start 0.10

4T-58 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 118 6.4 17010 6.4 0.00 1.8
2 126 6.4 7680 6.4 0.10 2.3
3 128 6.4 6410 6.4 0.10 2.3
4 130 6.4 5230 6.4 0.20 2.3
5 132 6.4 4010 6.4 0.20 2.4
5.9 (7.6m)
6 132 6.4 2640 6.4 0.30 2.4
6.2 (15.2m)
8 137 6.4 1630 6.4 0.40 2.4
10 142 6.4 1085 6.4 0.60 2.4
12 146 6.4 845 6.4 0.70 2.3
15 146 4.8 540 Edge Start 2.1
20 148 4.8 260 Edge Start 2.5
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-59

CUTMASTER A120
Mild Steel
80A
Air Plasma / Air Shield

Starter Cartridge
Standard Shield Cup
Deflector Tip Heavy Duty Starter Electrode
Maximum Life Shield Cup
Cartridge
9-8218 9-8213
9-8243 9-8211 9-8232
9-8237 9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.060 110 0.19 320 0.20 0.00 0.06
11 0.120 113 0.19 230 0.20 0.10 0.07
10 0.135 110 0.19 180 0.20 0.20 0.07
3/16 0.188 110 0.19 136 0.20 0.30 0.07
1/4 0.250 115 0.19 100 0.20 0.40 0.09
85 (25')
3/8 0.375 125 0.19 42 0.20 0.50 0.09
90 (50')
1/2 0.500 123 0.19 40 0.20 0.60 0.09
5/8 0.625 133 0.19 18 0.20 0.75 0.10
3/4 0.750 140 0.25 18 Edge Start 0.11
7/8 0.875 150 0.25 10 Edge Start 0.11
1 1.000 152 0.25 8 Edge Start 0.13

4T-60 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 109 4.8 8915 5.1 0.00 1.5
2 111 4.8 7415 5.1 0.10 1.7
3 113 4.8 5915 5.1 0.10 1.8
4 110 4.8 4095 5.1 0.30 1.7
5 111 4.8 3325 5.1 0.30 1.8
6 5.9 (7.6m) 114 4.8 2745 5.1 0.40 2.2
8 120 4.8 1775 5.1 0.50 2.3
6.2 (15.2m)
10 125 4.8 1060 5.1 0.50 2.3
12 123 4.8 1025 5.1 0.60 2.3
15 130 4.8 610 5.1 0.75 2.5
20 143 6.4 395 Edge Start 2.7
25 152 6.4 210 Edge Start 3.2
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-61

CUTMASTER A120
Stainless Steel
80A
Air Plasma / Air Shield

Starter Cartridge
Standard Shield Cup
Deflector Tip Heavy Duty Starter Electrode
Maximum Life Shield Cup
Cartridge
9-8218 9-8213
9-8243 9-8211 9-8232
9-8237 9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.063 110 0.19 340 0.25 0.00 0.06
11 0.125 115 .0.19 300 0.25 0.10 0.06
10 0.141 115 0.19 280 0.25 0.10 0.06
3/16 0.188 115 0.19 140 0.25 0.20 0.07
85 (25')
1/4 0.250 118 0.19 100 0.25 0.30 0.08
90 (50')
3/8 0.375 119 0.19 45 0.25 0.40 0.08
1/2 0.500 124 0.19 26 0.25 0.80 0.10
5/8 0.625 133 0.19 16 Edge Start 0.10
3/4 0.750 136 0.19 10 Edge Start 0.11

4T-62 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 108 4.8 9020 6.4 0.00 1.5
2 111 4.8 8380 6.4 0.00 1.5
3 114 4.8 7730 6.4 0.10 1.5
4 115 4.8 5865 6.4 0.20 1.6
5 115 4.8 3410 6.4 0.20 1.8
5.9 (7.6m)
6 117 4.8 2765 6.4 0.30 1.9
8 6.2 (15.2m) 119 4.8 1815 6.4 0.40 2.0
10 120 4.8 1070 6.4 0.60 2.1
12 123 4.8 765 6.4 0.80 2.3
15 131 4.8 475 Edge Start 2.5
20 137 4.8 205 Edge Start 3.0
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-63

CUTMASTER A120
Aluminum
80A
Air Plasma / Air Shield

Starter Cartridge
Standard Shield Cup
Deflector Tip Heavy Duty Starter Electrode
Maximum Life Shield Cup
Cartridge
9-8218 9-8213
9-8243 9-8211 9-8232
9-8237 9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.064 116 0.25 350 0.25 0.00 0.10
11 0.120 120 0.25 280 0.25 0.10 0.10
3/16 0.188 124 0.25 180 0.25 0.20 0.10
1/4 0.250 130 0.25 110 0.25 0.30 0.09
85 (25')
3/8 0.375 136 0.25 55 0.25 0.40 0.11
90 (50')
1/2 0.500 139 0.25 38 0.25 0.60 0.11
5/8 0.625 136 0.19 26 0.25 0.75 0.10
3/4 0.750 150 0.19 14 Edge Start 0.12
7/8 0.875 153 0.19 10 Edge Start 0.11

4T-64 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 114 6.4 8890 6.4 0.00 2.4
2 117 6.4 8420 6.4 0.00 2.5
3 120 6.4 7170 6.4 0.10 2.5
4 122 6.4 5710 6.4 0.20 2.5
5 125 6.4 4315 6.4 0.20 2.5
5.9 (7.6m)
6 129 6.4 3190 6.4 0.30 2.4
8 6.2 (15.2m) 133 6.4 2070 6.4 0.40 2.5
10 136 6.4 1330 6.4 0.50 2.7
12 138 6.4 1060 6.4 0.50 2.9
15 137 4.8 745 6.4 0.75 2.5
20 151 4.8 325 Edge Start 3.0
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-65

CUTMASTER A120
Mild Steel NOTE: For initial customer reference,additional
adjustments of setting maybe required to achieve
110A+ optial quality based on customer equipment
Air Plasma
Air Shield

9-8394 For use on

3/8" (10mm) thickness
material and down.

9-8395 For use on

1/2" (12mm) thickness
material and up.

Shield Cap Shield Cup Body Tip Gas Distributer Electrode Adaptor

9-8393 9-8391 9-8392 9-8390 9-8396

Initial Kerf Width

Material Gas Pressure Torch Working
Arc Voltage Travel Speed Piercing Pierce Delay @ Rec.
Thickness (Air) Height
Height Speed
PSI
Shield
(in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
Cap
length)

9-8394 1/4 0.250 165 0.190 100 0.25 0.50 0.090

9-8394 3/8 0.375 160 0.190 90 0.25 0.60 0.070

9-8395 1/2 0.500 162 0.190 70 0.25 0.70 0.085
9-8395 5/8 0.625 166 0.180 46 0.25 0.70 0.090
80-85
9-8395 3/4 0.750 165 0.190 37.5 0.25 0.80 0.095
9-8395 7/8 0.875 173 0.190 28 0.25 1.0 0.100
9-8395 1 1.000 173 0.190 25 Edge Start 0.120
9-8395 1-1/4 1.250 181 0.190 15 Edge Start 0.130
9-8395 1-1/2 1.500 185 0.160 12 Edge Start 0.150

4T-66 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
Shield Cap (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
9-8394 6 165 5 2540 6.3 0.5 2.3
9-8394 10 160 5 2286 6.3 0.6 1.8
9-8395 12 162 5 1778 6.3 0.7 2.2
9-8395 15 166 5 1168 6.3 0.7 2.3
9-8395 20 5.5-5.9 165 5 953 6.3 0.8 2.4

9-8395 25 173 5 711 Edge Start 2.5

9-8395 30 173 5 635 Edge Start 3.0
9-8395 35 181 5 381 Edge Start 3.3
9-8395 38 185 4 305 Edge Start 3.8
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-67

CUTMASTER A120
Stainless Steel
110A+ *NOTE: For initial customer reference, additional
Air Plasma adjustments of settings maybe required to achieve
Air Shield optimal quality based on customer equipment.

Shield Cap Shield Cup Body Tip Gas Distributer Electrode Adaptor

9-8395 9-8393 9-8391 9-8392 9-8390 9-8396

Kerf Width
Material Gas Pressure Torch Working Initial Piercing
Arc Voltage Travel Speed Pierce Delay @ Rec.
Thickness (Air) Height Height
Speed
PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)

1/4 0.250 168 0.18 120 0.30 0.10 0.050

3/8 0.375 164 0.18 75 0.30 0.10 0.052

1/2 0.500 166 0.18 50 0.30 0.30 0.055
80-85
5/8 0.625 182 0.18 30 0.30 1.00 0.070
3/4 0.750 178 0.19 25 0.30 1.20 0.075
1 1.000 183 0.190 12 Edge Start 0.075
1-1/4 1.250 188 0.190 8 Edge Start 0.075

4T-68 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
6 168 4.8 3048 7.2 0.1 1.3
10 164 4.8 1905 7.2 0.1 1.3
12 166 4.8 1270 7.2 0.3 1.4
15 5.5-5.9 182 4.8 762 7.2 1.0 1.8
20 178 6.4 635 7.2 1.2 1.9

25 183 6.4 305 Edge Start 1.9

32 188 6.4 204 Edge Start 1.9
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-69

CUTMASTER A120

Aluminum
110A+
Air Plasma *NOTE: For initial customer reference, additional
Air Shield adjustments of settings maybe required to achieve
optimal quality based on customer equipment.

Shield Cap Shield Cup Body Tip Gas Distributer Electrode Adaptor

9-8395 9-8393 9-8391 9-8392 9-8390 9-8396

Kerf Width
Material Gas Pressure Torch Working Initial Piercing
Arc Voltage Travel Speed Pierce Delay @ Rec.
Thickness (Air) Height Height
Speed
PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)

1/4 0.250 80 156 0.17 185 0.30 0.1 0.060

3/8 0.375 157 0.17 125 0.30 0.1 0.055

1/2 0.500 167 0.17 80 0.30 0.1 0.065
5/8 0.625 90 171 0.17 66 0.30 0.3 0.080
3/4 0.750 175 0.18 40 0.30 0.7 0.070
1 1.000 189 0.20 25 0.30 1.5 0.095

4T-70 OPERATION Manual 0-4989

 CUTMASTER A120

Material Torch Working Initial Piercing Kerf Width

Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
6 156 4.3 4699 7.2 0.1 1.5
5.5
10 157 4.3 3175 7.2 0.1 1.4
12 167 4.3 2032 7.2 0.1 1.6
15 171 4.3 1676 7.2 0.3 2.0
6.2
20 175 4.6 1016 7.2 0.7 1.8

25 189 5.1 635 7.2 1.5 2.4

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-71

CUTMASTER A120
4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip

Mild Steel
40A
Air Plasma / Air Shield

Starter Cartridge
Shield Cap Maximum Life Shield Cup Tip Heavy Duty Starter Electrode
Cartridge
9-8213
9-8245 9-8237 9-8208 9-8232
9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
20 0.036 107 0.16 130 0.16 0.0 0.06
16 0.060 113 0.16 120 0.16 0.0 0.06
14 0.075 108 0.16 90 0.16 0.1 0.06
12 0.105 111 0.16 75 0.16 0.2 0.06
75 (25')
10 0.135 114 0.16 65 0.16 0.3 0.07
80 (50')
3/16 0.188 115 0.16 65 0.16 0.4 0.07
1/4 0.250 118 0.16 45 0.16 0.5 0.07
3/8 0.375 123 0.16 23 0.16 1.2 0.08
1/2 0.500 128 0.16 18 0.16 2.0 0.08

4T-72 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 108 4.1 3266 4.1 0.0 1.4
2 108 4.1 2239 4.1 0.0 1.5
3 112 4.1 1794 4.1 0.1 1.7
4 5.2 (7.6) 114 4.1 1651 4.1 0.2 1.7
5 115 4.1 1578 4.1 0.3 1.7
5.5 (15.2)
6 117 4.1 1256 4.1 0.4 1.7
8 121 4.1 853 4.1 0.5 1.7
10 124 4.1 565 4.1 1.2 1.8
12 127 4.1 485 4.1 2.0 1.9
BOLD TYPE indicates maximum piercing parameters.

Manual 0-4989 OPERATION 4T-73

CUTMASTER A120
Stainless Steel
40A
Air Plasma / Air Shield

Starter Cartridge
Shield Cap Maximum Life Shield Cup Tip Heavy Duty Starter Electrode
Cartridge
9-8213
9-8245 9-8237 9-8208 9-8232
9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)

18 0.050 110 0.16 60 4.1 0.0 0.06

16 0.063 108 0.16 50 4.1 0.1 0.07
14 0.078 114 0.16 45 4.1 0.1 0.07
12 0.109 113 0.16 40 4.1 0.2 0.07
75 (25')
10 0.141 116 0.16 35 4.1 0.3 0.07
80 (50')
3/16 0.188 115 0.16 30 4.1 0.4 0.07
1/4 0.250 118 0.16 20 4.1 1.2 0.07
3/8 0.375 125 0.16 15 4.1 1.8 0.08
1/2 0.500 127 0.16 10 4.1 2.0 0.08

4T-74 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 109 4.1 1670 4.1 0.0 1.7
2 114 4.1 1140 4.1 0.1 1.8
3 114 4.1 980 4.1 0.2 1.8
4 5.2 (7.6) 116 4.1 845 4.1 0.3 1.8
5 115 4.1 725 4.1 0.4 1.8
5.5 (15.2)
6 117 4.1 565 4.1 0.5 2.0
8 122 4.1 440 4.1 1.5 2.0
10 125 4.1 360 4.1 1.8 2.0
12 127 4.1 280 4.1 2.0 2.2
BOLD TYPE indicates maximum piercing parameters.

Manual 0-4989 OPERATION 4T-75

CUTMASTER A120
Aluminum
40A
Air Plasma / Air Shield

Starter Cartridge
Shield Cap Maximum Life Shield Cup Tip Heavy Duty Starter Electrode
Cartridge
9-8213
9-8245 9-8237 9-8208 9-8232
9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
20 0.040 110 0.19 300 0.20 0.0 0.06
16 0.063 113 0.19 170 0.20 0.1 0.07
12 0.097 120 0.19 100 0.20 0.2 0.07
11 0.125 75 (25') 125 0.19 90 0.20 0.3 0.07
9 0.160 80 (50') 126 0.19 85 0.20 0.4 0.07
3/16 0.188 128 0.19 70 0.20 0.5 0.07
1/4 0.250 137 0.19 30 0.20 1.0 0.08
3/8 0.375 145 0.19 10 0.20 2.0 0.09

4T-76 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1.0 110 4.8 7660 5.1 0.0 1.6
2.0 116 4.8 3490 5.1 0.2 1.8
3.0 124 4.8 2350 5.1 0.3 1.8
4.0 5.2 (7.6) 126 4.8 2170 5.1 0.4 1.8
5.0 5.5 (15.2) 129 4.8 1630 5.1 0.6 1.8
6.0 135 4.8 990 5.1 1.0 1.9
8.0 141 4.8 500 5.1 1.6 2.0
10.0 146 4.8 180 5.1 2.1 2.3
BOLD TYPE indicates maximum piercing parameters.

Manual 0-4989 OPERATION 4T-77

CUTMASTER A120
Mild Steel
60A
Air Plasma / Air Shield

Starter Cartridge
Shield Cap Maximum Life Shield Cup Tip Heavy Duty Starter Electrode
Cartridge
9-8213
9-8238 9-8237 9-8210 9-8232
9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.060 128 0.19 250 0.20 0.00 0.09
14 0.075 129 0.19 237 0.20 0.10 0.09
11 0.120 126 0.19 200 0.20 0.10 0.08
10 0.135 128 0.19 142 0.20 0.10 0.09
3/16 0.188 132 0.19 115 0.20 0.20 0.09
85 (25')
1/4 0.250 134 0.19 80 0.20 0.30 0.08
90 (50')
3/8 0.375 132 0.19 34 0.20 0.70 0.10
1/2 0.500 144 0.19 23 0.20 0.75 0.10
5/8 0.625 150 0.19 14 Edge Start 0.10
3/4 0.750 145 0.19 14 Edge Start 0.10
1 1.000 160 0.19 4 Edge Start 0.12

4T-78 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 127 4.8 6804 5.1 0 2.2
2 129 4.8 5942 5.1 0.10 2.2
3 126 4.8 5080 5.1 0.10 0.1
4 130 4.8 3316 5.1 0.20 2.3
5 132 4.8 2794 5.1 0.20 2.2
5.9 (7.6m)
6 134 4.8 2230 5.1 0.30 2.1
8 6.2 (15.2m) 133 4.8 1425 5.1 0.40 2.3
10 134 4.8 822 5.1 0.60 2.5
12 141 4.8 646 5.1 0.75 2.5
15 148 4.8 419 Edge Start 2.6
20 147 4.8 318 Edge Start 2.7
25 159 4.8 118 Edge Start 3.0
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-79

CUTMASTER A120
Stainless Steel
60A
Air Plasma / Air Shield

Starter Cartridge
Shield Cap Maximum Life Shield Cup Tip Heavy Duty Starter Electrode
Cartridge

9-8213
9-8238 9-8237 9-8210 9-8232
9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.063 110 0.13 165 0.20 0.00 0.06
14 0.078 116 0.13 155 0.20 0.10 0.07
11 0.125 118 0.13 125 0.20 0.10 0.07
10 0.141 126 0.13 80 0.20 0.10 0.09
3/16 0.188 85 (25') 125 0.13 75 0.20 0.20 0.09
1/4 0.250 90 (50') 127 0.13 60 0.20 0.30 0.08
3/8 0.375 134 0.13 28 0.20 0.50 0.08
1/2 0.500 136 0.19 17 0.25 0.75 0.09
5/8 0.625 131 0.13 14 Edge Start 0.08
3/4 0.750 142 0.19 10 Edge Start 0.11

4T-80 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 101 3.3 4590 5.1 0.00 1.2
2 116 3.3 3925 5.1 0.10 1.7
3 118 3.3 3285 5.1 0.10 1.7
4 126 3.3 1985 5.1 0.20 2.2
5 5.9 (7.6m) 125 3.3 1850 5.1 0.20 2.1
6 127 3.3 1605 5.1 0.30 2.1
6.2 (15.2m)
8 131 3.3 1100 5.1 0.40 2.1
10 134 3.3 670 5.1 0.50 2.1
12 136 4.8 490 6.4 0.90 2.2
15 132 3.3 375 Edge Start 2.6
20 144 4.8 230 Edge Start 2.5
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-81

CUTMASTER A120
Aluminum
60A
Air Plasma / Air Shield

Starter Cartridge
Shield Cap Maximum Life Shield Cup Tip Heavy Duty Starter Electrode
Cartridge

9-8213
9-8238 9-8237 9-8210 9-8232
9-8277

Material Gas Pressure Torch Working Initial Piercing Kerf Width

Arc Voltage Travel Speed Pierce Delay
Thickness (Air) Height Height @ Rec. Speed

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.064 118 0.13 350 0.20 0.00 0.07
14 0.079 118 0.13 350 0.20 0.10 0.08
11 0.120 123 0.13 275 0.20 0.10 0.08
3/16 0.188 125 0.13 140 0.20 0.20 0.08
85 (25')
1/4 0.250 132 0.13 80 0.20 0.30 0.08
90 (50')
3/8 0.375 135 0.13 45 0.20 0.50 0.08
1/2 0.500 140 0.13 26 0.20 0.80 0.08
5/8 0.625 148 0.19 18 Edge start 0.10
3/4 0.750 155 0.19 12 Edge start 0.11

4T-82 OPERATION Manual 0-4989

 CUTMASTER A120
Material Torch Working Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Travel Speed Pierce Delay
Thickness Height Height @ Rec. Speed

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 118 6.4 8890 6.4 0.00 2
2 118 6.4 8890 6.4 0.10 2.0
3 123 6.4 7070 6.4 0.10 2.1
4 124 6.4 5095 6.4 0.20 2.0
5 5.9 (7.6m) 126 6.4 3335 6.4 0.20 2.0
6 130 6.4 2370 6.4 0.30 2.0
6.2 (15.2m)
8 134 6.4 1570 6.4 0.40 2.0
10 136 6.4 1070 6.4 0.60 2.0
12 139 6.4 765 6.4 0.70 2.0
15 146 4.8 515 Edge start 2.4
20 157 4.8 260 Edge start 2.7
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-83

CUTMASTER A120
Mild Steel
80A
Air Plasma / Air Shield

Starter Cartridge
Shield Cap Maximum Life Shield Cup Tip Heavy Duty Starter Electrode
Cartridge

9-8213
9-8239 9-8237 9-8211 9-8232
9-8277

Torch
Material Gas Pressure Initial Piercing Kerf Width
Arc Voltage Working Travel Speed Pierce Delay
Thickness (Air) Height @ Rec. Speed
Height
PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.060 115 0.13 280 0.20 0.00 0.06
11 0.120 112 0.13 190 0.20 0.10 0.06
10 0.135 110 0.13 176 0.20 0.20 0.06
3/16 0.188 122 0.19 135 0.20 0.30 0.08
1/4 0.250 127 0.19 100 0.20 0.40 0.09
85 (25')
3/8 0.375 134 0.19 40 0.20 0.50 0.10
90 (50')
1/2 0.500 136 0.19 36 0.20 0.60 0.10
5/8 0.625 145 0.19 18 Edge Start 0.11
3/4 0.750 147 0.19 14 Edge Start 0.11
7/8 0.875 146 0.19 10 Edge Start 0.12
1.000 1.000 152 0.187 8 Edge Start 0.13

4T-84 OPERATION Manual 0-4989

 CUTMASTER A120
Torch
Material Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Working Travel Speed Pierce Delay
Thickness Height @ Rec. Speed
Height

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 116 3.3 7895 5.1 0.00 1.6
2 114 3.3 6395 5.1 0.10 1.6
3 112 3.3 4895 5.1 0.10 1.5
4 115 4.8 4025 5.1 0.30 1.7
5 123 4.8 3300 5.1 0.30 2.0
5.9 (7.6m)
6 126 4.8 2735 5.1 0.40 2.2
8 6.2 (15.2m) 131 4.8 1745 5.1 0.50 2.5
10 134 4.8 1000 5.1 0.50 2.6
12 136 4.8 935 5.1 0.60 2.6
15 143 4.8 580 5.1 0.80 2.8
20 147 4.8 325 Edge Start 2.9
25 151 4.8 210 Edge Start 3.2
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-85

CUTMASTER A120
Stainless Steel
80A
Air Plasma / Air Shield

Starter Cartridge
Shield Cap Maximum Life Shield Cup Tip Heavy Duty Starter Electrode
Cartridge
9-8213
9-8239 9-8237 9-8211 9-8232
9-8277

Torch
Material Gas Pressure Initial Piercing Kerf Width
Arc Voltage Working Travel Speed Pierce Delay
Thickness (Air) Height @ Rec. Speed
Height
PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
16 0.063 114 0.125 340 0.2 0.00 0.06
11 0.125 115 0.125 260 0.2 0.10 0.06
10 0.141 116 0.125 250 0.2 0.10 0.06
3/16 0.188 115 0.125 170 0.2 0.20 0.07
85 (25')
1/4 0.250 118 0.125 85 0.2 0.30 0.08
3/8 0.375 90 (50') 127 0.19 45 0.25 0.40 0.09
1/2 0.500 136 0.19 16 0.25 0.75 0.11
5/8 0.625 143 0.19 10 Edge Start 0.12

3/4 0.750 146 0.19 8 Edge Start 0.11

4T-86 OPERATION Manual 0-4989

 CUTMASTER A120
Torch
Material Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Working Travel Speed Pierce Delay
Thickness Height @ Rec. Speed
Height

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 114 3.2 9410 5.1 0.00 1.5
2 114 3.2 8120 5.1 0.00 1.4
3 115 3.2 6830 5.1 0.10 1.4
4 116 3.2 5635 5.1 0.20 1.5
5 5.9 (7.6m) 115 3.2 4010 5.1 0.20 1.8
6 117 3.2 2640 5.1 0.30 2.0
6.2 (15.2m)
8 123 4.8 1630 6.4 0.40 2.1
10 128 4.8 1030 6.4 0.60 2.2
12 134 4.8 565 6.4 0.75 2.6
15 141 4.8 295 Edge Start 3.0
20 147 4.8 185 Edge Start 2.8
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-87

CUTMASTER A120
Aluminum
80A
Air Plasma / Air Shield

Starter Cartridge
Shield Cap Maximum Life Shield Cup Tip Heavy Duty Starter Electrode
Cartridge

9-8213
9-8239 9-8237 9-8211 9-8232
9-8277

Torch
Material Gas Pressure Initial Piercing Kerf Width
Arc Voltage Working Travel Speed Pierce Delay
Thickness (Air) Height @ Rec. Speed
Height
PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)

16 0.064 115 0.13 320 0.2 0.00 0.09

11 0.120 120 0.13 240 0.2 0.10 0.08
3/16 0.188 122 0.13 165 0.2 0.20 0.08
1/4 0.250 85 (25') 124 0.13 100 0.2 0.30 0.10
3/8 0.375 90 (50') 140 0.19 60 0.2 0.40 0.09
1/2 0.500 142 0.19 36 0.2 0.60 0.11
5/8 0.625 148 0.19 26 0.2 0.75 0.11
3/4 0.750 155 0.19 16 Edge Start 0.12

4T-88 OPERATION Manual 0-4989

 CUTMASTER A120
Torch
Material Initial Piercing Kerf Width
Gas Pressure (Air) Arc Voltage Working Travel Speed Pierce Delay
Thickness Height @ Rec. Speed
Height

Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 113 3.3 9020 5.1 0.00 2.4
2 116 3.3 7595 5.1 0.00 2.2
3 120 3.3 6165 5.1 0.10 2.0
4 121 3.3 5045 5.1 0.20 2.1
5 5.9 (7.6m) 122 3.3 3955 5.1 0.20 2.2
6 124 3.3 2905 5.1 0.30 2.3
6.2 (15.2m)
8 132 4.8 2010 5.1 0.40 2.3
10 140 4.8 1430 5.1 0.50 2.3
12 142 4.8 1045 5.1 0.60 2.6
15 146 4.8 730 5.1 0.75 2.7
20 157 4.8 330 Edge Start 3.2
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-4989 OPERATION 4T-89

CUTMASTER A120

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4T-90 OPERATION Manual 0-4989

 CUTMASTER A120
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

Care
fully clean the
interior

Art # A-07938_AC

Manual 0-4989 SERVICE 5-91

CUTMASTER A120
5.02 Maintenance Schedule 5.03 Common Faults
NOTE Problem -
Common Cause
Symptom
The actual frequency of maintenance may need
to be adjusted according to the operating en- Insufficient 1. Cutting speed too fast.
vironment. Penetration 2. Torch tilted too much.
3. Metal too thick.
Daily Operational Checks or Every Six Cutting Hours: 4. Worn torch parts
5. Cutting current too low.
1. Check torch consumable parts, replace if damaged 6. Non - Genuine Thermal Dynamics
or worn. parts used
7. Incorrect gas pressure
2. Check plasma and secondary supply and pressure/
flow. Main Arc 1. Cutting speed too slow.
Extinguishes 2. Torch standoff too high from
3. Purge plasma gas line to remove any moisture build- workpiece.
up. 3. Cutting current too high.
4. Work cable disconnected.
Weekly or Every 30 Cutting Hours: 5. Worn torch parts.
1. Check fan for proper operation and adequate air 6. Non - Genuine Thermal Dynamics
flow. parts used

2. Inspect torch for any cracks or exposed wires, replace Excessive Dross 1. Cutting speed too slow.
if necessary. Formation 2. Torch standoff too high from
workpiece.
3. Inspect input power cable for damage or exposed 3. Worn torch parts.
wires, replace if necessary. 4. Improper cutting current.
5. Non - Genuine Thermal Dynamics
Six Months or Every 720 Cutting Hours: parts used
6. Incorrect gas pressure
1. Check the in-line air filter(s), clean or replace as
required. Short Torch 1. Oil or moisture in air source.
Parts Life 2. Exceeding system capability
2. Check cables and hoses for leaks or cracks, replace
(material too thick).
if necessary.
3. Excessive pilot arc time
3. Check all contactor points for severe arcing or pits, 4. Gas pressure too low.
replace if necessary. 5. Improperly assembled torch.
6. Non - Genuine Thermal Dynamics
4. Vacuum dust and dirt out of the entire machine. parts used
Difficult Starting 1. Worn torch parts.
2. Non - Genuine Thermal Dynamics
CAUTION parts used.
Do not blow air into the power supply during 3. Incorrect gas pressure.
cleaning. Blowing air into the unit can cause
metal particles to interfere with sensitive electri-
cal components and cause damage to the unit.

5-92 SERVICE Manual 0-4989

 CUTMASTER A120
5.04 Fault Indicator
At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used.
To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count
the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator and 76 psi
indicators are ON indicating the version would be 2.3.

7
6
5 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 depend-
ing 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 0-4989 SERVICE 5-93

CUTMASTER A120
5.05 Basic Troubleshooting Guide

WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose
or repair unless you have had training in power electronics measurement and troubleshooting techniques.

Problem -
Possible Cause Recommended Action
Symptom
ON / OFF Switch 1. Primary power disconnect is in 1. Turn primary power disconnect switch to ON position.
is ON but the A/C OFF position.
Indicator does not 2. Primary fuses / breakers are 2. a) Have qualified person check primary fuses / breakers.
light blown or tripped. b) Connect unit to known good primary power receptacle
3. Units internal fuse blown. 3. a) Replace fuse.
b) If fuse blows again, return to authorized service center for
repair or replacement.
4. Faulty components in unit. 4. Return to authorized service center for repair or replacement.

Fault indicator 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.
3. Faulty components in unit. 3. Return to authorized service center for repair or replacement.

TEMPERATURE 1. Air flow through or around the 1. Refer to clearance information – section 2.04
indicator ON. unit is obstructed.
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 unit. 1. Connect gas supply to unit.
FAULT and MIN 2. Gas supply not turned ON.
pressure indicators 3. Gas supply pressure too low. 2. Turn gas supply ON.
flashing. 4. AIR PRESSURE CONTROL regulator 3. Set air supply inlet pressure to unit to 120 psi.
set too low. 4. Adjust regulator to set air pressure - see section 4.02.
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.

5-94 SERVICE Manual 0-4989

 CUTMASTER A120
Problem - Possible Cause Recommended Action
Symptom
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 missing
Gas flow is cycling cartridge 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 Repair
when torch switch switch circuit (Remote pendant Facility.
or remote switch switch circuit).
is closed (Or CNC 2. CNC Contoller 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 (Standard 6. Return to authorized service center for repair or
rate of blinking) replacement.

No Fault lights ON, 1. Failed components in unit. 1. Return to an authorized service center for repair.
no 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 0-4989 SERVICE 5-95

CUTMASTER A120
C. Filter Element Assembly Replacement
5.06 Power Supply Basic Parts Replacement
The Filter Element Assembly is in the rear panel. For better
system performance, the filter element should be checked
per the Maintenance Schedule (Subsection 5.02), and either
WARNING
cleaned or replaced.
Disconnect primary power to the system before
1. Remove power from the power supply; turn OFF the
disassembling the torch, leads, or power supply.
gas supply and bleed down the system.

This section describes procedures for basic parts replace- 2. Remove the system cover. See "A Cover Removal"
ment. For more detailed parts replacement procedures, in this section.
refer to the Power Supply Service Manual. 3. Locate the internal air line and the fitting from the
filter assembly. Number 1 in the following illustra-
A. Cover Removal tion.
1. Remove the upper and lower screws which secure 4. Hold a wrench or similar tool against the locking
the cover to the main assembly. Do not loosen the ring on the filter assembly fitting, then pull on the
lower screws inside the cut out slots in the bottom hose to release it. (Numbers 2 and 3 in the following
of the cover. illustration).

Upper
Screws

Lower
1
Screws

Slots

Lower
Screws

Art # A-07989

Art # A-08429

2. Carefully pull the Cover up and away from the unit.

B. Cover Installation
3 4
1. Reconnect the ground wire, if necessary. 5
2. Place the cover onto the power supply so that slots
in the bottom edges of the cover engage the lower
screws. 6mm
3. Tighten lower screws.
4. Reinstall and tighten the upper screws.

5-96 SERVICE Manual 0-4989

 CUTMASTER A120
5. Remove the fitting from the filter element assembly Optional Single-Stage Filter Element Replacement
by inserting a 6 mm hex wrench into the internal
These instructions apply to power supplies where the op-
hex fitting and turning it counter clock-wise (left).
tional Single-Stage Filter has been installed.
Numbers 4 and 5 in the previous illustration.
The Power Supply shuts down automatically when the Filter
6. Disconnect the input line from the filter element
Element becomes completely saturated. The Filter Element
assembly.
can be removed from its housing, dried, and reused. Allow
7. Remove the filter element assembly through the 24 hours for Element to dry. Refer to Section 6, Parts List,
rear opening. for replacement filter element catalog number.
NOTE 1. Remove power from power supply.
If replacing or cleaning just the filter element 2. Shut OFF air supply and bleed down system before
refer to the following illustration for disassembly. disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.
4. Turn the Filter Housing Cover counter-clockwise and
remove it. The Filter Element is located inside the
Housing.
Filter Element
Housing

Filter
Element
(Cat. No. 9-7741)

Spring
Art # A-07990
O-ring
8. Install the new or cleaned assembly by reversing (Cat. No. 9-7743) Assembled Filter
these procedures.
Cover
9. Turn ON the air supply and check for leaks before
reinstalling the 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 replace-
ment Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply.
NOTE
If unit leaks between housing and cover, inspect
the O-Ring for cuts or other damage.

Manual 0-4989 SERVICE 5-97

CUTMASTER A120
Optional Two-Stage Filter Element Replacement
The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue
to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog
number.
1. Shut OFF primary input power.
2. Shut OFF air supply and bleed down system.

WARNING
Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could
result.

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.
4. Note the location and orientation of the old Filter Elements.
5. Slide out the old Filter Elements.

First & Second

Stage
Cartridges
(as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above.
7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may
damage the gasket.
8. Slowly apply air pressure to the assembly, checking for leaks.
NOTE
A small amount of air leakage from the bottom fitting is normal.
This completes the parts replacement procedures.

5-98 SERVICE Manual 0-4989

 CUTMASTER A120
SECTION 5 TORCH:
SERVICE
5T.01 General Maintenance Upper Groove
with Vent Holes
NOTE Must Remain Open
Refer to Previous "Section 5 System" for common
and fault indicator descriptions. Upper O-Ring
in Correct Groove
Cleaning Torch Threads
Even if precautions are taken to use only clean air with a Lower O-Ring Art # A-03725
torch, eventually the inside of the torch becomes coated
with residue. This buildup can affect the pilot arc initia- Torch Head O-Ring
tion and the overall cut quality of the torch.

WARNING ATC Male Connector

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 compressed air.
Gas Fitting

CAUTION
Dry the torch thoroughly before reinstalling.

O-Ring Lubrication
An o-ring on the Torch Head and ATC Male Connector Art #A-03791_AB O-Ring
requires lubrication on a scheduled basis. This will allow #8-0525
the o-rings to remain pliable and provide a proper seal.
The o-rings will dry out, becoming hard and cracked if
ATC O-Ring
the lubricant is not used on a regular basis. This can
lead to potential performance problems.
NOTE
It is recommended to apply a very light film of o-ring
lubricant (Catalog # 8-4025) to the o-rings on a weekly DO NOT use other lubricants or grease, they may
basis. not be designed to operate within high tempera-
tures 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 0-4989 SERVICE 5T-99

CUTMASTER A120
5T.02 Inspection and Replacement of 4. Remove the tip. Check for excessive wear (indicated
Consumable Torch Parts (40A-80A) by an elongated or oversized orifice). Clean or re-
place the tip if necessary.
Good Tip Worn Tip
WARNING
Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the A-03406
AC indicator light of the Power Supply is ON.
Example of Tip Wear

Remove the consumable torch parts as follows:

5. Remove the starter cartridge. Check for excessive
NOTE wear, plugged gas holes, or discoloration. Check
The shield cup holds the tip and starter cartridge the lower end fitting for free motion. Replace if
in place. Position the torch with the shield cup necessary.
facing upward to prevent these parts from falling Spring-Loaded Spring-Loaded
out when the cup is removed. Lower End Fitting Lower End Fitting at Reset /
Full Compression Full Extension
1. Unscrew and remove the shield cup from the torch.
NOTE
Slag built up on the shield cup that cannot be
removed may effect the performance of the
system.
Art # A-08064_AC
2. Inspect the cup for damage. Wipe it clean or replace
if damaged. 6. Pull the Electrode straight out of the Torch Head.
Check the face of the electrode for excessive wear.
Refer to the following figure.

Art # A-08067

Shield Cups
New Electrode
3. On torches with a shield cup body and a shield
cap or deflector, ensure that the cap or deflector
is threaded snugly against the shield cup body. In
shielded drag cutting operations (only), there may
be an O-ring between the shield cup body and drag Worn Electrode
Art # A-03284
shield cap. Do not lubricate the O-ring.
Drag Shield Cap

Shield Electrode Wear

Cup Body

7. Reinstall the Electrode by pushing it straight into

the torch head until it clicks.
O-Ring No. 8-3488 8. Reinstall the desired starter cartridge and tip into
the torch head.
9. Hand tighten the shield cup until it is seated on the
torch head. If resistance is felt when installing the
Art # A-03878 cup, check the threads before proceeding.

This completes the parts replacement procedures.

5T-100 SERVICE Manual 0-4989

 CUTMASTER A120
5T.03 Inspection and Replacement of 4. Remove the tip. Check for excessive wear (indicated
Consumable Torch Parts (110 A) by an elongated or oversized orifice). Clean or re-
place the tip if necessary.

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.
Tip
Remove the consumable torch parts as follows:
5. Remove the gas distributor. Check for excessive
NOTE
wear, plugged gas holes, or discoloration.
The shield cup holds the tip and gas distributor
in place. Position the torch with the shield cup
facing upward to prevent these parts from falling
out when the cup is removed.
1. Unscrew and remove the shield cup from the torch.
NOTE
Slag built up on the shield cup that cannot be
removed may effect the performance of the
system. 6. Pull the Electrode straight out of the Torch Head.
2. Inspect the cup for damage. Wipe it clean or replace Check the face of the electrode for excessive wear.
if damaged.

Electrode
Shield Cups
7. Check and re-install the adapter.
3. On torches with a shield cup body and a shield cap,
ensure that the cap is threaded snugly against the
shield cup body.

Shield
Cap

Adapter
Shield 9-8394
Cup Body 8. Reinstall the Electrode by pushing it straight into
the torch head until it clicks.
9. Reinstall the desired gas distributor and tip into the
torch head.

9-8395 10. Hand tighten the shield cup until it is seated on the
torch head. If resistance is felt when installing the
cup, check the threads before proceeding.

This completes the parts replacement procedures.

Manual 0-4989 SERVICE 5T-101

CUTMASTER A120

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5T-102 SERVICE Manual 0-4989

 CUTMASTER A120
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:

Section "6.03 Power Supply Replacement"

Section "6.04 Replacement Power Supply Parts"
Section "6.05 Options and Accessories"
Section "6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)"
Section "6.07 Torch Consumable Parts (SL100)"
Section "6.08 Replacement Parts for Hand Torch"
NOTE
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization will
not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for
each type item. Also include the model and serial number of the power supply. Address all inquiries to your authorized
distributor.

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure
regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster A120 Power Supply
208/230 - 460VAC, Single or 3 Phase, 60Hz,
with 208/230 single phase input power cable and plug 3-1734-1
With 460 single phase input power cable 3-1734-2
1 400VAC, Non CE Power Supply
With 400V, 3 Phase input power cable 3-1734-3
1 400VAC, CE Power Supply
With 400V, 3 Phase input power cable 3-1734-4
1 600VAC, Power Supply
With 600V, 3 Phase input power cable 3-1734-5

Manual 0-4989 PARTS LIST 6-103

CUTMASTER A120
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 208 / 230 V Power Supply 9-0191
1 Input Power Cord for 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 Multi - Purpose Cart 7-8888
1 Automation Interface Kit
for Start/Stop, OK to move and Divided Arc Voltage) 9-8311
1 Automation Harness for Start/Stop and 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
1 Nylon Dust Cover 9-7071

Housing

Filter
Element
(Cat. No. 9-7741)

Spring

O-ring
First & Second
(Cat. No. 9-7743) Assembled Filter Stage
Cartridges
Cover (as marked)

Barbed Art # A-02942

Fitting Art # A-02476

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

6-104 PARTS LIST Manual 0-4989

 CUTMASTER A120

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Manual 0-4989 PARTS LIST 6-105

CUTMASTER A120
6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)
Item No. Qty Description Catalog No.
1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O-Ring 8-3487
3 1 Small O-Ring 8-3486
4 1 PIP Switch Kit 9-7036
5 1 PIP Plunger and Return Spring Kit 9-7045
6 Automated Leads Assemblies with ATC connectors
1 25 - foot / 7.6m Leads Assembly with ATC connector 4-3058
1 35 - foot / 10.6m Leads Assembly with ATC connector 4-3059
1 50 - foot / 15.2m Leads Assembly with ATC connector 4-3060
7 1 Rack 9-9448
8 1 Mounting Tube 9-9445
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 Pinion Assembly (does not include positioning tube) 7-2827
14 1 Torch Holder Sleeve 7-2896
15 1 Pinion Gear-Short 8-6074
16 1 Handwheel (Torch Holder) 9-4514
17 1 Low Profile Torch Holder (1 3/8 Dia) w/o Hardware 9-4515
18 1 Calibrated Torch Holder Bushing 9-4366
19 1 5/32 Dia x 5/8 Lg Slotted Spring Pin See Note 1
20 1 3/8-24 x 3/8 Soc Hd Set Screw, Cup Point See Note 1
21 2 1/4-20 x 5/8 Hex Socket Head Screw See Note 1
22 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point See Note 1
23 1 Solenoid Assembly 9-9447
24 1 Solenoid Cover 9-9446

NOTE
Purchase these parts locally.

6-106 PARTS LIST Manual 0-4989

 CUTMASTER A120

24 23

10
7

13

21
20
21
19
10 16

1
2 11

3
12
4
17
5 15

22
18

14

Art # A-07113

Manual 0-4989 PARTS LIST 6-107

CUTMASTER A120
6.07 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

50-60A
STANDOFF Drag Shield Cup
CUTTING 9-8235
Shield
Tips:
Cup Body,
9-8237 Shield Cap, Machine
50-60A 9-8238

Starter Heavy Duty 50-55A 9-8209 Shield Cup

Electrode Cartridge Starter Cartridge 60A 9-8210 9-8218 Shield Cap, Deflector
Auto 9-8232 9-8213 Non HF Only 9-8277 9-8243
Manual 9-8215
Drag Shield Cup
70-100A 9-8236
Tips:
Shield Drag Shield Cup
70-120A Cup Body, 120A 9-8258
STANDOFF 9-8237
CUTTING Shield Cap, Machine
70-100A 9-8239
Shield Cup Shield Cap, Machine
70A 9-8231 9-8218 120A 9-8256
80A 9-8211

Shield Cap, Deflector

40-120A 9-8243
GOUGING

Shield
Cup Body, Shield Cup, Gouging
9-8237 9-8241

Tips:
110A
STANDOFF Tip A 9-8225 (40 Amps Max.)
CUTTING
Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Shield Cap

9-8394 For use on 1/2"

(12mm) thickness
Shield Cup material and up.
9-8393
Adaptor Electrode Tips
Gas Distributer 110A 9-8391 9-8395 For use on 3/8"
9-8396 9-8390 (10mm) thickness
9-8392
material and down.
Art # H-0045

6-108 PARTS LIST Manual 0-4989

 CUTMASTER A120
6.08 Replacement Parts for Hand Torch
Item # Qty Description Catalog #
1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 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 Leads Assembly with ATC connector 4-7836
1 SL100, 50 - foot Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031
10 1 Torch Control Cable Adapter (includes item # 11) 7-3447
11 1 Through - Hole Protector 9-8103

5
6
3

Art # A-07993_AB

Manual 0-4989 PARTS LIST 6-109

CUTMASTER A120

This Page Intentionally Blank

6-110 PARTS LIST Manual 0-4989

 CUTMASTER A120
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-08793

Manual 0-4989 APPENDIX A-111

CUTMASTER A120
APPENDIX 2: DATA TAG INFORMATION

West Lebanon, NH USA 03784 Manufacturer's Name and/or

® Logo, Location, Model and
Model: Revision Level, Serial Number
S/N
Date of Mfr: and Production Code
Made in USA
Type of Power Regulatory Standard Covering
Supply (Note 1) 1/3 f1
f2 This Type of Power Supply

Output Current Type Duty Cycle Factor

Output Range (Amperage/
Voltage)
Plasma Cutting
Symbol X
I Duty Cycle Data (Note 3)
U0 =
U2
Rated No- Conventional
Load Voltage Load Voltage
Rated Maximum
Supply Current
Input Power
Symbol
U1 I 1max I 1eff Maximum Effective
1
1Ø 3Ø 1
1Ø 3Ø
Supply Current

Input Power
Specifications
(Phase, AC or DC
Hertz Rating) Manufacturer's Electrical
Schematic File Number
and Revision Level
Degree of Protection Rated Supply
Voltage (Note 2)

NOTES:
1. Symbol shown indicates single- or three-phase AC input, Standard Symbols
static frequency converter-transformer-rectifier, DC output. AC
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input DC
voltage requirements for the power supply as built. Ø Phase
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission. Art # A-03288_AC
TDC duty cycle value is determined under the power supply
manufacturer's test procedures.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.
4. Sections of the Data Tag may be applied to separate areas
of the power supply.

A-112 APPENDIX Manual 0-4989

 CUTMASTER A120
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 - Open

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_AB

Manual 0-4989 APPENDIX A-113

CUTMASTER A120
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

A-114 APPENDIX Manual 0-4989

 CUTMASTER A120
APPENDIX 4: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram

Torch: SL60 / SL100 Hand Torch

Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle 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_AB

Manual 0-4989 APPENDIX A-115

CUTMASTER A120
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-116 APPENDIX Manual 0-4989

 CUTMASTER A120

This Page Intentionally Blank

Manual 0-4989 APPENDIX A-117

CUTMASTER A120
APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS
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

INRUSH A
+12VDC RESISTORS PRI 1 PRI 1

+ TP2 MTH1 MTH2 TP1 +

K1

Q1

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

* CM102 & A80

TP8 MTH7 C7 & C10 not installed
MTH4 TP5

W1
_ AC1 80A_AC1
L1 7
L1 T1
K1 K2 K3 K4 K5 K6
PRIMARY L2 8
AC2 80A_AC2

AC INPUT L2 T2
L3 9 AC3 80A_AC3
L3 T3
GND 7A
L4 T4

SW2 J3
* 1 460_IN
BUSS BARS/JUMPERS
2

MTH8 TP4
*PRIMARY POWER INPUT VOLTAGE SELECTOR
(Closed for 230VAC input)
CONNECTIONS:
+12VDC
MOT1 J7 TP3
MTH6
FOR 3 PH:
REMOVE BUSS BARS/JUMPERS 1
BETWEEN L1 TO L4 & L2 TO L3 + FAN - 2 /FAN
Q2
CONNECT PRIMARY INPUT CABLE
TO L1,L2,L3 & GND
C5,C6,C9,C10*
+
FOR 1PH:
INSTALL BUSS BARS/JUMPERS J5
BETWEEN L1 TO L4 & L2 TO L3
SOL 1 1
CONNECT PRIMARY INPUT CABLE
TO BUSS BARS (L1/L4) & (L2/L3) 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 +12VDC
4 2 /FAN_ON
5 D
3 /CSR
4 CUR_SET
5 MAIN_PCB_ID PCB1
/230
/460

K1,K2 MAIN PCB ASSY

6 COMMON

K5,K6
J13 J12
1
2
3
4
5
6

3
2
1

T2
J1 K3,K4

1
2
3
FERRITE
FILTER +12VDC
J2

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
C12-13
+

PMTH4 PMTH4

PCB5 40/50 AMP PCB

A-09132_AC

A-118 APPENDIX Manual 0-4989

 CUTMASTER A120

A120 ONLY
1TORCH
TS1
PIP SWITCH

L1
TORCH SWITCH
J11
1
SEC1
+12VDC 2 SEC2 CHOKE1

ATC CONNECTOR
J1
1 1 AUTOMATION
TEMP /OVERTEMP 2 2
CIRCUIT TORCH SOLENOID
3 3
4 4
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 CNC INTERFACE STANDARD ON A80 & A120 UNITS
83
24VAC SUPPLY 7 CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS

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

40 PIN RIBBON CABLE SIGNALS

TEST POINTS 1 -V_OUT_SIGNAL M-L

D59 PCR 2 /TIP_VOLTS M-L
GND1 COMMON 3 /TIP_SENSE M-L
GND2
+12V1
COMMON
+12 VDC SUPPLY
4 /460V_IN L-M DIVIDE RATIO SET BY DIP SW DIV1
5 /230V_IN L-M
48V1 +48 VDC SUPPLY 6 CUR_SET L-M
D78 CSR I_DMD_1 CURRENT DEMAND 7 /RAR (RAPID AUTO RESTART) L-M DIV1-1 ON = 16.7:1 for SC11 DIV1-4 ON = 40:1 for Inova
TIP_SEN TIP DRAG SENSE 8 /INRUSH L-M
9 /W1_ON L-M
DIV1-2 ON = 20:1 for ESAB DIV1-5 ON = 50:1 for IHT:
10 SHDN L-M DIV1-3 ON = 30:1 SC3000 & 3100; Hypertherm®
11 /TORCH_SOLENOID L-M
12 /SOLENOID_ON L-M
DIV1-6 ON = 80:1 for TD iHC
13 /OK_TO_MOVE L-M
14 /FAN_ON L-M DIV1
15 /LATCH_ACTIVE L-M To -V OUT 1
16 /TORCH_SWITCH M-L on PCB1 -V0_1 J1
17 /PIP M-L VOLTAGE

6 5 4 3 2 1
18 AC_ON M-L 1 DIVIDER
1
19 CSR M-L CIRCUITS
FERRITE
20 /TORCH_SOLENOID_DETECT M-L
FILTER
21 /OVERTEMP M-L + - 2

22 V_IN M-L P10 J2 SW1 3 START / STOP (com)

*
+12V
23 +12VDC M-L
24 +12VDC M-L 1 1
4 START / STOP
25 COMMON M-L 5 DIVIDED ARC VOLTAGE (-)
26 COMMON M-L 2 2
29 MAIN_PCB_ID M-L 3 3
6 DIVIDED ARC VOLTAGE (+)
34
35
460_IN
+3.3VDC
M-L
L-M 4 4 OK TO MOVE
PCB4 7
36 TXD M-L
AUTOMATION
5 5 INTERFACE PCB 8 COMMON
37 RXD M-L
38 COMMON L-M (w / OHMIC) 9
6 6 ISO GND
39 D M-L
7 7
10 PLATE CONTACT COM
CONTACT PLATE CONTACT OUT
11
8 8 START / STOP
L2 12 OK TO MOVE
TIP OHMIC 13
SENSE OK TO MOVE
1
CIRCUITS 14 OK TO MOVE
To TIP1 OHMIC
on PCB1 CONTACT M-ARC START

OK to MOVE

J1
9-8309
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-09132_AC
Rev Revisions By Date PCB No:
VICTOR TECHNOLOGIES
AA INTRO ECO-B935 MNC 05/21/08 16052 Swingley Ridge Road Assy No:
Suite 300 Scale Supersedes
AB ECO B1116 MNC 09/11/08
St Louis, MO 63017 USA
AC ECO B1192 MNC 11/01/08
Date:
AD ECO B1357 RWH 03/31/09 Information Proprietary to THERMAL DYNAMICS CORPORATION. JANUARY 31, 2008
Not For Release, Reproduction, or Distribution without Written Consent.
AD ECO B1611 RWH 12/11/09
Drawn: References
NOTE: MNC
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF) Chk: App: Sheet
1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Friday, December 11, 2009 09:02:19
CUTMASTER 102/152/A80/A120 230/460V D 42X1315

Manual 0-4989 APPENDIX A-119

CUTMASTER A120
APPENDIX 6: SYSTEM SCHEMATIC, 400/600V 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*

* CEONLY
UNITS

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

*CM102/35mm/A80 Q2
C7 & C10 may not be installed C12-13
+

PMTH4 PMTH4

PCB5 40/50 AMP PCB

A-09130_AE
5 4

A-120 APPENDIX Manual 0-4989

 CUTMASTER A120

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 CNC INTERFACE STANDARD ON A80 & A120 UNITS
24VAC SUPPLY 7 CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS

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

TEST POINTS 1 -V_OUT_SIGNAL M-L

D59 PCR 2 /TIP_VOLTS M-L
GND1 COMMON 3 /TIP_SENSE M-L
GND2 COMMON 4 /460V_IN L-M
+12V1 +12 VDC SUPPLY 5 /230V_IN L-M DIVIDE RATIO SET BY DIP SW DIV1
48V1 +48 VDC SUPPLY 6 CUR_SET L-M
D78 CSR I_DMD_1 CURRENT DEMAND 7 /RAR (RAPID AUTO RESTART) L-M
TIP_SEN TIP DRAG SENSE 8 /INRUSH L-M DIV1-1 ON = 16.7:1 for SC11 DIV1-4 ON = 40:1 for Inova
9 /W1_ON L-M DIV1-2 ON = 20:1 for ESAB DIV1-5 ON = 50:1 for IHT:
10 SHDN L-M
11 /TORCH_SOLENOID L-M DIV1-3 ON = 30:1 SC3000 & 3100; Hypertherm®
12 /SOLENOID_ON L-M DIV1-6 ON = 80:1 for TD iHC
13 /OK_TO_MOVE L-M
14 /FAN_ON L-M DIV1
15 /LATCH_ACTIVE L-M To -V OUT 1
16 /TORCH_SWITCH M-L on PCB1 -V0_1 J1
17 /PIP M-L VOLTAGE

6 5 4 3 2 1
18 AC_ON M-L 1 DIVIDER
1
19 CSR M-L CIRCUITS
FERRITE ISO GND
20 /TORCH_SOLENOID_DETECT M-L + - 2
FILTER
21 /OVERTEMP M-L J2 SW1
22 V_IN M-L
P10 +12V 3 START / STOP (com)
*
23 +12VDC M-L
1 1
4 START / STOP
24 +12VDC M-L
25 COMMON M-L 2 2
5 DIVIDED ARC VOLTAGE (-)
26 COMMON M-L 6 DIVIDED ARC VOLTAGE (+)
29 MAIN_PCB_ID M-L 3 3
34 460_IN M-L 4 4 OK TO MOVE
PCB4 7
35 +3.3VDC L-M AUTOMATION
5 5 INTERFACE PCB 8 COMMON
36 TXD M-L
37 RXD M-L (w / OHMIC) 9
6 6 ISO GND
38 COMMON L-M PLATE CONTACT COM
10
39 D M-L 7 7
CONTACT PLATE CONTACT OUT
11
8 8 START / STOP
12 OK TO MOVE
L2 TIP OHMIC 13
SENSE OK TO MOVE
1
CIRCUITS 14 OK TO MOVE
To TIP1 OHMIC
on PCB1 CONTACT M-ARC START

OK to MOVE
B

9-8309
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-09130_AE
Rev Revisions By Date PCB No:
SEE

VICTOR TECHNOLOGIES
AA INTRO ECO B1357 RWH 03/31/09 16052 Swingley Ridge Road Assy No:
Suite 300 Scale Supersedes
AB ECO B1399 RWH 05/05/09
St Louis MO 63017 USA
AB ECO B1611 RWH 05/05/09
Date:
Information Proprietary to THERMAL DYNAMICS CORPORATION. MARCH 30, 2009
Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: References
A-12771

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, Size DWG No:
Last Modified: Friday, December 11, 2009 09:02:19
D
CM102/152/35mm/40mm/A80/A120 380/400/415/600V 42X1330
3 2 1

Manual 0-4989 APPENDIX A-121

CUTMASTER A120
APPENDIX 7: RAW ARC VOLTAGE
If raw arc voltage is necessary for the torch height control, the customer must supply an 18 AWG (1.0 mm2), single pair,
unshielded cable rated for 300V or greater. All work must be performed following applicable local and national codes.

1. Disconnect the power from the power supply.

2. Remove the screws that attach the power supply cover to the chassis. Remove the cover.

3. Route the cable through the customer supplied strain relief at the rear of the power supply.
Cut out for cable

Art # A-10286
4. On the main board use insulated type 1/4-inch ring lug terminal ends to connect to –Vout1 (- polarity) and WORK 1 (+
polarity).

! WARNING

The raw arc voltage can exceed 350VDC !!!!

WORK 1
-V OUT 1
WORK 1

-V OUT 1

J10

Art # A-10287

A-122 APPENDIX Manual 0-4989

 CUTMASTER A120

Art # A-10288_AB

-V_out2 (-) Polarity Work2 (+) Polarity

5. Tighten the strain relief.

6. Replace the cover.

7. Connect the cable to negative and positive of Torch Height Control .

Manual 0-4989 APPENDIX A-123

CUTMASTER A120
APPENDIX 8 : MOD BUSS HARNESS CONNECTION(OPTIONAL)
NOTE!
These instructions are based on your system having the MOD BUSS feature
installed. You can get a kit to add to your existing system if you need to.

1. Remove the plug from the rear panel of your system shown here by loosening the two screws on the top and
bottom.

Art#H-0043

A-124 APPENDIX Manual 0-4989

 CUTMASTER A120
2. Connect your CNC wiring according to the following diagram.

1 1

RS485 TX +

RS485 TX -

RS485 RX +

RS485 RX -

RS485 GND

5 5
Art # A-15219

3. Reinstall your newly wired plug to the rear panel and secure the two screws to avoid loose connections.

Manual 0-4989 APPENDIX A-125

CUTMASTER A120
APPENDIX 9: PUBLICATION HISTORY
Cover Date Rev. Change(s)

June 30, 2008 AA Manual released.

Sept. 19, 2008 AB Added CE information Per ECOB.
Jan. 27, 2009 AC Updated art in section 3 to show all the information for the two stage filter per
ECOB1248. Updated power supply and input wiring specs per ECOB1197
Apr. 1, 2009 AD Updated Cover, system specs and input wiring specs in section 2, system catalog
number in section 6 and Appendix with 600V schematic info per ECOB1346.
May 29, 2009 AE Updated 400V/600V schematic in appendix per ECOB1399 and updated 230/460V
schematic per ECOB1357. Corrected part numbers in section 6 per ECOB1201.
Oct. 20, 2009 AF Updated Electrode and Tip part numbers per ECOB1494 changing 9-8215 to 9-8232
and 9-8253 to 9-8233.
Jan. 7, 2010 AG Updated "Power Supply Input Cable Wiring Requirements" with metric power
cable sizes in Section 2. Updated torch consumables art section 4T and 6. Updated
automation interface and harness descriptions and part numbers per ECOB1282.
Feb. 25, 2010 AH Updated CNC cable part numbers in section 6 per ECOB1637.
Mar. 14, 2011 AI Updated power cord part number in section 6 per ECOB1234.
June 22, 2011 AJ Added Appendix 7: Raw Arc Voltage
Oct. 18, 2011 AK Corrected CutMaster 230V power cord number in section 6 per ECOB2128.
Mar. 20, 2012 AL Updated ART A-08066 and changed COO text, per ECOB2149.
June 11, 2012 AM Corrected warranty chart in section 1 to show US and None US terms per
ECOB2252
Aug. 20, 2012 AN Added Opening the Contactor Cover text per ECOB2122. Inserted Victor
Technologies branding text.
Dec. 7, 2012 AO Add Heavy Duty Start Cartridge 80×144(9-8277) to automated 1Torch per ECO-
B2305.
Nov. 6, 2013 AP Updated Declaration of Conformity. Made the following changes per ECO B2527:
updated cover to show new Victor Thermal Dynamics trade dress, updated thank
you text, changed headers and footers, changed logo on art on pages A-2, A-7, A-9,
updated rear cover.
Oct. 24, 2014 AQ Updated page 2 of section 3T with jumper information and warning per ECOB2673
July 15, 2016 AR Moved "Declaration of Content" page and added "Safety" page. Changed logo on
Front Cover and Inside Front Cover from "Victor Thermal Dynamics" to
"Thermal Dynamics" per VCR-01839
Apr. 06, 2022 AT Updated page 56 of section 4T with part number changes from 9-8233 to 9-8212 in the
100A cut chart and updated Declaration of Conformity as per ECR-05505
Nov 16, 2023 AU Added 110A Cut charts in section 4T

A-126 APPENDIX Manual 0-4989

This Page Intentionally Blank
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