ESAB A120 Operating Manual

CUTMASTER® A120

OUTPUT MAX OUTPUT INPUT POWER

VOLTAGEVOLTAGEVOLTAGE

INPUT POWER

VOLTAGE

AUTOMATED PLASMA CUTTING SYSTEM

Operating

Manual

Revision: AA Issue Date: August 30, 2015 Manual No.: 0-5430

120

AMPS

PHASE PHASE

Art # A-12879

380-400V208-230V

esab.eu

600V460V

WE APPRECIATE YOUR BUSINESS!

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

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

ESAB is a Global Brand of manual and automation Plasma Cutting Products.

We distinguish ourselves from our competition through market-leading, dependable
products that have stood the test of time. We pride ourselves on technical innovation,
competitive prices, excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve
a safer working environment within the welding industry.

WARNING

!

Read and understand this entire Manual and your employer’s safety practices before 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 0-5430

Published by:
ESAB Group Inc.
2800 Airport Rd.
Denton, TX 76208
[phone]

www.esab.eu

Copyright 2015 by ESAB

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or
damage caused by any error or omission in this Manual, whether such error results from negli­gence, accident, or any other cause.

For Printing Material Specification refer to document 47x1909
Original Publication Date: August 30, 2015
Revision Date:

Record the following information for Warranty purposes:

Where Purchased:_______________________________ __________________

Purchase Date:__________________________________ __________________

Power Supply Serial #:___________________________ ___________________

Torch Serial #:___________________________________ _________________

i

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

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

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with
the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained
equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be
replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends
that a telephone or written request for service advice be made to the Authorized Distributor from whom it
was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manu­facturer. The user of this equipment shall have the sole responsibility for any malfunction which results from
improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufac­turer or a service facility designated by the manufacturer.

!

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

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

1.0 Safety Precautions......................................................................................1-1

SECTION 2 SYSTEM: INTRODUCTION .................................................................................2-1

2.01 How To Use This Manual............................................................................2-1

2.02 Equipment Identification .............................................................................2-1

2.03 Receipt Of Equipment ................................................................................2-1

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

2.05 Input Wiring Specifications .........................................................................2-3

2.06 Power Supply Features ..............................................................................2-4

SECTION 2 TORCH: INTRODUCTION .............................................................................. 2T-1

2T.01 Scope of Manual.......................................................................................2T-1

2T.02 General Description ..................................................................................2T-1

2T.03 Specifications ..........................................................................................2T-1

2T.04 Options And Accessories .........................................................................2T-2

2T.05 Introduction to Plasma .............................................................................2T-2

SECTION 3 SYSTEM: INSTALLATION .................................................................................3-1

3.01 Unpacking...................................................................................................3-1

3.02 Lifting Options ............................................................................................3-1

3.03 Power Supply location and Mounting ........................................................3-1

3.04 Opening the Contactor Cover ....................................................................3-1

3.05 Primary Input Power Connections ..............................................................3-1

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

SECTION 3 TORCH: INSTALLATION ................................................................................. 3T-1

3T.01 Torch Connections ...................................................................................3T-1

3T.02 CNC Connection.......................................................................................3T-1

3T.03 Automation Interface PCB with Ohmic Sense ..........................................3T-2

3T.04 Setting Up Automation or Machine Torch ................................................3T-3

SECTION 4 SYSTEM: OPERATION .......................................................................................4-1

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

4.02 Preparations for Operation .........................................................................4-2

SECTION 4 TORCH: OPERATION ...................................................................................... 4T-1

4T.01 Machine and Automated Torch Operation ...............................................4T-1

4T.02 Automation Torch Parts Selection ............................................................4T-1

4T.03 Machine and Hand Torch Parts Selection ................................................4T-2

4T.04 Cut Quality ................................................................................................4T-3

4T.05 General Cutting Information .....................................................................4T-3

4T.06 Hand Torch Operation ..............................................................................4T-4

4T.07 Gouging ....................................................................................................4T-7

4T.08 Recommended Cutting Speeds for Machine and

Automated Torches With Exposed Tip .....................................................4T-8

4T.09 Recommended Cutting Speeds for Machine and

Automated Torches With Shielded Tip ...................................................4T-40

TABLE OF CONTENTS

PATENT INFORMATION .................................................................................................... 4T-70

SECTION 5 SYSTEM: SERVICE .............................................................................................5-1

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

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

5.03 Common Faults ..........................................................................................5-2

5.04 Fault Indicator .............................................................................................5-3

5.05 Basic Troubleshooting Guide .....................................................................5-4

5.06 Power Supply Basic Parts Replacement ....................................................5-6

SECTION 5 TORCH: SERVICE ............................................................................................ 5T-1

5T.01 General Maintenance ................................................................................5T-1

5T.02 Inspection and Replacement of Consumable Torch Parts .......................5T-2

SECTION 6: PARTS LISTS .....................................................................................................6-1

6.01 Introduction ................................................................................................6-1

6.02 Ordering Information...................................................................................6-1

6.03 Power Supply Replacement .......................................................................6-1

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

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

6.06 Torch Replacement Parts SL100SV Torch

(with Solenoid on Mounting Tube) ....................................................6-4

6.07 Torch Consumable Parts (SL100) ...............................................................6-6

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

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM) ....................................................................................................... A-1

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

APPENDIX 3: TORCH PIN - OUT DIAGRAMS .................................................................... A-4

APPENDIX 4: TORCH CONNECTION DIAGRAMS ............................................................. A-6

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS ..................................................... A-8

APPENDIX 6: SYSTEM SCHEMATIC, 400/600V UNITS ................................................... A-10

APPENDIX 7: RAW ARC VOLTAGE .................................................................................. A-12

Revision History ................................................................................................................... A-14

CUTMASTER A120

SECTION 1: SAFETY

1.0 Safety Precautions

Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works
on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that
apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition
to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator
and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

- Always wear recommended personal safety equipment, such as safety glasses, flame proof
clothing, safety gloves.

- Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualified electrician.

- Appropriate fire extinguishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

Dispose of electronic equipment at the recycling facility!

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

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

0-5430 GENERAL INFORMATION

1-1

CUTMASTER A120

Arc welding and cutting can be injurious to yourself and others. Take

WARNING

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with
applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your
breathing zone and the general area.

ARC R AYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and filter
lens and wear protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable
materials nearby.

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

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmuffs or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

Do not use the power source for thawing frozen pipes.

WARNING

Class A equipment is not intended for use in residential locations

CAUTION

CAUTION

CAUTION

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

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

Read and understand the instruction manual before
installing or operating.

!

1-2

GENERAL INFORMATION 0-5430

CUTMASTER A120

!

!

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specication or part

numbers listed on page i.

To ensure safe operation, read the entire manual, in­cluding the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAU­TION, DANGER and NOTE may appear. Pay par­ticular attention to the information provided under these
headings. These special annotations are easily recog­nized as follows:

NOTE!

An operation, procedure, or back­ground information which requires
additional emphasis or is helpful in

efcient operation of the system.

CAUTION

!

A procedure which, if not properly
followed, may cause damage to the
equipment.

2.02 EquipmentIdentication

The unit’s identication number (specication or part

number), model, and serial number usually appear on
a data tag attached to the rear panel. Equipment which
does not have a data tag such as torch and cable as-

semblies are identied only by the specication or part

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

2.03 Receipt Of Equipment

When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there

is any damage, notify the carrier immediately to le a

claim. Furnish complete information concerning dam­age claims or shipping errors to the location in your area
listed in the inside back cover of this manual.

Include all equipment identication numbers as described

above along with a full description of the parts in error.

Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.

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.

DANGER

Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.

Additional copies of this manual may be purchased by
contacting ESAB at the address and phone number in
your area listed on back cover of this manual. Include
the Owner’s Manual number and equipment identica­tion numbers.

Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the ESAB
web site listed below

http://www.esab.eu

0-5430 INTRODUCTION

2-1

CUTMASTER A120

150 mm

2.04 PowerSupplySpecications

CutmasterA120PowerSupplySpecications

Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz

230 VAC (187 - 253 VAC), 3 Phase, 50/60 Hz

380 VAC (360 - 440 VAC), 3 Phase, 50/60 Hz

400 VAC (360 - 440 VAC), 3 Phase, 50 Hz

460 VAC (414 - 506 VAC), Single Phase, 60 Hz

460 VAC (414 - 506 VAC), 3 Phase, 60 Hz

600 VAC (540 - 630), 3 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 IEC

Duty Cycle **60% 80% 100%

Current 120 120 100

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 specied by the International Electro-Technical Commission. These
specications include calculating an output voltage based upon power supply rated current. To fa-

cilitate 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

63 lb / 28.6 kg

26.3"

0.668 m

24"

610 mm

Art # A-07925_AB

6"

150 mm

6"

INTRODUCTION 0-5430

2-2

150 mm

6"

CUTMASTER A120

2.05 InputWiringSpecications

Cutmaster A120 Power Supply Input Cable Wiring Requirements

Input

voltage

Volts Hz kVA I max I eff Fuse

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

NOTE!

Refer to Local and National Codes or local authority having jurisdiction for proper wiring require­ments.

The suggested sizes are based on exible power cable with power plug installations. For hard-

wired installations refer to local or national codes.
I1max is taken at TDC rated minimum duty cycle.

I1eff is taken at TDC 100% rated duty cycle

Freq Power

Input

(amps)

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

Suggested Sizes

Flexible Cord

(Min. AWG)

Flexible Cord

(Min. mm2)

0-5430 INTRODUCTION

2-3

CUTMASTER A120

Ar

rk Cable

and Clamp

Input Power Cord

Input

Art # A-08461

2.06 Power Supply Features

t # A-08460

Mounting Rails

Automation Interface
Cable Port

Power Selection

Control Panel

Torch Leads
Receptacle

Wo

Filter Assembly

Gas Inlet Port

INTRODUCTION 0-5430

2-4

SECTION 2 TORCH:

44.5 mm

18.875" / 479 mm

16 mm

1.175" / 30 mm

2.875”
73 mm

t # A-02998

15.875" / 403 mm

16 mm

(95 mm)

INTRODUCTION

CUTMASTER A120

The standard automation torch has a position­ing tube with rack & pinch block assembly and a
solenoid valve.

2T.01 Scope of Manual

This manual contains descriptions, operating instructions
and maintenance procedures for the 1Torch Models

SL100/Manual and SL100/Mechanized Plasma Cutting

Torches. Service of this equipment is restricted to prop-

erly trained personnel; unqualied personnel are strictly

cautioned against attempting repairs or adjustments not
covered in this manual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understanding
of the characteristics and capabilities of this equipment
will assure the dependable operation for which it was
designed.

2T.02 General Description

Plasma torches are similar in design to the automotive
spark plug. They consist of negative and positive sec­tions separated by a center insulator. Inside the torch,
the pilot arc starts in the gap between the negatively
charged electrode and the positively charged tip. Once
the pilot arc has ionized the plasma gas, the superheated

column of gas ows through the small orice in the torch

tip, which is focused on the metal to be cut.

/

1.75" /

0.625" /

12.285" / 312 mm

1.375" / 35 mm

4.95" / 126 mm

Art # A-07402_AC

2. Machine Torch, Model

The standard machine torch has a positioning
tube with rack & pinch block assembly.

9.285" / 236 mm

1.375" / 35 mm

1.75" /

44.5 mm

0.625" /

4.95" / 126 mm

1.175" / 30 mm

Ar

3. Hand/Manual Torch, Models

The hand torch head is at 75° to the torch handle.

The hand torches include a torch handle and torch
trigger assembly.

10.125" (257 mm)

A single torch lead provides gas from a single source to
be used as both the plasma and secondary gas. The

air ow is divided inside the torch head. Single - gas

operation provides a smaller sized torch and inexpensive
operation.

NOTE!

Refer to Section "2T.05 Introduction

to Plasma" on page 2T-2, for a more
detailed description of plasma torch
operation.
Refer to the Appendix Pages for ad-

ditional specications as related to the

Power Supply used.

2T.03 Specications

A. TorchCongurations

1. Automation Torch, Model

3.75"

Art # A-03322_AB

1.17" (29 mm)

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20 ft / 6.1 m, with ATC connectors

• 50 ft / 15.2 m, with ATC connectors

Machine / Automation Torches are available as

follows:

• 5 foot / 1.5 m, with ATC connectors

• 10 foot / 3.05 m, with ATC connectors

• 25 foot / 7.6 m, with ATC connectors

• 50 foot / 15.2 m, with ATC connectors

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

0-5430 INTRODUCTION

2T-1

CUTMASTER A120

!

C

12 VDC circuit rating

2T.05 Introduction to Plasma

E. Type Cooling

Combination of ambient air and gas stream through
torch.

F. Torch Ratings

Automated / Machine Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current 120 Amps

Voltage (V

Arc Striking Voltage 7kV

Ambient

Temperature

Duty Cycle 100% @ 120 Amps @ 400 scfh

Maximum Current 120 Amps

Voltage (V

Arc Striking Voltage 7kV

peak

Manual Torch Ratings

peak

100% @ 100 Amps @ 400 scfh

80% @ 120 Amps @ 400 scfh

) 500V

) 500V

104° F

40° C

104° F

40° C

A. Plasma Gas Flow

Plasma is a gas which has been heated to an
extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma to
transfer an electrical arc to the workpiece. The metal
to be cut or removed is melted by the heat of the arc
and then blown away.

While the goal of plasma arc cutting is separation of
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.

In a Plasma Cutting Torch a cool gas enters Zone B,
where a pilot arc between the electrode and the torch
tip heats and ionizes the gas. The main cutting arc
then transfers to the workpiece through the column
of plasma gas in Zone C.

G. Gas Requirements

Automated, Manual and Machine Torch Gas

Specications

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and

Gouging)

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh

142 - 235 lpm

WARNING

This torch is not to be used with

oxygen (O2).

NOTE!

Operating pressure varies with torch
model, operating amperage, and torch
leads length. Refer to gas pressure set­tings charts for each model.

H. Direct Contact Hazard

For standoff tip the recommended standoff is 3/16
inches / 4.7 mm.

_

Power

Supply

+

B

Workpiece

A-08331

Typical Torch Head Detail

By forcing the plasma gas and electric arc through a

small orice, the torch delivers a high concentration

of heat to a small area. The stiff, constricted plasma

arc is shown in Zone C. Direct current (DC) straight

polarity is used for plasma cutting, as shown in the
illustration.

A

2T.04 Options And Accessories

For options and accessories, see section 6.

INTRODUCTION 0-5430

2T-2

Zone A channels a secondary gas that cools the
torch. This gas also assists the high velocity plasma

gas in blowing the molten metal out of the cut allow-

up

To

up

up

Remote Pendant

To

A-02997

r

ing for a fast, slag - free cut.

B. Gas Distribution

CUTMASTER A120

The single gas used is internally split into plasma
and secondary gases.

The plasma gas ows into the torch through the

negative lead, through the starter cartridge, around

the electrode, and out through the tip orice.

The secondary gas ows down around the outside

of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc.

C. Pilot Arc

When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot arc
creates a path for the main arc to transfer to the work.

D. Main Cutting Arc

DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
through the torch lead. The positive output is con­nected to the workpiece via the work cable and to
the torch through a pilot wire.

E. Parts - In - Place (PIP)

AT C

AT C

To AT C

PIP Sw itch

CNC Start

PIP Sw itch

Automation To rch

PIP Sw itch

Sh ield C

Sh ield C

Art # A-08168

Sh ield C

Parts - In - Place Circuit Diagram for Machine Torch

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

When the shield cup is properly installed, it closes
a switch. The torch will not operate if this switch is
open.

To Control

Torch Switch

Cable Wiring

PIP Switch

Torch Trigge

Shield Cup

Parts - In - Place Circuit Diagram for Hand Torch

0-5430 INTRODUCTION

2T-3

CUTMASTER A120

This Page Intentionally Blank

INTRODUCTION 0-5430

2T-4

SECTION 3 SYSTEM:

!

Art# A-11478

INSTALLATION

CUTMASTER A120

2. Place the unit in the desired position and mark
where the four keyway holes in the mounting rails

touch.

3.01 Unpacking

1. Use the packing lists to identify and account for
each item.

2. Inspect each item for possible shipping damage.
If damage is evident, contact your distributor and
/ or shipping company before proceeding with the
installation.

3. Record Power Supply and Torch model and serial
numbers, purchase date and vendor name, in the
information block at the front of this manual.

3.02 Lifting Options

The Power Supply includes hand holds in the front and
rear panels for hand lifting only. Be sure unit is lifted
and transported safely and securely.

WARNING

Do not touch live electrical parts.
Disconnect input power cord before
moving unit.
FALLING EQUIPMENT can cause
serious personal injury and can damage
equipment.

3. Remove the unit and using these markings,
prepare holes for mounting hardware.

4. Insert proper hardware. If using hardware that

screws into the mounting surface, leave all four
loose enough for the thickness of the rail to slide
under the head and washer if used.

5. Lower the power supply over the mounting

hardware and slide forward or backward until the
keyway stops against the mounting hardware.

6. Secure the hardware to the rail.

3.04 Opening the Contactor Cover

The input power cord is connected to the main contac­tor, the contactor is located inside a box with a snap on
cover. The cover is held in place with two or more snap
lock tabs. To remove the cover release the front latch and
tilt the cover up about ½ inch. Then squeeze both sides
of the cover and lift it straight up. See the Primary Input
Power Connections section for the necessary changes
to the Contactor. Remember to replace the Contactor
Cover when the changes are complete.

• Only persons of adequate physical strength should
lift the unit.

• Lift unit by the handles, using two hands. Do not

use straps for lifting.

• Use optional cart or similar device of adequate
capacity to move unit.

• Place unit on a proper skid and secure in place
before transporting with a fork lift or other vehicle.

3.03 Power Supply location and Mounting

NOTE!

It is recommended that the unit be
secured to a suitable surface using the
mounting rails.

1. First choose an appropriate location for mount­ing the power supply. Choose one that allows
for free movement of torch leads, complies with

ventilation per section 2.04 and provides a safe
rm surface where the unit can be secured.

1

2

1

2

Contactor cover

3.05 Primary Input Power Connections

CAUTION

!

Check your power source for correct
voltage before plugging in or connecting
the unit. Check the Voltage Selector at
the rear of the unit for correct setting be­fore plugging in or connecting the unit.
The primary power source, fuse, and
any extension cords used must conform
to local electrical code and the recom­mended circuit protection and wiring

requirements as specied in Section 2.

0-5430 INSTALLATION

3-1

CUTMASTER A120

Screws

Art # A-08316

Art # A-08493

Most units are shipped from the factory with a 230 Volt
input power cable wired to the input contactor in the

single - phase conguration. The following illustrations
and directions are for changing that conguration to a

different voltage and or to three - phase operation or back
again if a change had already been made.

A. Cover Removal

1. Remove the upper and lower screws which
secure the cover to the main assembly. Do not
loosen the lower screws inside the cut out slots
in the bottom of the cover.

NOTE!

The upper screws and lower screws
are not the same. Do not mix them.
The upper screws are for threading into
the plastic of the front and rear panels.

DO NOT use the ner threaded lower

screws for this.

NOTE!

When installing the upper screws, at­tempt to reuse the original threads. The
easiest way to do this is by turning the
screw counter-clockwise until you feel
the threads line up, then begin to turn
the screw clockwise to tighten. Do not

over tighten.

C. Input Power Selection

Set the Input Voltage Selection Switch at the rear of the
unit based on the primary input voltage it is connected

to. Low is 208/230 VAC and high is 460 VAC.

LO

HI

S

Upper
Screws

Lower

Slots

Lower
Screws

Art # A-08429

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

B. Cover Installation

D. Quick Guide to Phase Wiring

The following illustration and directions are for changing
phase of the power supply.

Input Power Cable Connections

Single-Phase (1ø) and Jumper Settings

Store copper jumpers on base plate

L1

L2

L3

L4

GND

Three-Phase (3ø)

L1

L2

L3

L4

GND

Single and Three Phase Input Power Wiring

NOTE!

There are two jumpers used for the
single phase 230V setting and none for
three phase.

E. Connections to Single Phase Input Power

WARNING

!

Disconnect input power from the power
supply and input cable before attempt­ing this procedure.

1. Reverse previous procedures for cover installa­tion.

These instructions are for changing the input power and

or cable on the 208/230, 400, 460 VAC Power Supply to

Single - Phase input power.

INSTALLATION 0-5430

3-2

1. Remove the Power Supply cover.

!

See "A. Cover Removal".

2. Disconnect the original input power cable from
the main input contactor and the chassis ground
connection.

3. Loosen the through-hole protector on the back

panel of the power supply. Pull the original power
cable out of the power supply.

4. If the power cable being used is not the factory

- supplied cable, use a three - conductor input
power cable for the voltage desired and strip back
the insulation on the individual wires.

5. Pass the cable being used through the access

opening in the back panel of the power supply.

Refer to Section 2 for power cable specications.

CAUTION

!

6. Connect the wires as follows.

7. With a little slack in the wires, tighten the through

8. Reinstall the Power Supply cover.

9. Connect the opposite end of individual wires to

10. Connect the input power cable (or close the main

F. Connections to Three Phase Input Power

The primary power source and power
cable must conform to local electrical
code and the recommended circuit pro-

tection and wiring requirements (refer to

table in Section 2).

• Connect Bus Bar Jumpers on the contactor

as shown in prior illustration and on label in
the power supply.

• Green / Yellow wire to Ground.

- hole protector to secure the power cable.

See "B. Cover Installation".

a customer supplied plug or main disconnect.

disconnect switch) to supply power.

CUTMASTER A120

3. Loosen the through-hole protector on the back

panel of the power supply. Pull the original power
cable out of the power supply.

4. Using a customer supplied four - conductor input

power cable for the voltage desired, strip back
the insulation on the individual wires.

5. Pass the cable being used through the access

opening in the back panel of the power supply.

Refer to Section 2 for power cable specications.

CAUTION

!

6. Connect the wires as follows.

7. With a little slack in the wires, tighten the through

8. Reinstall the Power Supply cover. See "B.

9. Connect the opposite end of individual wires to

10. Connect the input power cable (or close the main

3.06 Gas Connections

Connecting Gas Supply to Unit

The connection is the same for compressed air or high
pressure cylinders. Refer to the following subsections

if an optional air line lter is to be installed.

The primary power source and power
cable must conform to local electrical
code and the recommended circuit pro-

tection and wiring requirements (refer to

table in Section 2).

• Wires to L1, L2 and L3 input. It does not

matter what order these wires are attached.
See previous illustration and on label in the
power supply.

• Green / Yellow wire to Ground.

- hole protector to secure the power cable.

Cover Installation".

a customer supplied plug or main disconnect.

disconnect switch) to supply power.

WARNING

Disconnect input power from the power
supply and input cable before attempt­ing this procedure.

These instructions are for changing the input power and

or cable on the 208/230, 400, 460 VAC Power Supply to

Three - Phase input power.

1. Remove the Power Supply cover.
See "A. Cover Removal".

2. Disconnect the original input power cable from
the main input contactor and the chassis ground
connection.

0-5430 INSTALLATION

1. Connect the air line to the inlet port. The illustra-

tion shows typical ttings as an example.

NOTE!

For a secure seal, apply thread seal-

ant to the tting threads, according

to the manufacturer's instructions.

Do Not use Teon tape as a thread

sealer, as small particles of the tape
may break off and block the small air
passages in the torch.

3-3

CUTMASTER A120

rt

Filter Assembly

Gas Supply
Hose

to 1/4” (6mm) Fitting

Art # A-08319

Hose Clam

rt

Filter Assembly

Inlet Po

Hose Clamp

Art # A-08320

1/4 NPT or ISO-R

Air Connection to Inlet Port

Installing Optional Single - Stage Air Filter

An optional lter kit is recommended for improved lter­ing with compressed air, to keep moisture and debris
out of the torch.

1. Attach the Single - Stage Filter Hose to the Inlet

Port.

2. Attach the Filter Assembly to the lter hose.

3. Connect the air line to the Filter. The illustration

shows typical ttings as an example.

NOTE!

For a secure seal, apply thread seal-

ant to the tting threads, according

to the manufacturer's instructions.

Do Not use Teon tape as a thread

sealer, as small particles of the tape
may break off and block the small air
passages in the torch. Connect as
follows:

Inlet Po

p

Gas Supply
Hose

1/4 NPT to 1/4"

(6mm) Fitting

Optional Single - Stage Filter Installation

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s specications 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 mate-

rial. Briey 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
ows 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 tting threads, accord­ing to manufacturer's instructions.

Do Not use Teon tape as a thread

sealer, as small particles of the tape
may break off and block the small air
passages in the torch.

INSTALLATION 0-5430

3-4

Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line lter is also for use on

compressed air shop systems. Filter removes moisture

and contaminants to at least 5 microns.

Connect the air supply as follows:

Regulator/Filter

wo Stage

Art # A-07945_AC

Hose Clamp

1. Attach the Two Stage Filter bracket to the back
of the power supply per instructions supplied with

the lter assembly.

NOTE!

For a secure seal, apply thread
sealant to the tting threads accord­ing to manufacturer's instructions.

Do Not use Teon 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 lter outlet hose to the

inlet port of the Regulator / Filter Assembly.

3. Use customer - supplied ttings to connect the air
line to the Filter. A 1/4 NPT to 1/4" hose barbed
tting is shown as an example.

CUTMASTER A120

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 tting threads, accord­ing to manufacturer's instructions.

Do Not use Teon tape as a thread

sealer, as small particles of the tape
may break off and block the small air
passages in the torch.

Assembly

Regulator
Input

Gas Supply
Hose

1/4 NPT to 1/4”
(6mm) Fitting

2-Stage Filter
Inlet Port (IN)

Outlet Port
(OUT)

T
Filter
Assembly

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 specications 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 mate-

rial. Briey 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
ows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the cylinder.

0-5430 INSTALLATION

3-5

CUTMASTER A120

This Page Intentionally Blank

INSTALLATION 0-5430

3-6

CUTMASTER A120

A
Cab

Art # A-08464

Art # A-08323_AB

Plasma

Divided

oltage

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Supply.

Connect only the ESAB model SL100SV / Automation,
SL100 / Mechanical or SL100 / Manual Torch to this

power supply. Maximum torch leads length is 100 feet

/ 30.5 m, including extensions.

WARNING

Disconnect primary power at the source
before connecting the torch.

1. Align the ATC male connector (on the torch lead)

with the female receptacle. Push the male con­nector into the female receptacle. The connec­tors should push together with a small amount
of pressure.

2. Secure the connection by turning the locking nut
clockwise until it clicks. DO NOT use the locking
nut to pull the connection together. Do not use
tools to secure the connection.

3T.02 CNC Connection

1. Locate the interface connection port on the rear

of the power supply.

utomation Interface

le Port

2. Note the pin-out of the connector and that the
customer supplied connector matches.

Start / Stop
Signal

Arc
V

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)
position.

2. Put the Function Control switch in the SET
position.

3. Place a welding lter lens in front of the torch and

turn ON the air. Do not start an arc!

Any oil or moisture in the air will be visible on the lens.

Cutting Machine
OK to Move

2

1

0-5430 INSTALLATION

3T-1

CUTMASTER A120

GND

-12V

3T.03 Automation Interface PCB with Ohmic Sense

The new Automation Interface PCB with Ohmic Sense adds additional selectable divided voltage ratios and

selectable polarity of the divided signal. The board also has Ohmic sensing for use with the iHC XT via

either the exposed torch tip or via a separate Shield Cup using the Ohmic clip. The ohmic sensing will also

provide collision sensing when used with the iHC XT or iCNC.

Signals at the CNC connector (J1 on this board) are START / STOP on J1-3 (common) and J1-4 (+); Isolated

& Divided Arc voltage on J1-5 (-) and J1-6 (+); PLATE CONTACT OUT (relay contact) between J1-10 and
J1-11; OK TO MOVE OUT (relay contact) between J1-12 and J1-14.

Voltage divider;

The 6 position DIP switch, DIV1, makes available the following divide ratios:

DIV1-1 ON = 16.7:1 for SC11; DIV1-2 ON = 20:1 for EASB; DIV1-3 ON = 30:1;

DIV1-4 ON = 40:1 for Inova; DIV1-5 ON = 50:1 for IHT, SC3000 & 3100; Hypertherm®;

DIV1-6 ON = 80:1 for TD iHC

NOTE!

Only one position should be on at a time.

Divided arc voltage signal is isolated, either the positive signal (J1-6) or negative (J1-5) may be grounded

or both can be oating.

Ohmic sensing and Collision via exposed TIP:

With a connection made from the PCB4 terminal TIP to the main board PCB1 terminal TIP1 contact of the

exposed tip with the work while nding height is sensed and activates the signal PLATE CONTACT OUT at

J1-11. SW2 set to 0 can disable this sensing.

During cutting the exposed tip contacting the work will close the relay contact between J1-10 and J1-11

which is interpreted by the iHC as a collision. This feature may be disabled by setting SW3 to 0.

NOTE!

If TIP1 on PCB1 (main board) is not connected to TIP terminal on PCB4 both SW2 and SW3 must
be set to “0” (off) position else the plate contact signal will be active all the time.

Ohmic sensing and Collision via shield cup Ohmic Clip.

The Plasma Adapter Cable for use with the iHC XT for this Automation Interface PCB with Ohmic Sense

includes a connection to pin 13 which can be connected to a wire from the ohmic clip. Note that this adapter

cable is different from the one used with the separate iHC voltage divider board. When the shield cup, with
contact from the ohmic clip, contacts work during height nding it closes the relay between J1-10 and J1-11
providing the PLATE CONTACT signal to the iHC. During cutting the iHC interprets this contact as a collision

and retracts the torch.

Indicators:

LED indicators START, M-ARC and CONTACT are provided to show when START (torch trigger) is ON,

when OK to Move (M-ARC) is on, and when Plate Contact is active.

Rating:

The OK to Move and the Plate Contact Out are relay contacts rated for maximum of 30VAC or DC at 1 amp

maximum.

Start SW input requires a switch or relay contact rated for at least 12VDC at 3 ma.

START

INSTALLATION 0-5430

3T-2

J1-3

J1-4

3k

CUTMASTER A120

)

DIVIDE RATIO SET BY DIP SW DIV1

DIV1-1 ON = 16.7:1 for SC11
DIV1-2 ON = 20:1 for ESAB
DIV1-3 ON = 30:1

To -V OUT 1
on PCB1

P10

1

2

3

4

5

6

7

8

To TIP1
on PCB1

J2

*

1

2

3

4

5

6

7

8

-V0_1

+12V

START / STOP

1

TIP

1

CONTACT

VOLTAGE
DIVIDER
CIRCUITS

OK TO MOVE

DIV1-4 ON = 40:1 for Inova
DIV1-5 ON = 50:1 for IHT:

DIV1-6 ON = 80:1 for TD iHC

DIV1

123456

ISO GND

-

+

SW1

PCB4

AUTOMATION
INTERFACE PCB
(w / OHMIC)

OHMIC
SENSE
CIRCUITS

M-ARC

OK to MOVE

ISO GND

START

SC3000 & 3100; Hypertherm

J1

1

2

START / STOP (com)

3

START / STOP

4

DIVIDED ARC VOLTAGE (-)

5

DIVIDED ARC VOLTAGE (+

6

7

COMMON

8

9

PLATE CONTACT COM

CONTACT

OK TO MOVE

10

PLATE CONTACT OUT

11

OK TO MOVE

12

13

OK TO MOVE

14

Art # A-09819_AC

OHMIC

®

3. Connect CNC to the power supply.

3T.04 Setting Up Automation or Machine Torch

NOTE!

An adapter is required to be installed in
the power supply if converting a hand
torch system to operate a machine or
automation torch.

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.

WARNING

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

0-5430 INSTALLATION

3T-3

CUTMASTER A120

Wo

rkpiece

Automated and Machine Torch Set - Up

Pinch Block
Assembly

Square

A-02585

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.

INSTALLATION 0-5430

3T-4

CUTMASTER A120

+

12

3

5

6

7

9

10

SECTION 4 SYSTEM:

OPERATION

4.01 Front Panel Controls / Features

See Illustration for numbering Identification

1. Output Current Control

Sets the desired output current. Output settings

up to 60 Amps may be used for drag cutting (with

the torch tip contacting the workpiece) or higher for
standoff cutting.

2. Function Control

Function Control Knob, Used to select between the
different operating modes.

SET Used to purge the air through the unit
and torch and leads and to adjust gas pressure.

RUN Used for general cutting operations

RAPID AUTO RESTART Allows for faster

restarting of the Pilot Arc for uninterrupted cutting.

4

MAX

MIN

A

PSI BAR

MAXMAX

MINMIN

!

+

Art# A-07886

8

6. Temp Indicator

Indicator is normally OFF. Indicator is ON when

internal temperature exceeds normal limits. Let the

unit cool before continuing operation.

LATCH Used for longer hand held or

mechanical cuts. (Does not apply to automation).

Once a cutting arc is established, the torch switch
can be released. The cutting arc will remain ON
until the torch is lifted away from the work piece,
the torch leaves the edge of the work piece the
torch switch is activated again or if one of the sys­tem interlocks is activated.

3. ON OFF Power Switch

ON / OFF Switch controls input power to the
power supply. Up is ON, down is OFF.

4. Air/Gas Pressure Control

The Pressure
"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 op­eration. Blinking light indicates unit is in protective
interlock mode. Shut unit OFF, shut OFF or discon­nect input power, correct the fault, and restart the

unit. Refer to Section 5 for details.

7. Gas Indicator

Indicator is ON when minimum input gas pressure
for power supply operation is present. Minimum

pressure for power supply operation is not sufcient

for torch operation.

8. DC Indicator

Indicator is ON when DC output circuit is active.

9. ! Fault Error Indicator

Indicator is ON when Fault circuit is active. See sec-

tion 5 for explanations of fault lights.

Control is used in the

0-5430 OPERATION

4-1

CUTMASTER A120

Art # A-08170

Art # A-04509

10. Pressure Indicators

PSI BAR

MAX MAX

90 6.3

85 5.9

80

5.5

75

5.2

70

4.8

65

4.5

MINMIN

The Indicators will illuminate according to the pres-

sure set by the Pressure Control Knob (number 4).

4.02 Preparations for Operation

At the start of each operating session:

WARNING

Disconnect primary power at the source
before assembling or disassembling
power supply, torch parts, or torch and
leads assemblies.

Torch Parts Selection

Check the torch for proper assembly and appropriate
torch parts. The torch parts must correspond with
the type of operation, and with the amperage output

of this Power Supply (120 amps maximum). Refer to
Section 4T.07 and following for torch parts selection.

Torch Connection

Check that the torch is properly connected. Only
ESAB 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, Specications.

2. Connect the input power cable (or close the main

disconnect switch) to supply power to the system.

Connect Work Cable

Clamp the work cable to the workpiece or cutting
table. The area must be free from oil, paint and rust.
Connect only to the main part of the workpiece; do
not connect to the part to be cut off.

Power ON

Place the Power Supply ON / OFF switch to the ON
(up) position. AC indicator turns ON. Gas

indicator turns ON if there is sufcient gas pres­sure for power supply operation and the cooling
fans turn ON.

NOTE!

Minimum pressure for power supply op­eration is lower than minimum for torch
operation.
The cooling fans will turn ON as soon
as the unit is turned ON. After the unit

is idle for ten (10) minutes the fans will

turn OFF. The fans will come back ON
as soon as the torch switch (Start Sig­nal) is activated or if the unit is turned
OFF, then turned ON again. If an over
temperature condition occurs, the fans
will continue to run while the condition

exists and for a ten (10) minute period

once the condition is cleared.

Set Operating Pressure

1. Place the Power Supply Function Control knob

to the SET position. Gas will ow.

2. For Standoff cutting, adjust gas pressure from 70

- 85 psi / 4.8 - 5.9 bar (LED's in center of control

panel). Refer to the Standoff chart for pressure
setting details.

Air Source

Ensure source meets requirements (refer to Section

2). Check connections and turn air supply ON.

OPERATION 0-5430

4-2

1

2

Art# A-07946

MIN

MAX

A

PSI BAR

MAXMAX

MINMIN

!

STANDOFF

Cutmaster A120 Gas Pressure Settings

Leads Length

Up to 50'

(7.6 m)

Each additional

25' (7.6 m)

SL100

(Hand Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

+

SL100

(Mechanized Torch)

SL100 SV

(Automation Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

CUTMASTER A120

Pre-flow

With hand or mechanical torch, there will be a .5
second pre-ow of the gas. Pre-ow does not apply

to automation torch use.

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 arc. With the knob in the RAPID AUTO
RESTART position, when the torch leaves the work­piece the pilot arc restarts instantly, and the cutting
arc restarts instantly when the pilot arc contacts the

workpiece. (Use the 'Rapid Auto Restart' position

when cutting expanded metal or gratings, or in goug­ing or trimming operations when an uninterrupted

restart is desired). And with the knob in the LATCH

position the main cutting arc will be maintained after
the torch switch is released.

Typical Cutting Speeds

Cutting speeds vary according to torch output am­perage, the type of material being cut, and operator

skill. Refer to Section 4T.08 and following for greater

details.

Output current setting or cutting speeds may be
reduced to allow slower cutting when following a
line, or using a template or cutting guide while still
producing cuts of excellent quality.

3. For Drag cutting (60 Amps and below), adjust gas

Postflow

pressure from 75 - 95 psi / 5.2 - 6.5 bar (LED's in

center of control panel). Refer to the Drag Cutting
chart for pressure setting details.

Release the trigger to stop the cutting arc. Gas con-

tinues to ow for approximately 20 seconds. During
post - ow, if the user moves the trigger release to

DRAG (60 Amps or less)

Cutmaster A120 Gas Pressure Settings

Leads Length

Up to 25'

(7.6 m)

Each additional

25' (7.6 m)

SL100

(Hand Torch)

80 psi

5.5 bar

Add 5 psi

0.4 bar

Select Current Output Level

the rear and presses the trigger, the pilot arc starts.
The main arc transfers to the workpiece if the torch
tip is within transfer distance to the workpiece.

Shutdown

Turn the ON / OFF switch to OFF (down).
All Power Supply indicators shut OFF. Unplug the
input power cord or disconnect input power. Power
is removed from the system.

1. Place the Function Control Knob in one of the
three operating positions available:

RUN ,

RAPID AUTO RESTART

or LATCH . Gas ow stops.

2. Set the output current to desired amperage with
the Output Current Control Knob.

0-5430 OPERATION

4-3

CUTMASTER A120

This Page Intentionally Blank

OPERATION 0-5430

4-4

SECTION 4 TORCH:

Standoff Distance

CUTMASTER A120

Automation and Machine Torch Operation

OPERATION

4T.01 Machine and Automated Torch

Operation

Cutting With Machine or Automated Torch

These torches are activated by remote control pen­dant or by a remote interface device such as CNC.

1. To start a cut at the plate edge, position the center
of the torch along the edge of the plate.

Travel Speed

Proper travel speed is indicated by the trail of the
arc which is seen below the plate. The arc can be
one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiece
surface. This arc is generally recommended
for the best cut using air plasma on stainless or
aluminum.

2. Leading Arc

The leading arc is directed in the same direction
as torch travel. A ve degree leading arc is gen­erally recommended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direc­tion as torch travel.

For optimum smooth surface quality, the travel speed
should be adjusted so that only the leading edge
of the arc column produces the cut. If the travel
speed is too slow, a rough cut will be produced as
the arc moves from side to side in search of metal
for transfer.

Travel speed also affects the bevel angle of a cut.
When cutting in a circle or around a corner, slowing
down the travel speed will result in a squarer cut.
The power source output should be reduced also.
Refer to the appropriate Control Module Operating
Manual for any Corner Slowdown adjustments that
may be required.

Piercing With Machine or Automated Torch

To pierce, the arc should be started with the torch
positioned as high as possible above the plate while
allowing the arc to transfer and pierce. This standoff
helps avoid having molten metal blow back onto the
front end of the torch.

When operating with a cutting machine, a pierce or
dwell time is required. Torch travel should not be
enabled until the arc penetrates the bottom of the
plate. As motion begins, torch standoff should be

reduced to the recommended 1/8 - 1/4 inch (3-6 mm)

distance for optimum speed and cut quality. Clean
spatter and scale from the shield cup and the tip as
soon as possible. Spraying or dipping the shield cup
in anti - spatter compound will minimize the amount
of scale which adheres to it.

4T.02 Automation Torch Parts Selection

Direction of Torch Travel

Straight Arc

Trailing Arc

A-02586

Leading Arc

0-5430 OPERATION

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter Cartridge

Change the torch parts for a different operation as fol­lows:

Check the torch for proper consumable parts. The
parts supplied in the torch may not be correct for
the operator’s chosen amperage level or operation

type. Use Deector in mechanized applications that

do not require “Ohmic-Touch” initial height sensing.
Use Shield Cap and Ohmic Clip in mechanized ap­plications that require “Ohmic-Touch” initial height
sensing. The torch parts must correspond with the
type of operation.

NOTE!

Refer to Sections 4T.08 and following

for additional information on torch parts.

4T-1

CUTMASTER A120

Deflector

A-03510_AB

WARNING

Disconnect primary power at the source
before assembling or disassembling
torch parts, or torch and leads assem­blies.

NOTE!

The shield cup holds the tip and starter
cartridge in place. Position the torch
with the shield cup facing upward to
keep these parts from falling out when
the cup is removed.

1. If attached, remove the ohmic clip then unscrew
and remove the shield cup assembly from the
torch head. Wipe it clean or replace if damaged

2. Remove the Electrode by pulling it straight out

of the Torch Head.

Torch Head

Electrode

Art # A-04173_AB

4T.03 Machine and Hand Torch Parts

Selection

Depending on the type of operation to be done deter­mines the torch parts to be used.

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter
Cartridge

NOTE!

Refer to Section 4T.08 and following for

additional information on torch parts.

Change the torch parts for a different operation as fol­lows:

WARNING

Disconnect primary power at the source
before assembling or disassembling
torch parts, or torch and leads assem­blies.

Start Cartridge

Tip

Ohmic Clip
(If installed)

Shield Cup Body

Shield Cap

Automation Torch Parts

3. Install the replacement Electrode by pushing it
straight into the torch head until it clicks.

4. Install the starter cartridge and desired tip for the

operation into the torch head.

5. Hand tighten the shield cup assembly until it is

seated on the torch head. If resistance is felt
when installing the cup, check the threads before
proceeding

NOTE!

The shield cup holds the tip and starter
cartridge in place. Position the torch
with the shield cup facing upward to
keep these parts from falling out when
the cup is removed.

1. Unscrew and remove the shield cup assembly
from the torch head.

2. Remove the Electrode by pulling it straight out of

the Torch Head.

Torch Head

Electrode

Start Cartridge

Tip

Shield Cup

6. If used, attach the ohmic clip to the shield cup.

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

OPERATION 0-5430

4T-2

3. Install the replacement Electrode by pushing it

Kerf Width

Drag Lines

!

straight into the torch head until it clicks.

4. Install the starter cartridge and desired tip for the

operation into the torch head.

CUTMASTER A120

Top - Edge Rounding

Rounding on the top edge of a cut due to wearing
from the initial contact of the plasma arc on the
workpiece.

5. Hand tighten the shield cup assembly until it is

seated on the torch head. If resistance is felt
when installing the cup, check the threads before
proceeding.

4T.04 Cut Quality

NOTE!

Cut quality depends heavily on setup
and parameters such as torch standoff,
alignment with the workpiece, cutting
speed, gas pressures, and operator
ability.

Cut quality requirements differ depending on applica­tion. For instance, nitride build - up and bevel angle
may be major factors when the surface will be welded
after cutting. Dross - free cutting is important when n­ish cut quality is desired to avoid a secondary cleaning
operation. The following cut quality characteristics are

illustrated in the following gure:

Cut Surface
Bevel Angle

Top

Spatter

Top Edge

Rounding

Dross

Build-Up

Cut Surface

Cut Quality Characteristics

A-00007

Bottom Dross Buildup

Molten material which is not blown out of the cut area

and resolidies on the plate. Excessive dross may

require secondary cleanup operations after cutting.

Kerf Width

The width of the cut (or the width of material removed

during the cut).

Top Spatter (Dross)

Top spatter or dross on the top of the cut caused by
slow travel speed, excess cutting height, or cutting

tip whose orice has become elongated.

4T.05 General Cutting Information

WARNING

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

CAUTION

!

Sparks from the cutting process can
cause damage to coated, painted, and
other surfaces such as glass, plastic
and metal.

Cut Surface

The desired or specied condition (smooth or rough)

of the face of the cut.

Nitride Build - Up

Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.

These buildups may create difculties if the material

is to be welded after the cutting process.

Bevel Angle

The angle between the surface of the cut edge and
a plane perpendicular to the surface of the plate.

A perfectly perpendicular cut would result in a 0°

bevel angle.

0-5430 OPERATION

NOTE!

Handle torch leads with care and protect

them from damage.

Piloting

Piloting is harder on parts life than actual cutting
because the pilot arc is directed from the electrode
to the tip rather than to a workpiece. Whenever
possible, avoid excessive pilot arc time to improve
parts life.

Torch Standoff

Improper standoff (the distance between the torch tip

and workpiece) can adversely affect tip life as well as

shield cup life. Standoff may also signicantly affect

4T-3

CUTMASTER A120

Left Side

A-00512

A-00024_AB

1/8" - 3/8" (3 - 9mm)

the bevel angle. Reducing standoff will generally
result in a more square cut.

Edge Starting

For edge starts, hold the torch perpendicular to the

workpiece with the front of the tip near (not touching)

the edge of the workpiece at the point where the cut
is to start. When starting at the edge of the plate, do
not pause at the edge and force the arc to "reach"
for the edge of the metal. Establish the cutting arc
as quickly as possible.

Direction of Cut

In the torches, the plasma gas stream swirls as it
leaves the torch to maintain a smooth column of
gas. This swirl effect results in one side of a cut be­ing more square than the other. Viewed along the
direction of travel, the right side of the cut is more
square than the left.

Cut Angle

Right Side

Cut Angle

4T.06 Hand Torch Operation

Standoff Cutting With Hand Torch

NOTE!

For best performance and parts life,
always use the correct parts for the type
of operation.

1. The torch can be comfortably held in one hand
or steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the holding technique that feels most comfortable
and allows good control and movement.

NOTE!

The tip should never come in contact
with the workpiece except during drag
cutting operations.

2. Depending on the cutting operation, do one of
the following:

a) For edge starts, hold the torch perpendicular

to the workpiece with the front of the tip on
the edge of the workpiece at the point where
the cut is to start.

Side Characteristics Of Cut

To make a square - edged cut along an inside
diameter of a circle, the torch should move coun­terclockwise around the circle. To keep the square
edge along an outside diameter cut, the torch should
travel in a clockwise direction.

Dross

When dross is present on carbon steel, it is com­monly referred to as either “high speed, slow speed,
or top dross”. Dross present on top of the plate is
normally caused by too great a torch to plate dis­tance. "Top dross" is normally very easy to remove
and can often be wiped off with a welding glove.
"Slow speed dross" is normally present on the bottom
edge of the plate. It can vary from a light to heavy
bead, but does not adhere tightly to the cut edge,

and can be easily scraped off. "High speed dross"

usually forms a narrow bead along the bottom of

the cut edge and is very difcult to remove. When

cutting a troublesome steel, it is sometimes useful
to reduce the cutting speed to produce "slow speed
dross". Any resultant cleanup can be accomplished
by scraping, not grinding.

b) For standoff cutting, hold the torch 1/8 - 3/8 in

(3-9 mm) from the workpiece as shown below.

Torch

Shield Cup

Standoff Distance

Standoff Distance

3. Hold the torch away from your body.

4. Slide the trigger release toward the back of the

torch handle while simultaneously squeezing the
trigger. The pilot arc will start.

OPERATION 0-5430

4T-4

CUTMASTER A120

t # A-03383

Tr igger

Art # A-04034

A-03539

Trigger

Trigger Release

A-02986

5. Bring the torch within transfer distance to the

work. The main arc will transfer to the work, and
the pilot arc will shut OFF.

NOTE!

The gas preow and postow are a

characteristic of the power supply and
not a function of the torch.

1

2

Tr igger Release

3

Shield Cup

Standoff Guide

Torch Tip

Workpiece

Shield Cup With Straight Edge

The drag shield cup can be used with a non conduc­tive straight edge to make straight cuts by hand.

WARNING

The straight edge must be non - con­ductive.

Non-Conductive

Straight Edge
Cutting Guide

4

Ar

6. Cut as usual. Simply release the trigger assem­bly to stop cutting.

7. Follow normal recommended cutting practices as

provided in the power supply operator's manual.

NOTE!

When the shield cup is properly in­stalled, there is a slight gap between the
shield cup and the torch handle. Gas
vents through this gap as part of normal
operation. Do not attempt to force the
shield cup to close this gap. Forcing
the shield cup against the torch head or
torch handle can damage components.

8. For a consistent standoff height from the work­piece, install the standoff guide by sliding it
onto the torch shield cup. Install the guide with
the legs at the sides of the shield cup body to
maintain good visibility of the cutting arc. During
operation, position the legs of the standoff guide
against the workpiece.

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when cutting

3/16 inch (4.7 mm) solid metal with relatively smooth

surface.

Drag Cutting With a Hand Torch

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

or less.

NOTE!

For best parts performance and life,
always use the correct parts for the type
of operation.

1. Install the drag cutting tip and set the output cur­rent.

2. The torch can be comfortably held in one hand
or steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the holding technique that feels most comfortable
and allows good control and movement.

4. Keep the torch in contact with the workpiece

during the cutting cycle.

0-5430 OPERATION

5. Hold the torch away from your body.

4T-5

CUTMASTER A120

t # A-03383

Tr igger

6. Slide the trigger release toward the back of the

torch handle while simultaneously squeezing the
trigger. The pilot arc will start.

Trigger

Trigger Release

A-02986

back end for maximum heat protection. Choose
the technique that feels most comfortable and
allows good control and movement.

NOTE!

The tip should never come in contact
with the workpiece except during drag
cutting operations.

2. Angle the torch slightly to direct blowback par-

ticles away from the torch tip (and operator)

rather than directly back into it until the pierce is
complete.

7. Bring the torch within transfer distance to the

work. The main arc will transfer to the work, and
the pilot arc will shut OFF.

NOTE!

The gas preow and postow are a

characteristic of the power supply and
not a function of the torch.

1

2

Tr igger Release

3

4

Ar

8. Cut as usual. Simply release the trigger assem­bly to stop cutting.

9. Follow normal recommended cutting practices as
provided in the power supply operator's manual.

NOTE!

When the shield cup is properly in­stalled, there is a slight gap between the
shield cup and the torch handle. Gas
vents through this gap as part of normal
operation. Do not attempt to force the
shield cup to close this gap. Forcing
the shield cup against the torch head or
torch handle can damage components.

3. In a portion of the unwanted metal start the
pierce off the cutting line and then continue the

cut onto the line. Hold the torch perpendicular to

the workpiece after the pierce is complete.

4. Hold the torch away from your body.

5. Slide the trigger release toward the back of the

torch handle while simultaneously squeezing the
trigger. The pilot arc will start.

Trigger

Trigger Release

A-02986

6. Bring the torch within transfer distance to the

work. The main arc will transfer to the work, and
the pilot arc will shut OFF.

NOTE!

The gas preow and postow are a

characteristic of the power supply and
not a function of the torch.
When the shield cup is properly in­stalled, there is a slight gap between the
shield cup and the torch handle. Gas
vents through this gap as part of normal
operation. Do not attempt to force the
shield cup to close this gap. Forcing
the shield cup against the torch head or
torch handle can damage components.

7. Clean spatter and scale from the shield cup and

the tip as soon as possible. Spraying the shield
cup in anti - spatter compound will minimize the
amount of scale which adheres to it.

Piercing With Hand Torch

Cutting speed depends on material, thickness, and the
operator’s ability to accurately follow the desired cut line.

1. The torch can be comfortably held in one hand
or steadied with two hands. Position the hand to

The following factors may have an impact on system
performance:

press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to

• Torch parts wear

the torch head for maximum control or near the

OPERATION 0-5430

4T-6

• Air quality

!

35°

A-00941_AB

• Line voltage uctuations

• Torch standoff height

• Proper work cable connection

4T.07 Gouging

WARNING

Be sure the operator is equipped with
proper gloves, clothing, eye and ear
protection and that all safety precau­tions at the front of this manual have
been followed. Make sure no part of
the operator’s body comes in contact
with the workpiece when the torch is
activated.
Disconnect primary power to the system
before disassembling the torch, leads,
or power supply.

CUTMASTER A120

Lead Angle

The angle between the torch and workpiece depends
on the output current setting and torch travel speed.

The recommended lead angle is 35°. At a lead angle
greater than 45° the molten metal will not be blown

out of the gouge and may be blown back onto the

torch. If the lead angle is too small (less than 35°),

less material may be removed, requiring more pass­es. In some applications, such as removing welds
or working with light metal, this may be desirable.

Torch Head

Standoff Height

CAUTION

!

Gouging Parameters

Gouging performance depends on parameters such

as torch travel speed, current level, lead angle (the

angle between the torch and workpiece), and the dis-

tance between the torch tip and workpiece (standoff).

Sparks from plasma gouging can cause
damage to coated, painted or other sur­faces such as glass, plastic, and metal.
Check torch parts. The torch parts must
correspond with the type of operation.

Refer to Section 4T.09, Torch Parts

Selection.

CAUTION

!

Torch Travel Speed

Touching the torch tip or shield cup to
the work surface will cause excessive
parts wear.

NOTE!

Refer to Appendix Pages for additional
information as related to the Power Sup­ply used.

Optimum torch travel speed is dependent on current

setting, lead angle, and mode of operation (hand or

machine torch).

Workpiece

Gouging Angle and Standoff Distance

Standoff Distance

The tip to work distance affects gouge quality and

depth. Standoff distance of 1/8 - 1/4 inch (3 - 6

mm) allows for smooth, consistent metal removal.
Smaller standoff distances may result in a severance
cut rather than a gouge. Standoff distances greater

than 1/4 inch (6 mm) may result in minimal metal

removal or loss of transferred main arc.

Slag Buildup

Slag generated by gouging on materials such as car­bon and stainless steels, nickels, and alloyed steels,
can be removed easily in most cases. Slag does not
obstruct the gouging process if it accumulates to the

side of the gouge path. However, slag build - up can

cause inconsistencies and irregular metal removal
if large amounts of material build up in front of the
arc. The build - up is most often a result of improper
travel speed, lead angle, or standoff height.

Current Setting

Current settings depend on torch travel speed,

mode of operation (hand or machine torch), and the

amount of material to be removed.

0-5430 OPERATION

4T-7

CUTMASTER A120

4T.08 Recommended Cutting Speeds for Machine and Automated Torches With

Exposed Tip

Mild Steel
40A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

20 0.036

16 0.060 103 0.14 140 0.18 0.0 0.05

14 0.075 105 0.14 120 0.18 0.1 0.06

12 0.105 108 0.14 80 0.18 0.2 0.06

10 0.135 110 0.14 60 0.18 0.3 0.06

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

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

70 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

101 0.14 160 0.18 0.0 0.05

Tip

9-8208

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-8

CUTMASTER A120

Material

Thickness

(mm)

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

5 112 3.6 1345 4.6 0.4 1.6

6 116 3.6 1100 4.6 0.5 1.7

8 118 3.6 815 4.6 1.0 1.7

10 119 3.6 595 4.6 1.5 1.8

12 120 3.6 435 5.1 2.0 1.8

Gas Pressure

(Air)

Bar

(torch lead

length)

4.8 (7.6m)

5.2 (15.2m)

BOLD TYPE indicates maximum piercing parameters.

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

101 3.6 3990 4.6 0.0 1.1

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-9

CUTMASTER A120

Stainless Steel
40A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

18 0.050

16 0.063 100 0.19 50 0.20 0.00 0.07

14 0.078 105 0.19 45 0.20 0.10 0.07

12 0.109 110 0.19 40 0.20 0.20 0.07

10 0.141 108 0.19 35 0.20 0.30 0.07

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

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Tip

9-8208

Torch

Working

Height

110 0.19 60 0.20 0.00 0.07

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

1/2 0.500 118 0.19 8 Edge start 0.09

OPERATION 0-5430

4T-10

CUTMASTER A120

Material

Thickness

(mm)

1

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

5 111 4.8 715 5.1 0.4 1.8

6 118 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.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6)

5.5 (15.2)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

112 4.8 1670 4.8 0.0 1.7

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-11

CUTMASTER A120

Aluminum
40A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

20 0.040

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 0.125 115 0.16 90 0.18 0.3 0.07

9 0.160 113 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

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

70 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Tip

9-8208

Torch

Working

Height

95 0.16 300 0.16 0.0 0.06

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-12

CUTMASTER A120

Material

Thickness

(mm)

1.0

2.0 104 4.1 3500 4.1 0.2

3.0 115 4.1 2350 4.6 0.3

4.0 113 4.6 2170 4.6 0.4

5.0 118 4.6 1740 4.6 0.5

6.0 125 4.6 1015 4.6 0.8

8.0 139 4.6 500 Edge Start

10.0 153 4.6 180 Edge Start

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

Gas Pressure

(Air)

Bar

(torch lead

length)

4.8 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

95 4.1 7620 4.1 0.0

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

1.5

1.6

1.7

1.7

1.8

1.9

2.0

2.2

0-5430 OPERATION

4T-13

CUTMASTER A120

Mild Steel
60A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.060

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

1/4 0.250 122 0.19 80 0.19 0.30 0.08

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

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Tip

9-8210

Torch

Working

Height

118 0.19 290 0.19 0.00 0.08

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-14

CUTMASTER A120

Material

Thickness

(mm)

1

2 120 4.8 7015 4.0 0.10 1.9

3 11 8 4.8 4570 4.8 0.10 2.1

4 120 4.8 3650 4.8 0.20 1.9

5 121 4.8 2465 4.8 0.20 2.1

6 122 4.8 2145 4.8 0.30 2.0

8 123 4.8 1635 4.8 0.40 2.2

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.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

115 4.8 7540 4.8 0 2.1

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-15

CUTMASTER A120

Stainless Steel
60A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.063

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 0.188 122 0.19 90 0.20 0.20 0.08

1/4 0.250 123 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

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Tip

9-8210

Torch

Working

Height

119 0.19 350 0.20 0.00 0.05

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

5/8 0.625 132 0.19 14 Edge Start 0.11

3/4 0.750 135 0.19 10 Edge Start 0.10

OPERATION 0-5430

4T-16

CUTMASTER A120

Material

Thickness

(mm)

1

2 11 6 4.8 7560 5.1 0.10 1.7

3 122 4.8 4365 5.1 0.10 1.7

4 11 9 4.8 2865 5.1 0.20 2.1

5 122 4.8 2195 5.1 0.20 2.1

6 123 4.8 1790 5.1 0.30 2.2

8 127 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

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

124 4.8 10890 5.1 0.00 0.8

136 4.8 230 Edge Start 2.5

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-17

CUTMASTER A120

Aluminum
60A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.064

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

1/4 0.250 132 0.25 85 0.25 0.30 0.09

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

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

123 0.25 440 0.25 0.00 0.08

Tip

9-8210

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-18

CUTMASTER A120

Material

Thickness

(mm)

1

2 126 6.4 7680 6.4 0.10

3 128 6.4 6410 6.4 0.10

4 130 6.4 5230 6.4 0.20

5 132 6.4 4010 6.4 0.20

6 132 6.4 2640 6.4 0.30

8 137 6.4 1630 6.4 0.40

10 142 6.4 1085 6.4 0.60

12 146 6.4 845 6.4 0.70

15 146 4.8 540 Edge Start 2.1

20 148 4.8 260 Edge Start

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

118 6.4 17010 6.4 0.00

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

1.8

2.3

2.3

2.3

2.4

2.4

2.4

2.4

2.3

2.5

0-5430 OPERATION

4T-19

CUTMASTER A120

Mild Steel
80A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.060

11 0.120

10 0.135

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

7/8 0.875

1 1.000

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.19 320 0.20

113 0.19 230 0.20

110 0.19 180 0.20

110 0.19 136 0.20

115 0.19 100 0.20

125 0.19 42 0.20

123 0.19 40 0.20

133 0.19 18 0.20

140 0.25 18 Edge Start

150 0.25 10 Edge Start

152 0.25 8 Edge Start

Tip

9-8211

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

Electrode

9-8232

Pierce Delay

0.00

0.10

0.20

0.30

0.40

0.50

0.60 0.09

0.75 0.10

Kerf Width

@ Rec.

Speed

0.06

0.07

0.07

0.07

0.09

0.09

0.11

0.11

0.13

OPERATION 0-5430

4T-20

CUTMASTER A120

Material

Thickness

(mm)

1

2 111 4.8 7415 5.1 0.10 1.7

3 11 3

4 11 0 4.8 4095 5.1 0.30 1.7

5 111

6 11 4

8 120

10 125

12 123

15 130

20 143

25 152

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

109 4.8 8915 5.1 0.00 1.5

Torch

Working

Height

4.8

4.8

4.8

4.8

4.8

4.8

4.8

6.4

6.4

Travel Speed

5915

3325

2745

1775

1060

1025

610

395 Edge Start 2.7

210 Edge Start 3.2

Initial

Piercing

Height

5.1

5.1

5.1

5.1

5.1

5.1

5.1

Pierce Delay

0.10 1.8

0.30 1.8

0.40 2.2

0.50 2.3

0.50 2.3

0.60 2.3

0.75 2.5

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-21

CUTMASTER A120

Stainless Steel
80A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16 0.063

11 0.125

10 0.141

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4

0.750

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.19 340 0.25 0.00

115 .0.19 300 0.25 0.10

115 0.19 280 0.25 0.10

115 0.19 140 0.25 0.20

118 0.19 100 0.25 0.30

119 0.19 45 0.25 0.40

124 0.19 26 0.25 0.80 0.10

133 0.19 16 Edge Start 0.10

136 0.19 10 Edge Start 0.11

Tip

9-8211

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

0.06

0.06

0.06

0.07

0.08

0.08

OPERATION 0-5430

4T-22

CUTMASTER A120

Material

Thickness

(mm)

1

2 111 4.8 8380 6.4 0.00 1.5

3

4 11 5 4.8 5865 6.4 0.20 1.6

5

6

8

10

12

15

20 137 4.8 205 Edge Start 3.0

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

108 4.8 9020 6.4 0.00 1.5

114 4.8 7730 6.4 0.10 1.5

115 4.8 3410 6.4 0.20 1.8

117 4.8 2765 6.4 0.30 1.9

119 4.8 1815 6.4 0.40 2.0

120 4.8 1070 6.4 0.60 2.1

123 4.8 765 6.4 0.80 2.3

131 4.8 475 Edge Start 2.5

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-23

CUTMASTER A120

Aluminum
80A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

16

11

3/16

1/4

3/8

1/2

5/8

3/4

0.064

0.120

0.188

0.250

0.375

0.500

0.625

0.750

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

120 0.25 280 0.25 0.10

124 0.25 180 0.25 0.20

130 0.25 110 0.25 0.30

136 0.25 55 0.25 0.40

139 0.25 38 0.25 0.60

136 0.19 26 0.25 0.75 0.10

150 0.19 14 Edge Start 0.12

Starter Cartridge

Tip

Heavy Duty Starter

Cartridge

9-8211

Torch

Working

Height

116 0.25 350 0.25 0.00

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

0.10

0.10

0.10

0.09

0.11

0.11

7/8 0.875 153 0.19 10 Edge Start 0.11

OPERATION 0-5430

4T-24

CUTMASTER A120

Material

Thickness

(mm)

1

2 11 7 6.4 8420 6.4 0.00 2.5

3 120 6.4 7170 6.4

4 122 6.4 5710 6.4 0.20 2.5

5 125 6.4 4315 6.4

6 129 6.4 3190 6.4

8 133 6.4 2070 6.4

10 136 6.4 1330 6.4

12 138 6.4 1060 6.4

15 137 4.8 745 6.4

20 151 4.8 325 Edge Start 3.0

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

114 6.4 8890 6.4

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

0.00

0.10

0.20

0.30

0.40

0.50

0.50

0.75

Kerf Width

@ Rec.

Speed

2.4

2.5

2.5

2.4

2.5

2.7

2.9

2.5

0-5430 OPERATION

4T-25

CUTMASTER A120

Mild Steel
100A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

1-1/4 1.250 128 0.18 8

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

Tip

9-8212

Torch

Working

Height

110 0.18 85 0.20 0.10 0.09

112 0.18 75 0.20

115 0.18 45 0.20

118 0.18 30 0.20

120 0.18 20 0.20

123 0.18 15 Edge Start

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Edge Start

Electrode

9-8232

Pierce Delay

0.20

0.40

0.60

1.20 0.12

Kerf Width

@ Rec.

Speed

0.09

0.10

0.11

0.12

0.13

OPERATION 0-5430

4T-26

CUTMASTER A120

Material

Thickness

(mm)

6

8 111 4.6 2030 5.1 0.10 2.3

10 112

12 114 4.6 1310 5.1 0.40 2.5

15 117

20 120

25 123

30 127

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

110 4.6 2200 5.1 0.10 2.3

Torch

Working

Height

4.6

4.6

4.6

4.6

4.6

Travel Speed

1790

870

490

390

250

Initial

Piercing

Height

5.1

5.1

5.0

Edge Start

Edge Start

Pierce Delay

0.20 2.3

0.60 2.7

1.20 3.0

Kerf Width

@ Rec.

Speed

3.0

3.2

0-5430 OPERATION

4T-27

CUTMASTER A120

Stainless Steel
100A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000 135

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

102 0.16 100

106 0.16 65

109 0.16 45

123 0.19 20

128 0.19 15 Edge Start 0.12

Starter Cartridge

Tip

Heavy Duty Starter

Electrode

Cartridge

9-8212

Torch

Working

Height

0.19 10 Edge Start 0.13

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

0.18

0.18

0.18

0.23

9-8232

Kerf Width

Pierce Delay

0.00 0.09

0.10 0.10

0.30 0.10

2.00 0.11

@ Rec.

Speed

OPERATION 0-5430

4T-28

CUTMASTER A120

Material

Thickness

(mm)

6

8 104 4.1 2080 4.6 0.10 2.4

10 106

12 108 4.1 1255 4.6 0.30 2.4

15 11 9

20 129

25 135

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

102 4.1 2630 4.6 0.00 2.3

Torch

Working

Height

4.1

4.6

4.8

4.8

Travel Speed

1575

685

360

260

Initial

Piercing

Height

4.6

5.7 2.00

Pierce Delay

Edge Start

Edge Start

0.20 2.4

Kerf Width

@ Rec.

Speed

2.7

3.1

3.2

0-5430 OPERATION

4T-29

CUTMASTER A120

Aluminum
100A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.19 100 0.20

124 0.19 65 0.20

128 0.19 45 0.20

132 0.19 35 0.20

135 0.19 20 0.20 2.00 0.13

140 0.19 10 Edge Start 0.13

Tip

9-8212

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

Electrode

9-8232

Pierce Delay

0.00

0.20

0.30

0.50

Kerf Width

@ Rec.

Speed

0.09

0.10

0.11

0.11

OPERATION 0-5430

4T-30

CUTMASTER A120

Material

Thickness

(mm)

6

8 11 7 4.8 2080 5.1 0.10 2.5

10 125

12 127 4.8 1255 5.1 0.30 2.7

15 131

20 136

25 140

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

109 4.8 2630 5.1 0.00 2.3

Torch

Working

Height

4.8

4.8

4.8

4.8

Travel Speed

1575

960

470

270

Initial

Piercing

Height

5.1

5.1 0.50

6.0 2.00

Pierce Delay

Edge Start

0.20 2.7

Kerf Width

@ Rec.

Speed

2.8

3.3

3.4

0-5430 OPERATION

4T-31

CUTMASTER A120

Mild Steel
120A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

7/8 0.875

1 1.000

1-1/4 1.250

1-1/2 1.500

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

134 0.19 150 0.25

141 0.19 85 0.25

141 0.19 70 0.25

146 0.19 45 0.25

150 0.19 30 0.25

160 0.25 25 Edge Start 0.14

163 0.25 19 Edge Start

168 0.25 12 Edge Start

172 0.25 8 Edge Start

Tip

9-8233

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

Electrode

9-8232

Pierce Delay

0.10

0.30

0.80

1.00

1.20

Kerf Width

@ Rec.

Speed

0.11

0.11

0.12

0.12

0.12

0.14

0.15

0.16

OPERATION 0-5430

4T-32

CUTMASTER A120

Material

Thickness

(mm)

6.0

8.0 138 4.8 2950 6.4 0.2 2.7

10.0 141

12.0 141 4.8 1860 6.4 0.6 2.9

15.0 145

20.0 153

25.0 163

30.0 167

35.0 170

40.0 173

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

133 4.8 3990 6.4 0.1 2.5

Torch

Working

Height

4.8

4.8

4.8

6.4

6.4

6.4

6.4

Travel Speed

2100

1320

720

500

355

255

175

Initial

Piercing

Height

6.4

6.4

6.4

Edge Start

Edge Start

Edge Start

Edge Start

Pierce Delay

0.4 2.8

1.0 3.0

1.2 3.2

Kerf Width

@ Rec.

Speed

3.6

3.8

4.0

4.2

0-5430 OPERATION

4T-33

CUTMASTER A120

Stainless Steel
120A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

1-1/4 1.250

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

133 0.19 180 0.25

136 0.19 100 0.25

140 0.19 60 0.25

152 0.25 40 0.30

154 0.25 26 Edge Start 0.14

159 0.25 16 Edge Start 0.14

167 0.25 8 Edge Start

Tip

9-8233

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

Electrode

9-8232

Pierce Delay

0.20

0.40

0.80

1.20

Kerf Width

@ Rec.

Speed

0.10

0.11

0.11

0.13

0.14

OPERATION 0-5430

4T-34

CUTMASTER A120

Material

Thickness

(mm)

6

8 135 4.8 3520 6.4 0.2 2.7

10 137

12 139 4.8 1750 6.4 0.8 2.9

15 149

20 155

25 159

30 165

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

133 4.8 4800 6.4 0.2 2.6

Torch

Working

Height

4.8

6.4

6.4

6.4

6.4

Travel Speed

2390

1160

625

425

260

Initial

Piercing

Height

6.4

7.6 1.2

Pierce Delay

Edge Start

Edge Start

Edge Start

0.5 2.8

Kerf Width

@ Rec.

Speed

3.4

3.6

3.6

3.6

0-5430 OPERATION

4T-35

CUTMASTER A120

Aluminum
120A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

Standard Shield Cup

Maximum Life Shield Cup

9-8218

9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

139 0.19 180 0.25

140 0.19 110 0.25

143 0.19 75 0.25

156 0.25 50 0.30

161 0.25 34 Edge Start 0.13

167 0.25 23 Edge Start 0.14

Tip

9-8233

Torch

Working

Height

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213

9-8277

Travel Speed

Piercing

Initial

Height

Electrode

9-8232

Pierce Delay

0.30

0.50

0.80

1.00

Kerf Width

@ Rec.

Speed

0.11

0.11

0.11

0.12

OPERATION 0-5430

4T-36

CUTMASTER A120

Material

Thickness

(mm)

6

8 140 4.8 3650 6.4 0.2 2.8

10 140

12 142 4.8 2100 6.4 0.8 2.8

15 152

20 162

25 167

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

139 4.8 4770 6.4 0.2 2.8

Torch

Working

Height

4.8

6.4

6.4

6.4

Travel Speed

2660

1445

820

600

Initial

Piercing

Height

6.4

7.6 1.2

Pierce Delay

Edge Start

Edge Start

0.5 2.8

Kerf Width

@ Rec.

Speed

3.0

3.4

3.4

0-5430 OPERATION

4T-37

CUTMASTER A120

This Page Intentionally Blank

OPERATION 0-5430

4T-38

CUTMASTER A120

This Page Intentionally Blank

0-5430 OPERATION

4T-39

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

9-8245 9-8237 9-8208

Heavy Duty Starter

Cartridge

9-8213

9-8277

Electrode

9-8232

Material

Thickness

(GA) (in) inch

20 0.036

16 0.060 113 0.16 120 0.16 0.0 0.06

14 0.075 108 0.16 90 0.16 0.1 0.06

12 0.105 111 0.16 75 0.16 0.2 0.06

10 0.135 114 0.16 65 0.16 0.3 0.07

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

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

107 0.16 130 0.16 0.0 0.06

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-40

CUTMASTER A120

Material

Thickness

(mm)

1

2 108 4.1 2239 4.1 0.0 1.5

3 112 4.1 1794 4.1 0.1 1.7

4 114 4.1 1651 4.1 0.2 1.7

5 115 4.1 1578 4.1 0.3 1.7

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6)

5.5 (15.2)

BOLD TYPE indicates maximum piercing parameters.

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

108 4.1 3266 4.1 0.0 1.4

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-41

CUTMASTER A120

Stainless Steel
40A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8245 9-8237 9-8208

Material

Thickness

(GA) (in) inch

18 0.050

16 0.063 108 0.16 50 4.1 0.1 0.07

14 0.078 114 0.16 45 4.1 0.1 0.07

12 0.109 113 0.16 40 4.1 0.2 0.07

10 0.141 116 0.16 35 4.1 0.3 0.07

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

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.16 60 4.1 0.0 0.06

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-42

CUTMASTER A120

Material

Thickness

(mm)

1

2 114 4.1 1140 4.1 0.1 1.8

3 114 4.1 980 4.1 0.2 1.8

4 116 4.1 845 4.1 0.3 1.8

5 115 4.1 725 4.1 0.4 1.8

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6)

5.5 (15.2)

BOLD TYPE indicates maximum piercing parameters.

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

109 4.1 1670 4.1 0.0 1.7

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-43

CUTMASTER A120

Aluminum
40A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8245 9-8237 9-8208

Material

Thickness

(GA) (in) inch

20 0.040

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 0.125 125 0.19 90 0.20 0.3 0.07

9 0.160 126 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

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.19 300 0.20 0.0 0.06

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-44

CUTMASTER A120

Material

Thickness

(mm)

1.0

2.0 116 4.8 3490 5.1 0.2

3.0 124 4.8 2350 5.1 0.3

4.0 126 4.8 2170 5.1 0.4

5.0 129 4.8 1630 5.1 0.6

6.0 135 4.8 990 5.1 1.0

8.0 141 4.8 500 5.1 1.6 2.0

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6)

5.5 (15.2)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

110 4.8 7660 5.1 0.0

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

10.0 146 4.8 180 5.1 2.1 2.3

BOLD TYPE indicates maximum piercing parameters.

Kerf Width

@ Rec.

Speed

1.6

1.8

1.8

1.8

1.8

1.9

0-5430 OPERATION

4T-45

CUTMASTER A120

Mild Steel
60A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8238 9-8237 9-8210

Material

Thickness

(GA) (in) inch

16 0.060

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 11 5 0.20 0.20 0.09

1/4 0.250 134 0.19 80 0.20 0.30 0.08

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

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

128 0.19 250 0.20 0.00 0.09

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-46

CUTMASTER A120

Material

Thickness

(mm)

1

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

6 134 4.8 2230 5.1 0.30 2.1

8 133 4.8 1425 5.1 0.40 2.3

10 134 4.8 822 5.1 0.60 2.5

12 141 4.8 646 5.1 0.75 2.5

15 148 4.8 419 Edge Start 2.6

20 147 4.8 318 Edge Start 2.7

25 159 4.8 118 Edge Start 3.0

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

127 4.8 6804 5.1 0 2.2

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-47

CUTMASTER A120

Stainless Steel
60A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8238 9-8237 9-8210

Material

Thickness

(GA) (in) inch

16 0.063

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 0.188 125 0.13 75 0.20 0.20 0.09

1/4 0.250 127 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

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

110 0.13 165 0.20 0.00 0.06

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-48

CUTMASTER A120

Material

Thickness

(mm)

1

2 11 6 3.3 3925 5.1 0.10 1.7

3 11 8 3.3 3285 5.1 0.10 1.7

4 126 3.3 1985 5.1 0.20 2.2

5 125 3.3 1850 5.1 0.20 2.1

6 127 3.3 1605 5.1 0.30 2.1

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

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

101 3.3 4590 5.1 0.00 1.2

144 4.8 230 Edge Start 2.5

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

0-5430 OPERATION

4T-49

CUTMASTER A120

Aluminum
60A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8238 9-8237 9-8210

Material

Thickness

(GA) (in) inch

16 0.064

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

1/4 0.250 132 0.13 80 0.20 0.30 0.08

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

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

118 0.13 350 0.20 0.00 0.07

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-50

CUTMASTER A120

Material

Thickness

(mm)

1

2 11 8 6.4 8890 6.4 0.10

3 123 6.4 7070 6.4 0.10

4 124 6.4 5095 6.4 0.20

5 126 6.4 3335 6.4 0.20

6 130 6.4 2370 6.4 0.30

8 134 6.4 1570 6.4 0.40 2.0

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

118 6.4 8890 6.4 0.00

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

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.

Kerf Width

@ Rec.

Speed

2

2.0

2.1

2.0

2.0

2.0

0-5430 OPERATION

4T-51

CUTMASTER A120

Mild Steel
80A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8211

Material

Thickness

(GA) (in) inch

16 0.060

11 0.120 112 0.13 190 0.20 0.10 0.06

10 0.135 110 0.13 176 0.20 0.20 0.06

3/16 0.188 122 0.19 135 0.20 0.30 0.08

1/4 0.250 127 0.19 100 0.20 0.40 0.09

3/8 0.375 134 0.19 40 0.20 0.50 0.10

1/2 0.500 136 0.19 36 0.20 0.60 0.10

5/8 0.625 145 0.19 18 Edge Start 0.11

3/4 0.750 147 0.19 14 Edge Start 0.11

7/8 0.875 146 0.19 10 Edge Start 0.12

1.000 1.000 152 0.187 8 Edge Start 0.13

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

115 0.13 280 0.20 0.00 0.06

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-52

CUTMASTER A120

Material

Thickness

(mm)

1

2 114

3 112

4 115

5 123

6 126 4.8 2735 5.1 0.40 2.2

8 131 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.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

116

Torch

Working

Height

3.3

3.3

3.3

4.8

4.8

Travel Speed

7895

6395

4895

4025

3300

Initial Piercing

Height

5.1 0.00

5.1

5.1

5.1

5.1

Pierce Delay

0.10 1.6

0.10 1.5

0.30 1.7

0.30 2.0

Kerf Width

@ Rec.

Speed

1.6

0-5430 OPERATION

4T-53

CUTMASTER A120

Stainless Steel
80A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8211

Material

Thickness

(GA) (in) inch

16 0.063

11 0.125

10 0.141

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4

0.750

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

114 0.125 340 0.2 0.00

115 0.125 260 0.2 0.10

116 0.125 250 0.2 0.10

115 0.125 170 0.2 0.20

118 0.125 85 0.2 0.30

127 0.19 45 0.25 0.40

136 0.19 16 0.25 0.75 0.11

143 0.19 10 Edge Start 0.12

146 0.19 8 Edge Start 0.11

Torch

Working

Height

9-8213

9-8277

Travel Speed

Initial Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

0.06

0.06

0.06

0.07

0.08

0.09

OPERATION 0-5430

4T-54

CUTMASTER A120

Material

Thickness

(mm)

1

2

3

4

5

6 117 3.2 2640 5.1 0.30 2.0

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.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

114

114 3.2 8120 5.1 0.00 1.4

115 3.2 6830 5.1 0.10 1.4

116 3.2 5635 5.1 0.20 1.5

115 3.2 4010 5.1 0.20 1.8

Torch

Working

Height

3.2

Travel Speed

9410

Initial Piercing

Height

5.1 0.00

Pierce Delay

Kerf Width

@ Rec.

Speed

1.5

0-5430 OPERATION

4T-55

CUTMASTER A120

Aluminum
80A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8211

Material

Thickness

(GA) (in) inch

16

11

3/16

1/4

3/8

1/2

5/8

3/4

0.064

0.120

0.188

0.250

0.375

0.500

0.625

0.750

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

115 0.13 320 0.2 0.00

120 0.13 240 0.2 0.10

122 0.13 165 0.2 0.20

124 0.13 100 0.2 0.30

140 0.19 60 0.2 0.40

142 0.19 36 0.2 0.60

148 0.19 26 0.2 0.75 0.11

155 0.19 16 Edge Start 0.12

Torch

Working

Height

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

0.09

0.08

0.08

0.10

0.09

0.11

OPERATION 0-5430

4T-56

CUTMASTER A120

Material

Thickness

(mm)

1

2 11 6 3.3 7595 5.1

3 120 3.3 6165 5.1

4 121 3.3 5045 5.1

5 122 3.3 3955 5.1

6 124 3.3 2905 5.1 0.30 2.3

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.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

113 3.3 9020 5.1

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

0.00

0.00

0.10

0.20

0.20

Kerf Width

@ Rec.

Speed

2.4

2.2

2.0

2.1

2.2

0-5430 OPERATION

4T-57

CUTMASTER A120

Mild Steel
100A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8233

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

1-1/4 1.250 135 0.16 8

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

114 0.16 85 0.18 0.00 0.08

112 0.16 70 0.18 0.20 0.09

115 0.16 40 0.18 0.30 0.10

123 0.16 30 0.18 0.40 0.10

127 0.16 20 0.18 0.80 0.11

133 0.16 12 Edge Start 0.12

Torch

Working

Height

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

Edge Start

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

0.12

OPERATION 0-5430

4T-58

CUTMASTER A120

Material

Thickness

(mm)

6 11 4

8 11 3

10 112

12 114

15 121

20 128 4.1 475 5.0 0.80 2.8

25 133 4.1 315 Edge Start 2.9

30 134 4.1 230 Edge Start 3.1

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

Gas Pressure

(Air)

Bar

(torch lead

length)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

Torch

Working

Height

4.1

4.1

4.1

4.1

4.1

Travel Speed

2210

1960

1665

1185

830

Initial

Piercing

Height

4.6 0.00

4.6

4.6

4.6

4.6

Pierce Delay

0.10 2.2

0.20 2.3

0.30 2.4

0.40 2.5

Kerf Width

@ Rec.

Speed

2.0

0-5430 OPERATION

4T-59

CUTMASTER A120

Stainless Steel
100A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8212

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

114 0.16 110 0.18 0.00 0.08

116 0.16 70 0.18 0.10 0.09

119 0.16 45 0.18 0.30 0.10

130 0.19 20 0.23 2.00 0.11

135 0.19 15 0.23 2.80 0.11

140 0.19 10 Edge Start 0.11

Torch

Working

Height

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-60

CUTMASTER A120

Material

Thickness

(mm)

6

8 11 5

10 116

12 118

15 127

20 136 4.8 360 5.7 2.80 2.8

25 140 4.8 260 Edge Start 2.8

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

114

Torch

Working

Height

4.1

4.1

4.1

4.1

4.6

Travel Speed

2900

2265

1685

1285

685

Initial

Piercing

Height

4.6 0.00

4.6

4.6

4.6

5.7

Pierce Delay

0.10 2.2

0.20 2.4

0.30 2.4

2.00 2.7

Kerf Width

@ Rec.

Speed

2.0

0-5430 OPERATION

4T-61

CUTMASTER A120

Aluminum
100A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8212

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

121 0.18 110 0.19 0.00 0.10

129 0.18 60 0.19 0.20 0.10

135 0.18 45 0.19 0.30 0.11

133 0.18 32 0.19 0.60 0.11

138 0.18 25 0.19 2.00 0.11

143 0.18 15 Edge Start 0.14

Torch

Working

Height

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-62

CUTMASTER A120

Material

Thickness

(mm)

6

8 125

10 130

12 134

15 134

20 139 4.6 595 6.0 2.00 3.0

25 143 4.6 395 Edge Start 3.6

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

120

Torch

Working

Height

4.6

4.6

4.6

4.6

4.6

Travel Speed

2920

2135

1470

1230

905

Initial

Piercing

Height

4.8 0.00

4.8

4.8

4.8

4.8

Pierce Delay

0.10 2.5

0.20 2.6

0.30 2.7

0.60 2.9

Kerf Width

@ Rec.

Speed

2.5

0-5430 OPERATION

4T-63

CUTMASTER A120

Mild Steel
120A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8256 9-8237 9-8233

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375 140 0.125 85 0.20 0.20 0.11

1/2 0.500 142 0.125 75 0.20 0.50 0.10

5/8 0.625 144 0.125 45 0.20 0.70 0.11

3/4 0.750 150 0.125 30 0.25 1.50 0.12

7/8 0.875 158 0.175 25 Edge Start 0.13

1 1.000 160 0.175 22 Edge Start 0.14

1-1/4 1.250 165 0.175 15 Edge Start 0.17

1-1/2 1.500 171 0.175 8 Edge Start 0.15

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

139 0.125 160 0.20 0.20 0.11

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-64

CUTMASTER A120

Material

Thickness

(mm)

6

8 140

10 140

12 142

15 143

20 152 4.8 725 6.4 1.6 3.1

25 160 4.8 570 Edge Start 3.6

30 164 4.8 430 Edge Start 4.0

35 168 4.8 290 Edge Start 4.3

40 173 4.45 150 Edge Start 4.4

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

139

Torch

Working

Height

4.8

4.8

6.4

6.4

4.8

Travel Speed

4270

3070

2120

1960

1355

Initial

Piercing

Height

5.08 0.20

5.1

5.08

5.08

5.08

Pierce Delay

0.2 2.8

0.30 2.8

0.50 2.8

0.70 2.8

Kerf Width

@ Rec.

Speed

2.8

0-5430 OPERATION

4T-65

CUTMASTER A120

Stainless Steel
120A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8256 9-8237 9-8233

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375 140 0.13 100 0.20 0.40 0.12

1/2 0.500 142 0.15 65 0.25 0.80 0.12

5/8 0.625 152 0.15 40 0.25 1.00 0.12

3/4 0.750 150 0.15 26 Edge Start 0.13

1 1.000 155 0.15 16 Edge Start 0.13

1-1/4 1.250 165 0.15 8 Edge Start 0.13

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

140 0.13 180 0.20 0.30 0.11

Torch

Working

Height

Travel Speed

9-8213

9-8277

Initial

Piercing

Height

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-66

CUTMASTER A120

Material

Thickness

(mm)

6

8 140

10 140

12 142

15 149

20 151 6.4 620 Edge Start 3.3

25 155 6.4 420 Edge Start 3.3

30 162 6.4 260 Edge Start 3.3

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

140

Torch

Working

Height

4.8

4.8

4.8

4.8

6.4

Travel Speed

4800

3520

2410

1850

1190

Initial

Piercing

Height

5.1 0.3

5.1

5.1

6.4

6.4

Pierce Delay

0.4 2.7

0.6 3.0

0.8 3.1

1.0 3.1

Kerf Width

@ Rec.

Speed

2.8

0-5430 OPERATION

4T-67

CUTMASTER A120

Aluminum
120A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8256 9-8237 9-8233

Material

Thickness

(GA) (in) inch

1/4 0.250

3/8 0.375 142 0.13 110 0.20 0.30 0.11

1/2 0.500 148 0.13 75 0.20 0.50 0.11

5/8 0.625 156 0.15 45 0.25 0.80 0.11

3/4 0.750 158 0.15 35 Edge Start 0.11

1 1.000 164 0.15 23 Edge Start 0.12

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Arc Voltage

Volts (in) (ipm) (in) (sec) (in)

140 0.13 180 0.20 0.20 0.10

Torch

Working

Height

9-8213

9-8277

Travel Speed

Initial

Piercing

Height

9-8232

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 0-5430

4T-68

CUTMASTER A120

Material

Thickness

(mm)

6

8 141

10 143

12 147

15 154

20 159 4.8 845 Edge Start 2.9

25 164 4.8 605 Edge Start 3.0

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

140

Torch

Working

Height

4.8

4.8

4.8

4.8

4.8

Travel Speed

4770

3650

2660

2100

1355

Initial

Piercing

Height

5.1 0.2

5.1

5.1

5.1

6.4

Pierce Delay

0.3 2.6

0.4 2.7

0.5 2.8

0.8 2.8

Kerf Width

@ Rec.

Speed

2.6

0-5430 OPERATION

4T-69