ESAB Cutmaster 120 Plasma Cutting System SL100 1TORCH Instruction manual

ESAB Cutmaster® 120

PLASMA CUTTING SYSTEM

SL100 1Torch™

Operating
Manual

Art # A-12769_AB

120

Revision: AB Issue Date: April 15, 2015 Manual No.: 0-5380

208/230V

400V

460V

esab.com.br

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.com.br.

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
ESAB Cutmaster® 120 with SL100 1Torch™
Operating Manual Number 0-5380

Published by:
ESAB

2800 Airport Rd.
Denton, TX 76208

www.esab.com.br

Copyright 2015 by ESAB

All rights reserved.

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

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

Original Publication Date: April 15, 2015
Revision Date: April 15, 2015

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ________________

Purchase Date:__________________________________ ________________

Power Supply Serial #:___________________________ ________________

Torch Serial #:___________________________________ ________________

i

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar
with the principles of operation and safe practices for arc welding and cutting equip­ment, we urge you to read our booklet, “Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this 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 AN D 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 Opening the Contactor Cover .....................................................................3-1

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

3.05 Gas Connections ........................................................................................3-3

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

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

3T.02 Setting Up Mechanical Torch ....................................................................3T-1

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

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

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

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

4T.01 Torch Parts Selection ...............................................................................4T-1

4T.02 Cut Quality ................................................................................................4T-1

4T.03 General Cutting Information ......................................................................4T-2

4T.04 Hand Torch Operation ..............................................................................4T-3

4T.05 Gouging ....................................................................................................4T-6

4T.06 Mechanized Torch Operation ...................................................................4T-7

4T.07 Parts Selection for SL100 Torch Cutting ..................................................4T-9

4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip ......4T-10

4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip ......4T-14

PATENT INFORMATION .....................................................................................................4T-20

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

6.06 Replacement Parts for Hand Torch ...........................................................6-3

6.07 Replacement Parts - for Machine Torches with Unshielded Leads ............6-4

6.08 Replacement Shielded Machine Torch Leads Assemblies ........................ 6-6

6.09 Torch Consumable Parts (SL100) ..............................................................6-7

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

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

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

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

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

Revision History .................................................................................................................... A-8

ESAB CUTMASTER 120

SECTION 1: SAFETY

1.0 Safety Precautions

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

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

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

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

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

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

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

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

5. General precautions:

- Make sure the return cable is connected securely.

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

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

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

Dispose of electronic equipment at the recycling facility!

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

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

Manual 0-5380 GENERAL INFORMATION

1-1

ESAB CUTMASTER 120

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.

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

CAUTION

CAUTION

CAUTION

Class A equipment is not intended for use in residential locations
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.

!

GENERAL INFORMATION Manual 0-5380

1-2

ESAB CUTMASTER 120

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part
numbers listed on page i.

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

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

NOTE!

An operation, procedure, or background
information which requires additional
emphasis or is helpful in efficient operation
of the system.

CAUTION

!

!

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

WARNING

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

2.02 Equipment Identification

The unit’s identification number (specification or part
number), model, and serial number usually appear on
a data tag attached to the rear panel. Equipment which
does not have a data tag such as torch and cable as­semblies are identified only by the specification or part
number printed on loosely attached card or the shipping
container. Record these numbers on the bottom of page
i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to file a
claim. Furnish complete information concerning damage
claims or shipping errors to the location in your area
listed in the inside back cover of this manual.

Include all equipment identification numbers as de­scribed above along with a full description of the parts
in error.

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

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

!

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 identifica­tion 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.com.br

avoided, will result in immediate, serious
personal injury or loss of life.

Manual 0-5380 INTRODUCTION

2-1

ESAB CUTMASTER 120

2.04 Power Supply Specifications

ESAB Cutmaster® 120 Power Supply Specifications

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

230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50 Hz
460 VAC (414 - 506 VAC), Single Phase, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz

600 VAC (540 - 630), Three Phase, 60 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 120 Amps, Continuously Adjustable
Power Supply Gas

Filtering Ability

ESAB Cutmaster® 120 Power Supply Duty Cycle *

Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)

All Units Duty Cycle **60% 80% 100%

* 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

Particulates to 5 Microns

Operating Range 0° - 50° C

Current 120 120 100

DC Voltage 128 128 120

IEC IEC IEC

NOTE!

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

Power Supply Dimensions & Weight Ventilation Clearance Requirements

10.75"

273 mm

Art # A-08358_AB

16.375"

416 mm

63 lb / 28.6 kg

30.5"

774.7 mm

24"

610 mm

6"

150 mm

Art # A-07925_AB

150 mm

6"

150 mm

6"

INTRODUCTION Manual 0-5380

2-2

2.05 Input Wiring Specifications

ESAB Cutmaster® 120 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

230 60 27.6 118 95 125 4 Type W
460 60 35 76 68 100 4

3 Phase 208 60 21.6 60 55 60 4

230 60 22.3 56 50 60 4
380 50 23 35 32 40 8
400 50 23.6 34 31 40 8
460 60 29.5 37 33 40 8
600 60 29.0 28 25 30 10

Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code

Freq Power

Input

ESAB CUTMASTER 120

Suggested Sizes

Flexible Cord

(amps)

(Min. AWG)

NOTE!

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

The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.

I1max is taken at TDC rated minimum duty cycle.

I1eff is taken at TDC 100% rated duty cycle.

Manual 0-5380 INTRODUCTION

2-3

ESAB CUTMASTER 120

Handle and Leads Wrap

and Clamp

2.06 Power Supply Features

Art # A-08359

Control Panel

To rch Leads Receptacle

Input Power Selection

Filter Assembly

Gas Inlet Port

Input Power Cord

Work Cable

Port for Optional Automation
Interface Cable

Art # A-08360

INTRODUCTION Manual 0-5380

2-4

ESAB CUTMASTER 120

SECTION 2 TORCH:

INTRODUCTION

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 properly trained personnel; unqualified personnel are
strictly cautioned against attempting repairs or adjust­ments not covered in this manual, at the risk of voiding
the Warranty.

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

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 flows through the small orifice in the torch
tip, which is focused on the metal to be cut.

A single torch lead provides gas from a single source to
be used as both the plasma and secondary gas. The
air flow is divided inside the torch head. Single - gas
operation provides a smaller sized torch and inexpen­sive operation.

NOTE!

Refer to Section "2T.05 Introduction to
Plasma", for a more detailed description of
plasma torch operation.
Refer to the Appendix Pages for additional
specifications as related to the Power Sup­ply used.

2T.03 Specifications

A. Torch Configurations

1. Hand/Manual Torch, Models

The hand torch head is at 75° to the torch handle.
The hand torches include a torch handle and
torch trigger assembly.

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

2. Mechanized Torch, Model

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

15.875" / 403 mm

9.285" / 236 mm

1.375" / 35 mm

1.75" /

44.5 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 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

0.625" /
16 mm

4.95" / 126 mm

1.175" / 30 mm

Art # A-03322_AB

Art # A-02998

C. Torch Parts

D. Parts - In - Place (PIP)

E. Type Cooling

Manual 0-5380 INTRODUCTION

Starter Cartridge, Electrode, Tip, Shield Cup

Torch Head has built - in switch

12 VDC circuit rating

Combination of ambient air and gas stream through
torch.

2T-1

ESAB CUTMASTER 120

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

G. Gas Requirements

Manual and Mechanized Torch Gas

)

peak

Mechanized Torch Ratings

)

peak

Specifications

104° F

40° C

100% @ 100 Amps @ 400 scfh

120 Amps

500V

7kV

104° F

40° C

100% @ 100 Amps @ 400 scfh

120 Amps

500V

7kV

2T.05 Introduction to Plasma

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.

Gas (Plasma and Secondary)

Operating Pressure

Refer to NOTE

Maximum Input Pressure

Gas Flow (Cutting and

Gouging)

Compressed Air

60-95psi

4.1-6.5bar

125psi/8.6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.

2T.04 Options And Accessories

Foroptionsandaccessories,seesection6.

_

Power

Supply

A

+

B

Workpiece

C

Typical Torch Head Detail

By forcing the plasma gas and electric arc through
a small orifice, the torch delivers a high concentra­tion of heat to a small area. The stiff, constricted
plasma arc is shown in Zone C. Direct current (DC)
straight polarity is used for plasma cutting, as shown
in the illustration.

Zone A channels a secondary gas that cools the
torch. This gas also assists the high velocity plasma
gas in blowing the molten metal out of the cut al­lowing for a fast, slag - free cut.

A-00002

INTRODUCTION Manual 0-5380

2T-2

ESAB CUTMASTER 120

Remote Pendant

B. Gas Distribution

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

The plasma gas flows into the torch through the
negative lead, through the starter cartridge, around
the electrode, and out through the tip orifice.

The secondary gas flows down around the outside
of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc.

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)

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

A-02997

Torch Trigger

Shield Cup

Parts - In - Place Circuit Diagram for Hand Torch

To AT C

PIP Sw itch

CNC Start

Sh ield Cup

To AT C

To AT C

PIP Sw itch

Automation Torch

PIP Sw itch

Sh ield Cup

Art # A-08168

Sh ield Cup

Parts - In - Place Circuit Diagram for Machine Torch

Manual 0-5380 INTRODUCTION

2T-3

ESAB CUTMASTER 120

This Page Intentionally Blank

INTRODUCTION Manual 0-5380

2T-4

ESAB CUTMASTER 120

SECTION 3 SYSTEM:

INSTALLATION

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 a handle 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.

3.03 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.

1

2

1

2

Art# A-11478

Contactor cover

WARNING

!

FALLING EQUIPMENT can cause serious per­sonal injury and can damage equipment.
HANDLE is not for mechanical lifting.

• 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.

3.04 Primary Input Power Connections

CAUTION

!

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

Single-Phase (1ø) and Jumper Settings

Store copper jumpers on base plate

L1

L2

L3

L4

Check your power source for correct volt­age before plugging in or connecting the
unit. Check the Voltage Selector at the rear
of the unit for correct setting before plug­ging in or connecting the unit. The primary
power source, fuse, and any extension
cords used must conform to local electrical
code and the recommended circuit protec­tion and wiring requirements as specified in
Section 2.

Input Power Cable Connections

Three-Phase (3ø)

L1

L2

L3

L4

GND

GND

Single and Three Phase Input Power Wiring

Art # A-08493

Manual 0-5380 INSTALLATION

NOTE!

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

3-1

ESAB CUTMASTER 120

A. Connections to Single Phase Input Power

WARNING

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

These instructions are for changing the input power and or cable
on the 208/230, 400, 460 VAC Power Supply to Single - Phase
input power.

1. Remove the Power Supply cover per instructions found in
section 5.

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

3. Loosen the through - hole protector on the back panel of
the power supply. Pull the original power cable out of the
power supply.

4. If the power cable being used is not the factory - sup­plied cable, use a three - conductor input power cable for
the voltage desired and strip back the insulation on the
individual wires.

5. Pass the cable being used through the access opening in
the back panel of the power supply. Refer to Section 2 for
power cable specifications.

CAUTION

!

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

6. Connect the wires as follows.

• ConnectBusBarJumpersonthecontactorasshown

in prior illustration and on label in the power supply.

• Green/YellowwiretoGround.

7. Reinstall the Power Supply cover per instructions found in
section 5.

8. Connect the opposite end of individual wires to a customer
supplied plug or main disconnect.

9. Connect the input power cable (or close the main discon­nect switch) to supply power.

B. Connections to Three Phase Input Power

WARNING

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

These instructions are for changing the input power and or cable
on the 208/230, 400, 460 VAC Power Supply to Three - Phase
input power.

1. Remove the Power Supply cover per instructions found in
section 5.

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

3. Loosen the through - hole protector on the back panel of
the power supply. Pull the original power cable out of the
power supply.

4. Using a customer supplied four - conductor input power
cable for the voltage desired, strip back the insulation on
the individual wires.

5. Pass the cable being used through the access opening in
the back panel of the power supply. Refer to Section 2 for
power cable specifications.

CAUTION

!

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

6. Connect the wires as follows.

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

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

• Green/YellowwiretoGround.

7. With a little slack in the wires, tighten the through - hole
protector to secure the power cable.

8. Reinstall the Power Supply cover per instructions found in
section 5.

9. Connect the opposite end of individual wires to a customer
supplied plug or main disconnect.

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

nect switch) to supply power.

INSTALLATION Manual 0-5380

3-2

ESAB CUTMASTER 120

Regulator/Filter

3.05 Gas Connections

Connecting Gas Supply to Unit

The connection is the same for compressed air or high pressure
cylinders. Refer to the following two subsections if an optional air
line filter is to be installed.

1. Connect the air line to the inlet port. The illustration shows
typical fittings as an example.

NOTE!

For a secure seal, apply thread sealant to
the fitting threads, according to manufac­turer's instructions. Do not use Teflon tape
as a thread sealer, as small particles of the
tape may break off and block the small air
passages in the torch.

Regulator/Filter
Assembly

Inlet Port

Installing Optional Single - Stage Air Filter

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

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

2. Attach the Filter Assembly to the filter hose.

3. Connect the air line to the Filter. The illustration shows
typical fittings as an example.

NOTE!

For a secure seal, apply thread sealant to
the fitting threads, according to the maker's
instructions. Do Not use Teflon tape as a
thread sealer, as small particles of the tape
may break off and block the small air pas­sages in the torch. Connect as follows:

Assembly

Inlet Port

Hose Clamp

Gas Supply
Hose

Art # A-07943

Air Connection to Inlet Port

1/4 NPT or ISO-R
to 1/4” (6mm) Fitting

Hose Clamp

Gas Supply
Hose

Art # A-07944

1/4 NPT to 1/4"

(6mm) Fitting

Optional Single - Stage Filter Installation

Manual 0-5380 INSTALLATION

3-3

ESAB CUTMASTER 120

Regulator/Filter

Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture and contaminants to at
least 5 microns.

Connect the air supply as follows:

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

NOTE!

For a secure seal, apply thread sealant to the fitting threads according to manufacturer's instructions. Do
Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air
passages in the torch.

2. Connect the two stage filter outlet hose to the inlet port of the Regulator / Filter Assembly.

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

Assembly

Regulator
Input

Hose Clamp

Gas Supply
Hose

1/4 NPT to 1/4”
(6mm) Fitting

2-Stage Filter
Inlet Port (IN)

Outlet Port
(OUT)

Two Stage
Filter
Assembly

Art # A-07945_AC

Optional Two - Stage Filter Installation

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regulators.

2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder
valve to blow out any dust which may be present.

3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100 psi (6.9 bar)
maximum and flows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the cylinder.

NOTE!

Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do
Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air
passages in the torch.

INSTALLATION Manual 0-5380

3-4

ESAB CUTMASTER 120

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Supply.
Connect only the ESAB model SL100 / Manual or SL100
/ Mechanical Torch to this power supply. Maximum
torch leads length is 100 feet / 30.5 m, including exten­sions.

WARNING

Disconnect primary power at the source

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

2. Secure the connection by turning the locking nut

before connecting the torch.

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

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 Setting Up Mechanical Torch

NOTE!

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

WARNING

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

The mechanical torch includes a positioning tube with
rack and pinch block assembly.

1. Mount the torch assembly on the cutting table.

2. To obtain a clean vertical cut, use a square to
align the torch perpendicular to the surface of
the workpiece.

Pinch Block
Assembly

2

Art # A-07885

1

Connecting the Torch to the Power Supply

3. The system is 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.

Square

Workpiece

A-02585

Mechanical Torch Set - Up

3. The proper torch parts (shield cup, tip, start
cartridge, and electrode) must be installed for
the type of operation. Refer to Section 4T.07,
Torch Parts Selection for details.

3. Place a welding filter lens in front of the torch
and turn ON the air. Do not start an arc!

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

lens.

Manual 0-5380 INSTALLATION

3T-1

ESAB CUTMASTER 120

This Page Intentionally Blank

INSTALLATION Manual 0-5380

3T-2

ESAB CUTMASTER 120

12

3

!

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.

LATCH Used for longer hand held cuts.

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

4

MAX

MIN

A

PSI BAR

MAXMAX

MINMIN

!

5

8

7

6

10

9

6. Temp Indicator

Indicator is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Let the
unit cool before continuing operation.

7. Gas Indicator

Indicator is ON when minimum input gas pressure
for power supply operation is present. Minimum
pressure for power supply operation is not sufficient
for torch operation.

8. DC Indicator

Indicator is ON when DC output circuit is active.

+

Art# A-07886

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

4. Air/Gas Pressure Control

The Pressure Control is used in the "SET" mode
to adjust the air/gas pressure. Pull the knob out to
adjust and push in to lock.

5. AC Indicator

Steady light indicates power supply is ready for
operation. Blinking light indicates unit is in protec­tive interlock mode. Shut unit OFF, shut OFF or
disconnect input power, correct the fault, and restart
the unit. Refer to Section 5 for details.

Manual 0-5380 OPERATION

9.

Fault Error Indicator

Indicator is ON when Fault circuit is active. See
section 5 for explanations of fault lights.

10. Pressure Indicators

PSI BAR

MAX MAX

90 6.3

85 5.9

80

5.5

75

5.2

70

4.8

65

4.5

MINMIN

Art # A-08170

The Indicators will illuminate according to the pres­sure set by the Pressure Control Knob (number 4).

4-1

ESAB CUTMASTER 120

Art # A-04509

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.

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 sufficient 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

Check Primary Input Power Source

1. Check the power source for proper input volt­age. Make sure the input power source meets
the power requirements for the unit per Section
2, Specifications.

2. Connect the input power cable (or close the
main disconnect switch) to supply power to the
system.

Air Source

Ensure source meets requirements (refer to Section

2). Check connections and turn air supply ON.

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.

1. Place the Power Supply Function Control knob

to the SET position. Gas will flow.

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.

OPERATION Manual 0-5380

4-2

1

2

MIN

MAX

A

PSI BAR

MAXMAX

MINMIN

!

+

Art# A-07946

STANDOFF

ESAB Cutmaster® 120 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)

75 psi

5.2 bar

Add 5 psi

0.4 bar

ESAB CUTMASTER 120

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

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or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 con­tinues to flow for approximately 20 seconds. During
post - flow, if the user moves the trigger release to
the rear and presses the trigger, the pilot arc starts.

DRAG (60 amps or less)

ESAB Cutmaster® 120 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

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.

Select Current Output Level

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

RUN ,

RAPID AUTO RESTART

or LATCH . Gas flow stops.

Manual 0-5380 OPERATION

4-3

ESAB CUTMASTER 120

This Page Intentionally Blank

OPERATION Manual 0-5380

4-4

ESAB CUTMASTER 120

Kerf Width

Cut Surface
Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

SECTION 4 TORCH:

OPERATION

4T.01 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.07 and following for ad­ditional information on torch parts.

Change the torch parts for a different operation as fol­lows:

WARNING

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

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

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

4. Install the starter cartridge and desired tip for

the operation into the torch head.

5. Hand tighten the shield cup assembly until it is
seated on the torch head. If resistance is felt
when installing the cup, check the threads before
proceeding.

4T.02 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 fin­ish cut quality is desired to avoid a secondary cleaning
operation. The following cut quality characteristics are
illustrated in the following figure:

NOTE!

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

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

2. Remove the Electrode by pulling it straight out
of the Torch Head.

Torch Head

Electrode

Start Cartridge

Tip

Shield Cup

A-03510_AB

Cut Quality Characteristics

Cut Surface

The desired or specified condition (smooth or rough)
of the face of the cut.

Nitride Build - Up

Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material
is to be welded after the cutting process.

Manual 0-5380 OPERATION

4T-1

ESAB CUTMASTER 120

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

Bevel Angle

The angle between the surface of the cut edge and
a plane perpendicular to the surface of the plate.
A perfectly perpendicular cut would result in a 0°
bevel angle.

Top - Edge Rounding

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

Bottom Dross Buildup

Molten material which is not blown out of the cut
area and resolidifies on the plate. Excessive dross
may require secondary cleanup operations after
cutting.

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 orifice has become elongated.

4T.03 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.

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 signifi­cantly affect 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.

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.

OPERATION Manual 0-5380

4T-2

ESAB CUTMASTER 120

Shield Cup

Torch

Standoff Distance

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

A-02986

Trigger

Trigger Release

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

4T.04 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.

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

in (3-9 mm) from the workpiece as shown

below.

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.

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.

Manual 0-5380 OPERATION

5. Bring the torch within transfer distance to the
work. The main arc will transfer to the work, and
the pilot arc will shut OFF.

NOTE!

The gas preflow and postflow are a char­acteristic of the power supply and not a
function of the torch.

4T-3

ESAB CUTMASTER 120

3

4

Art # A-03383

Tr igger

2

1

Tr igger Release

Art # A-04034

A-03539

Non-Conductive

Straight Edge
Cutting Guide

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

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.

Using Drag Shield Cup With Straight Edge

7. Follow normal recommended cutting practices

8. For a consistent standoff height from the work-

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.

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

Shield Cup

Standoff Guide

Torch Tip

Workpiece

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!

Drag cutting can only be performed at 60
amps or less.
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.

3. Keep the torch in contact with the workpiece
during the cutting cycle.

4. Hold the torch away from your body.

OPERATION Manual 0-5380

4T-4

ESAB CUTMASTER 120

A-02986

Trigger

Trigger Release

5. Slide the trigger release toward the back of the
torch handle while simultaneously squeezing the
trigger. The pilot arc will start.

6. Bringthe torchwithin transferdistance to the

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

NOTE!

The gas preflow and postflow are a char­acteristic of the power supply and not a
function of the torch.

Tr igger

Piercing With Hand Torch

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

NOTE!

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

2. Angle the torch slightly to direct blowback
particles away from the torch tip (and operator)
rather than directly back into it until the pierce
is complete.

3. In a portion of the unwanted metal start the
pierce off the cutting line and then continue the
cut onto the line. Hold the torch perpendicular
to the workpiece after the pierce is complete.

1

2

Tr igger Release

3

4

Art # A-03383

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

8. 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.

4. Hold the torch away from your body.

5. Slide the trigger release toward the back of the
torch handle while simultaneously squeezing the
trigger. The pilot arc will start.

Trigger

Trigger Release

A-02986

6. Bringthe torchwithin transferdistance to the

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

NOTE!

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

Manual 0-5380 OPERATION

4T-5

ESAB CUTMASTER 120

35°

Workpiece

Torch Head

Standoff Height

A-00941_AB

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

Cutting speed depends on material, thickness, and
the operator’s ability to accurately follow the desired
cut line. The following factors may have an impact on
system performance:

• Torchpartswear

• Airquality

• Linevoltageuctuations

• Torchstandoffheight

• Properworkcableconnection

4T.05 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.

Torch Travel Speed

NOTE!

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

Optimum torch travel speed is dependent on current
setting, lead angle, and mode of operation (hand or
machine torch).

Current Setting

Current settings depend on torch travel speed,
mode of operation (hand or machine torch), and the
amount of material to be removed.

Pressure Setting

Even though the setting is within the specified range,
if the torch does not pilot well the pressure may
need to be reduced.

Lead Angle

The angle between the torch and workpiece de­pends on the output current setting and torch travel
speed. The recommended lead angle is 35°. At a
lead angle greater than 45° the molten metal will
not be blown out of the gouge and may be blown
back onto the torch. If the lead angle is too small
(less than 35°), less material may be removed, re­quiring more passes. In some applications, such
as removing welds or working with light metal, this
may be desirable.

CAUTION

!

Sparks from plasma gouging can cause
damage to coated, painted or other sur­faces such as glass, plastic, and metal.
Check torch parts. The torch parts must
correspond with the type of operation. Refer
to Section 4T.07, Torch Parts Selection.

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 distance between the torch tip and workpiece
(standoff).

CAUTION

!

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

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.

OPERATION Manual 0-5380

4T-6

ESAB CUTMASTER 120

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.

4T.06 Mechanized Torch Operation

Cutting With Mechanized Torch

The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC.

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

Travel Speed

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

1. Straight Arc

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

2. Leading Arc

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

3. Trailing Arc

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

Manual 0-5380 OPERATION

4T-7

ESAB CUTMASTER 120

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

Mechanized Torch Operation

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 Torch

To pierce with a machine torch, 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.

OPERATION Manual 0-5380

4T-8

4T.07 Parts Selection for SL100 Torch Cutting

Ohmic Clip

Manual Torch

9-8259

ESAB CUTMASTER 120

Ohmic Clip

Automation Torch

9-8224

Electrode

Auto 9-8232

Manual 9-8215

Starter

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Starter Cartridge

Non HF Only 9-8277

70-120A

STANDOFF

CUTTING

Tip:

20A 9-8205
30A 9-8206
40A 9-8208

Tips:

50-55A 9-8209

60A 9-8210

Tips:

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine
40A 9-8245

Shield Cap, Deflector
9-8243

Drag Shield Cup
9-8235

Shield Cap, Machine
50-60A 9-8238

Shield Cap, Deflector
9-8243

Drag Shield Cup
70-100A 9-8236

Drag Shield Cup
120A 9-8258

Shield Cap, Machine
70-100A 9-8239

Shield Cap, Machine
120A 9-8256

Shield Cap, Deflector
9-8243

40-120A

GOUGING

Tips:

Tip A 9-8225 (40 Amps Max.)

Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Art # A-08066_AG

Manual 0-5380 OPERATION

Tip E 9-8254 (60 - 120 Amps)

Shield

Cup Body,

9-8237

Shield Cup, Gouging

9-8241

4T-9

ESAB CUTMASTER 120

4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip

Type Torch: SL100 With Exposed Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.036 0.9 9-8208 104 40 340 8.64 0.19 4.8 65 4.5 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 108 40 250 6.35 0.19 4.8 65 4.5 55 170 0.10 0.2 5.1

0.075 1.9 9-8208 108 40 190 4.83 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 110 40 105 2.67 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 113 40 60 1.52 0.19 4.8 65 4.5 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 111 40 40 1.02 0.19 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 124 40 21 0.53 0.19 4.8 65 4.5 55 170 NR NR NR

0.500 12.7 9-8208 123 40 11 0.28 0.19 4.8 65 4.5 55 170 NR NR NR

0.625 15.9 9-8208 137 40 7 0.18 0.19 4.8 65 4.5 55 170 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.036 0.9 9-8208 103 40 355 9.02 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1

0.05 1.3 9-8208 98 40 310 7.87 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 98 40 240 6.10 0.125 3.2 65 4.5 55 170 0.10 0.2 5.1

0.078 2.0 9-8208 100 40 125 3.18 0.125 3.2 65 4.5 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 124 40 20 0.51 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 122 40 15 0.38 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 126 40 10 0.25 0.187 4.8 65 4.5 55 170 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.032 0.8 9-8208 110 40 440 11.18 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1

0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1

0.064 1.6 9-8208 112 40 250 6.35 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1

0.079 2.0 9-8208 112 40 200 5.08 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1

0.125 3.2 9-8208 118 40 100 2.54 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 120 40 98 2.49 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1

0.250 6.4 9-8208 123 40 50 1.27 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 134 40 16 0.41 0.187 4.8 65 4.5 55 170 NR NR NR

OPERATION Manual 0-5380

4T-10

ESAB CUTMASTER 120

Type Torch: SL100 With Exposed Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8 70 4.8 90 245 0.00 0.19 4.8

0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8

0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8

0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8

0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 70 4.8 90 245 0.20 0.19 4.8

0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.19 4.8

0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 70 4.8 90 245 0.50 0.19 4.8

0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 70 4.8 90 245 0.75 0.19 4.8

0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8 70 4.8 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1

0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1

0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 70 4.8 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1

0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 70 4.8 90 245 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.00 0.25 6.4

0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4

0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4

0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 70 4.8 90 245 0.20 0.25 6.4

0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 70 4.8 90 245 0.30 0.25 6.4

0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 70 4.8 90 245 0.50 0.25 6.4

0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 70 4.8 90 245 0.80 0.25 6.4

0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 70 4.8 90 245 NR NR NR

Manual 0-5380 OPERATION

4T-11

ESAB CUTMASTER 120

Type Torch: SL100 With Exposed Tip

Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 113 80 320 8.13 0.19 4.8 65 4.5 115 340 0.00 0.19 4.8

0.120 3.0 9-8211 113 80 230 5.84 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8

0.135 3.4 9-8211 115 80 180 4.57 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8

0.188 4.8 9-8211 114 80 140 3.56 0.19 4.8 65 4.5 115 340 0.20 0.19 4.8

0.250 6.4 9-8211 114 80 100 2.54 0.19 4.8 65 4.5 115 340 0.30 0.19 4.8

0.375 9.5 9-8211 117 80 42 1.07 0.19 4.8 65 4.5 115 340 0.40 0.19 4.8

0.500 12.7 9-8211 120 80 33 0.84 0.19 4.8 65 4.5 115 340 0.60 0.19 4.8

0.625 15.9 9-8211 133 80 22 0.56 0.19 4.8 65 4.5 115 340 0.75 0.19 4.8

0.750 19.1 9-8211 128 80 18 0.46 0.19 4.8 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 133 80 10 0.25 0.19 4.8 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 132 80 9 0.23 0.19 4.8 65 4.5 115 340 NR NR NR

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 120 80 340 8.64 0.25 6.4 65 4.5 115 340 0.00 0.25 6.4

0.120 3.0 9-8211 120 80 300 7.62 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4

0.135 3.4 9-8211 120 80 280 7.11 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 120 80 140 3.56 0.25 6.4 65 4.5 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 120 80 100 2.54 0.25 6.4 65 4.5 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 126 80 50 1.27 0.25 6.4 65 4.5 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 129 80 28 0.71 0.25 6.4 65 4.5 115 340 0.80 0.25 6.4

0.625 15.9 9-8211 135 80 20 0.51 0.25 6.4 65 4.5 115 340 1.00 0.25 6.4

0.750 19.1 9-8211 143 80 10 0.25 0.25 6.4 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 143 80 9 0.23 0.25 6.4 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 146 80 8 0.20 0.25 6.4 65 4.5 115 340 NR NR NR

Type Torch: SL100 with Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8211 120 80 350 8.89 0.25 6.4 65 4.5 115 340 0.00 0.25 6.4

0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 124 80 180 4.57 0.25 6.4 65 4.5 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 128 80 110 2.79 0.25 6.4 65 4.5 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 136 80 55 1.40 0.25 6.4 65 4.5 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 139 80 38 0.97 0.25 6.4 65 4.5 115 340 0.60 0.25 6.4

0.625 15.9 9-8211 142 80 26 0.66 0.25 6.4 65 4.5 115 340 0.75 0.25 6.4

0.750 19.1 9-8211 145 80 24 0.61 0.25 6.4 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 153 80 10 0.25 0.25 6.4 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 162 80 6 0.15 0.25 6.4 65 4.5 115 340 NR NR NR

OPERATION Manual 0-5380

4T-12

ESAB CUTMASTER 120

Type Torch: SL100 With Exposed Tip

Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250 6.4

0.375 9.5

0.500 12.7

0.625 15.9

0.750 19.0

1.000 25.4

9-8212 110 100 105 2.65 0.190 4.8 75 5.2 130 390

9-8212 117 100 70 1.75 0.190 4.8 75 5.2 130 390

9-8212 120 100 50 1.25 0.190 4.8 75 5.2 130 390

9-8212 125 100 35 0.90 0.190 4.8 75 5.2 130 390

9-8212 131 100 18 0.45 0.190 4.8 75 5.2 130 390

9-8212

135

100

10

0.25

0.190

4.8 75 5.2 130 390

0.200 5.1

0.4

0.200 5.1

0.5

0.200 5.1

0.6

1.0 0.200

2.0 0.250

NR NR NR

5.1

6.4

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250

0.375

0.500

0.625

0.750

1.000

6.4 9-8212

9.5 9-8212

12.7 9-8212

15.9 9-8212

19.0 9-8212

25.4 9-8212

118

122

126

133

138

139

100

100

100

100

100

100

90

55

30

20

15

10

2.30

1.40

0.75

0.50

0.40

0.25

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

0.5 0.250

0.8 0.250

1.0 0.250

1.5 0.250

NR NR

NR NR

6.4

6.4

6.4

6.4

NR

NR

Type Torch: SL100 with Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250 6.4 9-8212 108 100 120 3.05 0.190 4.8 65 4.5 120 360 0.2 0.225 5.7

0.375 9.5 9-8212 117 100 65 1.65 0.190 4.8 65 4.5 120 360 0.4 0.225 5.7

0.500 12.7 9-8212 120 100 45 1.15 0.190 4.8 65 4.5 120 360 0.5 0.225 5.7

0.625 15.9 9-8212 125 100 30 0.75 0.190 4.8 65 4.5 120 360 0.8 0.225 5.7

0.750 19.0 9-8212 131 100 25 0.65 0.190 4.8 65 4.5 120 360 1.0 0.225 5.7

1.000

25.4 9-8212

140

Type Torch: SL100 With Exposed Tip

100

10

0.25

0.190

4.8 65 4.5 120 360

Type Material: Mild Steel

NR NR

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250 6.4

0.375 9.5

0.500 12.7

0.625 15.9

0.750 19.0

0.875 22.2

1.000 25.4

1.250 31.8

1.500 38.1

9-8253 138 120 150 3.81 0.19 4.8 75 5.2 180 360

9-8253 140 120 85 2.16 0.19 4.8 75 5.2 180 360

9-8253 144 120 70 1.78 0.19 4.8 75 5.2 180 360

9-8253 152 120 45 1.14 0.19 4.8 75 5.2 180 360

9-8253 155 120 30 0.76 0.19 4.8 75 5.2 180 360

9-8253 160 120 25 0.64 0.25 6.4 75 5.2 180 360

9-8253 164 120 20 0.51 0.25 6.4 75 5.2 180 360

9-8253 170 120 12 0.30 0.25 6.4 75 5.2 180 360

9-8253 180 120 8 0.20 0.25 6.4 75 5.2 180 360

0.10

0.30

0.50

0.70

0.90

NR NR NR

NR NR NR

NR NR NR

NR NR NR

0.25 6.4

0.25 6.4

0.25 6.4

0.25 6.4

0.25 6.4

NR

Manual 0-5380 OPERATION

4T-13

ESAB CUTMASTER 120

Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

6.4 9-8253

0.250

0.375

0.500

0.625

0.750

1.000

1.250

9.5 9-8253

12.7 9-8253

15.9 9-8253

19.0 9-8253

25.4 9-8253

31.8 9-8253

135

144

146

155

164

164

170

Type Torch: SL100 with Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250 6.4 9-8253 142 120 190 4.83 0.19 4.8 75 5.2 180 360 0.30 0.25 6.4

0.375 9.5 9-8253 145 120 120 3.05 0.19 4.8 75 5.2 180 360 0.50 0.25 6.4

0.500 12.7 9-8253 151 120 70 1.78 0.19 4.8 75 5.2 180 360 0.80 0.25 6.4

0.625 15.9 9-8253 162 120 50 1.27 0.25 6.4 75 5.2 180 360 1.00 0.28 7.0

0.750 19.0 9-8253 164 120 34 0.86 0.25 6.4 75 5.2 180 360 NR NR NR

1.000 25.4 9-8253 170 120 20 0.51 0.25 6.4 75 5.2 180 360 NR NR NR

120

120

120

120

120

120

120

180

100

60

40

26

18

9

4.57

2.54

1.52

1.02

0.66

0.46

0.23

4.8 75 5.2 180 360

0.19

4.8 75 5.2 180 360

0.19

4.8 75 5.2 180 360

0.19

6.4 75 5.2 180 360

0.25

6.4 75 5.2 180 360

0.25

6.4 75 5.2 180 360

0.25

6.4 75 5.2 180 360

0.25

0.20 0.25

0.40 0.25

0.80 0.25

1.20 0.28

NR NR

NR NR

NR NR

6.4

6.4

6.4

7.0

NR

NR

NR

NOTE!

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pres­sure to 70 psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.

4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip

Type Torch: SL100 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.036 0.9 9-8208 114 40 170 4.32 0.19 4.8 65 4.5 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 120 40 90 2.29 0.19 4.8 65 4.5 55 170 0.10 0.2 5.1

0.075 1.9 9-8208 121 40 80 2.03 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 122 40 75 1.91 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 123 40 30 0.76 0.19 4.8 65 4.5 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 125 40 25 0.64 0.19 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 138 40 11 0.28 0.19 4.8 65 4.5 55 170 NR NR NR

0.500 12.7 9-8208 142 40 7 0.18 0.19 4.8 65 4.5 55 170 NR NR NR

0.625 15.9 9-8208 152 40 3 0.08 0.19 4.8 65 4.5 55 170 NR NR NR

OPERATION Manual 0-5380

4T-14

ESAB CUTMASTER 120

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.036 0.9 9-8208 109 40 180 4.57 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1

0.05 1.3 9-8208 105 40 165 4.19 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 115 40 120 3.05 0.125 3.2 65 4.5 55 170 0.10 0.2 5.1

0.078 2.0 9-8208 120 40 65 1.65 0.187 4.8 65 4.5 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 125 40 25 0.64 0.187 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 132 40 20 0.51 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 130 40 15 0.38 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 130 40 10 0.25 0.187 4.8 65 4.5 55 170 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.032 0.8 9-8208 116 40 220 5.59 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1

0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1

0.064 1.6 9-8208 118 40 180 4.57 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1

0.079 2.0 9-8208 116 40 150 3.81 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1

0.125 3.2 9-8208 130 40 75 1.91 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 132 40 60 1.52 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1

0.250 6.4 9-8208 134 40 28 0.71 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 143 40 11 0.28 0.187 4.8 65 4.5 55 170 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 70 4.8 90 245 0.00 0.2 5.1

0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1

0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1

0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1

0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 70 4.8 90 245 0.20 0.2 5.1

0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.2 5.1

0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 70 4.8 90 245 0.50 0.2 5.1

0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 70 4.8 90 245 0.75 0.2 5.1

0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 70 4.8 90 245 NR NR NR

Manual 0-5380 OPERATION

4T-15

ESAB CUTMASTER 120

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8210 110 60 165 4.19 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 116 60 155 3.94 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 115 60 125 3.18 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.135 3.4 9-8210 118 60 80 2.03 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.188 4.8 9-8210 120 60 75 1.91 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 121 60 60 1.52 0.13 3.2 70 4.8 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 129 60 28 0.71 0.13 3.2 70 4.8 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 135 60 17 0.43 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1

0.625 15.9 9-8210 135 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 142 60 10 0.25 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 70 4.8 90 245 0.80 0.20 5.1

0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 128 80 280 7.11 0.19 4.8 65 4.5 115 340 0.00 0.2 5.1

0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1

0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1

0.188 4.8 9-8211 128 80 137 3.48 0.19 4.8 65 4.5 115 340 0.20 0.2 5.1

0.250 6.4 9-8211 131 80 100 2.54 0.19 4.8 65 4.5 115 340 0.30 0.2 5.1

0.375 9.5 9-8211 134 80 40 1.02 0.19 4.8 65 4.5 115 340 0.50 0.2 5.1

0.500 12.7 9-8211 136 80 36 0.91 0.19 4.8 65 4.5 115 340 0.60 0.2 5.1

0.625 15.9 9-8211 145 80 21 0.53 0.19 4.8 65 4.5 115 340 0.75 0.2 5.1

0.750 19.1 9-8211 144 80 14 0.36 0.19 4.8 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 149 80 11 0.28 0.19 4.8 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 162 80 8 0.20 0.19 4.8 65 4.5 115 340 NR NR NR

OPERATION Manual 0-5380

4T-16

ESAB CUTMASTER 120

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 110 80 340 8.50 0.125 3.2 65 4.5 115 340 0.00 0.2 5.1

0.120 3.0 9-8211 115 80 260 6.50 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1

0.135 3.4 9-8211 113 80 250 6.25 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1

0.188 4.8 9-8211 114 80 170 4.25 0.125 3.2 65 4.5 115 340 0.20 0.2 5.1

0.250 6.4 9-8211 116 80 85 2.13 0.125 3.2 65 4.5 115 340 0.30 0.2 5.1

0.375 9.5 9-8211 123 80 45 1.13 0.125 3.2 65 4.5 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 133 80 18 0.45 0.125 3.2 65 4.5 115 340 0.75 0.25 6.4

0.625 15.9 9-8211 135 80 16 0.40 0.125 3.2 65 4.5 115 340 1.00 0.25 6.4

0.750 19.1 9-8211 144 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 137 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 140 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR

Type Torch: SL100 With Shielded Tip

Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8211 115 80 320 8.13 0.13 3.2 65 4.5 115 340 0.00 0.25 6.4

0.12 3.0 9-8211 120 80 240 6.10 0.13 3.2 65 4.5 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 120 80 165 4.19 0.13 3.2 65 4.5 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 124 80 100 2.54 0.13 3.2 65 4.5 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 138 80 60 1.52 0.19 4.8 65 4.5 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 141 80 36 0.91 0.19 4.8 65 4.5 115 340 0.60 0.25 6.4

0.625 15.9 9-8211 142 80 26 0.66 0.19 4.8 65 4.5 115 340 0.75 0.25 6.4

0.750 19.1 9-8211 150 80 18 0.46 0.19 4.8 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 156 80 8 0.20 0.19 4.8 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 164 80 6 0.15 0.19 4.8 65 4.5 115 340 NR NR NR

Type Torch: SL100 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250 6.4

0.375 9.5

0.500 12.7

0.625 15.9

0.750 19.0

1.000 25.4

9-8212

9-8212

9-8212

9-8212

9-8212

9-8212

124

127

132

136

140

147

100

100

100

100

100

100

110

75

50

30

18

10

2.80

1.90

1.30

0.75

0.45

0.25

0.180

0.180

0.180

0.180

0.190

0.190

4.6 75 5.2 130 390

4.6 75 5.2 130 390

4.6 75 5.2 130 390

4.6 75 5.2 130 390

4.8 75 5.2 130 390

4.8 75 5.2

130

390

0.4 0.200

0.5 0.200

0.6 0.200

0.8 0.200

2.0 0.225

NR NR

5.1

5.1

5.1

5.1

5.7

NR

Manual 0-5380 OPERATION

4T-17

ESAB CUTMASTER 120

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250

0.375

0.500

0.625

0.750

1.000

6.4 9-8212

9.5 9-8212

12.7 9-8212

15.9 9-8212

19.0 9-8212

25.4 9-8212

121 100 110

125 100 60

132 100 35

137 100 20

144 100 15

154 100 8

2.80

1.50

0.90

0.50

0.40

0.20

0.125

0.150

0.150

0.150

0.190

0.190

3.2 75 5.2 130 390

3.8 75 5.2 130 390

3.8 75 5.2 130 390

3.8 75 5.2 130 390

4.8 75 5.2 130 390

4.8 75 5.2 130 390

0.5 0.200

0.8 0.200

1.0 0.200

2.0 0.225

NR NR

NR NR

5.1

5.1

5.1

5.7

NR

NR

Type Torch: SL100 With Shielded Tip

Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250

0.375

0.500

0.625

0.750

1.000

6.4 9-8212

9.5 9-8212

12.7 9-8212

15.9 9-8212

19.0 9-8212

25.4 9-8212

120

128

130

135

140

148

100

100

100

100

100

100

120

65

45

30

25

10

3.05

1.65

1.15

0.75

0.65

0.25

0.180

0.180

0.180

0.180

0.180

0.190

65 4.5 105 360

65 4.5 105 360

65 4.5 105 360

65 4.5 105 360

65 4.5 105 360

65 4.5

105 360 NR NR

0.2 0.225

0.4 0.225

0.5 0.225

0.8 0.225

1.0 0.225

Type Torch: SL100 With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250 6.4

0.375 9.5

0.500 12.7

0.625 15.9

0.750 19.0

0.875 22.2

1.000 25.4

1.250 31.8

1.500 38.1

9-8253

9-8253

9-8253

9-8253

9-8253

9-8253

9-8253

9-8253

9-8253

140

142

144

150

154

158

160

170

176

120

120

120

120

120

120

120

120

120

165

85

75

50

30

25

20

13

8

4.19

2.16

1.91

1.27

0.76

0.64

0.51

0.33

0.20

0.125

0.125

0.125

0.125

0.150

0.150

0.150

0.175

0.175

3.2

3.2

3.2

3.2

3.8

3.8

3.8

4.4

4.4

75

75

75

75

75

75

75

75

75

5.2

5.2

5.2

5.2

5.2

5.2

5.2

5.2

5.2

180

360 0.20

180

360 0.50

180

360 0.70

180

360 0.80

180

360 1.50

180

360 NR NR

180

360 NR NR

180

360 NR NR

180

360 NR NR

0.20

0.20

0.20

0.20

0.20

5.7

5.7

5.7

5.7

5.7

NR

5.1

5.1

5.1

5.1

5.1

NR

NR

NR

NR

OPERATION Manual 0-5380

4T-18

ESAB CUTMASTER 120

Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250

0.375

0.500

0.625

0.750

1.000

1.250

6.4 9-8253

9.5 9-8253

12.7 9-8253

15.9 9-8253

19.1 9-8253

25.4 9-8253

31.8 9-8253

136 120 180

144 120 100

149 120 60

153 120 40

157 120 30

162 120 20

165 120 10

4.57

2.54

1.52

1.02

0.76

0.51

0.25

0.13

0.13

0.13

0.15

0.15

0.15

0.15

3.2

3.2

3.2

3.8

3.8

3.8

3.8

75

75

75

75

75

75

75

5.2 180 360

5.2 180 360

5.2 180 360

5.2 180 360

5.2 180 360

5.2 180 360

5.2 180 360

0.20 0.20

0.40 0.20

0.80 0.20

1.20 0.20

NR NR

NR NR

NR NR

5.1

5.1

5.1

5.1

NR

NR

NR

Type Torch: SL100 With Shielded Tip

Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.250

0.375

0.500

0.625

0.750

1.000

6.4 9-8253

9.5 9-8253

12.7 9-8253

15.9 9-8253

19.1 9-8253

25.4 9-8253

144

148

152

162

163

168

120

120

120

120

120

120

190

120

75

45

35

20

4.83

3.05

1.91

1.14

0.89

0.51

0.13

0.13

0.15

0.15

0.15

0.15

3.2

3.2

3.8

3.8

3.8

3.8

75

75

75

75

75

75

5.2 180 360

5.2 180 360

5.2 180 360

5.2 180 360

5.2 180 360

5.2 180 360

0.20 0.20

0.50 0.20

0.70 0.20

1.00 0.20

NR NR

NR NR

5.1

5.1

5.1

5.1

NR

NR

NOTE!

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pres­sure to 70 psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.

Manual 0-5380 OPERATION

4T-19

ESAB CUTMASTER 120

PATENT INFORMATION

Plasma Cutting Torch Patents

The following parts are covered under U.S. and Foreign Patents as follows:

Catalog # Description Patent(s)

 9-8215 Electrode USPatNo(s)6163008;6987238

Other Pat(s) Pending

 9-8213 Cartridge USPatNo(s)6903301;6717096;6936786;
   6703581;D496842;D511280;D492709;
   D499620;D504142OtherPat(s)Pending
 9-8205 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8206 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8207 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8252 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8208 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8209 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8210 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8231 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8211 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8212 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8253 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8225 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8226 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8227 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8228 Tip USPatNo(s)6774336;7145099;6933461

Other Pat(s) Pending

 9-8241 ShieldCap USPatNo(s)6914211;D505309

Other Pat(s) Pending

 9-8243 ShieldCap USPatNo(s)6914211;D493183

Other Pat(s) Pending

 9-8235 ShieldCap USPatNo(s)6914211;D505309

Other Pat(s) Pending

 9-8236 ShieldCap USPatNo(s)6914211;D505309

Other Pat(s) Pending

 9-8237 ShieldCup USPatNo(s)6914211;D501632;D511633

Other Pat(s) Pending

 9-8238 ShieldCap USPatNo(s)6914211;D496951

Other Pat(s) Pending

 9-8239 ShieldCap USPatNo(s)6914211;D496951

Other Pat(s) Pending

 9-8244 ShieldCap USPatNo(s)6914211;D505309

Other Pat(s) Pending

OPERATION Manual 0-5380

4T-20

ESAB CUTMASTER 120

Catalog # Description Patent(s)

 9-8245 ShieldCap USPatNo(s)6914211;D496951

Other Pat(s) Pending

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

Catalog # Description

9-8235  ShieldCap
9-8236  ShieldCap
9-8237  ShieldCup
9-8238  ShieldCap
9-8239  ShieldCap
9-8244  ShieldCap
9-8245  ShieldCap

Manual 0-5380 OPERATION

4T-21

ESAB CUTMASTER 120

This Page Intentionally Blank

OPERATION Manual 0-5380

4T-22

5.01 General Maintenance

ESAB CUTMASTER 120

SECTION 5 SYSTEM:

SERVICE

Warning!
Disconnect input power before maintaining.

Visual check of
torch tip and electrode

Visually inspect the torch body tip,
electrode, start cartridge and shield cup

Maintain more often
if used under severe
conditions

Each Use

Weekly

Visually inspect the
cables and leads.
Replace as needed

Replace all
broken parts

3 Months

Clean
exterior
of power supply

6 Months

Visually check and
Carefully clean the
interior

Art # A-07938_AB

Manual 0-5380 SERVICE

5-1

ESAB CUTMASTER 120

5.02 Maintenance Schedule

NOTE!

The actual frequency of maintenance may
need to be adjusted according to the oper­ating environment.

Daily Operational Checks or Every Six Cutting

Hours:

1. Check torch consumable parts, replace if dam­aged or worn.

2. Check plasma and secondary supply and pres­sure/flow.

3. Purge plasma gas line to remove any moisture
build-up.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air
flow.

2. Inspect torch for any cracks or exposed wires,
replace if necessary.

3. Inspect input power cable for damage or ex­posed wires, replace if necessary.

Six Months or Every 720 Cutting Hours:

5.03 Common Faults

Problem - Symptom Common Cause

Insufficient Penetration 1. Cutting speed too fast.

2. Torch tilted too much.

3. Metal too thick.

4. Worn torch parts

5. Cutting current too low.

6. Non - Genuine ESAB parts used

7. Incorrect gas pressure

Main Arc Extinguishes 1. Cutting speed too slow.

2. Torch standoff too high from
workpiece.

3. Cutting current too high.

4. Work cable disconnected.

5. Worn torch parts.

6. Non - Genuine ESAB parts used

Excessive Dross

Formation

1. Cutting speed too slow.

2. Torch standoff too high from
workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine ESAB parts used

6. Incorrect gas pressure

1. Check the in-line air filter(s), clean or replace as
required.

2. Check cables and hoses for leaks or cracks,
replace if necessary.

3. Check all contactor points for severe arcing or
pits, replace if necessary.

4. Vacuum dust and dirt out of the entire machine.

CAUTION

!

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

Short Torch Parts Life 1. Oil or moisture in air source.

2. Exceeding system capability (material
too thick).

3. Excessive pilot arc time

4. Gas pressure too low.

5. Improperly assembled torch.

6. Non - Genuine ESAB parts used

Difficult Starting 1. Worn torch parts.

2. Non - Genuine ESAB parts used.

3. Incorrect gas pressure.

SERVICE Manual 0-5380

5-2

ESAB CUTMASTER 120

5.04 Fault Indicator

At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used.

To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit
count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator
and 75 psi indicators are ON indicating the version would be 2.3.

7
6

5

4
3
2

1

0

MAX

MIN

A

PSI BAR

MAXMAX

MINMIN

!

+

5

3

1

4

2

Art# A-07988

When the ! "Fault" indicator is ON or blinking it will be accompanied by one of the pressure indicator lights
depending on what the Fault is. The following table explains each of those Faults.

Pressure

Fault

Indicator

Max Over Pressure

90 Internal Error

85 Check Consumables

80 Consumables Missing

75 Start Error

70 Parts in Place

65 Input Power

Min Under Pressure

NOTE!

Fault explanations are covered in the following tables.

Manual 0-5380 SERVICE

5-3

ESAB CUTMASTER 120

5.05 Basic Troubleshooting Guide

WARNING

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

Problem - Symptom Possible Cause Recommended Action

ON / OFF Switch is ON
but the A/C Indicator
does not light

Fault indicator flashing,
65 PSI indicator
flashing

1. Primary power disconnect is in OFF
position.

2. Primary fuses / breakers are blown
or tripped.

3. Units internal fuse blown.

4. Faulty components in unit.

1. INPUT VOLTAGE SELECTION
SWITCH set for incorrect voltage.

2. Primary input voltage problem.

3. Faulty components in unit.

1. Turn primary power disconnect switch to ON position.

2. a) Have qualified person check primary fuses / breakers.
b) Connect unit to known good primary power receptacle

3. a) Replace fuse.
b) If fuse blows again, return to authorized service center for
repair or replacement.

4. Return to authorized service center for repair or replacement.

1. Set INPUT VOLTAGE SELECTION SWITCH to match primary input
voltage.

2. Have qualified person check primary voltage to insure it meets
unit requirements see section 2.05.

3. Return to authorized service center for repair or replacement.

TEMPERATURE
indicator ON. FAULT
indicator flashing.

GAS LED OFF, FAULT
and MIN pressure
indicators flashing.

FAULT and 70 PSI
indicators flashing.

FAULT and 75 PSI
indicators flashing.

1. Air flow through or around the unit
is obstructed.

2. Duty cycle of the unit has been
exceeded

3. Failed components in unit

1. Gas supply not connected to unit.

2. Gas supply not turned ON.

3. Gas supply pressure too low.

4. AIR PRESSURE CONTROL regulator
set too low.

5. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to
power supply.

3. Problem in torch and leads PIP
circuit.

4. Failed components in unit.

1. Start signal is active when ON/OFF
SWITCH is turned to ON position.

2. Problem in the torch and leads
switch circuit.

3. Failed components in unit.

1. Refer to clearance information – section 2.04

2. Allow unit to cool.

3. Return to authorized service center for repair or replacement.

1. Connect gas supply to unit.

2. Turn gas supply ON.

3. Set air supply inlet pressure to unit to 120 psi.

4. Adjust regulator to set air pressure - see section 4.02.

5. Return to authorized service center for repair or replacement.

1. Hand tighten the shield cup until it is snug.

2. Insure torch ATC is securely fastened to unit.

3. Replace torch and leads or return to authorized service center for
repair or replacement.

4. Return to authorized service center for repair or replacement.

1. Start can be active for one of the following:

•Handtorchswitchheldclosed
•Handpendantswitchheldclosed
•CNCSTARTsignalisactivelow

Release the START signal source

2. Replace torch and leads or return to authorized service center for
repair or replacement.

3. Return to authorized service center for repair or replacement.

SERVICE Manual 0-5380

5-4

Problem - Symptom Possible Cause Recommended Action

FAULT & 80 PSI
indicators flashing.
Gas flow is cycling ON
and OFF.

Nothing happens when
torch switch or remote
switch is closed (Or
CNC START signal is
active) No gas flow,
DC LED OFF.

1. Torch shield cup is loose.

2. Torch tip, electrode or starter
cartridge missing.

3. Torch starter cartridge is stuck.

4. Open conductor in torch leads.

5. Problem in the torch and leads
switch circuit.

6. Failed components in unit.

1. Problem in the torch and leads
switch circuit (Remote pendant
switch circuit).

2. CNC Controller device not providing
Start signal.

3. Failed components in unit.

1. Tighten shield cup by hand. Do not overtighten.

2. Turn OFF power supply. Remove shield cup. Install missing parts.

3. Turn OFF power supply. Bleed down system pressure. Remove
shield cup, tip and starter cartridge. Check starter cartridge lower
end fitting for free movement. Replace if fitting does not move freely.

4. Replace torch and leads or return to authorized service center for
repair or replacement.

5. Replace torch and leads or return to authorized service center for
repair or replacement.

6. Return to authorized service center for repair or replacement.

1. Take Torch and Leads (Remote Pendant) to Authorized Repair
Facility.

2. Contact Controller manufacturer.

3. Return to authorized service center for repair or replacement.

ESAB CUTMASTER 120

FAULT and 85 PSI
indicators flashing.

No Fault lights ON, no
arc in torch.

Fault and 90 PSI
indicators flashing

Pilot arc is ON but
cutting arc will not
establish

Torch cutting is
diminished

1. Upper O-Ring on torch head is in
wrong position.

2. Torch starter cartridge is stuck.

3. Worn or faulty torch parts.

4. Shorted Torch.

5. Temporary Short indicated by 5
blinks per second.

6. Power Supply Failure (Standard
rate of blinking)

1. Failed components in unit. 1. Return to an authorized service center for repair.

1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that does not

1. Work cable not connected to work
piece.

2. Work cable/connector broken.

3. Failed components in unit.

1. Incorrect current setting.

2. Worn torch consumables.

3. Poor work cable connection to
work piece.

4. Torch being moved too fast.

5. Excessive oil or water in torch.

6. Failed components in unit.

1. Remove shield cup from torch; check upper O-Ring position;
correct if necessary.

2. Turn OFF power supply. Bleed down system pressure. Remove
shield cup, tip and starter cartridge. Check starter cartridge lower
end fitting for free movement. Replace if fitting does not move freely.

3. Inspect torch consumable parts. Replace if necessary.

4. Replace torch and leads or return to an authorized service center
for repair.

5. Release torch switch and reactivate.

6. Return to authorized service center for repair or replacement.

clear the fault, return to an authorized service center for repair.

1. Connect work cable.

2. Replace work cable.

3. Return to an authorized service center for repair.

1. Check and adjust to proper setting.

2. Check torch consumables and replace as needed.

3. Check the connection of the Work Lead to the work piece.

4. Reduce cutting speed.

5. Refer to "Check air quality" in section 3 Torch.

6. Return to an authorized service center for repair.

Manual 0-5380 SERVICE

5-5

ESAB CUTMASTER 120

5.06 Power Supply Basic Parts Replacement

WARNING

!

This section describes procedures for basic parts
replacement. For more detailed parts replacement
procedures, refer to the Power Supply Service Manual.

A. Cover Removal

1. Remove the upper and lower screws which

Disconnect primary power to the system
before disassembling the torch, leads, or
power supply.

secure the cover to the main assembly. Do not
loosen the lower screws inside the cut out slots
in the bottom of the cover.

Upper
Screws

Lower
Screws

C. Filter Element Assembly Replacement

The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should
be checked per the Maintenance Schedule (Subsection

5.02), and either cleaned or replaced.

1. Remove power from the power supply; turn OFF
the gas supply and bleed down the system.

2. Remove the system cover. See "A Cover Re­moval" in this section.

3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
illustration.

4. Hold a wrench or similar tool against the locking
ring on the filter assembly fitting, then pull on
the hose to release it. (Numbers 2 and 3 in the
following illustration).

1

Slots

Lower
Screws

Art # A-08429

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

B. Cover Installation

1. Reconnect the ground wire, if necessary.

2. Place the cover onto the power supply so that
slots in the bottom edges of the cover engage
the lower screws.

Art # A-07989

2

3

4

5

6mm

3. Tighten lower screws.

4. Reinstall and tighten the upper screws.

SERVICE Manual 0-5380

5-6

ESAB CUTMASTER 120

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

5. Remove the fitting from the filter element as-

sembly by inserting a6 mm hex wrench into

the internal hex fitting and turning it counter
clock-wise (left). Numbers 4 and 5 in the previ­ous illustration.

6. Disconnecttheinputlinefromthelterelement

assembly.

7. Remove the filter element assembly through the
rear opening.

NOTE!

If replacing or cleaning just the filter ele­ment refer to the following illustration for
disassembly.

Filter Element

Optional Single-Stage Filter Element Replacement

These instructions apply to power supplies where the
optional Single-Stage Filter has been installed.

The Power Supply shuts down automatically when the
Filter Element becomes completely saturated. The
Filter Element can be removed from its housing, dried,
and reused. Allow 24 hours for Element to dry. Refer

toSection6,PartsList,forreplacementlterelement

catalog number.

1. Remove power from power supply.

2. Shut OFF air supply and bleed down system
before disassembling Filter to change Filter Ele­ment.

3. Disconnect gas supply hose.

4. Turn the Filter Housing Cover counter-clockwise
and remove it. The Filter Element is located
inside the Housing.

Art # A-07990

8. Install the new or cleaned assembly by reversing
these procedures.

9. TurnONtheairsupplyandcheckforleaksbefore

reinstalling the cover.

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and
set Element aside to dry.

6. Wipe inside of housingclean, then insert the

replacement Filter Element open side first.

7. Replace Housing on Cover.

8. Reattach gas supply.

NOTE!

If unit leaks between housing and cover,
inspect the O-ring for cuts or other damage.

Manual 0-5380 SERVICE

5-7

ESAB CUTMASTER 120

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

Optional Two-Stage Filter Element Replacement

The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will

continueto operate but cutqualitymaybecomeunacceptable.RefertoSection 6, PartsList,forreplacement

filter element catalog number.

1. Shut OFF primary input power.

2. Shut OFF air supply and bleed down system.

WARNING

!

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

4. Note the location and orientation of the old Filter Elements.

5. Slide out the old Filter Elements.

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

Optional Two-Stage Filter Replacement

6. SlidethereplacementFilterElementsintotheFilterAssembly,withthesameorientationasnotedinStep

4 above.

7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque
may damage the gasket.

8. Slowly apply air pressure to the assembly, checking for leaks.

NOTE!

A small amount of air leakage from the bottom fitting is normal.

This completes the parts replacement procedures.

SERVICE Manual 0-5380

5-8

SECTION 5 TORCH:

ATC Male Connector

Art #A-03791

Gas Fitting

O-Ring

SERVICE

ESAB CUTMASTER 120

5T.01 General Maintenance

NOTE!

Refer to Previous "Section 5: System" for
common and fault indicator descriptions.

Cleaning Torch

Even if precautions are taken to use only clean air
with a torch, eventually the inside of the torch be­comes coated with residue. This buildup can affect
the pilot arc initiation and the overall cut quality of
the torch.

WARNING

Disconnect primary power to the system
before disassembling the torch or torch
leads.
DO NOT touch any internal torch parts
while the AC indicator light of the Power
Supply is ON.

The inside of the torch should be cleaned with elec­trical contact cleaner using a cotton swab or soft wet
rag. In severe cases, the torch can be removed from
the leads and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and blowing
it through with compressed air.

Upper Groove
with Vent Holes
Must Remain Open

Upper O-Ring
in Correct Groove

Threads

Lower O-Ring

Torch Head O-Ring

Art # A-03725

CAUTION

!

O-Ring Lubrication

An o-ring on the Torch Head and ATC Male Con­nector requires lubrication on a scheduled basis.
This will allow the o-rings to remain pliable and
provide a proper seal. The o-rings will dry out,
becoming hard and cracked if the lubricant is not
used on a regular basis. This can lead to potential
performance problems.

It is recommended to apply a very light film of o­ring lubricant (Catalog # 8-4025) to the o-rings on
a weekly basis.

Dry the torch thoroughly before reinstalling.

ATC O-Ring

NOTE!

DO NOT use other lubricants or grease,
they may not be designed to operate
within high temperatures or may contain
“unknown elements” that may react with
the atmosphere. This reaction can leave
contaminants inside the torch. Either of
these conditions can lead to inconsistent
performance or poor parts life.

Manual 0-5380 SERVICE

5T-1

ESAB CUTMASTER 120

Drag Shield Cap

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

Good Tip

Worn Tip

A-03406

Spring-Loaded

Worn Electrode

New Electrode

Art # A-03284

5T.02 Inspection and Replacement of

Consumable Torch Parts

WARNING

Disconnect primary power to the system

Remove the consumable torch parts as follows:

1. Unscrew and remove the shield cup from the

before disassembling the torch or torch
leads.
DO NOT touch any internal torch parts
while the AC indicator light of the Power
Supply is ON.

NOTE!

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

torch.

4. Remove the tip. Check for excessive wear
(indicated by an elongated or oversized orifice).
Clean or replace the tip if necessary.

Example of Tip Wear

5. Remove the starter cartridge. Check for exces­sive wear, plugged gas holes, or discoloration.
Check the lower end fitting for free motion.
Replace if necessary.

Lower End Fitting
Full Compression

Spring-Loaded
Lower End Fitting at Reset /
Full Extension

NOTE!

Slag built up on the shield cup that cannot
be removed may effect the performance of
the system.

2. Inspect the cup for damage. Wipe it clean or
replace if damaged.

Art # A-08067

Shield Cups

3. On torches with a shield cup body and a shield
cap or deflector, ensure that the cap or deflector
is threaded snugly against the shield cup body.
In shielded drag cutting operations (only), there
may be an O-ring between the shield cup body
and drag shield cap. Do not lubricate the O-ring.

Art # A-08064_AC

6. PulltheElectrodestraightoutoftheTorchHead.

Check the face of the electrode for excessive
wear. Refer to the following figure.

Electrode Wear

7. Reinstall the Electrode by pushing it straight into

the torch head until it clicks.

8. Reinstall the desired starter cartridge and tip into

the torch head.

9. Handtightentheshieldcupuntilitisseatedon

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

This completes the parts replacement procedures.

SERVICE Manual 0-5380

5T-2

ESAB CUTMASTER 120

SECTION 6: PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:

Section "6.03 Power Supply Replacement"

Section "6.04 Replacement Power Supply Parts"

Section "6.05 Options and Accessories"

Section "6.06 Replacement Parts for Hand Torch"

Section "6.07 Replacement Parts - for Machine Torches with Unshielded Leads"

Section "6.08 Replacement Shielded Machine Torch Leads Assemblies"

Section "6.09 Torch Consumable Parts (SL100)"

NOTE!

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns

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

6.02 Ordering Information

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

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas
pressure regulator / filter, and operating manual.

Qty Description Catalog #

1 ESAB Cutmaster® 120 Power Supply with 400VAC, 3 phase
input power cable 0559317302

Manual 0-5380 PARTS LIST

6-1

ESAB CUTMASTER 120

6.04 Replacement Power Supply Parts

Qty Description Catalog #

1 Regulator 9-0115
1 Filter Assembly Replacement Element 9-0116
1 Input Power Cord for 208 / 230 V Power Supply 9-0191
1 460/600V Power Supply 9-0209

6.05 Options and Accessories

Qty Description Catalog #

1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two - Stage Filter Kit (includes Hose & Mounting Screws 9-9387
Bracket, Filter Mounting (not shown) 9-9386
1 Two - Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Extended Work Cable (50 ft / 15.2 m) with Clamp 9-8529
1 Automation Interface Kit 9-8311
1 Automation Harness 9-9385
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008
1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

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

PARTS LIST Manual 0-5380

6-2

ESAB CUTMASTER 120

6.06 Replacement Parts for Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
2 1 Trigger Assembly Replacement Kit 9-7034
3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O-ring 8-3487
6 1 Small O-ring 8-3486
7 Leads Assemblies with ATC connectors (includes switch assemblies)
1 SL100, 20 - foot Leads Assembly with ATC connector 4-7836
1 SL100, 50 - foot Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031
10 1 Torch Control Cable Adapter (includes item # 11) 7-3447
11 1 Through - Hole Protector 9-8103

1

8

2

4

5
6

3

7

Manual 0-5380 PARTS LIST

Art # A-07993_AB

6-3

ESAB CUTMASTER 120

6.07 Replacement Parts - for Machine Torches with Unshielded Leads

Item No. Qty Description Catalog No.

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O-ring 8-3487
3 1 Small O-ring 8-3486
4 1 PIP Switch Kit 9-7036
5 Unshielded Automated Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853
6 Unshielded Mechanized Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845
7 1 11” / 279 mm Rack 9-7041
8 1 11” / 279 mm Mounting Tube 9-7043
9 1 End Cap Assembly 9-7044
10 2 Body, Mounting, Pinch Block 9-4513
11 1 Pin, Mounting, Pinch Block 9-4521
12 1 Torch Holder Sleeve 7-2896
13 1 PIP Plunger and Return Spring Kit 9-7045
1 Pinion Assembly (Not shown) 7-2827
1 5” / 126 mm Positioning Tube (Not shown) 9-7042

NOTE!

* Does not include Control Cable Adapter or Through - Hole Protector.

Refer to Section 6.09 for Replacement Shielded Leads Assemblies.

PARTS LIST Manual 0-5380

6-4

ESAB CUTMASTER 120

9

7

10

8

10

1

2

11

13

3

4

12

5 & 6

A-07994_AB

Manual 0-5380 PARTS LIST

6-5

ESAB CUTMASTER 120

6.08 Replacement Shielded Machine Torch Leads Assemblies

Item No. Qty Description Catalog No.

1 Mechanized Shielded Leads Assemblies with ATC Connectors
1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846
1 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847
1 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848
1 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849

1

Remote Pendant Adapter is
present on Mechanized leads only.

Torch Continuity
('PIP') Switch

A-03684

PARTS LIST Manual 0-5380

6-6

6.09 Torch Consumable Parts (SL100)

Ohmic Clip

Manual Torch

9-8259

ESAB CUTMASTER 120

Ohmic Clip

Automation Torch

9-8224

Electrode

Auto 9-8232

Manual 9-8215

Starter

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Starter Cartridge

Non HF Only 9-8277

70-120A

STANDOFF

CUTTING

Tip:

20A 9-8205
30A 9-8206
40A 9-8208

Tips:

50-55A 9-8209

60A 9-8210

Tips:

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine
40A 9-8245

Shield Cap, Deflector
9-8243

Drag Shield Cup
9-8235

Shield Cap, Machine
50-60A 9-8238

Shield Cap, Deflector
9-8243

Drag Shield Cup
70-100A 9-8236

Drag Shield Cup
120A 9-8258

Shield Cap, Machine
70-100A 9-8239

Shield Cap, Machine
120A 9-8256

Shield Cap, Deflector
9-8243

40-120A

GOUGING

Tips:

Tip A 9-8225 (40 Amps Max.)

Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Art # A-08066_AG

Manual 0-5380 PARTS LIST

Tip E 9-8254 (60 - 120 Amps)

Shield

Cup Body,

9-8237

Shield Cup, Gouging

9-8241

6-7

ESAB CUTMASTER 120

This Page Intentionally Blank

PARTS LIST Manual 0-5380

6-8

ESAB CUTMASTER 120

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

Connect work cable to workpiece.

Set output amperage.

System is ready

for operation.

ON / OFF switch to ON

AC indicator ON.

GAS indicator ON

pressure is adequate

for power supply operation.

ACTION:

RESULT:

ACTION:

RESULT:

when input

Power circuit ready.

ACTION:

RUN /

Rapid Auto Restart /

SET / LATCH switch

to SET

RESULT:

Gas flows to set

pressure.

Torch moved away from work (while

ACTION:

RUN / Rapid Auto Restart /

SET / LATCH

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

or to

LATCH

is used for specific applications

(torch switch can be released

after main arc transfer).

RESULT: Gas flow stops.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate

Torch switch (START)

RESULT:

Fans turn on. Gas flows briefly,

then stops.Gas restarts.

DC indicator ON

Pilot arc established.

ACTION:

Release Torch switch.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

(Fans will continue to run for

10 minutes after the Torch switch

[START] is removed)

PILOT ARC

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fans shut off.

Main arc stops.

Pilot arc automatically

restarts.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

Art #A-07979_AB

Manual 0-5380 APPENDIX

A-1

ESAB CUTMASTER 120

1/ 3

f

f

1

2

Mo de l:

U

1

1

1

1max 1eff

I

I

U

2

3Ø

3Ø1Ø

1Ø

S/N

U

0

=

X

Standard Symbols

Ø

AC

DC

Phase

NOTES:

1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.

2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.

3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission.
Duty cycle value is determined under the power supply
manufacturer's test procedures.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.

4. Sections of the Data Tag may be applied to separate areas
of the power supply.

I

Art # A-12765_AA

Da te of Mf r:

Output Range (Amperage/
Voltage)

Type of Power
Supply (Note 1)

Output Current Type

Rated No­Load Voltage

Plasma Cutting
Symbol

Manufacturer's Name and/or
Logo, Location, Model and
Revision Level, Serial Number
and Production Code

Conventional
Load Voltage

Regulatory Standard Covering
This Type of Power Supply

Duty Cycle Data (Note 3)

Duty Cycle Factor

Input Power
Specifications
(Phase, AC or DC
Hertz Rating)

Input Power
Symbol

Rated Supply
Voltage (Note 2)

Rated Maximum
Supply Current

Maximum Effective
Supply Current

Degree of Protection

Manufacturer's Electrical
Schematic File Number
and Revision Level

APPENDIX 2: DATA TAG INFORMATION

APPENDIX Manual 0-5380

A-2

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

1

2

3

4

5

6

7

8

5

6

7

8

1

2

3

4

ATC Female Receptacle

Front View

Pilot

Pilot

6 - Open

7 - Open

8 - Open

5 - Open

Negative /
Plasma

6 - Open

7 - Open

5 - Open

2 - PIP

3 - Switch

4 - Switch

1 - PIP

4 - Green /
Switch

2- Orange /
PIP

3 - White /
Switch

1 - Black /
PIP

Negative /
Plasma

8 - Ground

ATC Male Connector

Front View

A-03701

ATC Female Receptacle

Front View

ATC Male Connector

Front View

Negative / Plasma

3 - White ­Pendant
Connector

4- Black ­Pendant
Connector

2 - Orange /
PIP

1 - Black /
PIP

Pilot

2 - PIP

1 - PIP

6 - Open

7 - Open

5 - Open

8 - Ground

8 - Green ­Pendant
Connector
Ground

5 - White /
Not Used

7 - Green /
Not Used

6 - Open

UNSHIELDED MACHINE TORCH

3 - Switch

4 - Switch

Art # A-03799

Negative / Plasma

Pilot

1

2

3

4

5

6

7

8

5

6

8

1

2

3

4

7

A. Hand Torch Pin - Out Diagram

B. Mechanized (Machine) Torch Pin - Out Diagram

ESAB CUTMASTER 120

Manual 0-5380 APPENDIX

A-3

ESAB CUTMASTER 120

To rch: SL60 / SL100 Hand Torch
Leads: To rch Leads with ATC Connector
Power Supply: with ATC Receptacle

Pilot

Negative / Plasma

Power
Supply

PIP

Switch

Male

ATC Leads

Connector

AT C Female

Receptacle

Pilot

Negative / Plasma

Black

Orange

Torch
Leads

Torch

Head

To Power Supply

Circuitry

Art # A-03797

1

2

5

6

4

3

8

7

1

2

5

6

4

3

8

7

Torch

Switch

Green

White

To Power Supply

Circuitry

To rch: Unshielded Mechanized SL100 Machine Torch
Leads: Leads with ATC Connector and
Remote Pendant Connector
Power Supply: with ATC Female Receptacle

Pilot

Negative / Plasma

Power
Supply

To Remote Control

Remote

Pendant

Connector

PIP

Switch

Not

Used

Male

AT C Leads

Connector

AT C Female

Receptacle

Pilot Lead

Negative / Plasma Lead

Torch
Leads

Torch

Head

Art # A-03798

1

2

5

6

4

3

8

7

To Power Supply

Circuitry

Green

To Power Supply

Circuitry

1

2

5

6

4

3

8

7

Black

White

Green

Black

Orange

White

APPENDIX 4: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

B. Mechanized Torch Connection Diagram

APPENDIX Manual 0-5380

A-4

ESAB CUTMASTER 120

This Page Intentionally Blank

Manual 0-5380 APPENDIX

A-5

ESAB CUTMASTER 120

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

D

L1

L2

L3

GND

380/400/415V
OR 600V
3 PH AC INPUT

PRIMARY POWER CONNECTIONS:
USE L1, L2, L3 & GND

C

*

CE UNITS
ONLY

*

5

J1J1

SW1SW1

1 3

1
2
3
4

2 4

5

+12VDC

K1K1

EMI

*

CHOKE

EMI
FILTER

1

1

2

2

3

3

4

4

MOT1MOT1

FAN

+ -

SOL 1SOL 1

W1W1

SERIAL PORT

/INRUSH

W1W1

7

L1

T1

8

L2

T2

9

L3

T3

7A

L4

T4

+12VDC

J7J7

1
2

J5J5

1
2
3

5

6

24VAC

J6J6

1

24VAC RET

2

J4J4

3.3VDC

1

TXD

2

RXD

3
4

D

5

J13J13

/FAN

/SOLENOID

1 /OVERTEMP
2 /FAN_ON
3 /CSR
4 CUR_SET
5 MAIN_PCB_ID
6 COMMON

12345

INRUSH
RESISTORS

6

BIAS
SUPPLY

TP2TP2

+

D1

_

J14J14

SYNC

MTH1MTH1

+12VDC
BIAS
SUPPLY

MTH7MTH7

TP8TP8

AC1AC1

80A_AC180A_AC1

80A_AC280A_AC2

AC2AC2

AC3AC3

80A_AC380A_AC3

4

PRI 3PRI 3

B

PRI 2PRI 2

PRI 2PRI 2

A

PRI 1PRI 1

C3,C4,C7,C8*+C3,C4,C7,C8*

+

C5,C6,C9,C10*+C5,C6,C9,C10*

+

PRI 1PRI 1

MTH2MTH2

TP1TP1

MTH4MTH4

TP5TP5

MTH8MTH8

TP4TP4

TP3TP3

MTH6MTH6

+

Q1

Q2

T1T1

PRI 4 PRI 4

C

D

_

MAIN PCB ASSY

PCB1

T2T2

FERRITE

B

MOT2MOT2

FAN

MOT3MOT3

FAN

FILTER

J4J4

123456789

10

+12VDC

+-

J1J1

1

/FAN

2

+-

J2J2

1
2

+12VDC

J9J9

SYNC

+

D1

A

_

40/50 AMP PCB

PCB5

A-09130_AD

5

+12VDC

J2J2

1
2

J3J3

1

2

PRI 1 PRI 1

A

PRI 3PRI 3

PRI 2 PRI 2

B

PRI 4PRI 4

C

D

+

AC1AC1

PMTH1PMTH1

PMTH4PMTH4

40A_AC140A_AC1

AC2AC2

40A_AC240A_AC2

AC3AC3

40A_AC340A_AC3

PMTH1PMTH1

PMTH4PMTH4

PCB2

INPUT CAPACITOR PCB

C16-17+C16-17

+

C12-13+C12-13

PMTH2PMTH2

PMTH3PMTH3

+

PMTH2PMTH2

PMTH3PMTH3

Q1

Q2

_

4

APPENDIX Manual 0-5380

A-6

ESAB CUTMASTER 120

3

TS1TS1

/START

/PIP

PILOT IGBTQ5PILOT IGBT

+12VDC

L1L1

L2L2

-V OUT 1-V OUT 1

ELECTRODE1ELECTRODE1

WORK1WORK1

TIP1TIP1

J10J10

1
2
3
4
5
6
7
8

J2

J11J11

1

D59 PCRD59 PCR

D78 CSRD78 CSR

+12VDC

2

TEMP

/OVERTEMP

CIRCUIT

NTCNTC

D3

TEST POINTS

GND1

COMMON

GND2

COMMON

+12V1

+12 VDC SUPPLY

48V1

+48 VDC SUPPLY

I_DMD_1

CURRENT DEMAND

TIP_SEN

TIP DRAG SENSE

SEC1SEC1

SEC2SEC2

CHOKE1CHOKE1

Q5

24VAC RETURN

24VAC SUPPLY

OK-TO-MOVE

(5A @ 250VAC / 30VDC)

2

ATC CONNECTOR

J1J1

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

E64

E35

J9J9

78

1

79

2

80

3

81

4

82

5
6

83

7

P10P10

1
2
3
4
5
6
7
8

40 PIN RIBBON CABLE SIGNALS

1

FERRITE
FILTER

-V_OUT_SIGNAL

2

/TIP_VOLTS

3

/TIP_SENSE

4

/460V_IN

5

/230V_IN

6

CUR_SET

7

/RAR (RAPID AUTO RESTART)

8

/INRUSH

9

/W1_ON

10

SHDN

11

/TORCH_SOLENOID

12

/SOLENOID_ON

13

/OK_TO_MOVE

14

/FAN_ON

15

/LATCH_ACTIVE

16

/TORCH_SWITCH

17

/PIP

18

AC_ON

19

CSR

20

/TORCH_SOLENOID_DETECT

21

/OVERTEMP

22

V_IN

23

+12VDC

24

+12VDC

25

COMMON

26

COMMON

29

MAIN_PCB_ID

34

460_IN

35

+3.3VDC

36

TXD

37

RXD

38

COMMON

39

D

M-L
M-L
M-L
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
M-L
L-M
M-L
M-L
L-M
M-L

-

+

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

To -V OUT 1
on PCB1

E1E1

P2P2

P10P10

1
2
3
4
5
6
7
8

+12VDC

1

1

2

2
3

3
4

4

5

5

6

6

7

7

8

8

AUTOMATION
INTERFACE PCB

K1K1

J2J2

14
13
12
11
10
9
8
7
6
5
4
3
2
1

PCB4

P1P1

1TORCH

PIP SWITCHPIP SWITCH

TORCH SWITCHTORCH SWITCH

AUTOMATION
TORCH SOLENOID

OK TO MOVE

}

/START / STOP

}

*

123

K1

1

WORKWORK

CNC PINOUT

13

47

811

1214

*

To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS / 16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50

J1J1

1
2
3

/START / STOP

}

4

(-)

*

5

DIVIDED ARC VOLTS

}

(+)

6

(-)

7

ARC VOLTS

8

}

(W/ 100K IN SERIES (2))

(+)

9
10
11
12

OK-TO-MOVE

13

}

14

D

C

B

Current ControlCurrent Control

LATCH

SET

RUN

RAR

ACAC

OVERTEMPOVERTEMP

GASGAS

DCDC

ERRORERROR

J1

FAULT

ERROR IND

MAX
90
85
80
75
70
65
MIN

TEST POINTS

TP1
TP2
TP3
TP4
TP5
TP6
TP7

+12VDC

OVER PRESSURE
INTERNAL ERROR
SHORTED TORCH
CONSUMABLES MISSING
START ERROR
PARTS IN PLACE
INPUT POWER
UNDER PRESSURE

GND
+12 VDC
+5 VDC

3.3 VDC

0.v - 5.0 VDC / 0-100PSI

1.8 VDC
CURRENT DEMAND

D1D1

LOGIC PCB

PCB3

SEE A-09130

INTRO ECO B1357

AA

ECO B1399RWH

AB

ECO B1611 RWH

AB

Last Modified:

Last Modified:

Last Modified:

Friday, December 11, 20091109:02:19

0-100PSI / 0-4.5VDC

MAXMAX

9090

8585

8080

7575

7070

6565

MINMIN

+5VDC

RWH

FILTER
AIR
INLET

J3J3

3
2
1

DateByRevisionsRev

DateByRevisionsRev

DateByRevisionsRev

03/31/09

05/05/09

05/05/09

Information Proprietary to ESAB

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:

NOTE:

NOTE:

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

TITLE:

TITLE:

TITLE:

09:02:19

09:02:19

CM102/152/35mm/40mm/A80/A120 380/400/415/600V

GAS CONTROL

REGULATOR

PRESSURE
TRANSDUCER

SCHEMATIC,

SCHEMATIC,

SCHEMATIC,

1

SOLENOID
VALVE

123

ATC

A-12771_AB

PCB No:

PCB No:

PCB No:

Assy No:

Assy No:

Assy No:

SupersedesScale

SupersedesScale

SupersedesScale

Date:

Date:

Date:

MARCH 30, 2009

Drawn: References

Drawn: References

Drawn: References

RWH

Chk: App:

Chk: App:

Chk: App:

11

11

DWG No:

Size

DWG No:

Size

DWG No:

Size

D

D

D

42X1330

42X1330

42X1330

A

Sheet

Sheet

Sheet

of

of

of

SEC1SEC1

SEC2SEC2

CHOKE1CHOKE1

D2

NTCNTC

3

TEMP
CIRCUIT

/OVERTEMP

+OUT_1+OUT_1

2

Manual 0-5380 APPENDIX

A-7

ESAB CUTMASTER 120

Revision History

Date Rev Description

01/15/2015 AA Manual release

05/22/2015 AB Miscellaneous corrections and updates

APPENDIX Manual 0-5380

A-8

This Page Intentionally Blank

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