Thermal Dynamics CUTMASTER A120 Operating Manual

380­400

A120

™

CUTMASTER

AUTOMATED PLASMA
CUTTING SYSTEM

Operating Manual

Rev. AB Date: September 19, 2008 Manual # 0-4989
Operating Features:

WE APPRECIATE YOUR BUSINESS!

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

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

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators
Worldwide.

Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.

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

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

!

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operat­ing, or servicing the equipment.

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

Plasma Cutting Power Supply
CutMaster™ A120
SL100 1Torch™
Operating Manual Number 0-4989

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermal-dynamics.com

Copyright 2008 by
Thermadyne Corporation

All rights reserved.

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

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

Printed in the United States of America

Original Publication Date: June 30, 2008
Revision date: September 19, 2008

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ________________

Purchase Date:__________________________________ ________________

Power Supply Serial #:___________________________ ________________

Torch Serial #:___________________________________ ________________

i

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION ............................................................................................1-1

1.01 Notes, Cautions and Warnings .....................................................................................1-1

1.02 Important Safety Precautions .......................................................................................1-1

1.03 Publications ..................................................................................................................1-2

1.04 Note, Attention et Avertissement ..................................................................................1-3

1.05 Precautions De Securite Importantes ...........................................................................1-3

1.06 Documents De Reference ............................................................................................1-5

1.07 Declaration of Conformity .............................................................................................1-6

1.08 Statement of Warranty .................................................................................................. 1-7

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3.01 Unpacking 3-1

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

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

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

3.05 Gas Connections ..........................................................................................................3-4

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

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

3T.02 CNC Connection ......................................................................................................... 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 Machine and Automated Torch Operation .................................................................. 4T-1

4T.02 Automation Torch Parts Selection ............................................................................... 4T-2

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

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

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

4T.06 Hand Torch Operation ................................................................................................. 4T-5

4T.07 Gouging 4T-8
4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip 4T-10
4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip 4T-36

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

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

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

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

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

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

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

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

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

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

6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) .............6-4

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

6.08 Torch Consumable Parts (SL100) .................................................................................6-8

6.09 Replacement Parts for Hand Torch ..............................................................................6-9

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

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

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

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

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

APPENDIX 6: SYSTEM SCHEMATIC, 400V UNITS ........................................................................ A-8

APPENDIX 7: Publication History .................................................................................................. A-10

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ................................... Inside Rear Cover

cutmaster a120

!

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to
highlight important information. These highlights are categorized as
follows:

NOTE

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.

1.02 Important Safety Precautions

• The kinds of fumes and gases from the plasma arc depend on
the kind of metal being used, coatings on the metal, and the
different processes. You must be very careful when cutting
or welding any metals which may contain one or more of the
following:

Antimony Chromium Mercury

Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should
be supplied with the material you are using. These MSDSs
will give you the information regarding the kind and amount of
fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications in
this manual.

• Use special equipment, such as water or down draft cutting
tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or
explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlo­rinated solvents and cleansers. Remove all sources of these
vapors.

• This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.

Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the proper
function of cardiac pacemakers, hearing aids, or other
electronic health equipment. Persons who work near
plasma arc cutting applications should consult their
medical health professional and the manufacturer of
the health equipment to determine whether a hazard
exists.

To prevent possible injury, read, understand and follow
all warnings, safety precautions and instructions before
using the equipment. Call 1-603-298-5711 or your local
distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be
dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your
head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to
remove all fumes and gases.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and
produces high voltage electrical energy. This electric energy can cause
severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work
piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or
damp.

• Install and maintain equipment according to NEC code, refer
to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or
repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma
arc.

• Be sure there is no combustible or flammable material in the
workplace. Any material that cannot be removed must be
protected.

• Ventilate all flammable or explosive vapors from the work­place.

Manual 0-4989 1-1 GENERAL INFORMATION

cutmaster a120

• Do not cut or weld on containers that may have held combus­tibles.

• Provide a fire watch when working in an area where fire hazards
may exist.

• Hydrogen gas may be formed and trapped under aluminum
workpieces when they are cut underwater or while using a water
table. DO NOT cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated or dissipated.
Trapped hydrogen gas that is ignited will cause an explosion.

1.03 Publications

Refer to the following standards or their latest revisions for more
information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
obtainable from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,
obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can
cause noise levels to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear
plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound)
do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsec­tion 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma
arc process produces very bright ultra violet and infra red light. These
arc rays will damage your eyes and burn your skin if you are not
properly protected.

• To protect your eyes, always wear a welding helmet or shield.
Also always wear safety glasses with side shields, goggles or
other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin
from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace
lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective
booths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/
ASC Z49.1:

Minimum Protective Suggested
Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

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

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces
chemicals known to the State of California to cause cancer, birth defects
and other reproductive harm. Wash hands after handling. (California

Health & Safety Code § 25249.5 et seq.)

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superintendent
of Documents, U.S. Government Printing Office, Washington,
D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable
from American National Standards Institute, 1430 Broadway,
New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT-
TING AND WELDING PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY
10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards As­sociation, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable
from the National Welding Supply Association, 1900 Arch
Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM­MENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS AND PIPING THAT
HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO­TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-2 Manual 0-4989

1.04 Note, Attention et Avertissement

!

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont
utilisés pour mettre en relief des informations à caractère important.
Ces mises en relief sont classifiées comme suit :

cutmaster a120

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépen­dent du genre de métal utilisé, des revêtements se trouvant sur le
métal et des différents procédés. Vous devez prendre soin lorsque
vous coupez ou soudez tout métal pouvant contenir un ou plusieurs
des éléments suivants:

NOTE

Toute opération, procédure ou renseignement général
sur lequel il importe d’insister davantage ou qui contribue
à l’efficacité de fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter l’endommagement
du matériel en cas de non-respect de la procédure en
question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de
l’opérateur ou des autres personnes se trouvant dans
la zone de travail en cas de non-respect de la procédure
en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL
DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT
PRÉSENTER DES RISQUES ET DES DANGERS DE
SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magnétique qui
peuvent interférer la fonction propre d’un “pacemaker”
cardiaque, les appareils auditif, ou autre matériel de santé
electronique. Ceux qui travail près d’une application à
l’arc au jet de plasma devrait consulter leur membre pro­fessionel de médication et le manufacturier de matériel de
santé pour déterminer s’il existe des risques de santé.

Il faut communiquer aux opérateurs et au personnel
TOUS les dangers possibles. Afin d’éviter les blessures
possibles, lisez, comprenez et suivez tous les avertisse­ments, toutes les précautions de sécurité et toutes les
consignes avant d’utiliser le matériel. Composez le +
603-298-5711 ou votre distributeur local si vous avez
des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent
présenter des risques et des dangers de santé.

antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières
(sigle américain “MSDS”); celles-ci devraient être fournies avec le
matériel que vous utilisez. Les MSDS contiennent des renseigne­ments quant à la quantité et la nature de la fumée et des gaz pouvant
poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz
de votre lieu de travail, consultez l’article 1 et les documents cités
à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit
d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se
trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant
des solvants et des produits de nettoyage chlorés. Eliminez toute
source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de
la fumée ou des gaz pouvant contenir des éléments reconnu dans
L’état de la Californie, qui peuvent causer des défauts de naissance
et le cancer. (La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet
de plasma requiert et produit de l’énergie électrique haute tension. Cette
énergie électrique peut produire des chocs graves, voire mortels, pour
l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
gants et des vêtements secs. Isolez-vous de la pièce de travail ou
des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide
ou moite.

• Montez et maintenez le matériel conformément au Code électrique
national des Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien
ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez
votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.

Manual 0-4989 1-3 GENERAL INFORMATION

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes,
des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma

cutmaster a120

produit du métal, des étincelles, des scories chaudes pouvant mettre
le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne
se trouve sur le lieu de travail. Protégez toute telle matière qu’il
est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables
ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer
des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone
présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces
de travail en aluminium lorsqu’elles sont coupées sous l’eau ou
sur une table d’eau. NE PAS couper les alliages en aluminium sous
l’eau ou sur une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé explosera
si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
pas correctement.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
supérieurs aux limites normalement acceptables. Vous dú4ez vous
protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également
les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels
(le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez
l’article 1, page 5.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb,
ou engendre des produits chimiques, reconnus par l’état de
Californie comme pouvant être à l’origine de cancer, de mal­formations fœtales ou d’autres problèmes de reproduction.

Il fau t s e l a v er les main s a p rès tout e m a n ipula t i on.

(Code de Californie de la sécurité et santé, paragraphe 25249.5 et
suivants)

• Pour protéger vos yeux, portez toujours un casque ou un écran
de soudeur. Portez toujours des lunettes de sécurité munies de
parois latérales ou des lunettes de protection ou une autre sorte
de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de
l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état.
Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail
contre les rayons de l’arc en fournissant des cabines ou des écrans
de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommenda­tion qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est caché
par moiceau de travail.

GENERAL INFORMATION 1-4 Manual 0-4989

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant
été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION
DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd.,
Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès
du Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (Ameri­can National Standards Institute), 1430 Broadway, New York, NY
10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PRO­TECTRICES, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018

cutmaster a120

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM­MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À
LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT
RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de
la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE,
disponible auprès de l’American National Standards Institute, 1430
Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible
auprès de l’American National Standards Institute, 1430 Broadway,
New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ
DES PRODUITS COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les
Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION
EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS
ASSOCIÉS, disponible auprès de la National Fire Protection As­sociation, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUD­AGE, disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE
ET LA COUPE, disponible auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE,
disponible auprès de l’Association Nationale de Fournitures de
Soudage (National Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103

Manual 0-4989 1-5 GENERAL INFORMATION

cutmaster a120

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA

age Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement
of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/
EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* For environments with increased hazard of electrical shock, Power Supplies bearing the mark conform to EN50192 when used in

conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process.

This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs
as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all
design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative: Steve Ward

Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

Operations Director

GENERAL INFORMATION 1-6 Manual 0-4989

cutmaster a120

1.08 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser

that new Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of this warranty are free of defects in material and
workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal Dynamics Corporation shall, upon
notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics’ specifications,
instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.

This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.

Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the
time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation
will provide instructions on the warranty procedures to be implemented.

Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of
sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.

LIMITED WARRANTY PERIOD

Product

Power Supply Components

(Parts and Labor)

Torch and Leads

(Parts and Labor)

CUTMASTER™ A40 4 Years 1 Year

CUTMASTER™ A60 4 Years 1 Year

CUTMASTER™ A80 4 Years 1 Year

CUTMASTER™ A120 4 Years 1 Year

This warranty does not apply to:

1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.

2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon industry

standards.

In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:

1. Repair of the defective product.

2. Replacement of the defective product.

3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.

4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.

These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned
for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.

LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such
as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics with respect to any contract, or anything
done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered
by or furnished by Thermal Dynamics whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as
expressly provided herein, exceed the price of the goods upon which liability is based.

This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics
product.

This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.

Effective September 4, 2007

Manual 0-4989 1-7 GENERAL INFORMATION

cutmaster a120

GENERAL INFORMATION 1-8 Manual 0-4989

cutmaster a120

!

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specication

or part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay
particular attention to the information provided
under these headings. These special annotations
are easily recognized as
follows:

WARNING

A WARNING gives information regarding
possible personal injury.

CAUTION

A CAUTION refers to possible equipment dam­age.

NOTE

2.02 Equipment Identification

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

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

as torch and cable assemblies are identied
only by the specication or part number

printed on loosely attached card or the shipping
container. Record these numbers on the bottom of
page 1 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 car-

rier immediately to le a claim. Furnish complete

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

Include all equipment identication numbers as

described above along with a full description of
the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging
the equipment when using bars, hammers, etc., to
un-crate the unit.

A NOTE offers helpful information concerning
certain operating procedures.

Additional copies of this manual may be
purchased by contacting Thermadyne at the
address and phone number in your area listed
in the inside back cover of this manual. Include
the Owner’s Manual number and equipment

identication numbers.

Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format
by going to the
Thermal Dynamics web site listed below and
clicking on Thermal Dynamics and then on the
Literature link:
http://www.thermal-dynamics.com

Manual 0-4989 2-1 INTRODUCTION

cutmaster a120

26.3"

0.668 m

63 lb / 28.6 kg

10"

254 mm

13.78"

350 mm

Art # A-08459

6"

150 mm

24"

0.6 m

6"

150 mm

6"

150 mm

Art # A-07925

2.04 Power Supply Specifications

CutMaster A120 Power Supply Specifications

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

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

Input Power

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

400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

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

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

Input Power Cable Power Supply includes input cable.

Output Current 30 - 120 Amps, Continuously Adjustable

Power Supply Gas

Particulates to 5 Microns

Filtering Ability

CutMaster A120 Power Supply Duty Cycle *

Ambient Temperature

Duty Cycle Ratings @ 40° C (104° F)
Opperating Range 0° - 50° C

Duty Cycle N/A 80%** 100%

Current 120 110

All Units

IEC IEC IEC

DC Voltage 128 124

* NOTE: The duty cycle will be reduced if the primary input power (AC) is low
or the output voltage (DC) is higher than shown in this chart.
**Using a 208/230 VAC input will reduce this duty cycle to 50%

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

INTRODUCTION 2-2 Manual 0-4989

2.05 Input Wiring Specifications

CutMaster A120 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

cutmaster a120

Volts Hz kVA I max I eff

Fuse

(amps)

Flexible Cord

(Min. AWG)

208 60 26.2 126 115 150 4 Type W

1 Phase

230 60 27.6 120 106 125 4 Type W

460 60 35 76 38 100 8

208 60 21.6 60 55 60 4

230 60 22.3 56 50 60 4

3 Phase

380 50 23 35 32 40 8

400 50 23.6 34 31 40 8

460 60 29.5 37 33 40 8

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTES

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

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

I1max is taken at TDC rated minimum duty cycle.

I1eff is taken at TDC 100% rated duty cycle

Manual 0-4989 2-3 INTRODUCTION

cutmaster a120

Art # A-08460

Mounting Rails

Torch Leads
Receptacle

Control Panel

Work Cable
and Clamp

Input Power Cord

Automation Interface
Cable Port

Gas Inlet Port

Filter Assembly

Input Power Selection

Art # A-08461

2.06 Power Supply Features

INTRODUCTION 2-4 Manual 0-4989

cutmaster a120

Art # A-07402_AB

1.75" /

44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" /

16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm

2.875” /
73 mm

Art # A-02998

1.75" /

44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" /
16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

Art # A-03322_AB

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 person-

nel; unqualied personnel are strictly cautioned

against attempting repairs or adjustments not
covered in this manual, at the risk of voiding the
Warranty.
Read this manual thoroughly. A complete under­standing of the characteristics and capabilities of
this equipment will assure the dependable opera­tion for which it was designed.

2T.02 General Description

2T.03 Specifications

A. Torch Configurations

1. Automation Torch, Model

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

2. Machine Torch, Model

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

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

gas ows through the small orice in the torch tip,

which is focused on the metal to be cut.
A single torch lead provides gas from a single
source to be used as both the plasma and second-

ary gas. The air ow is divided inside the torch

head. Single - gas operation provides a smaller
sized torch and inexpensive operation.

NOTE

Refer to Section 2T.05, Introduction To Plasma,
for a more detailed description of plasma torch
operation.

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

3. Hand/Manual Torch, Models

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

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20 ft / 6.1 m, with ATC connectors

• 50 ft / 15.2 m, with ATC connectors
Machine / Automation Torches are available

as follows:

Manual 0-4989 2T-1 INTRODUCTION

• 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

cutmaster a120

!

A-08331

Workpiece

Power

Supply

+

_

C

B

A

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

12 vdc circuit rating

E. Type Cooling

Combination of ambient air and gas stream through
torch.

F. Torch Ratings

Automated / Machine Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

peak

)

100% @ 100 Amps @ 400 scfh

80% @ 120 Amps @ 400 scfh

104° F

40° C

120 Amps

500V

7kV

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.

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.

Manual Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

peak

)

100% @ 120 Amps @ 400 scfh

104° F

40° C

120 Amps

500V

7kV

G. Gas Requirements

Automated, Manual and Machine Torch Gas

Specications

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and Gouging)

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh
142 - 235 lpm

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.

WARNING

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

Typical Torch Head Detail

INTRODUCTION 2T-2 Manual 0-4989

cutmaster a120

PIP Switch

Shield Cup

To ATC

CNC Start

PIP Switch

Shield Cup

PIP Switch

Shield Cup

Remote Pendant

Automation Torch

To ATC

To ATC

Art # A-08168

A-02997

Torch Trigger

PIP Switch

Shield Cup

To Control

Cable Wiring

Torch Switch

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.

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

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.

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.

Parts - In - Place Circuit Diagram for Machine

Torch

Parts - In - Place Circuit Diagram for Hand Torch

Manual 0-4989 2T-3 INTRODUCTION

cutmaster a120

This Page Intentionally Blank

INTRODUCTION 2T-4 Manual 0-4989

cutmaster a120

!

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

WARNING

Do not touch live electrical parts.

Disconnect input power cord before moving
unit.

FALLING EQUIPMENT can cause serious
personal injury and can damage equipment.

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

• Lift unit by the handles, using two hands.
Do not use straps for lifting.

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

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

3.03 Power Supply location and
Mounting

NOTE

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

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

2.04 and provides a safe rm surface where

the unit can be secured.

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

in the mounting rails touch.

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

4. Insert proper hardware. If using hardware
that screws into the mounting surface,
leave all four loose enough for the thick­ness of the rail to slide under the head and
washer if used.

5. Lower the power supply over the mounting
hardware and slide forward or backward
until the keyway stops against the mount­ing hardware.

6. Secure the hardware to the rail.

3.04 Primary Input Power
Connections

CAUTION

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

Manual 0-4989 3-1 INSTALLATION

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

contactor in the single - phase conguration.

The following illustrations and directions are for

changing that conguration to a different voltage

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

cutmaster a120

Art # A-08429

Lower
Screws

Lower
Screws

Slots

Upper
Screws

S

LO

HI

Art # A-08316

Art # A-08493

Input Power Cable Connections

Three-Phase (3ø)

Store copper jumpers on base plate

Single-Phase (1ø) and Jumper Settings

GND

L1

L2

L3

L4

GND

L1

L2

L3

L4

A. Cover Removal

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

Note

The upper screws and lower screws are not the
same. Do not mix them. The upper screws are
for threading into the plastic of the front and rear
panels. DO NOT use the finer threaded lower
screws for this.

C. Input Power Selection

Set the Input Voltage Selection Switch at the rear
of the unit based on the primary input voltage it
is connected to. Low is 208/230 VAC and high is
460 VAC.

D. Quick Guide to Phase Wiring

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

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

B. Cover Installation

1. Reverse previous procedures for cover
installation.

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

tighten.

NOTE

Single and Three Phase Input Power Wiring

NOTE

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

INSTALLATION 3-2 Manual 0-4989

cutmaster a120

E. Connections to Single Phase Input Power

WARNING

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

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

1. Remove the Power Supply cover per in­structions found in this subsection A.

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

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

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

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

power cable specications.

CAUTION

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 con-

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

• Green / Yellow wire to Ground.

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

8. Reinstall the Power Supply cover see sub­section B.

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

10. Connect the input power cable (or close

the main disconnect switch) to supply
power.

F. Connections to Three Phase Input Power

WARNING

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

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

1. Remove the Power Supply cover per in­structions found in this subsection A.

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 specications.

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).

Manual 0-4989 3-3 INSTALLATION

cutmaster a120

Art # A-08320

Inlet Port

Filter Assembly

Hose Clamp

Gas Supply
Hose

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

6. Connect the wires as follows.

• Wires to L1, L2 and L3 input. It does
not matter what order these wires are at­tached. See previous illustration and on
label in the power supply.

• Green / Yellow wire to Ground.

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

8. Reinstall the Power Supply cover see sub­section B.

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

10. Connect the input power cable (or close

the main disconnect switch) to supply

power.

3.05 Gas Connections

Connecting Gas Supply to Unit

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

subsections if an optional air line lter is to be

installed.

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

illustration shows typical ttings 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.

Air Connection to Inlet Port

Installing Optional Single - Stage Air Filter

An optional lter kit is recommended for im­proved ltering with compressed air, to keep

moisture and debris out of the torch.

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

2. Attach the Filter Assembly to the lter

hose.

3. Connect the air line to the Filter. The

illustration shows typical ttings as an

example.

NOTE

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

INSTALLATION 3-4 Manual 0-4989

cutmaster a120

Art # A-08319

Hose Clamp

1/4 NPT to 1/4"

(6mm) Fitting

Inlet Port

Gas Supply
Hose

Filter Assembly

Art # A-07945_AB

Regulator/Filter
Assembly

Regulator
Input

2-Stage Filter
Inlet Port (IN)

Outlet Port
(OUT)

Two Stage
Filter
Assembly

Gas Supply
Hose

1/4 NPT to 1/4”
(6mm) Fitting

Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line lter is also

for use on compressed air shop systems. Filter
removes moisture and contaminants to at least 5
microns.

Connect the air supply as follows:

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

supplied with the lter assembly.

NOTE

For a secure seal, apply thread sealant to the 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.

Optional Single - Stage Filter Installation

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air
supply:

1. Refer to the manufacturer’s specications

for installation and maintenance proce­dures for high pressure regulators.

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

3. The cylinder must be equipped with an
adjustable high - pressure regulator capable

of outlet pressures up to 100 psi (6.9 bar)
maximum and ows of at least 300 scfh
(141.5 lpm).

4. Connect supply hose to the cylinder.

NOTE

Pressure should be set at 100 psi (6.9 bar) at the
high pressure cylinder regulator.

Supply hose must be at least 1/4 inch (6 mm)

I.D.

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

Manual 0-4989 3-5 INSTALLATION

2. Connect the two stage lter outlet hose to

the inlet port of the Regulator / Filter As­sembly.

3. Use customer - supplied ttings to connect

the air line to the Filter. A 1/4 NPT to 1/4"

hose barbed tting is shown as an example.

Optional Two - Stage Filter Installation

cutmaster a120

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air
supply:

1. Refer to the manufacturer’s specications

for installation and maintenance proce­dures for high pressure regulators.

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

3. The cylinder must be equipped with an
adjustable high - pressure regulator capable

of outlet pressures up to 100 psi (6.9 bar)
maximum and ows of at least 300 scfh
(141.5 lpm).

4. Connect supply hose to the cylinder.

NOTE

Pressure should be set at 100 psi (6.9 bar) at the
high pressure cylinder regulator.

Supply hose must be at least 1/4 inch (6 mm)
I.D.

For a secure seal, apply thread sealant to the 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 3-6 Manual 0-4989

cutmaster a120

1

2

Art # A-07885

Automation Interface
Cable Port

Art # A-08464

Art # A-08323

Plasma
Start / Stop
Signal

Cutting Machine
OK to Move

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Sup­ply. Connect only the Thermal Dynamics model
SL100SV / Automation, SL100 / Mechanical
or SL100 / Manual Torch to this power supply.
Maximum torch leads length is 100 feet / 30.5 m,
including extensions.

WARNING

Disconnect primary power at the source
before connecting the torch.

1. Align the ATC male connector (on the

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

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

Check Air Quality

To test the quality of air:

1. Put the ON / OFF switch in the ON

(up) position.

2. Put the Function Control switch in the SET

position.

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

torch and turn on the air. Do not start an
arc!

Any oil or moisture in the air will be visible

on the lens.

3T.02 CNC Connection

1. Locate the interface connection port on the
rear of the power supply.

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

Connecting the Torch to the Power Supply

3. The system is now ready for operation.

Manual 0-4989 3T-1 INSTALLATION

3. Connect CNC to the power supply.

cutmaster a120

A-02585

Workpiece

Square

Pinch Block
Assembly

3T.03 Setting Up Automation or

Machine Torch

NOTE

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

WARNING

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

The Automation and Machine torch include a
positioning tube with rack and pinch block assem­bly.

1. Mount the torch assembly on the cutting
table.

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

Automated and Machine Torch Set - Up

3. The proper torch parts (shield cup, tip, start

cartridge, and electrode) must be installed
for the type of operation. Refer to Section
4T.08, Torch Parts Selection for details.

INSTALLATION 3T-2 Manual 0-4989

SECTION 4 SYSTEM:

+

A

+

PSI BAR

MAX MAX

MIN MIN

!

1 2

3

4

5

6

7

8

9

Art# A-07886

MIN

MAX

10

PSI BAR

MAX MAX

MIN MIN

80

75

70

65

5.5

85 5.9

90 6.3

5.2

4.8

4.5

Art # A-08170

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.

cutmaster a120

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 or
mechanical cuts. (Does not apply to automation).
Once a cutting arc is established, the torch switch
can be released. The cutting arc will remain on un­til the torch is lifted away from the work piece, the
torch leaves the edge of the work piece the torch
switch is activated again or if one of the system
interlocks is activated.

3. On Off Power Switch

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

4. Air/Gas Pressure Control

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.

9. !Fault Error Indicator

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

10. Pressure Indicators

The Pressure

Control is used in the "SET"

mode to adjust the air/gas pressure. Pull the knob

out to adjust and push in to lock.

5. AC Indicator

Steady light indicates power supply is ready for op-

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

Manual 0-4989 4-1 OPERATION

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

cutmaster a120

Art # A-04509

A

+

PSI BAR

MAX MAX

MIN MIN

!

1

2

Art# A-07946

MIN

MAX

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
Thermal Dynamics model SL100 / Manual or SL100
/ Mechanical Torches may be connected to this
Power Supply. See Section 3T of this manual.

Check Primary Input Power Source

1. Check the power source for proper input
voltage. Make sure the input power source
meets the power requirements for the unit

per Section 2, Specications.

2. Connect the input power cable (or close the

main disconnect switch) to supply power to
the system.

Air Source

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

1. Place the Power Supply Function Control

knob to the SET position. Gas will

ow.

2. For Standoff cutting, adjust gas pressure

from 70 - 85 psi / 4.8 - 5.9 bar (LED's

in center of control panel). Refer to the
Standoff chart for pressure setting details.

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.

OPERATION 4-2 Manual 0-4989

cutmaster a120

STANDOFF

CutMaster A120 Gas Pressure Settings

SL100

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

(Mechanized Torch)

SL100 SV

(Automation Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

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

adjust gas pressure from 75 - 95 psi / 5.2

- 6.5 bar (LED's in center of control panel).

Refer to the Drag Cutting chart for pres­sure setting details.

DRAG (60 Amps or less)

CutMaster A120 Gas Pressure

Settings

Leads

Length

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

Pre-flow

With hand or mechanical torch, there will be a .5
second pre-flow of the gas. Pre-flow does not apply
to automation torch use.

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.

Postflow

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 ow stops.

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

Release the trigger to stop the cutting arc. Gas con­tinues to flow for approximately 20 seconds. During
post - flow, if the user moves the trigger release to
the rear and presses the trigger, the pilot arc starts.
The main arc transfers to the workpiece if the torch
tip is within transfer distance to the workpiece.

Shutdown

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

Manual 0-4989 4-3 OPERATION

cutmaster a120

This Page Intentionally Blank

OPERATION 4-4 Manual 0-4989

cutmaster a120

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

SECTION 4 TORCH:

OPERATION

4T.01 Machine and Automated Torch

Operation

Cutting With Machine or Automated Torch

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

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

Travel Speed

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

1. Straight Arc

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

2. Leading Arc

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

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

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

Piercing With Machine or Automated Torch

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

When operating with a cutting machine, a pierce or
dwell time is required. Torch travel should not be
enabled until the arc penetrates the bottom of the
plate. As motion begins, torch standoff should be
reduced to the recommended 1/8 - 1/4 inch (3-6
mm) distance for optimum speed and cut quality.
Clean spatter and scale from the shield cup and the
tip as soon as possible. Spraying or dipping the
shield cup in anti - spatter compound will minimize
the amount of scale which adheres to it.

3. Trailing Arc

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

Automation and Machine Torch Operation

Manual 0-4989 4T-1 OPERATION

cutmaster a120

Art # A-04173

Electrode

Start Cartridge

Tip

Ohmic Clip
(If Installed)

Torch Head

Shield Cup Body

Shield Cap

Deflector

4T.02 Automation Torch Parts

Selection

Check the torch for proper consumable parts. The
parts supplied in the torch may not be correct for the
operator’s chosen amperage level. The torch parts
must correspond with the type of operation.

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter
Cartridge

NOTE

Refer to Sections 4T.08 and following for
additional information on torch parts.

Change the torch parts for a different operation as
follows:

WARNING

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

NOTE

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

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

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

Automation Torch Parts

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

4. Install the starter cartridge and desired tip

for the operation into the torch head.

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

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

4T.03 Machine and Hand Torch Parts

Selection

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

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter
Cartridge

OPERATION 4T-2 Manual 0-4989

cutmaster a120

Kerf Width

Cut Surface
Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

NOTE

Refer to Section 4T.08 and following for additional
information on torch parts.

Change the torch parts for a different operation as
follows:

WARNING

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

NOTE

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

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

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

4T.04 Cut Quality

NOTES

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 cut-

ting is important when nish cut quality is desired

to avoid a secondary cleaning operation. The
following cut quality characteristics are illustrated

in the following gure:

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

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

4. Install the starter cartridge and desired tip

for the operation into the torch head.

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

Cut Quality Characteristics

Cut Surface

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

Nitride Build - Up

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

Bevel Angle

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

Top - Edge Rounding

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

Manual 0-4989 4T-3 OPERATION

cutmaster a120

!

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

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.05 General Cutting Information

WARNINGS

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

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.

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.

Side Characteristics Of Cut

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

Dross

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

OPERATION 4T-4 Manual 0-4989

cutmaster a120

A-02986

Trigger

Trigger Release

3

4

Art # A-03383

Trigger

2

1

Trigger Release

4T.06 Hand Torch Operation

Standoff Cutting With Hand Torch

NOTE

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

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

NOTE

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

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

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.

2. Depending on the cutting operation, do one
of the following:
a. For edge starts, hold the torch perpen-

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

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

- 3/8 in (3-9 mm) from the workpiece as

shown below.

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

7. Follow normal recommended cutting
practices as provided in the power supply

operator's manual.

Standoff Distance

3. Hold the torch away from your body.

Manual 0-4989 4T-5 OPERATION

cutmaster a120

Shield Cup

Workpiece

Standoff Guide

Art # A-04034

Torch Tip

A-03539

Non-Conductive

Straight Edge
Cutting Guide

A-02986

Trigger

Trigger Release

NOTE

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

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

Shield Cup With Straight Edge

Drag Cutting With a Hand Torch

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

NOTE

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

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

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

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

5. Hold the torch away from your body.

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

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

WARNING

The straight edge must be non - conduc-

tive.

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when cutting
3/16 inch (4.7 mm) solid metal with relatively

smooth surface.

OPERATION 4T-6 Manual 0-4989

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

NOTE

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

3

4

Art # A-03383

Trigger

2

1

Trigger Release

A-02986

Trigger

Trigger Release

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

9. Follow normal recommended cutting
practices as provided in the power supply

operator's manual.

NOTE

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

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.

cutmaster a120

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

4. Hold the torch away from your body.

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

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.

NOTES

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

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

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

Manual 0-4989 4T-7 OPERATION

cutmaster a120

!

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.07 Gouging

WARNINGS

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.

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.

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.

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

CAUTION

Sparks from plasma gouging can cause damage
to coated, painted or other surfaces such as glass,
plastic, and metal.

Check torch parts. The torch parts must
correspond with the type of operation. Refer to
Section 4T.09, Torch Parts Selection.

Gouging Parameters

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

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.

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

OPERATION 4T-8 Manual 0-4989

cutmaster a120

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.

Manual 0-4989 4T-9 OPERATION

cutmaster a120

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

With Exposed Tip

Mild Steel
40A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

20

16

14

12

10

3/16 0.188 111 0.14 55 0.18 0.4 0.06

1/4 0.250 117 0.14 40 0.18 0.5 0.07

3/8 0.375 119 0.14 25 0.18 1.2 0.07

1/2 0.500 120 0.14 15 0.2 2.0 0.07

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.036

0.060 103 0.14 140 0.18 0.0 0.05

0.075 105 0.14 120 0.18 0.1 0.06

0.105 108 0.14 80 0.18 0.2 0.06

0.135 110 0.14 60 0.18 0.3 0.06

70 (25')

75 (50')

Arc Voltage

Volts

101 0.14 160 0.18 0.0 0.05

Tip Starter Cartridge Electrode

9-8208 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

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

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-10 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2

3

4

5

6

8

10

12

Gas Pressure

(Air)

Bar

(torch lead

length)

4.8 (7.6m)

5.2 (15.2m)

BOLD TYPE indicates maximum piercing parameters.

Torch

Arc Voltage

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

101

105 3.6 2920 4.6 0.1 1.4

109 3.6 1810 4.6 0.3 1.5

110 3.6 1470 4.6 0.3 1.6

112 3.6 1345 4.6 0.4 1.6

116 3.6 1100 4.6 0.5 1.7

118 3.6 815 4.6 1.0 1.7

119 3.6 595 4.6 1.5 1.8

120 3.6 435 5.1 2.0 1.8

Working

Height

3.6

Travel Speed

3990 4.6 0.0 1.1

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4989 4T-11 OPERATION

cutmaster a120

Stainless Steel
40A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

18

16

14

12

10

3/16 0.188 110 0.19 30 0.20 0.40 0.07

1/4 0.250 120 0.19 18 0.20 0.50 0.08

3/8 0.375 126 0.19 10 0.20 2.00 0.08

1/2 0.500 118 0.19 8 Edge start 0.09

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.050

0.063 100 0.19 50 0.20 0.00 0.07

0.078 105 0.19 45 0.20 0.10 0.07

0.109 110 0.19 40 0.20 0.20 0.07

0.141 108 0.19 35 0.20 0.30 0.07

75 (25')

80 (50')

Arc Voltage

Volts

110 0.19 60 0.20 0.00 0.07

Tip Starter Cartridge Electrode

9-8208 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

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

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-12 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2

3

4

5

6

8

10

12

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6)

5.5 (15.2)

Torch

Arc Voltage

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

112

105 4.8 1140 5.1 0.1 1.8

109 4.8 980 5.1 0.2 1.8

109 4.8 845 5.1 0.3 1.8

111 4.8 715 5.1 0.4 1.8

118 4.8 525 5.1 0.5 2.0

123 4.8 350 5.1 1.5 2.0

125 4.8 245 5.1 2.0 2.0

120 4.8 215 Edge Start 2.2

Working

Height

4.8

Travel Speed

1670 4.8 0.0 1.7

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4989 4T-13 OPERATION

cutmaster a120

Aluminum
40A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

20

16

12

11

9

3/16 0.188 116 0.18 75 0.18 0.5 0.07

1/4 0.250 128 0.18 30 0.18 1.0 0.08

3/8 0.375 150 0.18 10 Edge Start 0.09

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.040

0.063 97 0.16 170 0.16 0.0 0.06

0.097 113 0.16 100 0.16 0.2 0.07

0.125 115 0.16 90 0.18 0.3 0.07

0.160 113 0.18 85 0.18 0.4 0.07

70 (25')

75 (50')

Arc Voltage

Volts

95 0.16 300 0.16 0.0 0.06

Tip Starter Cartridge Electrode

9-8208 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

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

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-14 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1.0

2.0 104 4.1 3500 4.1 0.2

3.0 115 4.1 2350 4.6 0.3

4.0 113 4.6 2170 4.6 0.4

5.0 118 4.6 1740 4.6 0.5

6.0 125 4.6 1015 4.6 0.8

8.0 139 4.6 500 Edge Start

10.0 153 4.6 180 Edge Start

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

Gas Pressure

(Air)

Bar

(torch lead

length)

4.8 (7.6m)

5.2 (15.2m)

Arc Voltage

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

95 4.1 7620 4.1 0.0

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

1.5

1.6

1.7

1.7

1.8

1.9

2.0

2.2

Manual 0-4989 4T-15 OPERATION

cutmaster a120

Mild Steel
60A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

16

14

11

10

3/16 0.188 121 0.19 100 0.19 0.20 0.08

1/4 0.250 122 0.19 80 0.19 0.30 0.08

3/8 0.375 124 0.19 50 0.19 0.50 0.09

1/2 0.500 132 0.19 26 0.19 0.75 0.10

5/8 0.625 135 0.19 19 Edge Start 0.10

3/4 0.750 136 0.19 14 Edge Start 0.08

1

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.060

0.075 120 0.19 285 0.19 0.10 0.08

0.120 118 0.19 180 0.19 0.10 0.08

0.135 119 0.19 176 0.19 0.10 0.07

85 (25')

90 (50')

1.000 150 0.19 6 Edge Start 0.11

Arc Voltage

Volts

118 0.19 290 0.19 0.00 0.08

Tip Starter Cartridge Electrode

9-8210 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

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

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-16 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2

3

4

5

6

8

10

12

15

20

25

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Torch

Arc Voltage

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

115

120 4.8 7015 4.0 0.10 1.9

118 4.8 4570 4.8 0.10 0.1

120 4.8 3650 4.8 0.20 1.9

121 4.8 2465 4.8 0.20 2.1

122 4.8 2145 4.8 0.30 2.0

123 4.8 1635 4.8 0.40 2.2

125 4.8 1180 4.8 0.60 2.4

130 4.8 795 4.8 0.75 2.4

134 4.8 530 Edge Start 2.4

138 4.8 325 Edge Start 2.2

149 4.8 165 Edge Start 2.7

Working

Height

4.8

Travel Speed

7540 4.8 0 2.1

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4989 4T-17 OPERATION

cutmaster a120

Stainless Steel
60A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

16

14

11

10

3/16 0.188 122 0.19 90 0.20 0.20 0.08

1/4 0.250 123 0.19 65 0.20 0.30 0.09

3/8 0.375 130 0.19 30 0.20 0.50 0.09

1/2 0.500 132 0.19 21 0.20 0.90 0.08

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.063

0.078 116 0.19 300 0.20 0.10 0.07

0.125 123 0.19 150 0.20 0.10 0.07

0.141 118 0.19 125 0.20 0.10 0.08

85 (25')

90 (50')

Arc Voltage

Volts

119 0.19 350 0.20 0.00 0.05

Tip Starter Cartridge Electrode

9-8210 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

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

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

5/8 0.625 132 0.19 14 Edge Start 0.11

3/4 0.750 135 0.19 10 Edge Start 0.10

OPERATION 4T-18 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2

3

4

5

6

8

10

12

15

20

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Torch

Arc Voltage

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

124

116 4.8 7560 5.1 0.10 1.7

122 4.8 4365 5.1 0.10 1.7

119 4.8 2865 5.1 0.20 2.1

122 4.8 2195 5.1 0.20 2.1

123 4.8 1790 5.1 0.30 2.2

127 4.8 1190 5.1 0.40 2.2

130 4.8 725 5.1 0.50 2.2

132 4.8 580 5.1 0.90 2.1

132 4.8 405 Edge Start 2.6

136

Working

Height

4.8

4.8

Travel Speed

10890 5.1 0.00 0.8

230 Edge Start 2.5

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4989 4T-19 OPERATION

cutmaster a120

Aluminum
60A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

16

14

11

3/16 0.188 132 0.25 170 0.25 0.20 0.09

1/4 0.250 132 0.25 85 0.25 0.30 0.09

3/8 0.375 141 0.25 45 0.25 0.50 0.10

1/2 0.500 148 0.25 30 0.25 0.80 0.09

5/8 0.625 145 0.19 18 Edge Start 0.08

3/4 0.750 147 0.19 12 Edge Start 0.10

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.064

0.079 126 0.25 300 0.25 0.10 0.09

0.120 128 0.25 250 0.25 0.10 0.09

85 (25')

90 (50')

Arc Voltage

Volts

123 0.25 440 0.25 0.00 0.08

Tip Starter Cartridge Electrode

9-8210 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

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

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-20 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2 126 6.4 7680 6.4 0.10

3 128 6.4 6410 6.4 0.10

4 130 6.4 5230 6.4 0.20

5 132 6.4 4010 6.4 0.20

6 132 6.4 2640 6.4 0.30

8 137 6.4 1630 6.4 0.40

10 142 6.4 1085 6.4 0.60

12 146 6.4 845 6.4 0.70

15 146 4.8 540

20 148 4.8 260

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

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

118 6.4 17010 6.4 0.00

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Edge Start

Edge Start

Pierce Delay

Kerf Width

@ Rec.

Speed

1.8

2.3

2.3

2.3

2.4

2.4

2.4

2.4

2.3

2.1

2.5

Manual 0-4989 4T-21 OPERATION

cutmaster a120

Mild Steel
80A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

16 0.060

11 0.120

10 0.135

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

7/8 0.875

1 1.000

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

110 0.19 320 0.20

113 0.19 230 0.20

110 0.19 180 0.20

110 0.19 136 0.20

115 0.19 100 0.20

125 0.19 42 0.20

123 0.19 40 0.20

133 0.19 18 0.20

140 0.25 18 Edge Start

150 0.25 10 Edge Start

152 0.25 8 Edge Start

Tip Starter Cartridge Electrode

9-8211

Torch

Working

Height

(in)

9-8213

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

9-8215

0.00

0.10

0.20

0.30

0.40

0.50

0.60 0.09

0.75 0.10

Kerf Width

@ Rec.

Speed

0.06

0.07

0.07

0.07

0.09

0.09

0.11

0.11

0.13

OPERATION 4T-22 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2 111 4.8 7415 5.1 0.10 1.7

3 113

4 110 4.8 4095 5.1 0.30 1.7

5 111

6 114

8 120

10 125

12 123

15 130

20 143

25 152

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

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

109

Torch

Working

Height

4.8

4.8

4.8

4.8

4.8

4.8

4.8

4.8

6.4

6.4

Travel Speed

8915 5.1 0.00 1.5

5915

3325

2745

1775

1060

1025

610

395 Edge Start 2.7

210 Edge Start 3.2

Initial

Piercing

Height

5.1

5.1

5.1

5.1

5.1

5.1

5.1

Pierce Delay

0.10 1.8

0.30 1.8

0.40 2.2

0.50 2.3

0.50 2.3

0.60 2.3

0.75 2.5

Kerf Width

@ Rec.

Speed

Manual 0-4989 4T-23 OPERATION

cutmaster a120

Stainless Steel
80A
Air Plasma / Air Shield

Deector

9-8243

(GA)

16

11

10

Material

Thickness

(in) inch

0.063

0.125

0.141

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4

0.750

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

110 0.19 340 0.25 0.00

115 .0.19 300 0.25 0.10

115 0.19 280 0.25 0.10

115 0.19 140 0.25 0.20

118 0.19 100 0.25 0.30

119 0.19 45 0.25 0.40

124 0.19 26 0.25 0.80 0.10

133 0.19 16 Edge Start 0.10

136 0.19 10 Edge Start 0.11

Tip Starter Cartridge Electrode

9-8211

Torch

Working

Height

(in)

9-8213

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

9-8215

Kerf Width

@ Rec.

Speed

0.06

0.06

0.06

0.07

0.08

0.08

OPERATION 4T-24 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2

3

4

5

6

8

10

12

15

20 137 4.8 205 Edge Start 3.0

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

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

108

111 4.8 8380 6.4 0.00 1.5

114 4.8 7730 6.4 0.10 1.5

115 4.8 5865 6.4 0.20 1.6

115 4.8 3410 6.4 0.20 1.8

117 4.8 2765 6.4 0.30 1.9

119 4.8 1815 6.4 0.40 2.0

120 4.8 1070 6.4 0.60 2.1

123 4.8 765 6.4 0.80 2.3

131 4.8 475 Edge Start 2.5

Torch

Working

Height

4.8

Travel Speed

9020 6.4 0.00 1.5

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4989 4T-25 OPERATION

cutmaster a120

Aluminum
80A
Air Plasma / Air Shield

Deector

9-8243

(GA)

16

11

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Material

Thickness

(in) inch

0.064

0.120

3/16

1/4

3/8

1/2

5/8

3/4

7/8 0.875 153 0.19 10 Edge Start 0.11

0.188

0.250

0.375

0.500

0.625

0.750

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

116 0.25 350 0.25 0.00

120 0.25 280 0.25 0.10

124 0.25 180 0.25 0.20

130 0.25 110 0.25 0.30

136 0.25 55 0.25 0.40

139 0.25 38 0.25 0.60

136 0.19 26 0.25 0.75 0.10

150 0.19 14 Edge Start 0.12

Tip Starter Cartridge Electrode

9-8211

Torch

Working

Height

(in)

9-8213

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

9-8215

Kerf Width

@ Rec.

Speed

0.10

0.10

0.10

0.09

0.11

0.11

OPERATION 4T-26 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2 117 6.4 8420 6.4 0.00 2.5

3 120 6.4 7170 6.4

4 122 6.4 5710 6.4 0.20 2.5

5 125 6.4 4315 6.4

6 129 6.4 3190 6.4

8 133 6.4 2070 6.4

10 136 6.4 1330 6.4

12 138 6.4 1060 6.4

15 137 4.8 745 6.4

20 151 4.8 325 Edge Start 3.0

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

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

114 6.4 8890 6.4

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

0.00

0.10

0.20

0.30

0.40

0.50

0.50

0.75

Kerf Width

@ Rec.

Speed

2.4

2.5

2.5

2.4

2.5

2.7

2.9

2.5

Manual 0-4989 4T-27 OPERATION

cutmaster a120

Mild Steel
100A
Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

1-1/4 1.250 128 0.18 8

Material

Thickness

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Gas Pressure

(Air)

Arc Voltage

Volts

110 0.18 85 0.20 0.10 0.09

112 0.18 75 0.20

115 0.18 45 0.20

118 0.18 30 0.20

120 0.18 20 0.20

123 0.18 15 Edge Start

Arc Voltage

Tip Starter Cartridge Electrode

9-8212

Torch

Working

Height

(in)

Torch

Working

Height

9-8213

Initial

Travel Speed

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

Travel Speed

Piercing

Height

Edge Start

Initial

Piercing

Height

Pierce Delay

Pierce Delay

9-8215

0.20

0.40

0.60

1.20 0.12

Kerf Width

@ Rec.

Speed

0.09

0.10

0.11

0.12

0.13

Kerf Width

@ Rec.

Speed

Bar

(mm)

6

8 111 4.6 2030 5.1 0.10 2.3

10 112

12 114 4.6 1310 5.1 0.40 2.5

15 117

20 120

25 123

30 127

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

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

OPERATION 4T-28 Manual 0-4989

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

110

4.6

4.6

4.6

4.6

4.6

4.6

2200 5.1 0.10 2.3

1790

870

490

390

250

5.1

5.1

5.0

Edge Start

Edge Start

0.20 2.3

0.60 2.7

1.20 3.0

3.0

3.2

Stainless Steel
100A
Air Plasma / Air Shield

cutmaster a120

Deector

9-8243

Thickness

(GA)

Thickness

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Material

(in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000 135

Material

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Gas Pressure

(Air)

Arc Voltage

Volts

Arc Voltage

Tip Starter Cartridge Electrode

9-8212

Torch

Working

Height

(in)

102 0.16 100

106 0.16 65

109

123 0.19 20

128 0.19 15 Edge Start 0.12

0.16 45

0.19 10 Edge Start 0.13

Torch

Working

Height

Travel Speed

Travel Speed

9-8213

Initial

Piercing

Height

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

0.18

0.18

0.18

0.23

Initial

Piercing

Height

Pierce Delay

Pierce Delay

9-8215

Kerf Width

@ Rec.

Speed

0.00 0.09

0.10 0.10

0.30 0.10

2.00 0.11

Kerf Width

@ Rec.

Speed

Bar

(mm)

6

8 104 4.1 2080 4.6 0.10 2.4

10 106

12 108 4.1 1255 4.6 0.30 2.4

15 119

20 129

25 135

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

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

Manual 0-4989 4T-29 OPERATION

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

102

4.1

4.1

4.6

4.8

4.8

2630 4.6 0.00 2.3

1575

685

360

260

4.6

5.7 2.00

Edge Start

Edge Start

0.20 2.4

2.7

3.1

3.2

cutmaster a120

Aluminum
100A
Air Plasma / Air Shield

Deector

9-8243

Thickness

(GA)

Thickness

Material

(in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

Material

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Gas Pressure

(Air)

Arc Voltage

Volts

Arc Voltage

Tip Starter Cartridge Electrode

9-8212 9-8213 9-8215

Torch

Working

Height

(in)

110 0.19 100 0.20

124 0.19 65 0.20

128 0.19 45 0.20

132 0.19 35 0.20

135 0.19 20 0.20 2.00 0.13

140 0.19 10 Edge Start 0.13

Torch

Working

Height

Travel Speed

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

Travel Speed

Initial

Piercing

Height

Initial

Piercing

Height

Pierce Delay

0.00

0.20

0.30

0.50

Pierce Delay

Kerf Width

@ Rec.

Speed

0.09

0.10

0.11

0.11

Kerf Width

@ Rec.

Speed

Bar

(mm)

6

8 117 4.8 2080 5.1 0.10 2.5

10 125

12 127 4.8 1255 5.1 0.30 2.7

15 131

20 136

25 140

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

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

OPERATION 4T-30 Manual 0-4989

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

109

4.8

4.8

4.8

4.8

4.8

2630 5.1 0.00 2.3

1575

960

470

270

5.1

5.1 0.50

6.0 2.00

Edge Start

0.20 2.7

2.8

3.3

3.4

cutmaster a120

This Page Intentionally Blank

Manual 0-4989 4T-31 OPERATION

cutmaster a120

Mild Steel
120A
Air Plasma / Air Shield

Deector

9-8243

Thickness

(GA)

1-1/4 1.250

1-1/2 1.500

Material

(in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

7/8 0.875

1 1.000

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Arc Voltage

Volts

Tip Starter Cartridge Electrode

9-8253

Torch

Working

Height

(in)

134 0.19 150 0.25

141 0.19 85 0.25

141 0.19 70 0.25

146 0.19 45 0.25

150 0.19 30 0.25

160 0.25 25 Edge Start 0.14

163 0.25 19 Edge Start

168 0.25 12 Edge Start

172 0.25 8 Edge Start

Travel Speed

9-8213

Initial

Piercing

Height

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

Pierce Delay

0.10

0.30

0.80

1.00

1.20

9-8215

Kerf Width

@ Rec.

Speed

0.11

0.11

0.12

0.12

0.12

0.14

0.15

0.16

OPERATION 4T-32 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

6.0

8.0 138 4.8 2950 6.4 0.2 2.7

10.0 141

12.0 141 4.8 1860 6.4 0.6 2.9

15.0 145

20.0 153

25.0 163

30.0 167

35.0 170

40.0 173

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Arc Voltage

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

133

Torch

Working

Height

4.8

4.8

4.8

4.8

6.4

6.4

6.4

6.4

Travel Speed

3990 6.4 0.1 2.5

2100

1320

720

500

355

255

175

Initial

Piercing

Height

6.4

6.4

6.4

Edge Start

Edge Start

Edge Start

Edge Start

Pierce Delay

0.4 2.8

1.0 3.0

1.2 3.2

Kerf Width

@ Rec.

Speed

3.6

3.8

4.0

4.2

Manual 0-4989 4T-33 OPERATION

cutmaster a120

Stainless Steel
120A
Air Plasma / Air Shield

Deector

9-8243

Thickness

(GA)

1-1/4 1.250

Thickness

Material

(in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

Material

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Gas Pressure

(Air)

Arc Voltage

Volts

Arc Voltage

Tip Starter Cartridge Electrode

9-8253

Torch

Working

Height

(in)

133 0.19 180 0.25

136 0.19 100 0.25

140 0.19 60 0.25

152 0.25 40 0.30

154 0.25 26 Edge Start 0.14

159 0.25 16 Edge Start 0.14

167 0.25 8 Edge Start

Torch

Working

Height

Travel Speed

Travel Speed

9-8213

Initial

Piercing

Height

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

Initial

Piercing

Height

Pierce Delay

Pierce Delay

0.20

0.40

0.80

1.20

9-8215

Kerf Width

@ Rec.

Speed

0.10

0.11

0.11

0.13

0.14

Kerf Width

@ Rec.

Speed

Bar

(mm)

6

8 135 4.8 3520 6.4 0.2 2.7

10 137

12 139 4.8 1750 6.4 0.8 2.9

15 149

20 155

25 159

30 165

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

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

OPERATION 4T-34 Manual 0-4989

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

133

4.8

4.8

6.4

6.4

6.4

6.4

4800 6.4 0.2 2.6

2390

1160

625

425

260

6.4

7.6 1.2

Edge Start

Edge Start

Edge Start

0.5 2.8

3.4

3.6

3.6

3.6

Aluminum
120A
Air Plasma / Air Shield

cutmaster a120

Deector

9-8243

Thickness

(GA)

Thickness

Material

(in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

Material

Standard Shield Cup

Maximum Life Shield Cup

9-8218
9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Gas Pressure

(Air)

Arc Voltage

Volts

139 0.19 180 0.25

140 0.19 110 0.25

143 0.19 75 0.25

156 0.25 50 0.30

161 0.25 34 Edge Start 0.13

167 0.25 23 Edge Start 0.14

Arc Voltage

Tip Starter Cartridge Electrode

9-8253

Torch

Working

Height

(in)

Torch

Working

Height

9-8213

Initial

Travel Speed

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

Travel Speed

Piercing

Height

Initial

Piercing

Height

Pierce Delay

Pierce Delay

9-8215

0.30

0.50

0.80

1.00

Kerf Width

@ Rec.

Speed

0.11

0.11

0.11

0.12

Kerf Width

@ Rec.

Speed

Bar

(mm)

6

8 140 4.8 3650 6.4 0.2 2.8

10 140

12 142 4.8 2100 6.4 0.8 2.8

15 152

20 162

25 167

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

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Manual 0-4989 4T-35 OPERATION

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

139

4.8

4.8

6.4

6.4

6.4

4770 6.4 0.2 2.8

2660

1445

820

600

6.4

7.6 1.2

Edge Start

Edge Start

0.5 2.8

3.0

3.4

3.4

cutmaster a120

4T.09 Recommended Cutting Speeds for Machine and Automated Torches

With Shielded Tip

Mild Steel
40A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8245 9-8237 9-8208 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

20

16

14

12

10

3/16 0.188 115 0.16 65 0.16 0.4 0.07

1/4 0.250 118 0.16 45 0.16 0.5 0.07

3/8 0.375 123 0.16 23 0.16 1.2 0.08

1/2 0.500 128 0.16 18 0.16 2.0 0.08

Material

Thickness

0.036

0.060 113 0.16 120 0.16 0.0 0.06

0.075 108 0.16 90 0.16 0.1 0.06

0.105 111 0.16 75 0.16 0.2 0.06

0.135 114 0.16 65 0.16 0.3 0.07

(mm)

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Gas Pressure

(Air)

Bar

(torch lead

length)

Arc Voltage

Volts

107 0.16 130 0.16 0.0 0.06

Arc Voltage

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

Torch

Working

Height

(in)

Torch

Working

Height

Travel Speed

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

Travel Speed

Initial

Piercing

Height

Initial

Piercing

Height

Pierce Delay

Pierce Delay

Kerf Width

@ Rec.

Speed

Kerf Width

@ Rec.

Speed

1

2

3

4

5

6

8

10

12

5.2 (7.6)

5.5 (15.2)

BOLD TYPE indicates maximum piercing parameters.

OPERATION 4T-36 Manual 0-4989

108

108 4.1 2239 4.1 0.0 1.5

112 4.1 1794 4.1 0.1 1.7

114 4.1 1651 4.1 0.2 1.7

115 4.1 1578 4.1 0.3 1.7

117 4.1 1256 4.1 0.4 1.7

121 4.1 853 4.1 0.5 1.7

124 4.1 565 4.1 1.2 1.8

127 4.1 485 4.1 2.0 1.9

4.1

3266

4.1

0.0 1.4

cutmaster a120

Stainless Steel
40A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8245 9-8237 9-8208 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

18

16

14

12

10

3/16 0.188 115 0.16 30 4.1 0.4 0.07

1/4 0.250 118 0.16 20 4.1 1.2 0.07

3/8 0.375 125 0.16 15 4.1 1.8 0.08

1/2 0.500 127 0.16 10 4.1 2.0 0.08

Material

Thickness

0.050

0.063 108 0.16 50 4.1 0.1 0.07

0.078 114 0.16 45 4.1 0.1 0.07

0.109 113 0.16 40 4.1 0.2 0.07

0.141 116 0.16 35 4.1 0.3 0.07

(mm)

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Gas Pressure

(Air)

Bar

(torch lead

length)

Arc Voltage

Volts

110 0.16 60 4.1 0.0 0.06

Arc Voltage

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

Torch

Working

Height

(in)

Torch

Working

Height

Travel Speed

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

Travel Speed

Initial

Piercing

Height

Initial

Piercing

Height

Pierce Delay

Pierce Delay

Kerf Width

@ Rec.

Speed

Kerf Width

@ Rec.

Speed

1

2

3

4

5

6

8

10

12

5.2 (7.6)

5.5 (15.2)

Manual 0-4989 4T-37 OPERATION

109

114 4.1 1140 4.1 0.1 1.8

114 4.1 980 4.1 0.2 1.8

116 4.1 845 4.1 0.3 1.8

BOLD TYPE indicates maximum piercing parameters.

115 4.1 725 4.1 0.4 1.8

117 4.1 565 4.1 0.5 2.0

122 4.1 440 4.1 1.5 2.0

125 4.1 360 4.1 1.8 2.0

127 4.1 280 4.1 2.0 2.2

4.1

1670 4.1 0.0 1.7

cutmaster a120

Aluminum
40A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8245 9-8237 9-8208 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

20

16

12

11

9

3/16 0.188 128 0.19 70 0.20 0.5 0.07

1/4 0.250 137 0.19 30 0.20 1.0 0.08

3/8 0.375 145 0.19 10 0.20 2.0 0.09

Material

Thickness

0.040

0.063 113 0.19 170 0.20 0.1 0.07

0.097 120 0.19 100 0.20 0.2 0.07

0.125 125 0.19 90 0.20 0.3 0.07

0.160 126 0.19 85 0.20 0.4 0.07

(mm)

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Gas Pressure

(Air)

Bar

(torch lead

length)

Arc Voltage

Volts

110 0.19 300 0.20 0.0 0.06

Arc Voltage

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

Torch

Working

Height

(in)

Torch

Working

Height

Travel Speed

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

Travel Speed

Initial

Piercing

Height

Initial

Piercing

Height

Pierce Delay

Pierce Delay

Kerf Width

@ Rec.

Speed

Kerf Width

@ Rec.

Speed

1.0

2.0 116 4.8 3490 5.1 0.2

3.0 124 4.8 2350 5.1 0.3

4.0 126 4.8 2170 5.1 0.4

5.0 129 4.8 1630 5.1 0.6

6.0 135 4.8 990

8.0 141 4.8 500 5.1 1.6 2.0

5.2 (7.6)

5.5 (15.2)

10.0 146 4.8 180 5.1 2.1 2.3

BOLD TYPE indicates maximum piercing parameters.

OPERATION 4T-38 Manual 0-4989

110 4.8 7660 5.1 0.0

5.1 1.0

1.6

1.8

1.8

1.8

1.8

1.9

cutmaster a120

This Page Intentionally Blank

Manual 0-4989 4T-39 OPERATION

cutmaster a120

Mild Steel
60A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8238 9-8237 9-8210 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

16

14

11

10

3/16 0.188 132 0.19 115 0.20 0.20 0.09

1/4 0.250 134 0.19 80 0.20 0.30 0.08

3/8 0.375 132 0.19 34 0.20 0.70 0.10

1/2 0.500 144 0.19 23 0.20 0.75 0.10

5/8 0.625 150 0.19 14 Edge Start 0.10

3/4 0.750 145 0.19 14 Edge Start 0.10

0.060

0.075 129 0.19 237 0.20 0.10 0.09

0.120 126 0.19 200 0.20 0.10 0.08

0.135 128 0.19 142 0.20 0.10 0.09

1

1.000 160 0.19 4 Edge Start 0.12

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

128 0.19 250 0.20 0.00 0.09

Torch

Working

Height

(in)

Travel Speed

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

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-40 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2

3

4

5

6

8

10

12

15

20

25

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Torch

Arc Voltage

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

127

129 4.8 5942 5.1 0.10 2.2

126 4.8 5080 5.1 0.10 0.1

130 4.8 3316 5.1 0.20 2.3

132 4.8 2794 5.1 0.20 2.2

134 4.8 2230 5.1 0.30 2.1

133 4.8 1425 5.1 0.40 2.3

134 4.8 822 5.1 0.60 2.5

141 4.8 646 5.1 0.75 2.5

148 4.8 419 Edge Start 2.6

147 4.8 318 Edge Start 2.7

159 4.8 118 Edge Start 3.0

Working

Height

4.8

Travel Speed

6804 5.1 0 2.2

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4989 4T-41 OPERATION

cutmaster a120

Stainless Steel
60A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8238 9-8237 9-8210 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

16

14

11

10

3/16 0.188 125 0.13 75 0.20 0.20 0.09

1/4 0.250 127 0.13 60 0.20 0.30 0.08

3/8 0.375 134 0.13 28 0.20 0.50 0.08

1/2 0.500 136 0.19 17 0.25 0.75 0.09

5/8 0.625 131 0.13 14 Edge Start 0.08

3/4 0.750 142 0.19 10 Edge Start 0.11

0.063

0.078 116 0.13 155 0.20 0.10 0.07

0.125 118 0.13 125 0.20 0.10 0.07

0.141 126 0.13 80 0.20 0.10 0.09

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

110 0.13 165 0.20 0.00 0.06

Torch

Working

Height

(in)

Travel Speed

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

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-42 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2

3

4

5

6

8

10

12

15

20

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Torch

Arc Voltage

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

101

116 3.3 3925 5.1 0.10 1.7

118 3.3 3285 5.1 0.10 1.7

126 3.3 1985 5.1 0.20 2.2

125 3.3 1850 5.1 0.20 2.1

127 3.3 1605 5.1 0.30 2.1

131 3.3 1100 5.1 0.40 2.1

134 3.3 670 5.1 0.50 2.1

136 4.8 490 6.4 0.90 2.2

132 3.3 375 Edge Start 2.6

144

Working

Height

3.3

4.8

Travel Speed

4590 5.1 0.00 1.2

230 Edge Start 2.5

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4989 4T-43 OPERATION

cutmaster a120

Aluminum
60A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8238 9-8237 9-8210 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

16

14

11

3/16 0.188 125 0.13 140 0.20 0.20 0.08

1/4 0.250 132 0.13 80 0.20 0.30 0.08

3/8 0.375 135 0.13 45 0.20 0.50 0.08

1/2 0.500 140 0.13 26 0.20 0.80 0.08

5/8 0.625 148 0.19 18 Edge start 0.10

3/4 0.750 155 0.19 12 Edge start 0.11

0.064

0.079 118 0.13 350 0.20 0.10 0.08

0.120 123 0.13 275 0.20 0.10 0.08

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

118 0.13 350 0.20 0.00 0.07

Torch

Working

Height

(in)

Travel Speed

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

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-44 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2 118 6.4 8890 6.4 0.10

3 123 6.4 7070 6.4 0.10

4 124 6.4 5095 6.4 0.20

5 126 6.4 3335 6.4 0.20

6 130 6.4 2370

8 134 6.4 1570 6.4 0.40 2.0

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

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

118 6.4 8890 6.4 0.00

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

6.4 0.30

Pierce Delay

10 136 6.4 1070 6.4 0.60 2.0

12 139 6.4 765 6.4 0.70 2.0

15 146 4.8 515 Edge start 2.4

20 157 4.8 260 Edge start 2.7

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

Kerf Width

@ Rec.

Speed

2

2.0

2.1

2.0

2.0

2.0

Manual 0-4989 4T-45 OPERATION

cutmaster a120

Mild Steel
80A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8239 9-8237 9-8211

Material

Thickness

(GA)

(in) inch

16

11

10

3/16 0.188 122 0.19 135 0.20 0.30 0.08

1/4 0.250 127 0.19 100 0.20 0.40 0.09

3/8 0.375 134 0.19 40 0.20 0.50 0.10

1/2 0.500 136 0.19 36 0.20 0.60 0.10

5/8 0.625 145 0.19 18 Edge Start 0.11

3/4 0.750 147 0.19 14 Edge Start 0.11

7/8

1.000

0.060

0.120 112 0.13 190 0.20 0.10 0.06

0.135 110 0.13 176 0.20 0.20 0.06

0.875 146 0.19 10 Edge Start

1.000 152 0.187 8 Edge Start

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

115 0.13 280 0.20 0.00 0.06

Torch

Working

Height

(in)

Travel Speed

9-8213

Initial Piercing

Height

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

Pierce Delay

9-8215

Kerf Width

@ Rec.

Speed

0.12

0.13

OPERATION 4T-46 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2 114

3 112

4 115

5 123

6 126 4.8 2735 5.1 0.40 2.2

8 131 4.8 1745 5.1 0.50 2.5

10 134 4.8 1000 5.1 0.50 2.6

12 136 4.8 935 5.1 0.60 2.6
15 143 4.8 580 5.1 0.80 2.8

20 147 4.8 325 Edge Start 2.9

25 151 4.8 210 Edge Start 3.2

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

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

116

Torch

Working

Height

3.3

3.3

3.3

4.8

4.8

Travel Speed

7895

6395

4895

4025

3300

Initial Piercing

Height

5.1 0.00

5.1

5.1

5.1

5.1

Pierce Delay

0.10 1.6

0.10 1.5

0.30 1.7

0.30 2.0

Kerf Width

@ Rec.

Speed

1.6

Manual 0-4989 4T-47 OPERATION

cutmaster a120

Stainless Steel
80A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8239 9-8237 9-8211

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

114 0.125 340 0.2 0.00

115 0.125 260 0.2 0.10

116 0.125 250 0.2 0.10

115 0.125 170 0.2 0.20

118 0.125 85 0.2 0.30

127 0.19 45 0.25 0.40

136 0.19 16 0.25 0.75 0.11

143 0.19 10 Edge Start 0.12

146 0.19 8 Edge Start 0.11

(GA)

16

11

10

Material

Thickness

(in) inch

0.063

0.125

0.141

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4

0.750

Torch

Working

Height

(in)

9-8213

Travel Speed

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

Initial Piercing

Height

Pierce Delay

9-8215

Kerf Width

@ Rec.

Speed

0.06

0.06

0.06

0.07

0.08

0.09

OPERATION 4T-48 Manual 0-4989

cutmaster a120

Material

Thickness

(mm)

1

2

3

4

5

6

8

10

12

15

20 147 4.8 185 Edge Start 2.8

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

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

114

114 3.2 8120 5.1 0.00 1.4

115 3.2 6830 5.1 0.10 1.4

116 3.2 5635 5.1 0.20 1.5

115 3.2 4010 5.1 0.20 1.8

117 3.2 2640 5.1 0.30 2.0

123 4.8 1630 6.4 0.40 2.1

128 4.8 1030 6.4 0.60 2.2

134 4.8 565 6.4 0.75 2.6

141 4.8 295 Edge Start 3.0

Torch

Working

Height

3.2

Travel Speed

9410

Initial Piercing

Height

5.1 0.00

Pierce Delay

Kerf Width

@ Rec.

Speed

1.5

Manual 0-4989 4T-49 OPERATION

cutmaster a120

Aluminum
80A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8239 9-8237 9-8211

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Gas Pressure

(Air)

Bar

(torch lead

length)

Arc Voltage

Volts

115 0.13 320 0.2 0.00

120 0.13 240 0.2 0.10

122 0.13 165 0.2 0.20

124 0.13 100 0.2 0.30

140 0.19 60 0.2 0.40

142 0.19 36 0.2 0.60

148 0.19 26 0.2 0.75 0.11

155 0.19 16 Edge Start 0.12

Arc Voltage

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

(GA)

16

11

Material

Thickness

(in) inch

0.064

0.120

3/16

1/4

3/8

1/2

5/8

3/4

Material

Thickness

0.188

0.250

0.375

0.500

0.625

0.750

(mm)

Torch

Working

Height

(in)

Torch

Working

Height

9-8213

Initial

Travel Speed

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

Travel Speed

Piercing

Height

Initial

Piercing

Height

Pierce Delay

Pierce Delay

9-8215

Kerf Width

@ Rec.

Speed

0.09

0.08

0.08

0.10

0.09

0.11

Kerf Width

@ Rec.

Speed

OPERATION 4T-50 Manual 0-4989

cutmaster a120

1

2 116 3.3 7595 5.1

3 120 3.3 6165 5.1

4 121 3.3 5045 5.1

5 122 3.3 3955 5.1

6 124 3.3 2905 5.1 0.30 2.3

8 132 4.8 2010 5.1 0.40 2.3

10 140 4.8 1430 5.1 0.50 2.3

12 142 4.8 1045 5.1 0.60 2.6

15 146 4.8 730 5.1 0.75 2.7

20 157 4.8 330 Edge Start 3.2

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

5.9 (7.6m)

6.2 (15.2m)

113 3.3 9020 5.1

0.00

0.00

0.10

0.20

0.20

2.4

2.2

2.0

2.1

2.2

Manual 0-4989 4T-51 OPERATION

cutmaster a120

Mild Steel
100A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8239 9-8237 9-8253 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

1-1/4 1.250 135 0.16 8

Material

Thickness

(mm)

6 114

8 113

10 112

12 114

15 121

20 128 4.1 475 5.0 0.80 2.8

25 133 4.1 315 Edge Start 2.9

30 134 4.1 230 Edge Start 3.1

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

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Gas Pressure

(Air)

Bar

(torch lead

length)

Arc Voltage

Volts

114 0.16 85 0.18 0.00 0.08

112 0.16 70 0.18 0.20 0.09

115 0.16 40 0.18 0.30 0.10

123 0.16 30 0.18 0.40 0.10

127 0.16 20 0.18 0.80 0.11

133 0.16 12 Edge Start 0.12

Arc Voltage

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

Torch

Working

Height

(in)

Torch

Working

Height

4.1

4.1

4.1

4.1

4.1

Initial

Travel Speed

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

Travel Speed

2210

1960

1665

1185

830

Piercing

Height

Initial

Piercing

Height

4.6 0.00

4.6

4.6

4.6

4.6

Pierce Delay

Edge Start

Pierce Delay

0.10 2.2

0.20 2.3

0.30 2.4

0.40 2.5

Kerf Width

@ Rec.

Speed

0.12

Kerf Width

@ Rec.

Speed

2.0

OPERATION 4T-52 Manual 0-4989

cutmaster a120

Stainless Steel
100A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8239 9-8237 9-8212

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts

114 0.16 110 0.18 0.00 0.08

116 0.16 70 0.18 0.10 0.09

119 0.16 45 0.18 0.30 0.10

130 0.19 20 0.23 2.00 0.11

135 0.19 15 0.23 2.80 0.11

140 0.19 10 Edge Start 0.11

Arc Voltage

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

114

(GA)

Material

Thickness

(in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

Material

Thickness

(mm)

6

8 115

10 116

12 118

15 127

20 136 4.8 360 5.7 2.80 2.8

25 140 4.8 260 Edge Start 2.8

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

Torch

Working

Height

(in)

Torch

Working

Height

4.1

4.1

4.1

4.1

4.6

9-8213

Initial

Travel Speed

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

Travel Speed

2900

2265

1685

1285

685

Piercing

Height

Initial

Piercing

Height

4.6 0.00

4.6

4.6

4.6

5.7

Pierce Delay

Pierce Delay

9-8215

0.10 2.2

0.20 2.4

0.30 2.4

2.00 2.7

Kerf Width

@ Rec.

Speed

Kerf Width

@ Rec.

Speed

2.0

Manual 0-4989 4T-53 OPERATION

cutmaster a120

Aluminum
100A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8239 9-8237 9-8212 9-8213 9-8215

(GA)

Material

Thickness

(in) inch

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4 0.750

1 1.000

Material

Thickness

(mm)

6

8 125

10 130

12 134

15 134

20 139 4.6 595 6.0 2.00 3.0

25 143

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

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

75 (50')

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts

121 0.18 110 0.19 0.00 0.10

129 0.18 60 0.19 0.20 0.10

135 0.18 45 0.19 0.30 0.11

133 0.18 32 0.19 0.60 0.11

138 0.18 25 0.19 2.00 0.11

143 0.18 15 Edge Start 0.14

Arc Voltage

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

120

Torch

Working

Height

(in)

Torch

Working

Height

4.6

4.6

4.6

4.6

4.6

4.6

Travel Speed

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

Travel Speed

2920

2135

1470

1230

905

395

Initial

Piercing

Height

Initial

Piercing

Height

4.8 0.00

4.8

4.8

4.8

4.8

Edge Start

Pierce Delay

Pierce Delay

0.10 2.5

0.20 2.6

0.30 2.7

0.60 2.9

Kerf Width

@ Rec.

Speed

Kerf Width

@ Rec.

Speed

2.5

3.6

OPERATION 4T-54 Manual 0-4989

cutmaster a120

Mild Steel
120A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8256 9-8237 9-8253

Material

Thickness

(GA)

(in) inch

1/4 0.250

3/8 0.375 140 0.125 85 0.20 0.20 0.11

1/2

5/8 0.625 144 0.125 45 0.20 0.70 0.11

3/4 0.750 150 0.125 30 0.25 1.50 0.12

7/8 0.875 158 0.175 25 Edge Start 0.13

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

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

Material

Thickness

0.500 142 0.125 75 0.20 0.50 0.10

1 1.000 160 0.175 22 Edge Start 0.14

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Gas Pressure

(Air)

Arc Voltage

Volts

139 0.125 160 0.20 0.20 0.11

Arc Voltage

Torch

Working

Height

(in)

Torch

Working

Height

Travel Speed

Travel Speed

9-8213

Initial

Piercing

Height

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

Initial

Piercing

Height

Pierce Delay

Pierce Delay

9-8215

Kerf Width

@ Rec.

Speed

Kerf Width

@ Rec.

Speed

Bar

(mm)

6

8 140

10 140

12 142

15 143

20 152 4.8 725 6.4 1.6 3.1

25 160 4.8 570 Edge Start 3.6

30 164 4.8 430 Edge Start 4.0

35 168 4.8 290 Edge Start 4.3

40 173 4.45 150 Edge Start 4.4

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

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Manual 0-4989 4T-55 OPERATION

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

139

4.8

4.8

6.4

6.4

4.8

4270

3070

2120

1960

1355

5.08 0.20

5.1

5.08

5.08

5.08

0.2 2.8

0.30 2.8

0.50 2.8

0.70 2.8

2.8

cutmaster a120

Stainless Steel
120A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8256 9-8237 9-8253 9-8215

Material

Thickness

(GA)

(in) inch

1/4 0.250

3/8 0.375 140 0.13 100 0.20 0.40 0.12

1/2

5/8 0.625 152 0.15 40 0.25 1.00 0.12

3/4 0.750 150 0.15 26 Edge Start 0.13

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

Material

Thickness

0.500 142 0.15 65 0.25 0.80 0.12

1 1.000 155 0.15 16 Edge Start 0.13

(mm)

6

8 140

10 140

12 142

15 149

20 151 6.4 620 Edge Start 3.3

25 155 6.4 420 Edge Start 3.3

30 162 6.4 260 Edge Start 3.3

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

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Gas Pressure

(Air)

Bar

(torch lead

length)

5.5 (7.6m)

5.5 (15.2m)

Arc Voltage

Volts

140 0.13 180 0.20 0.30 0.11

Arc Voltage

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

140

Torch

Working

Height

(in)

Torch

Working

Height

4.8

4.8

4.8

4.8

6.4

Travel Speed

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

Travel Speed

4800

3520

2410

1850

1190

Initial

Piercing

Height

Initial

Piercing

Height

5.1 0.3

5.1

5.1

6.4

6.4

Pierce Delay

Pierce Delay

0.4 2.7

0.6 3.0

0.8 3.1

1.0 3.1

Kerf Width

@ Rec.

Speed

Kerf Width

@ Rec.

Speed

2.8

OPERATION 4T-56 Manual 0-4989

cutmaster a120

Aluminum
120A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8256 9-8237 9-8253

Gas Pressure

(Air)

PSI

(torch lead

length)

80 (25')

80 (50')

Gas Pressure

(Air)

Bar

(torch lead

length)

Arc Voltage

Volts

140 0.13 180 0.20 0.20 0.10

Arc Voltage

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

(GA)

Material

Thickness

(in) inch

1/4 0.250

3/8 0.375 142 0.13 110 0.20 0.30 0.11

1/2

5/8 0.625 156 0.15 45 0.25 0.80 0.11

3/4 0.750 158 0.15 35 Edge Start 0.11

Material

Thickness

0.500 148 0.13 75 0.20 0.50 0.11

1 1.000 164 0.15 23 Edge Start 0.12

(mm)

Torch

Working

Height

(in)

Torch

Working

Height

9-8213

Initial

Travel Speed

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

Travel Speed

Piercing

Height

Initial

Piercing

Height

Pierce Delay

Pierce Delay

9-8215

Kerf Width

@ Rec.

Speed

Kerf Width

@ Rec.

Speed

6

8 141

10 143

12 147

15 154

20 159 4.8 845 Edge Start 2.9

25 164 4.8 605 Edge Start 3.0

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

5.5 (7.6m)

5.5 (15.2m)

Manual 0-4989 4T-57 OPERATION

140

4.8

4.8

4.8

4.8

4.8

4770

3650

2660

2100

1355

5.1 0.2

5.1

5.1

5.1

6.4

0.3 2.6

0.4 2.7

0.5 2.8

0.8 2.8

2.6

cutmaster a120

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 4T-58 Manual 0-4989

cutmaster a120

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 0-4989 4T-59 OPERATION

cutmaster a120

This Page Intentionally Blank

OPERATION 4T-60 Manual 0-4989

SECTION 5 SYSTEM:

5.01 General Maintenance

cutmaster a120

SERVICE

Manual 0-4989 5-1 SERVICE

cutmaster a120

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:

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.

5.03 Common Faults

Problem - Symptom Common Cause

Insufficient

Penetration

Main Arc

Extinguishes

Excessive Dross

Formation

Short Torch Parts Life1. Oil or moisture in air source.

Difficult Starting 1. Worn torch parts.

1. Cutting speed too fast.

2. Torch tilted too much.

3. Metal too thick.

4. Worn torch parts

5. Cutting current too low.

6. Non - Genuine Thermal Dynamics
parts used

7. Incorrect gas pressure

1. Cutting speed too slow.

2. Torch standoff too high from
workpiece.

3. Cutting current too high.

4. Work cable disconnected.

5. Worn torch parts.

6. Non - Genuine Thermal Dynamics
parts used

1. Cutting speed too slow.

2. Torch standoff too high from
workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine Thermal Dynamics
parts used

6. Incorrect gas pressure

2. Exceeding system capability
(material too thick).

3. Excessive pilot arc time

4. Gas pressure too low.

5. Improperly assembled torch.

6. Non - Genuine Thermal Dynamics
parts used

2. Non - Genuine Thermal Dynamics
parts used.

3. Incorrect gas pressure.

SERVICE 5-2 Manual 0-4989

5.04 Fault Indicator

A

+

PSI BAR

MAX MAX

MIN MIN

!

1

2

3

4

Art# A-07988

MIN

MAX

0

1

2

3

4

5

6

7

5

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

To determine the first digit, count the function indicators
left to right, 1 through 5. To determine the second digit
count the pressure indicators, reading from bottom to
top, 0 through 7. In the example below the Temp indica­tor and 76 psi indicators are on indicating the version
would be 2.3.

cutmaster a120

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

Pressure

Fault

Indicator

Max Over Pressure

90 Internal Error

85 Shorted Torch

80 Consumables Missing

75 Start Error

70 Parts in Place

65 Input Power

Min Under Pressure

Fault explantions are covered in the following
tables.

NOTE

Manual 0-4989 5-3 SERVICE

cutmaster a120

5.05 Basic Troubleshooting Guide

WARNING

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

Problem - Symptom Possible Cause Recommended Action

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

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 5-4 Manual 0-4989

cutmaster a120

Problem - Symptom Possible Cause Recommended Action

FAULT & 80 PSI
indicators flashing.
Gas flow is cycling on
and off.

1. Torch shield cup is loose.

2. Torch tip, electrode or starter
cartridge missing.

3. Torch start cartridge is stuck.

4. Open conductor in torch leads.

5. Problem in the torch and leads
switch circuit.

6. 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 start cartridge. Check start
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.

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

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

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

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

FAULT and 85 PSI
indicators flashing.

No Fault lights on, no
arc in torch.

FAULT and 85 PSI
indicators flashing

Pilot arc is on but
cutting arc will not
establish

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

2. CNC Contoller device not
providing Start signal.

3. Failed components in unit.

1. 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

1. Work cable not connected to
work piece.

2. Work cable/connector broken.

3. Failed components in unit.

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.

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 autorized service center for repair or replacement.

does not 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.

Torch cutting is
diminished

Manual 0-4989 5-5 SERVICE

1. Incorrect current setting.

2. Worn torch consumables.

3. Poor work cable connection to
work piece.

4. Torch being moved too fast.

5. Excessive oil or water in torch.

6. Failed components in unit.

1. Check and adjust to proper setting.

2. Check torch consumables and replace as needed.

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

4. Reduce cutting speed.

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

6. Return to an authorized service center for repair.

cutmaster a120

Art # A-08429

Lower
Screws

Lower
Screws

Slots

Upper
Screws

Art # A-07989

1

2

3

4

5

6mm

5.06 Power Supply Basic Parts
Replacement

WARNING

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

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

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).

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.

3. Tighten lower screws.

4. Reinstall and tighten the upper screws.

SERVICE 5-6 Manual 0-4989