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ESAB A120 Operating Manual

Automated plasma cutting system
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CUTMASTER
AUTOMATED PLASMA CUTTING SYSTEM
Operating
Manual
Revision: AA
Issue Date: August 30, 2015
A120
®
OUTPUT
MAX OUTPUT
INPUT POWER
120
PHASE
AMPS
Manual No.: 0-5430
INPUT POWER
VOLTAGE
VOLTAGE
208-230V
380-400V
PHASE
esab.eu
Art # A-12879
VOLTAGE
VOLTAGE
460V
600V

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Summary of Contents for ESAB A120

  • Page 1 CUTMASTER A120 ® AUTOMATED PLASMA CUTTING SYSTEM Operating Manual Art # A-12879 OUTPUT MAX OUTPUT INPUT POWER INPUT POWER VOLTAGE VOLTAGE VOLTAGE VOLTAGE 460V 600V 208-230V 380-400V PHASE PHASE AMPS esab.eu Revision: AA Issue Date: August 30, 2015 Manual No.: 0-5430...
  • Page 2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This prod- uct is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on the web at www.esab.eu.
  • Page 3 2800 Airport Rd. Denton, TX 76208 (940) 566-2000 www.esab.eu Copyright 2015 by ESAB All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negli- gence, accident, or any other cause.
  • Page 4 Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equip- ment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,”...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY .......................1-1 Safety Precautions..................1-1 SECTION 2 SYSTEM: INTRODUCTION .................2-1 2.01 How To Use This Manual................2-1 2.02 Equipment Identification ................2-1 2.03 Receipt Of Equipment ................2-1 2.04 Power Supply Specifications ..............2-2 2.05 Input Wiring Specifications .................2-3 2.06 Power Supply Features ................2-4 SECTION 2 TORCH: INTRODUCTION ................

  • Page 7: Table Of Contents

    TABLE OF CONTENTS PATENT INFORMATION ....................4T-70 SECTION 5 SYSTEM: SERVICE .....................5-1 5.01 General Maintenance ..................5-1 5.02 Maintenance Schedule ................5-2 5.03 Common Faults ..................5-2 5.04 Fault Indicator .....................5-3 5.05 Basic Troubleshooting Guide ..............5-4 5.06 Power Supply Basic Parts Replacement ............5-6 SECTION 5 TORCH: SERVICE ....................

  • Page 8: Section 1: Safety

    SECTION 1: SAFETY Safety Precautions Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment.
  • Page 9 CUTMASTER A120 Arc welding and cutting can be injurious to yourself and others. Take WARNING precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill. - Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.

  • Page 10: Section 2 System: Introduction

    Include the Owner’s Manual number and equipment identifica- tion numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the ESAB web site listed below http://www.esab.eu 0-5430...

  • Page 11: Power Supply Specifications

    Output Current 30 - 120 Amps, Continuously Adjustable Power Supply Gas Filtering Ability Particulates to 5 Microns Cutmaster A120 Power Supply Duty Cycle * Ambient Temperature Duty Cycle Ratings @ 40° C (104° F) Operating Range 0° - 50° C...

  • Page 12: Input Wiring Specifications

    CUTMASTER A120 2.05 Input Wiring Specifications Cutmaster A120 Power Supply Input Cable Wiring Requirements Input Freq Power Suggested Sizes voltage Input Volts I max I eff Fuse Flexible Cord Flexible Cord (amps) (Min. AWG) (Min. mm 1 Phase 26.2 4 Type W 25 Type W 27.6...

  • Page 13: Power Supply Features

    CUTMASTER A120 2.06 Power Supply Features Art # A-08460 Control Panel Torch Leads Receptacle Mounting Rails Work Cable and Clamp Automation Interface Cable Port Input Power Selection Filter Assembly Gas Inlet Port Input Power Cord Art # A-08461 INTRODUCTION 0-5430...

  • Page 14: Section 2 Torch: Introduction

    CUTMASTER A120 SECTION 2 TORCH: The standard automation torch has a position- ing tube with rack & pinch block assembly and a INTRODUCTION solenoid valve. 18.875" / 479 mm 2T.01 Scope of Manual 12.285" / 312 mm 2.875” / 73 mm...

  • Page 15: T.04 Options And Accessories

    CUTMASTER A120 12 VDC circuit rating 2T.05 Introduction to Plasma E. Type Cooling A. Plasma Gas Flow Combination of ambient air and gas stream through Plasma is a gas which has been heated to an torch. extremely high temperature and ionized so that it becomes electrically conductive.
  • Page 16 CUTMASTER A120 gas in blowing the molten metal out of the cut allow- Remote Pendant ing for a fast, slag - free cut. B. Gas Distribution The single gas used is internally split into plasma PIP Switch Shield Cup To ATC and secondary gases.
  • Page 17 CUTMASTER A120 This Page Intentionally Blank INTRODUCTION 0-5430 2T-4...

  • Page 18: Section 3 System: Installation

    CUTMASTER A120 SECTION 3 SYSTEM: 2. Place the unit in the desired position and mark where the four keyway holes in the mounting rails INSTALLATION touch. 3.01 Unpacking 3. Remove the unit and using these markings, prepare holes for mounting hardware.
  • Page 19 CUTMASTER A120 Most units are shipped from the factory with a 230 Volt NOTE! input power cable wired to the input contactor in the When installing the upper screws, at- single - phase configuration. The following illustrations tempt to reuse the original threads. The...

  • Page 20: Gas Connections

    CUTMASTER A120 1. Remove the Power Supply cover. 3. Loosen the through-hole protector on the back See "A. Cover Removal". panel of the power supply. Pull the original power cable out of the power supply. 2. Disconnect the original input power cable from the main input contactor and the chassis ground 4.
  • Page 21 CUTMASTER A120 Filter Assembly Filter Assembly Inlet Port Inlet Port Hose Clamp Gas Supply Hose Art # A-08319 Art # A-08320 Hose Clamp 1/4 NPT or ISO-R to 1/4” (6mm) Fitting 1/4 NPT to 1/4" Gas Supply Air Connection to Inlet Port...
  • Page 22 CUTMASTER A120 Connect the air supply as follows: NOTE! Pressure should be set at 100 psi 1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with (6.9 bar) at the high pressure cylin- the filter assembly.
  • Page 23 CUTMASTER A120 This Page Intentionally Blank INSTALLATION 0-5430...

  • Page 24: Section 3 Torch: Installation

    3T.01 Torch Connections Cable Port If necessary, connect the torch to the Power Supply. Connect only the ESAB model SL100SV / Automation, SL100 / Mechanical or SL100 / Manual Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions.

  • Page 25: T.03 Automation Interface Pcb With Ohmic Sense

    CUTMASTER A120 3T.03 Automation Interface PCB with Ohmic Sense The new Automation Interface PCB with Ohmic Sense adds additional selectable divided voltage ratios and selectable polarity of the divided signal. The board also has Ohmic sensing for use with the iHC XT via either the exposed torch tip or via a separate Shield Cup using the Ohmic clip.

  • Page 26: T.04 Setting Up Automation Or Machine Torch

    CUTMASTER A120 DIVIDE RATIO SET BY DIP SW DIV1 DIV1-1 ON = 16.7:1 for SC11 DIV1-4 ON = 40:1 for Inova DIV1-2 ON = 20:1 for ESAB DIV1-5 ON = 50:1 for IHT: DIV1-3 ON = 30:1 SC3000 & 3100; Hypertherm ®...
  • Page 27 CUTMASTER A120 Pinch Block Assembly Square Workpiece A-02585 Automated and Machine Torch Set - Up 3. The proper torch parts (shield cup, tip, start car- tridge, and electrode) must be installed for the type of operation. Refer to Section 4T.08, Torch Parts Selection for details.

  • Page 28: Section 4 System: Operation

    CUTMASTER A120 SECTION 4 SYSTEM: OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification 1. Output Current Control Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or higher for standoff cutting.

  • Page 29: Preparations For Operation

    (10) minute period Check that the torch is properly connected. Only once the condition is cleared. ESAB model SL100 / Manual or SL100 / Mechani- cal Torches may be connected to this Power Supply. Set Operating Pressure See Section 3T of this manual.
  • Page 30 And with the knob in the LATCH position the main cutting arc will be maintained after Art# A-07946 the torch switch is released. STANDOFF Cutmaster A120 Gas Pressure Settings Typical Cutting Speeds SL100 Cutting speeds vary according to torch output am- SL100...
  • Page 31 CUTMASTER A120 This Page Intentionally Blank OPERATION 0-5430...

  • Page 32: Section 4 Torch: Operation

    CUTMASTER A120 SECTION 4 TORCH: Automation and Machine Torch Operation OPERATION For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge 4T.01 Machine and Automated Torch of the arc column produces the cut. If the travel...

  • Page 33: T.03 Machine And Hand Torch Parts Selection

    CUTMASTER A120 4T.03 Machine and Hand Torch Parts WARNING Selection Disconnect primary power at the source before assembling or disassembling Depending on the type of operation to be done deter- torch parts, or torch and leads assem- mines the torch parts to be used.

  • Page 34: T.04 Cut Quality

    CUTMASTER A120 Top - Edge Rounding 3. Install the replacement Electrode by pushing it straight into the torch head until it clicks. Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the 4 .

  • Page 35: T.06 Hand Torch Operation

    CUTMASTER A120 4T.06 Hand Torch Operation the bevel angle. Reducing standoff will generally result in a more square cut. Standoff Cutting With Hand Torch Edge Starting NOTE! For edge starts, hold the torch perpendicular to the For best performance and parts life,...
  • Page 36 CUTMASTER A120 Trigger Shield Cup Standoff Guide Trigger Release Torch Tip A-02986 Workpiece Art # A-04034 5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and Shield Cup With Straight Edge the pilot arc will shut OFF.
  • Page 37 CUTMASTER A120 6. Slide the trigger release toward the back of the back end for maximum heat protection. Choose torch handle while simultaneously squeezing the the technique that feels most comfortable and trigger. The pilot arc will start. allows good control and movement.

  • Page 38: T.07 Gouging

    CUTMASTER A120 • Air quality Lead Angle • Line voltage fluctuations The angle between the torch and workpiece depends on the output current setting and torch travel speed. • Torch standoff height The recommended lead angle is 35°. At a lead angle •...

  • Page 39: T.08 Recommended Cutting Speeds For Machine And Automated Torches With Exposed Tip

    CUTMASTER A120 4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208...
  • Page 40 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3990 2920 1810 1470 4.8 (7.6m) 1345 5.2 (15.2m)
  • Page 41 CUTMASTER A120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 42 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 1670 1140 5.2 (7.6) 5.5 (15.2) Edge Start BOLD TYPE indicates maximum piercing parameters.
  • Page 43 CUTMASTER A120 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working...
  • Page 44 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7620 3500 2350 4.8 (7.6m) 2170 1740 5.2 (15.2m)
  • Page 45 CUTMASTER A120 Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 46 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7540 7015 0.10 4570 0.10 3650 0.20...
  • Page 47 CUTMASTER A120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 48 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 10890 0.00 7560 0.10 4365 0.10 2865 0.20...
  • Page 49 CUTMASTER A120 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working...
  • Page 50 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 17010 0.00 7680 0.10 6410 0.10 5230 0.20...
  • Page 51 CUTMASTER A120 Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 52 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8915 0.00 7415 0.10 5915 0.10 4095 0.30...
  • Page 53 CUTMASTER A120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 54 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 9020 0.00 8380 0.00 7730 0.10 5865 0.20...
  • Page 55 CUTMASTER A120 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working...
  • Page 56 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 8890 8420 0.00 0.10 7170 5710 0.20...
  • Page 57 CUTMASTER A120 Mild Steel 100A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8213 9-8218 9-8243 9-8212 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 58 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2200 0.10 2030 0.10 1790 0.20 5.2 (7.6m)
  • Page 59 CUTMASTER A120 Stainless Steel 100A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-821 9-8243 9-8212 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 60 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2630 0.00 2080 0.10 1575 0.20 5.2 (7.6m)
  • Page 61 CUTMASTER A120 Aluminum 100A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8212 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 62 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2630 0.00 2080 0.10 1575 0.20 5.2 (7.6m)
  • Page 63 CUTMASTER A120 Mild Steel 120A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8233 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 64 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3990 2950 10.0 2100 12.0 1860 5.5 (7.6m)
  • Page 65 CUTMASTER A120 Stainless Steel 120A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8233 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 66 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 4800 3520 2390 5.5 (7.6m) 1750 1160 5.5 (15.2m)
  • Page 67 CUTMASTER A120 Aluminum 120A Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8233 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 68 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 4770 3650 2660 5.5 (7.6m) 2100 5.5 (15.2m)
  • Page 69 CUTMASTER A120 This Page Intentionally Blank OPERATION 0-5430 4T-38...
  • Page 70 CUTMASTER A120 This Page Intentionally Blank 0-5430 OPERATION 4T-39...

  • Page 71: T.09 Recommended Cutting Speeds For Machine And Automated Torches With Shielded Tip

    CUTMASTER A120 4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277...
  • Page 72 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3266 2239 1794 1651 5.2 (7.6) 1578 5.5 (15.2)
  • Page 73 CUTMASTER A120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 74 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 1670 1140 5.2 (7.6) 5.5 (15.2) BOLD TYPE indicates maximum piercing parameters.
  • Page 75 CUTMASTER A120 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 76 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7660 3490 2350 5.2 (7.6) 2170 1630 5.5 (15.2)
  • Page 77 CUTMASTER A120 Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 78 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 6804 5942 0.10 5080 0.10 3316 0.20...
  • Page 79 CUTMASTER A120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 80 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 4590 0.00 3925 0.10 3285 0.10 1985 0.20...
  • Page 81 CUTMASTER A120 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 82 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8890 0.00 8890 0.10 7070 0.10 5095 0.20...
  • Page 83 CUTMASTER A120 Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec.
  • Page 84 CUTMASTER A120 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 7895 6395 0.10 4895 0.10 4025 0.30...
  • Page 85 CUTMASTER A120 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec.
  • Page 86 CUTMASTER A120 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 9410 8120 0.00 6830 0.10 5635 0.20...
  • Page 87 CUTMASTER A120 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 88 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 9020 0.00 7595 0.10 6165 0.20...
  • Page 89 CUTMASTER A120 Mild Steel 100A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8233 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 90 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 2210 1960 0.10 1665 0.20 1185 0.30...
  • Page 91 CUTMASTER A120 Stainless Steel 100A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8212 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 92 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 2900 0.00 2265 0.10 1685 0.20 5.2 (7.6m)
  • Page 93 CUTMASTER A120 Aluminum 100A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8212 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 94 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 2920 2135 0.10 1470 0.20 5.2 (7.6m)
  • Page 95 CUTMASTER A120 Mild Steel 120A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8256 9-8237 9-8233 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 96 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 5.08 0.20 4270 3070 5.08 2120 0.30...
  • Page 97 CUTMASTER A120 Stainless Steel 120A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8256 9-8237 9-8233 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 98 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 4800 3520 2410 5.5 (7.6m) 1850 5.5 (15.2m)
  • Page 99 CUTMASTER A120 Aluminum 120A Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8256 9-8237 9-8233 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 100 CUTMASTER A120 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 4770 3650 2660 5.5 (7.6m) 2100 5.5 (15.2m)

  • Page 101: Patent Information

    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 9-8232 Electrode US Pat No(s) 6163008; 6987238...
  • Page 102 CUTMASTER A120 Catalog # Description Patent(s) 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 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:...
  • Page 103 CUTMASTER A120 This Page Intentionally Blank OPERATION 0-5430 4T-72...

  • Page 104: Section 5 System: Service

    CUTMASTER A120 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the cables and leads. Replace as needed...

  • Page 105: Maintenance Schedule

    Daily Operational Checks or Every Six Cutting 4. Worn torch parts Hours: 5. Cutting current too low. 6. Non - Genuine ESAB parts used 1. Check torch consumable parts, replace if dam- 7. Incorrect gas pressure aged or worn. 2. Check plasma and secondary supply and pres- Main Arc 1.

  • Page 106: Fault Indicator

    CUTMASTER A120 5.04 Fault Indicator At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7.

  • Page 107: Basic Troubleshooting Guide

    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 trouble- shooting techniques. Problem - Symptom Possible Cause...
  • Page 108 CUTMASTER A120 Problem - Symptom Possible Cause Recommended Action FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten. indicators flashing. 2. Torch tip, electrode or starter 2. Turn OFF power supply. Remove shield cup. Install Gas flow is cycling cartridge missing.

  • Page 109: Power Supply Basic Parts Replacement

    CUTMASTER A120 C. Filter Element Assembly Replacement 5.06 Power Supply Basic Parts Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be WARNING checked per the Maintenance Schedule (Subsection Disconnect primary power to the system 5.02), and either cleaned or replaced.
  • Page 110 CUTMASTER A120 5. Remove the fitting from the filter element as- Optional Single-Stage Filter Element Replacement sembly by inserting a 6 mm hex wrench into the These instructions apply to power supplies where the internal hex fitting and turning it counter clock- optional Single-Stage Filter has been installed.
  • Page 111 CUTMASTER A120 Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unac- ceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.

  • Page 112: Section 5 Torch: Service

    CUTMASTER A120 SECTION 5 TORCH: SERVICE Upper Groove 5T.01 General Maintenance with Vent Holes Must Remain Open NOTE! Refer to Previous "Section 5 System" Upper O-Ring for common and fault indicator descrip- in Correct Groove tions. Threads Cleaning Torch Lower O-Ring...

  • Page 113: T.02 Inspection And Replacement Of Consumable Torch Parts

    CUTMASTER A120 Good Tip Worn Tip 5T.02 Inspection and Replacement of Consumable Torch Parts WARNING Disconnect primary power to the system before disassembling the torch or torch A-03406 leads. Example of Tip Wear DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

  • Page 114: Section 6: Parts Lists

    With 208/230 single phase input power cable and plug 0559317341 With 460 single phase input power cable 0559317342 Cutmaster A120 Non CE Power Supply 400VAC, With 400V, 3 Phase input power cable 0559317343 Cutmaster A120 CE Power Supply 400VAC, With 400V, 3 Phase input power cable...

  • Page 115: Replacement Power Supply Parts

    CUTMASTER A120 6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115 Filter Assembly Replacement Element 9-0116 Input Power Cord for 208 / 230 V Power Supply 9-0191 Input Power Cord for 400 V Power Supply 9-0216 6.05 Options and Accessories...
  • Page 116 CUTMASTER A120 This Page Intentionally Blank 0-5430 PARTS LIST...
  • Page 117 CUTMASTER A120 Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit 6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) Item No. Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14)
  • Page 118 CUTMASTER A120 Art # A-07113 0-5430 PARTS LIST...

  • Page 119: Torch Consumable Parts (Sl100)

    CUTMASTER A120 6.07 Torch Consumable Parts (SL100) Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243 9-8218 9-8208...

  • Page 120: Replacement Parts For Hand Torch

    CUTMASTER A120 6.08 Replacement Parts for Hand Torch Item # Description Catalog # Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 Trigger Assembly Replacement Kit 9-7034 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 Torch Head Assembly Replacement Kit (includes items No.
  • Page 121 CUTMASTER A120 This Page Intentionally Blank PARTS LIST 0-5430...
  • Page 122 CUTMASTER A120 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: RUN / Rapid Auto Restart / ON / OFF switch to ON Close external RUN / SET / LATCH disconnect switch. Rapid Auto Restart / switch to RUN...

  • Page 123: Appendix 2: Data Tag Information

    CUTMASTER A120 APPENDIX 2: DATA TAG INFORMATION Manufacturer's Name and/or Logo, Location, Model and Serial Number M odel : and Production Code Dat e of M f r : Type of Power Regulatory Standard Covering 1/ 3 Supply (Note 1)
  • Page 124 CUTMASTER A120 0-5430 APPENDIX...

  • Page 125: Appendix 3: Torch Pin - Out Diagrams

    CUTMASTER A120 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Ground 4 - Green /...
  • Page 126 CUTMASTER A120 B. Mechanized (Machine) Torch Pin - Out Diagram ATC Female Receptacle UNSHIELDED MACHINE TORCH ATC Male Connector Front View Front View Negative / Plasma Negative / Plasma 8 - Green - 4- Black - Pendant Pendant Connector 4 - Switch...

  • Page 127: Appendix 4: Torch Connection Diagrams

    CUTMASTER A120 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power Torch Torch Supply...
  • Page 128 CUTMASTER A120 B. Mechanized Torch Connection Diagram Torch: Unshielded Mechanized SL100 Machine Torch Leads: Leads with ATC Connector and Remote Pendant Connector To Remote Control Power Supply: with ATC Female Receptacle Remote ATC Female Male Pendant Receptacle ATC Leads Connector...

  • Page 129: Appendix 5: System Schematic, 208/460V Units

    CUTMASTER A120 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS PRI 3 PRI 3 PRI 4 PRI 4 BIAS SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 INRUSH +12VDC RESISTORS PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1 MTH2...
  • Page 130 PILOT IGBT WORK1 WORK1 WORK WORK /PIP /START 24VAC RETURN CNC INTERFACE STANDARD ON A80 & A120 UNITS 24VAC SUPPLY CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS OK TO MOVE CNC PINOUT OK-TO-MOVE (5A @ 250VAC / 30VDC) +12VDC...

  • Page 131: Appendix 6: System Schematic, 400/600V Units

    CUTMASTER A120 APPENDIX 6: SYSTEM SCHEMATIC, 400/600V UNITS PRI 4 PRI 4 PRI 3 PRI 3 BIAS SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 INRUSH +12VDC RESISTORS PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1 MTH2...
  • Page 132 PILOT IGBT WORK1 WORK1 WORK WORK /PIP /START 24VAC RETURN CNC INTERFACE STANDARD ON A80 & A120 UNITS 24VAC SUPPLY CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS CNC PINOUT OK TO MOVE OK-TO-MOVE (5A @ 250VAC / 30VDC) +12VDC...

  • Page 133: Appendix 7: Raw Arc Voltage

    CUTMASTER A120 APPENDIX 7: RAW ARC VOLTAGE If raw arc voltage is necessary for the torch height control, the customer must supply an 18 AWG (1.0 mm2), single pair, unshielded cable rated for 300V or greater. All work must be performed following applicable local and national codes.
  • Page 134 CUTMASTER A120 Art # A-10288_AB Work2 (+) Polarity -V_out2 (-) Polarity 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control . 0-5430 APPENDIX A-13...

  • Page 135: Revision History

    CUTMASTER A120 Revision History Date Description 09/25/2015 Manual release APPENDIX 0-5430 A-14...
  • Page 136 This page intentionally blank.
  • Page 137 ESAB Asia/Pacific Pte Ltd ESAB Nederland B.V. Singapore Amersfoort Tel: +65 6861 43 22 Tel: +31 33 422 35 55 Fax: +65 6861 31 95 Fax: +31 33 422 35 44 www.esab.eu Printed in China ©2015 ESAB Welding and Cutting Products...

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