A80 A120

DUTY CYCLE

80 120 80% 380/400V

AMPSAMPS

CUTMASTER A80, A120

®

AUTOMATED PLASMA CUTTING SYSTEM

Operating
Manual

Revision: AK Issue Date: February 11, 2015 Manual No.: 0-5119

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

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 ! WARNING
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Plasma Cutting Power Supply

CutMaster™ A80 SL100SV Torch™ Operating Manual No.: 0-5119
CutMaster™ A120 SL100SV Torch™ Operating Manual No.: 0-5119

Published by:
Victor Technologies, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711

www.thermal-dynamics.com

Copyright 2008, 2009, 2010, 2012, 2014, 2015 by

Victor Technologies International, Inc.

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.

Original Publication Date: December 10, 2008

Revision Date: February 11, 2015

Record the following information for Warranty purposes:

Where Purchased:_________________________________________________

Purchase Date:____________________________________________________

Power Supply Serial #:_____________________________________________

Torch Serial #:_____________________________________________________

i
 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...................................................................................................1-8

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...........................................................................................................3-3

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
 TABLE OF CONTENTS
4T.05 General Cutting Information........................................................................................ 4T-4
4T.06 Hand Torch Operation.................................................................................................. 4T-4
4T.07 Gouging 4T-7
4T.08 Recommended Cutting Speeds for Machine and Automated Torches With
Exposed Tip................................................................................................................. 4T-9
4T.09 Recommended Cutting Speeds for Machine and Automated Torches With
Shielded Tip............................................................................................................... 4T-24

PATENT INFORMATION................................................................................................................. 4T-39

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

SECTION 5 TORCH:
SERVICE.................................................................................................................................. 5T-1
5T.01 General Maintenance.................................................................................................. 5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts........................................... 5T-2

SECTION 6:
PARTS LISTS.............................................................................................................................6-1
6.01 Introduction....................................................................................................................6-1
6.02 Ordering Information......................................................................................................6-1
6.03 Power Supply Replacement..........................................................................................6-1
6.04 Replacement Power Supply Parts.................................................................................6-2
6.05 Options and Accessories...............................................................................................6-2
6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)..............6-4
6.07 Torch Consumable Parts (SL100)..................................................................................6-6
6.08 Replacement Parts for Hand Torch ...............................................................................6-7

APPENDIX 1: SEQUENCE OF OPERATION

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

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

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

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

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

APPENDIX 6: SYSTEM SCHEMATIC, 380V/400V-600V UNITS...................................................... A-8

APPENDIX 7: RAW ARC VOLTAGE ............................................................................................... A-10

APPENDIX 8: PUBLICATION HISTORY......................................................................................... A-12

INTERNATIONAL CONTACT INFORMATION................................................................. REAR COVER

This Page Intentionally Blank
 CUTMASTER A80, A120
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warn- GASES AND FUMES
ings are used to highlight important information. Gases and fumes produced during the plasma cut-
These highlights are categorized as follows: ting process can be dangerous and hazardous to your
NOTE health.

An operation, procedure, or background infor- • Keep all fumes and gases from the breathing area.
mation which requires additional emphasis or Keep your head out of the welding fume plume.
is helpful in efficient operation of the system. • Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
CAUTION depend on the kind of metal being used, coatings
A procedure which, if not properly followed, on the metal, and the different processes. You
may cause damage to the equipment. must be very careful when cutting or welding
any metals which may contain one or more of
the following:
! WARNING
Antimony Chromium Mercury
Arsenic Cobalt Nickel
A procedure which, if not properly followed, Barium Copper Selenium
may cause injury to the operator or others in Beryllium Lead Silver
the operating area. 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
WARNING information regarding the kind and amount of
fumes and gases that may be dangerous to your
Gives information regarding possible electrical
health.
shock injury. Warnings will be enclosed in a
box such as this. • For information on how to test for fumes and
gases in your workplace, refer to item 1 in Sub-
section 1.03, Publications in this manual.
1.02 Important Safety Precautions • 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
WARNING located.
OPERATION AND MAINTENANCE OF • Phosgene, a toxic gas, is generated from the
PLASMA ARC EQUIPMENT CAN BE vapors of chlorinated solvents and cleansers.
DANGEROUS AND HAZARDOUS TO Remove all sources of these vapors.
YOUR HEALTH. • WARNING: This product contains chemicals,
Plasma arc cutting produces intense electric and including lead, known to the State of California
magnetic emissions that may interfere with the to cause birth defects and other reproductive
proper function of cardiac pacemakers, hear- harm. Wash hands after handling.
ing aids, or other electronic health equipment.
Persons who work near plasma arc cutting ap-
plications should consult their medical health
professional and the manufacturer of the health ELECTRIC SHOCK
equipment to determine whether a hazard exists. Electric Shock can injure or kill. The plasma arc process
To prevent possible injury, read, understand uses and produces high voltage electrical energy. This
and follow all warnings, safety precautions and electric energy can cause severe or fatal shock to the
instructions before using the equipment. Call operator or others in the workplace.
1-603-298-5711 or your local distributor if you
have any questions.

Manual 0-5119 GENERAL INFORMATION 1-1

CUTMASTER A80, A120
• Never touch any parts that are electrically “live”
or “hot.”
• Wear dry gloves and clothing. Insulate yourself PLASMA ARC RAYS
from the work piece or other parts of the welding Plasma Arc Rays can injure your eyes and burn your
circuit. skin. The plasma arc process produces very bright
• Repair or replace all worn or damaged parts. ultra violet and infra red light. These arc rays will
• Extra care must be taken when the workplace is damage your eyes and burn your skin if you are not
moist or damp. properly protected.
• Install and maintain equipment according to • To protect your eyes, always wear a welding
NEC code, refer to item 9 in Subsection 1.03, helmet or shield. Also always wear safety glasses
Publications. with side shields, goggles or other protective eye
• Disconnect power source before performing any wear.
service or repairs. • Wear welding gloves and suitable clothing to
• Read and follow all the instructions in the Oper- protect your skin from the arc rays and sparks.
ating Manual. • Keep helmet and safety glasses in good condi-
tion. Replace lenses when cracked, chipped or
dirty.
FIRE AND EXPLOSION • Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
Fire and explosion can be caused by hot slag, sparks,
• Use the shade of lens as suggested in the follow-
or the plasma arc.
ing per ANSI/ASC Z49.1:
• Be sure there is no combustible or flammable Minimum Protective Suggested
material in the workplace. Any material that Arc Current Shade No. Shade No.
cannot be removed must be protected. Less Than 300* 8 9
• Ventilate all flammable or explosive vapors from 300 - 400* 9 12
the workplace.
400 - 800* 10 14
• Do not cut or weld on containers that may have
* These values apply where the actual arc is
held combustibles.
clearly seen. Experience has shown that lighter
• Provide a fire watch when working in an area filters may be used when the arc is hidden by
where fire hazards may exist. the workpiece.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table LEAD WARNING
unless the hydrogen gas can be eliminated or
dissipated. Trapped hydrogen gas that is ignited WARNING: This product contains chemicals, includ-
will cause an explosion. ing lead, known to the State of California to cause birth
defects and other reproductive harm. Wash hands
after handling.

NOISE
Noise can cause permanent hearing loss. Plasma arc
1.03 Publications
processes can cause noise levels to exceed safe limits. Refer to the following standards or their latest revi-
You must protect your ears from loud noise to prevent sions for more information:
permanent loss of hearing. 1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent
• To protect your hearing from loud noise, wear of Documents, U.S. Government Printing Office,
protective ear plugs and/or ear muffs. Protect Washington, D.C. 20402
others in the workplace. 2. ANSI Standard Z49.1, SAFETY IN WELDING AND
• Noise levels should be measured to be sure the CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126
decibels (sound) do not exceed safe levels.
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
• For information on how to test for noise, see item AND GAS WELDING AND CUTTING, obtainable
1 in Subsection 1.03, Publications, in this manual. from the Superintendent of Documents, U.S. Govern-
ment Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
1-2 GENERAL INFORMATION Manual 0-5119
 CUTMASTER A80, A120
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broad-
way, New York, NY 10018
! AVERTISSEMENT
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE Toute procédure pouvant provoquer des bles-
USE OF CUTTING AND WELDING PROCESSES, sures de l’opérateur ou des autres personnes se
obtainable from American National Standards Insti-
tute, 1430 Broadway, New York, NY 10018 trouvant dans la zone de travail en cas de non-
7. AWS Standard A6.0, WELDING AND CUTTING
respect de la procédure en question.
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126
AVERTISSEMENT
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO- Fournit l'information concernant des dommages
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
possibles de choc électrique. Des avertissements
seront enfermés dans une boîte de ce type.
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
1.05 Precautions De Securite
PROCESSES, obtainable from the National Fire Pro- Importantes
tection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson Davis
! AVERTISSEMENTS
Highway, Suite 501, Arlington, VA 22202 L’OPÉRATION ET LA MAINTENANCE DU
12. CSA Standard W117.2, CODE FOR SAFETY IN MATÉRIEL DE SOUDAGE À L’ARC AU JET
WELDING AND CUTTING, obtainable from the DE PLASMA PEUVENT PRÉSENTER DES
Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W RISQUES ET DES DANGERS DE SANTÉ.
1R3 Coupant à l’arc au jet de plasma produit de
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY l’énergie électrique haute tension et des émissions
obtainable from the National Welding Supply Associa- magnétique qui peuvent interférer la fonction
tion, 1900 Arch Street, Philadelphia, PA 19103 propre d’un “pacemaker” cardiaque, les appareils
14. American Welding Society Standard AWSF4.1, auditif, ou autre matériel de santé electronique.
RECOMMENDED SAFE PRACTICES FOR THE
Ceux qui travail près d’une application à l’arc
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE HELD au jet de plasma devrait consulter leur membre
HAZARDOUS SUBSTANCES, obtainable from the professionel de médication et le manufacturier
American Welding Society, 550 N.W. LeJeune Rd, de matériel de santé pour déterminer s’il existe
Miami, FL 33126 des risques de santé.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-
TORY PROTECTION, obtainable from American Il faut communiquer aux opérateurs et au per-
National Standards Institute, 1430 Broadway, New sonnel TOUS les dangers possibles. Afin d’éviter
York, NY 10018 les blessures possibles, lisez, comprenez et suivez
tous les avertissements, toutes les précautions de
sécurité et toutes les consignes avant d’utiliser le
1.04 Note, Attention et Avertissement matériel. Composez le + 603-298-5711 ou votre
Dans ce manuel, les mots “note,” “attention,” et distributeur local si vous avez des questions.
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
NOTE
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
Toute opération, procédure ou renseignement
plasma peuvent présenter des risques et des dangers
général sur lequel il importe d’insister davantage
de santé.
ou qui contribue à l’efficacité de fonctionnement
du système. • Eloignez toute fumée et gaz de votre zone de respi-
ration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
ATTENTION • Utilisez un appareil respiratoire à alimentation en
Toute procédure pouvant résulter l’endomma- air si l’aération fournie ne permet pas d’éliminer la
gement du matériel en cas de non-respect de la fumée et les gaz.
procédure en question.

Manual 0-5119 INFORMATIONS GÉNÉRALES 1-3

CUTMASTER A80, A120
• Les sortes de gaz et de fumée provenant de l’arc de • Débranchez l’alimentation électrique avant tout
plasma dépendent du genre de métal utilisé, des travail d’entretien ou de réparation.
revêtements se trouvant sur le métal et des différents
• Lisez et respectez toutes les consignes du Manuel
procédés. Vous devez prendre soin lorsque vous
de consignes.
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel INCENDIE ET EXPLOSION
arsenic cobalt plomb
Les incendies et les explosions peuvent résulter des
baryum cuivre sélénium
scories chaudes, des étincelles ou de l’arc de plasma.
béryllium manganèse vanadium
Le procédé à l’arc de plasma produit du métal, des
• Lisez toujours les fiches de données sur la sécurité étincelles, des scories chaudes pouvant mettre le feu
des matières (sigle américain “MSDS”); celles-ci aux matières combustibles ou provoquer l’explosion
devraient être fournies avec le matériel que vous de fumées inflammables.
utilisez. Les MSDS contiennent des renseignements
• Soyez certain qu’aucune matière combustible ou
quant à la quantité et la nature de la fumée et des
inflammable ne se trouve sur le lieu de travail.
gaz pouvant poser des dangers de santé.
Protégez toute telle matière qu’il est impossible de
• Pour des informations sur la manière de tester la retirer de la zone de travail.
fumée et les gaz de votre lieu de travail, consultez
• Procurez une bonne aération de toutes les fumées
l’article 1 et les documents cités à la page 5.
inflammables ou explosives.
• Utilisez un équipement spécial tel que des tables de
• Ne coupez pas et ne soudez pas les conteneurs ayant
coupe à débit d’eau ou à courant descendant pour
pu renfermer des matières combustibles.
capter la fumée et les gaz.
• Prévoyez une veille d’incendie lors de tout travail
• N’utilisez pas le chalumeau au jet de plasma dans
dans une zone présentant des dangers d’incendie.
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs. • Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
• Le phosgène, un gaz toxique, est généré par la fumée
sont coupées sous l’eau ou sur une table d’eau. NE
provenant des solvants et des produits de nettoyage
PAS couper les alliages en aluminium sous l’eau ou
chlorés. Eliminez toute source de telle fumée.
sur une table d’eau à moins que le gas hydrogène
• AVERTISSEMENT: Ce produit contient des pro- peut s’échapper ou se dissiper. Le gas hydrogène
duits chimiques, notamment du plomb, reconnu par accumulé explosera si enflammé.
l'État de la Californie pour causer des malforma-
tions congénitales et d'autres dommages touchant
le système reproductif. Se laver les mains après
manipulation. RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent bles-
ser vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons
CHOC ELECTRIQUE ultra-violets très forts. Ces rayons d’arc nuiront à vos
Les chocs électriques peuvent blesser ou même tuer. Le yeux et brûleront votre peau si vous ne vous protégez
procédé au jet de plasma requiert et produit de l’éner- pas correctement.
gie électrique haute tension. Cette énergie électrique
peut produire des chocs graves, voire mortels, pour • Pour protéger vos yeux, portez toujours un cas-
l’opérateur et les autres personnes sur le lieu de travail. que ou un écran de soudeur. Portez toujours des
lunettes de sécurité munies de parois latérales ou
• Ne touchez jamais une pièce “sous tension” ou des lunettes de protection ou une autre sorte de
“vive”; portez des gants et des vêtements secs. Iso- protection oculaire.
lez-vous de la pièce de travail ou des autres parties
du circuit de soudage. • Portez des gants de soudeur et un vêtement protec-
teur approprié pour protéger votre peau contre les
• Réparez ou remplacez toute pièce usée ou endom- étincelles et les rayons de l’arc.
magée.
• Maintenez votre casque et vos lunettes de protec-
• Prenez des soins particuliers lorsque la zone de tion en bon état. Remplacez toute lentille sale ou
travail est humide ou moite. comportant fissure ou rognure.
• Montez et maintenez le matériel conformément au • Protégez les autres personnes se trouvant sur la zone
Code électrique national des Etats-Unis. (Voir la de travail contre les rayons de l’arc en fournissant
page 5, article 9.) des cabines ou des écrans de protection.

1-4 INFORMATIONS GÉNÉRALES Manual 0-5119

 CUTMASTER A80, A120
• Utilisez la nuance de lentille qui est suggèrée dans 3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉ-
le recommendation qui suivent ANSI/ASC Z49.1: RATIONS DE COUPE ET DE SOUDAGE À L’ARC ET
AU GAZ, disponible auprès du Superintendent of Docu-
Nuance Minimum Nuance Suggerée ments, U.S. Government Printing Office, Washington,
Courant Arc Protective Numéro Numéro
D.C. 20402
Moins de 300* 8 9
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PRO-
300 - 400* 9 12 TECTION DES YEUX ET DU VISAGE AU TRAVAIL ET
DANS LES ECOLES, disponible de l’Institut Américain
400 - 800* 10 14
des Normes Nationales (American National Standards
* Ces valeurs s’appliquent ou l’arc actuel est Institute), 1430 Broadway, New York, NY 10018
observé clairement. L’experience a démontrer
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSU-
que les filtres moins foncés peuvent être utilisés RES PROTECTRICES, disponible auprès de l’American
quand l’arc est caché par moiceau de travail. National Standards Institute, 1430 Broadway, New York,
NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
BRUIT LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE
SOUDAGE, disponible auprès de l’American National
Le bruit peut provoquer une perte permanente de Standards Institute, 1430 Broadway, New York, NY 10018
l’ouïe. Les procédés de soudage à l’arc de plasma 7. Norme A6.0 de l’Association Américaine du Soudage
peuvent provoquer des niveaux sonores supérieurs (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS
aux limites normalement acceptables. Vous dú4ez vous AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES,
protéger les oreilles contre les bruits forts afin d’éviter disponible auprès de la American Welding Society, 550
une perte permanente de l’ouïe. N.W. LeJeune Rd., Miami, FL 33126

• Pour protéger votre ouïe contre les bruits forts, 8. Norme 51 de l’Association Américaine pour la Protec-
portez des tampons protecteurs et/ou des protec- tion contre les Incendies (NFPA), LES SYSTEMES À
tions auriculaires. Protégez également les autres GAZ AVEC ALIMENTATION EN OXYGENE POUR LE
SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS,
personnes se trouvant sur le lieu de travail.
disponible auprès de la National Fire Protection Associa-
• Il faut mesurer les niveaux sonores afin d’assurer tion, Batterymarch Park, Quincy, MA 02269
que les décibels (le bruit) ne dépassent pas les 9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL,
niveaux sûrs. disponible auprès de la National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
• Pour des renseignements sur la manière de tester
le bruit, consultez l’article 1, page 5. 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

PLOMB AVERTISSEMENT 11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE

DES GAZ COMPRIMÉS EN CYLINDRES, disponible
AVERTISSEMENT: Ce produit contient des produits auprès de l’Association des Gaz Comprimés (Compressed
chimiques, notamment du plomb, reconnu par l'État Gas Association), 1235 Jefferson Davis Highway, Suite
de la Californie pour causer des malformations congé- 501, Arlington, VA 22202
nitales et d'autres dommages touchant le système 12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE
reproductif. Se laver les mains après manipulation. SOUDAGE ET LA COUPE, disponible auprès de l’Asso-
ciation des Normes Canadiennes, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3
1.06 Documents De Reference 13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU
Consultez les normes suivantes ou les révisions les plus SOUDAGE, disponible auprès de l’Association Nationale
de Fournitures de Soudage (National Welding Supply
récentes ayant été faites à celles-ci pour de plus amples
Association), 1900 Arch Street, Philadelphia, PA 19103
renseignements :
14. Norme AWSF4.1 de l’Association Américaine de Soudage,
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
RECOMMANDATIONS DE PRATIQUES SURES POUR
PROTECTION DE LA SANTÉ, 29CFR 1910, disponible
LA PRÉPARATION À LA COUPE ET AU SOUDAGE
auprès du Superintendent of Documents, U.S. Govern-
DE CONTENEURS ET TUYAUX AYANT RENFERMÉ
ment Printing Office, Washington, D.C. 20402
DES PRODUITS DANGEREUX, disponible auprès de la
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS American Welding Society, 550 N.W. LeJeune Rd., Miami,
DE COUPE ET DE SOUDAGE, disponible auprès de FL 33126
la Société Américaine de Soudage (American Welding
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RES-
Society), 550 N.W. LeJeune Rd., Miami, FL 33126
PIRATOIRE, disponible auprès de l’American National
Standards Institute, 1430 Broadway, New York, NY 10018

Manual 0-5119 INFORMATIONS GÉNÉRALES 1-5

CUTMASTER A80, A120
1.07 Declaration of Conformity

Declaration of Conformity
We Victor Technologies International Inc.
of 16052 Swingley Ridge Road
Suite 300
Chesterfield, MO 63033 U.S.A.

in accordance with the following Directive(s):

• 2006/95/EC The Low Voltage Directive

• 2004/108/EC The Electromagnetic Compatibility (EMC) Directive

hereby declare that:

Equipment: Plasma Cutting Power Source
Model Name/Number: CutMaster A80, A120
Market Release Date: January 5, 2012

is in conformity with the applicable requirements of the following harmonized standards:

• EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC)
requirements
• EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.

Classification: The equipment described in this document is Class A and intended for industrial use.

Manufacturer’s Authorized Representative

Steve Ward V.P. Europe and General Manager
(Signature)
Address:Victor Technologies International Inc.
Europa Building Steve Ward
(Full Name)
Chorley N Industrial Park
Chorley, Lancashire, V.P. Europe and General Manager
England PR6 7BX (Position)

Date: May 13, 2014

! WARNING
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the
public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in
those locations, due to conducted as well as radiated disturbances.

1-6 GENERAL INFORMATION Manual 0-5119

 CUTMASTER A80, A120

Classification: The equipment described in this manual is Class A and intended for industrial use.

! WARNING
This Class A equipment is not intended for use in residential locations where the electrical power
is provided by the public low-voltage supply system. There may be potential difficulties in ensuring
electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

Manual 0-5119 GENERAL INFORMATION 1-7

CUTMASTER A80, A120
1.08 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Victor Technologies, Inc. warrants to the original
retail purchaser that new Victor 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, Victor Technologies, Inc. shall, upon notification thereof and substantiation that the product has
been stored operated and maintained in accordance with Victor 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.

Victor 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. Victor Technologies, Inc. must be notified within 30 days of any
failure, at which time Victor Technologies, Inc. will provide instructions on the warranty procedures to be implemented.

Victor Technologies, Inc. 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 Victor Thermal Dynamics
Distributor.

LIMITED WARRANTY PERIOD

Power Supply Components Torch and Leads
Product
(Parts and Labor) (Parts and Labor)
U.S. Non U.S.
CUTMASTER™ A40 4 Years 3 Years 1 Year
CUTMASTER™ A60 4 Years 3 Years 1 Year
CUTMASTER™ A80 4 Years 3 Years 1 Year
CUTMASTER™ A120 4 Years 3 Years 1 Year

This warranty does not apply to:

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

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

In the event of a claim under this warranty, the remedies shall be, at the discretion of Victor Technologies, Inc.

1. Repair of the defective product.

2. Replacement of the defective product.

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

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

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

LIMITATION OF LIABILITY: Victor Thermal Dynamics 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
Victor 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 Victor 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
Victor Thermal Dynamics product.

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

Effective September 4, 2007

1-8 GENERAL INFORMATION Manual 0-5119

 CUTMASTER A80, A120
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual 2.02 Equipment Identification
This Owner’s Manual applies to just specification or The unit’s identification number (specification or part
part numbers listed on page i. number), model, and serial number usually appear
on a data tag attached to the rear panel. Equipment
To ensure safe operation, read the entire manual, in-
which does not have a data tag such as torch and cable
cluding the chapter on safety instructions and warn-
assemblies are identified only by the specification or
ings.
part number printed on loosely attached card or the
Throughout this manual, the words WARNING, shipping container. Record these numbers on the
CAUTION, and NOTE may appear. Pay particular bottom of page 1 for future reference.
attention to the information provided under these
headings.
2.03 Receipt of Equipment
These special annotations are easily recognized as
follows: When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
NOTE equipment for possible damage due to shipping. If
An operation, procedure, or background infor- there is any damage, notify the carrier immediately to
mation which requires additional emphasis or file a claim. Furnish complete information concerning
is helpful in efficient operation of the system. damage claims or shipping errors to the location in
your area listed in the inside back cover of this manual.
Include all equipment identification numbers as
CAUTION described above along with a full description of the
A procedure which, if not properly followed, parts in error.
may cause damage to the equipment. Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the

! WARNING
equipment when using bars, hammers, etc., to un-crate
the unit.

A procedure which, if not properly followed,

may cause injury to the operator or others in
the operating area.

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

Additional copies of this manual may be purchased by

contacting Victor Thermal Dynamics 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 identification numbers.
Electronic copies of this manual can also be download-
ed at no charge in Acrobat PDF format by going to the
Victor Thermal Dynamics web site listed below and
clicking on the Literature link:
http://www.victorthermaldynamics.com

Manual 0-5119 INTRODUCTION 2-1

CUTMASTER A80, A120
2.04 Power Supply Specifications
CutMaster A80 Power Supply Specifications
380 VAC (360 - 480 VAC), Three Phase, 50/60 Hz
Input Power
400 VAC (360 - 480 VAC), Three Phase, 50 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 100 Amps, Continuously Adjustable
Power Supply Gas
Particulates to 5 Microns
Filtering Ability
CutMaster A80 Power Supply Duty Cycle *
Duty Cycle Ratings @ 40° C (104° F)
Ambient Temperature
Operating Range 0° - 50° C
Duty Cycle 60% 80% 100%
Current 100 80 70
All Units
IEC IEC IEC
DC Voltage 120 112 108
* 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.
CutMaster A120 Power Supply Specifications
380 VAC (360 - 480 VAC), Three Phase, 50/60 Hz
Input Power
400 VAC (360 - 480 VAC), Three Phase, 50 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 *
Duty Cycle Ratings @ 40° C (104° F)
Ambient Temperature
Operating Range 0° - 50° C
Duty Cycle 60% 80%** 100%
Current 120 120 100
All Units
IEC IEC IEC
DC Voltage 128 128 120
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output
voltage (DC) is higher than shown in this chart.

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.

2-2 INTRODUCTION Manual 0-5119

 CUTMASTER A80, A120
Power Supply Dimensions & Weight Ventilation Clearance Requirements
10"
254 mm

Art # A-08459

13.78"
350 mm Art # A-07925_AB

6"
150 mm

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

6" 6"
150 mm 150 mm

2.05 Input Wiring Specifications

CutMaster A80 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Flexible Cord Flexible Cord
Volts Hz kVA I1max I1eff Fuse (amps) (mm2) (AWG)
380 50 18.4 28 25 35 10 8
3 Phase
400 50 18.7 27 24 35 10 8
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
CutMaster A120 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Flexible Cord Flexible Cord
Volts Hz kVA I1max I1eff Fuse (amps) (mm2) (AWG)
380 60 23 35 32 35 6 10
3 Phase
400 50 23.6 34 31 35 6 10
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code

NOTE
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired 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 0-5119 INTRODUCTION 2-3

CUTMASTER A80, A120
2.06 Power Supply Features

Art # A-08460
Control Panel

Torch Leads
Receptacle

Mounting Rails

Work Cable
and Clamp

Automation Interface
Cable Port
Input Power Selection

Filter Assembly

Gas Inlet Port

Input Power Cord Art # A-08461

2-4 INTRODUCTION Manual 0-5119

 CUTMASTER A80, A120
SECTION 2 TORCH: 18.875" / 479 mm

12.285" / 312 mm
INTRODUCTION 2.875” /
73 mm

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

1.75" / 0.625" / 4.95" / 126 mm 1.175" / 30 mm
44.5 mm 16 mm
This manual contains descriptions, operating instruc- Art # A-07402_AC

tions and maintenance procedures for the 1Torch 2. Machine Torch, Model
Models SL100SV/Manual and SL100SV/Mechanized
Plasma Cutting Torches. Service of this equipment is The standard machine torch has a positioning
restricted to properly trained personnel; unqualified tube with rack & pinch block assembly.
personnel are strictly cautioned against attempting 15.875" / 403 mm
repairs or adjustments not covered in this manual, at 9.285" / 236 mm
the risk of voiding the Warranty.
Read this manual thoroughly. A complete under-
1.175" / 30 mm
standing of the characteristics and capabilities of this 1.375" / 35 mm
equipment will assure the dependable operation for 4.95" / 126 mm
1.75" / 0.625" /
which it was designed. 44.5 mm 16 mm Art # A-02998

3. Hand/Manual Torch, Models

2T.02 General Description The hand torch head is at 75° to the torch han-
Plasma torches are similar in design to the automotive dle. The hand torches include a torch handle
spark plug. They consist of negative and positive sec- and torch trigger assembly.
tions separated by a center insulator. Inside the torch, 10.125" (257 mm)
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 super-
heated column of gas flows through the small orifice
in the torch tip, which is focused on the metal to be cut.
3.75"
A single torch lead provides gas from a single source (95 mm)
Art # A-03322_AB
to be used as both the plasma and secondary gas. The
air flow is divided inside the torch head. Single - gas 1.17" (29 mm)
operation provides a smaller sized torch and inexpen-
sive operation.
B. Torch Leads Lengths
NOTE
Hand Torches are available as follows:
Refer to Section 2T.05, Introduction To Plasma,
for a more detailed description of plasma torch • 20 ft / 6.1 m, with ATC connectors
operation. • 50 ft / 15.2 m, with ATC connectors
Refer to the Appendix Pages for additional speci- Machine / Automation Torches are available as
fications as related to the Power Supply used. follows:

• 5 foot / 1.5 m, with ATC connectors

2T.03 Specifications • 10 foot / 3.05 m, with ATC connectors
• 25 foot / 7.6 m, with ATC connectors
A. Torch Configurations
• 50 foot / 15.2 m, with ATC connectors
1. Automation Torch, Model
C. Torch Parts
The standard automation torch has a positioning
tube with rack & pinch block assembly and a Starter Cartridge, Electrode, Tip, Shield Cup
solenoid valve.
D. Parts - In - Place (PIP)
Torch Head has built - in switch
12 VDC circuit rating

Manual 0-5119 INTRODUCTION 2T-1

CUTMASTER A80, A120
E. Type Cooling
Combination of ambient air and gas stream
through torch.
! WARNING
This torch is not to be used with oxygen (O2).
F. Torch Ratings
Automated / Machine Torch Ratings NOTE

Ambient 104° F Operating pressure varies with torch model, op-

Temperature 40° C erating amperage, and torch leads length. Refer
to gas pressure settings charts for each model.
100% @ 100 Amps @ 400 scfh
Duty Cycle
80% @ 120 Amps @ 400 scfh H. Direct Contact Hazard
Maximum
120 Amps For standoff tip the recommended standoff is 3/16
Current
inches / 4.7 mm.
Voltage (Vpeak) 500V
Arc Striking
Voltage
7kV 2T.04 Options and Accessories
For options and accessories, see section 6.
Manual Torch Ratings
CUTMASTER A80
2T.05 Introduction to Plasma
Ambient 104° F
Temperature 40° C
A. Plasma Gas Flow
Duty Cycle 100% @ 100 Amps @ 400 scfh
Plasma is a gas which has been heated to an ex-
Maximum tremely high temperature and ionized so that it
120 Amps
Current becomes electrically conductive. The plasma arc
Voltage (Vpeak) 500V cutting and gouging processes use this plasma to
transfer an electrical arc to the workpiece. The
Arc Striking metal to be cut or removed is melted by the heat
7kV
Voltage of the arc and then blown away.
Manual Torch Ratings
CUTMASTER A120 While the goal of plasma arc cutting is separation
of the material, plasma arc gouging is used to
Ambient 104° F remove metals to a controlled depth and width.
Temperature 40° C
In a Plasma Cutting Torch a cool gas enters Zone
Duty Cycle 100% @ 120 Amps @ 400 scfh B, where a pilot arc between the electrode and the
Maximum torch tip heats and ionizes the gas. The main cut-
120 Amps ting arc then transfers to the workpiece through
Current
the column of plasma gas in Zone C.
Voltage (Vpeak) 500V
Arc Striking
7kV
Voltage

G.Gas Requirements
Automated, Manual and Machine Torch Gas
Specifications
Gas (Plasma and Secondary) Compressed Air
Operating Pressure 60 - 95 psi
Refer to NOTE 4.1 - 6.5 bar

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow 300 - 500 scfh

(Cutting and Gouging) 142 - 235 lpm

2T-2 INTRODUCTION Manual 0-5119

 CUTMASTER A80, A120
D. Main Cutting Arc
DC power is also used for the main cutting arc.
The negative output is connected to the torch elec-
trode through the torch lead. The positive output
is connected to the workpiece via the work cable
and to the torch through a pilot wire.

E. Parts - In - Place (PIP)

The torch includes a 'Parts - In - Place' (PIP) cir-
cuit. When the shield cup is properly installed, it
closes a switch. The torch will not operate if this
A switch is open.
_
Power
Supply
+
B

Workpiece
C A-08331

Typical Torch Head Detail

By forcing the plasma gas and electric arc through

a small orifice, the torch delivers a high concentra-
tion 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
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.

Manual 0-5119 INTRODUCTION 2T-3

CUTMASTER A80, A120
Remote Pendant

To ATC PIP Switch Shield Cup

CNC Start

To ATC PIP Switch Shield Cup

Art # A-08168

Automation Torch

To ATC PIP Switch Shield Cup

Parts - In - Place Circuit Diagram for

Machine Torch

Torch Switch Torch Trigger

To Control
Cable Wiring
PIP Switch Shield Cup
A-02997

Parts - In - Place Circuit Diagram for Hand Torch

2T-4 INTRODUCTION Manual 0-5119

 CUTMASTER A80, A120
SECTION 3 SYSTEM: 3.03 Power Supply location and
Mounting
INSTALLATION
NOTE
3.01 Unpacking It is recommended that the unit be secured to a
suitable surface using the mounting rails.
1. Use the packing lists to identify and account
for each item. 1. First choose an appropriate location for mount-
ing the power supply. Choose one that allows
2. Inspect each item for possible shipping dam- for free movement of torch leads, complies
age. If damage is evident, contact your dis- with ventilation per section 2.04 and provides a
tributor and / or shipping company before safe firm surface where the unit can be secured.
proceeding with the installation.
2. Place the unit in the desired position and mark
3. Record Power Supply and Torch model and
serial numbers, purchase date and vendor
name, in the information block at the front of where the four keyway holes in
this manual. the mounting rails touch.
3. Remove the unit and using these markings,
prepare holes for mounting hardware.
3.02 Lifting Options
4. Insert proper hardware. If using hardware
The Power Supply includes hand holds in the front that screws into the mounting surface, leave
and rear panels for hand lifting only. Be sure unit is all four loose enough for the thickness of the
lifted and transported safely and securely. rail to slide under the head and washer if used.
5. Lower the power supply over the mounting
! WARNING
hardware and slide forward or backward
until the keyway stops against the mounting
hardware.
Do not touch live electrical parts.
Disconnect input power cord before moving unit. 6. Secure the hardware to the rail.

FALLING EQUIPMENT can cause serious per-

sonal injury and can damage equipment. 3.04 Primary Input Power Connections

• Only persons of adequate physical strength

should lift the unit. CAUTION
• Lift unit by the handles, using two hands. Do Check your power source for correct voltage
not use straps for lifting. before plugging in or connecting the unit. Check
the Voltage Selector at the rear of the unit for
• Use optional cart or similar device of adequate
correct setting before plugging in or connecting
capacity to move unit.
the unit. The primary power source, fuse, and
• Place unit on a proper skid and secure in place any extension cords used must conform to lo-
before transporting with a fork lift or other ve- cal electrical code and the recommended circuit
hicle. protection and wiring requirements as specified
in Section 2.
Most units are shipped from the factory with a 230 Volt
input power cable wired to the input contactor in the
single - phase configuration. The following illustra-
tions and directions are for changing that configuration
to a different voltage and or to three - phase operation
or back again if a change had already been made.

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

Manual 0-5119 INSTALLATION 3-1

CUTMASTER A80, A120
NOTE The following illustration and directions are for wiring
The upper screws and lower screws are not the three phase input power.
same. Do not mix them. The upper screws are Input Power Cable Connections
for threading into the plastic of the front and rear Three-Phase (3ø)
panels. DO NOT use the finer threaded lower
screws for this.
L1
L2
Upper

Art # A-08548
Screws L3
L4
Lower GND
Screws
Three Phase Input Power Wiring
Slots

Lower
D. Connections to Three Phase Input Power
Screws

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 Sup-
ply to Three - Phase input power.
1. Remove the Power Supply cover per instruc-
Art # A-08429 tions found in this subsection A.
2. Carefully pull the Cover up and away from the 2. Disconnect the original input power cable
unit. from the main input contactor and the chassis
ground connection.
B. Cover Installation 3. Loosen the through - hole protector on the back
1. Reverse previous procedures for cover instal- panel of the power supply. Pull the original
lation. power cable out of the power supply.

NOTE 4. Using a customer supplied four - conductor

input power cable for the voltage desired, strip
When installing the upper screws, attempt to back the insulation on the individual wires.
reuse the original threads. The easiest way to
do this is by turning the screw counter-clockwise 5. Pass the cable being used through the access
until you feel the threads line up, then begin to opening in the back panel of the power supply.
turn the screw clockwise to tighten. Do not Refer to Section 2 for power cable specifica-
over tighten. tions.

C Primary Input Power Connections

CAUTION
The primary power source and power cable must
CAUTION conform to local electrical code and the recom-
Check your power source for correct voltage mended circuit protection and wiring require-
before plugging in or connecting the unit. The ments (refer to table in Section 2).
primary power source, fuse, and any extension
cords used must conform to local electrical code 6. Connect the wires as follows.
and the recommended circuit protection and
• Wires to L1, L2 and L3 input. It does not
wiring requirements as specified in Section 2.
matter what order these wires are attached.
See previous illustration and on label in the
power supply.
• Green / Yellow wire to Ground.

3-2 INSTALLATION Manual 0-5119

 CUTMASTER A80, A120
7. With a little slack in the wires, tighten the NOTE
through - hole protector to secure the power For a secure seal, apply thread sealant to the
cable. fitting threads, according to the manufacturer's
8. Reinstall the Power Supply cover see subsec- instructions. Do Not use Teflon tape as a thread
tion B. sealer, as small particles of the tape may break
off and block the small air passages in the torch.
9. Connect the opposite end of individual wires to Connect as follows:
a customer supplied plug or main disconnect. Filter Assembly
10. Connect the input power cable (or close the
main disconnect switch) to supply power. Inlet Port

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 Art # A-08319
if an optional air line filter is to be installed.
1. Connect the air line to the inlet port. The il-
lustration shows typical fittings as an example. Hose Clamp

NOTE Gas Supply 1/4 NPT to 1/4"

Hose (6mm) Fitting
For a secure seal, apply thread sealant to the
fitting threads, according to manufacturer's Optional Single - Stage Filter Installation
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. Using High Pressure Air Cylinders
Filter Assembly
When using high pressure air cylinders as the air
supply:
Inlet Port
1. Refer to the manufacturer’s specifications for
installation and maintenance procedures for
high pressure regulators.
Hose Clamp

Gas Supply
Hose

Art # A-08320

1/4 NPT or ISO-R

to 1/4” (6mm) Fitting
Air Connection to Inlet Port

Installing Optional Single - Stage Air Filter

An optional filter kit is recommended for improved
filtering with compressed air, to keep moisture and
debris out of the torch.
1. Attach the Single - Stage Filter Hose to the Inlet
Port.
2. Attach the Filter Assembly to the filter hose.
3. Connect the air line to the Filter. The illustra-
tion shows typical fittings as an example.

Manual 0-5119 INSTALLATION 3-3

CUTMASTER A80, A120
2. Examine the cylinder valves to be sure they Using High Pressure Air Cylinders
are clean and free of oil, grease or any foreign
material. Briefly open each cylinder valve to When using high pressure air cylinders as the air
blow out any dust which may be present. supply:

3. The cylinder must be equipped with an adjust- 1. Refer to the manufacturer’s specifications for
able high - pressure regulator capable of outlet installation and maintenance procedures for
pressures up to 100 psi (6.9 bar) maximum and high pressure regulators.
flows of at least 300 scfh (141.5 lpm). 2. Examine the cylinder valves to be sure they
4. Connect supply hose to the cylinder. are clean and free of oil, grease or any foreign
material. Briefly open each cylinder valve to
NOTE blow out any dust which may be present.
Pressure should be set at 100 psi (6.9 bar) at the 3. The cylinder must be equipped with an adjust-
high pressure cylinder regulator. able high - pressure regulator capable of outlet
Supply hose must be at least 1/4 inch (6 mm) I.D. pressures up to 100 psi (6.9 bar) maximum and
For a secure seal, apply thread sealant to the flows of at least 300 scfh (141.5 lpm).
fitting threads, according to manufacturer's 4. Connect supply hose to the cylinder.
instructions. Do Not use Teflon tape as a thread
sealer, as small particles of the tape may break NOTE
off and block the small air passages in the torch. Pressure should be set at 100 psi (6.9 bar) at the
high pressure cylinder regulator.
Installing Optional Two - Stage Air Filter Kit Supply hose must be at least 1/4 inch (6 mm) I.D.
This optional two - stage air line filter is also for use on For a secure seal, apply thread sealant to the
compressed air shop systems. Filter removes moisture fitting threads, according to manufacturer's
and contaminants to at least 5 microns. instructions. Do Not use Teflon tape as a thread
sealer, as small particles of the tape may break
Connect the air supply as follows:
off and block the small air passages in the torch.
1. Attach the Two Stage Filter bracket to the back
of the power supply per instructions supplied
with the filter assembly.
NOTE
For a secure seal, apply thread sealant to the
fitting threads according to manufacturer's in-
structions. Do Not use Teflon tape as a thread
sealer as small particles of the tape may break
off and block the small air passages in the torch.
2. Connect the two stage filter outlet hose to the
inlet port of the Regulator / Filter Assembly.
3. Use customer - supplied fittings to connect the
air line to the Filter. A 1/4 NPT to 1/4" hose
barbed fitting is shown as an example.
Regulator/Filter
Assembly
2-Stage Filter
Regulator Inlet Port (IN)
Input
Outlet Port
(OUT)

Two Stage
Filter
Hose Clamp Assembly
Gas Supply
Hose

1/4 NPT to 1/4”

(6mm) Fitting

Art # A-07945_AC

Optional Two - Stage Filter Installation

3-4 INSTALLATION Manual 0-5119

 CUTMASTER A80, A120
Check Air Quality
SECTION 3 TORCH:
To test the quality of air:
INSTALLATION
1. Put the ON / OFF switch in the ON
3T.01 Torch Connections (up) position.

If necessary, connect the torch to the Power Supply.

Connect only the Thermal Dynamics model SL100SV 2. Put the Function Control switch in the SET
/ Automation, SL100 / Mechanical or SL100 / Manual position.
Torch to this power supply. Maximum torch leads 3. Place a welding filter lens in front of the torch
length is 100 feet / 30.5 m, including extensions. and turn ON the air. Do not start an arc!
Any oil or moisture in the air will be visible on
the lens.
WARNING
Disconnect primary power at the source before 3T.02 CNC Connection
connecting the torch.
1. Locate the interface connection port on the rear
of the power supply.
1. Align the ATC male connector (on the torch
lead) with the female receptacle. Push the
male connector into the female receptacle. The Automation Interface
connectors should push together with a small Cable Port
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.

Art # A-08464

2. Note the pin-out of the connector and that the

customer supplied connector matches.
Plasma
Start / Stop
Signal
2

1
Art # A-07885

Connecting the Torch to the Power Supply

3. The system is now ready for operation.

Cutting Machine
Art # A-08323
OK to Move

Manual 0-5119 INSTALLATION 3T-1

CUTMASTER A80, A120
There are three options for Divided Arc Voltage signal supplied from the automation interface pcb. This is selected
by connecting the black Jumper Plug on the P1 connector as follows:
Arc voltage / 16.67 Jumper not installed
Arc voltage / 30 Jumper Pins 1 & 2 . This is the factory default position of the jumper
Arc voltage / 50 Jumper Pins 2 & 3

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

* * To configure DIVIDED ARC VOLTS signal output

No jumper installed for ARC VOLTS /16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
1
2
3

To -V OUT 1 J3
on PCB1
E1 J2

1
2
P10 3
J1 +12VDC
4
} /START / STOP
1 1 5 (-)
2 2 6
} (+) *DIVIDED ARC VOLTS
3 3 K1 7 (-)
4
5
4
5
8
9
} (+) (W/ARC VOLTS
100K IN SERIES (2))
6 6 10
7 7 11
8 8 12
K1 13 } OK-TO-MOVE
14

AUTOMATION
PCB4 INTERFACE PCB

Art # A-09819_AB

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

3. Connect CNC to the power supply.

3T-2 INSTALLATION Manual 0-5119

 CUTMASTER A80, A120
3T.03 Setting Up Automation or Machine Torch
NOTE
An adapter is required to be installed in the power supply if converting a hand torch system to operate a 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.

Pinch Block
Assembly

Square

Workpiece
A-02585

Automated and Machine Torch Set - Up

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

Manual 0-5119 INSTALLATION 3T-3

CUTMASTER A80, A120

This Page Intentionally Blank

3T-4 INSTALLATION Manual 0-5119

 CUTMASTER A80, A120
For optimum smooth surface quality, the travel
SECTION 4 TORCH: speed should be adjusted so that only the leading
edge of the arc column produces the cut. If the
OPERATION travel speed is too slow, a rough cut will be pro-
duced as the arc moves from side to side in search
4T.01 Machine and Automated Torch of metal for transfer.
Operation Travel speed also affects the bevel angle of a cut.
When cutting in a circle or around a corner, slow-
Cutting With Machine or Automated Torch ing down the travel speed will result in a squarer
cut. The power source output should be reduced
These torches are activated by remote control pen- also. Refer to the appropriate Control Module
dant or by a remote interface device such as CNC. Operating Manual for any Corner Slowdown
1. To start a cut at the plate edge, position the adjustments that may be required.
center of the torch along the edge of the plate.
Piercing With Machine or Automated Torch
Travel Speed To pierce, the arc should be started with the torch
Proper travel speed is indicated by the trail of the positioned as high as possible above the plate
arc which is seen below the plate. The arc can be while allowing the arc to transfer and pierce. This
one of the following: standoff helps avoid having molten metal blow
back onto the front end of the torch.
1. Straight Arc
When operating with a cutting machine, a pierce or
A straight arc is perpendicular to the workpiece dwell time is required. Torch travel should not be
surface. This arc is generally recommended enabled until the arc penetrates the bottom of the
for the best cut using air plasma on stainless plate. As motion begins, torch standoff should be
or aluminum. reduced to the recommended 1/8 - 1/4 inch (3-6
mm) distance for optimum speed and cut quality.
2. Leading Arc
Clean spatter and scale from the shield cup and
The leading arc is directed in the same direc- the tip as soon as possible. Spraying or dipping
tion as torch travel. A five degree leading arc the shield cup in anti - spatter compound will
is generally recommended for air plasma on minimize the amount of scale which adheres to it.
mild steel.
3. Trailing Arc
The trailing arc is directed in the opposite direc-
tion as torch travel.

Dir
ect
ion
of T
orc
hT
rav Standoff Distance
el

Straight Arc

Trailing Arc

A-02586

Leading Arc
Automation and Machine Torch Operation

Manual 0-5119 OPERATION 4T-1

CUTMASTER A80, A120
3. Install the replacement Electrode by pushing
4T.02 Automation Torch Parts Selection it straight into the torch head until it clicks.
Check the torch for proper consumable parts. The 4. Install the starter cartridge and desired tip for
parts supplied in the torch may not be correct for the operation into the torch head.
the operator’s chosen amperage level. The torch
parts must correspond with the type of operation. 5. Hand tighten the shield cup assembly until
it is seated on the torch head. If resistance is
Torch parts: felt when installing the cup, check the threads
before proceeding
Shield Cup, Cutting Tip, Electrode and Starter
Cartridge 6. If used, attach the ohmic clip to the shield cup.

NOTE
4T.03 Machine and Hand Torch Parts
Refer to Sections 4T.08 and following for ad-
ditional information on torch parts. Selection
Change the torch parts for a different operation as Depending on the type of operation to be done deter-
follows: mines the torch parts to be used.
Type of operation:
Drag cutting, standoff cutting or gouging
WARNING
Torch parts:
Disconnect primary power at the source before
assembling or disassembling torch parts, or Shield Cup, Cutting Tip, Electrode and Starter
torch and leads assemblies. Cartridge
NOTE
NOTE Refer to Section 4T.08 and following for ad-
The shield cup holds the tip and starter cartridge ditional information on torch parts.
in place. Position the torch with the shield cup Change the torch parts for a different operation as
facing upward to keep these parts from falling follows:
out when the cup is removed.
1. If attached, remove the ohmic clip then un-
screw and remove the shield cup assembly WARNING
from the torch head. Wipe it clean or replace
if damaged Disconnect primary power at the source before
assembling or disassembling torch parts, or
2. Remove the Electrode by pulling it straight out torch and leads assemblies.
of the Torch Head.

Torch Head
Art # A-04173_AB
NOTE
The shield cup holds the tip and starter cartridge
Electrode in place. Position the torch with the shield cup
facing upward to keep these parts from falling
out when the cup is removed.
Start Cartridge
1. Unscrew and remove the shield cup assembly
Tip from the torch head.

Ohmic Clip 2. Remove the Electrode by pulling it straight out

(If installed) of the Torch Head.

Shield Cup Body

Deflector
Shield Cap

Automation Torch Parts

4T-2 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Cut Surface
Torch Head The desired or specified condition (smooth or
rough) of the face of the cut.
Electrode
Nitride Build - Up
Nitride deposits can be left on the surface of the cut
Start Cartridge when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the mate-
rial is to be welded after the cutting process.
Tip
Bevel Angle
Shield Cup The angle between the surface of the cut edge and
A-03510_AB
a plane perpendicular to the surface of the plate.
A perfectly perpendicular cut would result in a
Torch Parts 0° bevel angle.
(Drag Shield Cap & Shield Cup Body Shown)
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. Install the starter cartridge and desired tip for workpiece.
the operation into the torch head.
5. Hand tighten the shield cup assembly until Bottom Dross Buildup
it is seated on the torch head. If resistance is
Molten material which is not blown out of the
felt when installing the cup, check the threads
cut area and resolidifies on the plate. Excessive
before proceeding.
dross may require secondary cleanup operations
after cutting.
4T.04 Cut Quality
NOTES
Cut quality depends heavily on setup and param-
eters such as torch standoff, alignment with the
workpiece, cutting speed, gas pressures, and
operator ability.
Cut quality requirements differ depending on applica-
tion. For instance, nitride build - up and bevel angle
may be major factors when the surface will be welded
after cutting. Dross - free cutting is important when
finish cut quality is desired to avoid a secondary clean-
ing operation. The following cut quality characteristics
are illustrated in the following figure:
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter

Top Edge
Rounding

Dross
Build-Up
Cut Surface A-00007
Drag Lines

Cut Quality Characteristics

Manual 0-5119 OPERATION 4T-3

CUTMASTER A80, A120
Kerf Width Direction of Cut
The width of the cut (or the width of material In the torches, the plasma gas stream swirls as it
removed during the cut). leaves the torch to maintain a smooth column of
gas. This swirl effect results in one side of a cut
Top Spatter (Dross) being more square than the other. Viewed along
the direction of travel, the right side of the cut is
Top spatter or dross on the top of the cut caused by more square than the left.
slow travel speed, excess cutting height, or cutting Left Side
tip whose orifice has become elongated. Cut Angle
Right Side
Cut Angle
4T.05 General Cutting Information

! WARNING

Disconnect primary power at the source before A-00512

disassembling the power supply, torch, or torch
leads. Side Characteristics Of Cut

Frequently review the Important Safety Precau- To make a square - edged cut along an inside
tions at the front of this manual. Be sure the diameter of a circle, the torch should move coun-
operator is equipped with proper gloves, cloth- terclockwise around the circle. To keep the square
ing, eye and ear protection. Make sure no part edge along an outside diameter cut, the torch
of the operator’s body comes into contact with should travel in a clockwise direction.
the workpiece while the torch is activated.
Dross
When dross is present on carbon steel, it is com-
CAUTION monly referred to as either “high speed, slow
speed, or top dross”. Dross present on top of the
Sparks from the cutting process can cause dam- plate is normally caused by too great a torch to
age to coated, painted, and other surfaces such plate distance. "Top dross" is normally very easy to
as glass, plastic and metal. remove and can often be wiped off with a welding
glove. "Slow speed dross" is normally present on
NOTE
the bottom edge of the plate. It can vary from a
Handle torch leads with care and protect them light to heavy bead, but does not adhere tightly to
from damage. the cut edge, and can be easily scraped off. "High
speed dross" usually forms a narrow bead along
Piloting the bottom of the cut edge and is very difficult to
Piloting is harder on parts life than actual cutting remove. When cutting a troublesome steel, it is
because the pilot arc is directed from the electrode sometimes useful to reduce the cutting speed to
to the tip rather than to a workpiece. Whenever produce "slow speed dross". Any resultant clean-
possible, avoid excessive pilot arc time to improve up can be accomplished by scraping, not grinding.
parts life.

Torch Standoff
4T.06 Hand Torch Operation
Improper standoff (the distance between the torch Standoff Cutting With Hand Torch
tip and workpiece) can adversely affect tip life as
well as shield cup life. Standoff may also signifi- NOTE
cantly affect the bevel angle. Reducing standoff For best performance and parts life, always use
will generally result in a more square cut. the correct parts for the type of operation.

Edge Starting 1. The torch can be comfortably held in one hand

or steadied with two hands. Position the hand
For edge starts, hold the torch perpendicular to to press the Trigger on the torch handle. With
the workpiece with the front of the tip near (not the hand torch, the hand may be positioned
touching) the edge of the workpiece at the point close to the torch head for maximum control
where the cut is to start. When starting at the edge or near the back end for maximum heat protec-
of the plate, do not pause at the edge and force the tion. Choose the holding technique that feels
arc to "reach" for the edge of the metal. Establish most comfortable and allows good control and
the cutting arc as quickly as possible. movement.

4T-4 OPERATION Manual 0-5119

 CUTMASTER A80, A120
NOTE Trigger
The tip should never come in contact with the
workpiece except during drag cutting operations.
1
2. Depending on the cutting operation, do one of
2
the following:
Trigger Release
a. For edge starts, hold the torch perpendicu-
lar 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
- 3/8 in (3-9 mm) from the workpiece as
shown below.
4
Torch
Art # A-03383

6. Cut as usual. Simply release the trigger as-

sembly to stop cutting.
7. Follow normal recommended cutting practices
as provided in the power supply operator's
manual.
Shield Cup Standoff Distance NOTE
1/8" - 3/8" (3 - 9mm)
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
A-00024_AB
cup against the torch head or torch handle can
damage components.
Standoff Distance
8. For a consistent standoff height from the work-
3. Hold the torch away from your body. piece, install the standoff guide by sliding it
onto the torch shield cup. Install the guide
4. Slide the trigger release toward the back of the with the legs at the sides of the shield cup
torch handle while simultaneously squeezing body to maintain good visibility of the cutting
the trigger. The pilot arc will start. arc. During operation, position the legs of the
standoff guide against the workpiece.

Trigger

Shield Cup
Trigger Release
Standoff Guide
A-02986
Torch Tip
5. Bring the torch within transfer distance to the
Workpiece
work. The main arc will transfer to the work, Art # A-04034

and the pilot arc will shut OFF.

Shield Cup With Straight Edge
NOTE
The drag shield cup can be used with a non con-
The gas preflow and postflow are a character-
ductive straight edge to make straight cuts by
istic of the power supply and not a function of
hand.
the torch.

Manual 0-5119 OPERATION 4T-5

CUTMASTER A80, A120
7. Bring the torch within transfer distance to the
work. The main arc will transfer to the work,
WARNING and the pilot arc will shut OFF.
The straight edge must be non - conductive. NOTE
The gas preflow and postflow are a character-
istic of the power supply and not a function of
the torch.
Trigger

Non-Conductive
Straight Edge
1
Cutting Guide
2

Trigger Release
A-03539

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when cutting 3

3/16 inch (4.7 mm) solid metal with relatively
smooth surface.
4
Drag Cutting With a Hand Torch
Drag cutting works best on metal 1/4" (6 mm) Art # A-03383

thick or less.
8. Cut as usual. Simply release the trigger as-
NOTE sembly to stop cutting.
For best parts performance and life, always use 9. Follow normal recommended cutting practices
the correct parts for the type of operation. as provided in the power supply operator's
manual.
1. Install the drag cutting tip and set the output
current. NOTE
2. The torch can be comfortably held in one hand When the shield cup is properly installed, there
or steadied with two hands. Position the hand is a slight gap between the shield cup and the
to press the Trigger on the torch handle. With torch handle. Gas vents through this gap as part
the hand torch, the hand may be positioned of normal operation. Do not attempt to force the
close to the torch head for maximum control shield cup to close this gap. Forcing the shield
or near the back end for maximum heat protec- cup against the torch head or torch handle can
tion. Choose the holding technique that feels damage components.
most comfortable and allows good control and
movement. Piercing With Hand Torch
4. Keep the torch in contact with the workpiece 1. The torch can be comfortably held in one hand
during the cutting cycle. or steadied with two hands. Position the hand
to press the Trigger on the torch handle. With
5. Hold the torch away from your body.
the hand torch, the hand may be positioned
6. Slide the trigger release toward the back of the close to the torch head for maximum control
torch handle while simultaneously squeezing or near the back end for maximum heat pro-
the trigger. The pilot arc will start. tection. 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.
Trigger
2. Angle the torch slightly to direct blowback
particles away from the torch tip (and operator)
Trigger Release rather than directly back into it until the pierce
A-02986 is complete.

4T-6 OPERATION Manual 0-5119

 CUTMASTER A80, A120
3. In a portion of the unwanted metal start the 4T.07 Gouging
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.
! WARNING

5. Slide the trigger release toward the back of the Be sure the operator is equipped with proper
torch handle while simultaneously squeezing gloves, clothing, eye and ear protection and
the trigger. The pilot arc will start. that all safety precautions at the front of this
manual have been followed. Make sure no part
of the operator’s body comes in contact with the
workpiece when the torch is activated.
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
Trigger

Trigger Release CAUTION

A-02986
Sparks from plasma gouging can cause damage
6. Bring the torch within transfer distance to the to coated, painted or other surfaces such as
work. The main arc will transfer to the work, glass, plastic, and metal.
and the pilot arc will shut OFF. Check torch parts. The torch parts must corre-
NOTE spond with the type of operation. Refer to Section
4T.09, Torch Parts Selection.
The gas preflow and postflow are a character-
istic of the power supply and not a function of
the torch. Gouging Parameters
When the shield cup is properly installed, there Gouging performance depends on parameters
is a slight gap between the shield cup and the such as torch travel speed, current level, lead angle
torch handle. Gas vents through this gap as part (the angle between the torch and workpiece), and
of normal operation. Do not attempt to force the the distance between the torch tip and workpiece
shield cup to close this gap. Forcing the shield (standoff).
cup against the torch head or torch handle can
damage components.
7. Clean spatter and scale from the shield cup and CAUTION
the tip as soon as possible. Spraying the shield Touching the torch tip or shield cup to the work surface
cup in anti - spatter compound will minimize will cause excessive parts wear.
the amount of scale which adheres to it.
Cutting speed depends on material, thickness, and the Torch Travel Speed
operator’s ability to accurately follow the desired cut
NOTE
line. The following factors may have an impact on
system performance: Refer to Appendix Pages for additional informa-
tion as related to the Power Supply used.
• Torch parts wear
• Air quality Optimum torch travel speed is dependent on cur-
rent setting, lead angle, and mode of operation
• Line voltage fluctuations (hand or machine torch).
• Torch standoff height
• Proper work cable connection Current Setting
Current settings depend on torch travel speed,
mode of operation (hand or machine torch), and
the amount of material to be removed.

Manual 0-5119 OPERATION 4T-7

CUTMASTER A80, A120
Lead Angle
The angle between the torch and workpiece de-
pends 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 appli-
cations, such as removing welds or working with
light metal, this may be desirable.

Torch Head

35°

Standoff Height

Workpiece
A-00941_AB

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 sever-
ance cut rather than a gouge. Standoff distances
greater than 1/4 inch (6 mm) may result in mini-
mal metal removal or loss of transferred main arc.

Slag Buildup
Slag generated by gouging on materials such as
carbon and stainless steels, nickels, and alloyed
steels, can be removed easily in most cases. Slag
does not obstruct the gouging process if it accumu-
lates to the side of the gouge path. However, slag
build - up can cause inconsistencies and irregular
metal removal if large amounts of material build
up in front of the arc. The build - up is most often
a result of improper travel speed, lead angle, or
standoff height.

4T-8 OPERATION Manual 0-5119

 CUTMASTER A80, A120
4T.08 Recommended Cutting Speeds for Machine and Automated Torches With
Exposed Tip
Mild Steel
40A
Air Plasma / Air Shield

Standard Shield Cup

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

Torch Initial Kerf Width

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

PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
20 0.036 101 0.14 160 0.18 0.0 0.05
16 0.060 103 0.14 140 0.18 0.0 0.05
14 0.075 105 0.14 120 0.18 0.1 0.06
12 0.105 108 0.14 80 0.18 0.2 0.06
70 (25')
10 0.135 110 0.14 60 0.18 0.3 0.06
75 (50')
3/16 0.188 111 0.14 55 0.18 0.4 0.06
1/4 0.250 117 0.14 40 0.18 0.5 0.07
3/8 0.375 119 0.14 25 0.18 1.2 0.07
1/2 0.500 120 0.14 15 0.2 2.0 0.07
Torch Initial Kerf Width
Material Gas Pressure Travel
Arc Voltage Working Piercing Pierce Delay @ Rec.
Thickness (Air) Speed
Height Height Speed
Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1 101 3.6 3990 4.6 0.0 1.1
2 105 3.6 2920 4.6 0.1 1.4
3 109 3.6 1810 4.6 0.3 1.5
4 110 3.6 1470 4.6 0.3 1.6
4.8 (7.6 m)
5 112 3.6 1345 4.6 0.4 1.6
6 5.2 (15.2 m) 116 3.6 1100 4.6 0.5 1.7
8 118 3.6 815 4.6 1.0 1.7
10 119 3.6 595 4.6 1.5 1.8
12 120 3.6 435 5.1 2.0 1.8
BOLD TYPE indicates maximum piercing parameters.

Manual 0-5119 OPERATION 4T-9

CUTMASTER A80, A120
Stainless Steel
40A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup

9-8218
9-8243 9-8208 9-8213 9-8232
9-8237

Torch Initial Kerf Width

Material Gas Pressure Travel Pierce
Arc Voltage Working Piercing @ Rec.
Thickness (Air) Speed Delay
Height Height Speed
PSI
(GA) (in) inch (torch lead Volts (in) (ipm) (in) (sec) (in)
length)
18 0.050 110 0.19 60 0.20 0.00 0.07
16 0.063 100 0.19 50 0.20 0.00 0.07
14 0.078 105 0.19 45 0.20 0.10 0.07
12 0.109 110 0.19 40 0.20 0.20 0.07
75 (25')
10 0.141 108 0.19 35 0.20 0.30 0.07
80 (50')
3/16 0.188 110 0.19 30 0.20 0.40 0.07
1/4 0.250 120 0.19 18 0.20 0.50 0.08
3/8 0.375 126 0.19 10 0.20 2.00 0.08
1/2 0.500 118 0.19 8 Edge start 0.09
Torch Initial Kerf Width
Material Gas Pressure Travel Pierce
Arc Voltage Working Piercing @ Rec.
Thickness (Air) Speed Delay
Height Height Speed

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

4T-10 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Aluminum
40A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup

9-8218
9-8243 9-8208 9-8213 9-8232
9-8237

Torch Initial Kerf Width

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

20 0.040 95 0.16 300 0.16 0.0 0.06

16 0.063 97 0.16 170 0.16 0.0 0.06
12 0.097 113 0.16 100 0.16 0.2 0.07
11 0.125 70 (25') 115 0.16 90 0.18 0.3 0.07
9 0.160 75 (50') 113 0.18 85 0.18 0.4 0.07
3/16 0.188 116 0.18 75 0.18 0.5 0.07
1/4 0.250 128 0.18 30 0.18 1.0 0.08
3/8 0.375 150 0.18 10 Edge Start 0.09
Torch Initial Kerf Width
Material Gas Pressure Travel Pierce
Arc Voltage Working Piercing @ Rec.
Thickness (Air) Speed Delay
Height Height Speed
Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
1.0 95 4.1 7620 4.1 0.0 1.5
2.0 104 4.1 3500 4.1 0.2 1.6
3.0 115 4.1 2350 4.6 0.3 1.7
4.0 4.8 (7.6 m) 113 4.6 2170 4.6 0.4 1.7
5.0 5.2 (15.2 m) 118 4.6 1740 4.6 0.5 1.8
6.0 125 4.6 1015 4.6 0.8 1.9
8.0 139 4.6 500 Edge Start 2.0
10.0 153 4.6 180 Edge Start 2.2
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-5119 OPERATION 4T-11

CUTMASTER A80, A120
Mild Steel
60A
Air Plasma / Air Shield

Standard Shield Cup

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

Initial Kerf Width

Material Gas Pressure Torch Working Travel Pierce
Arc Voltage Piercing @ Rec.
Thickness (Air) Height Speed Delay
Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
16 0.060 118 0.19 290 0.19 0.00 0.08
14 0.075 120 0.19 285 0.19 0.10 0.08
11 0.120 118 0.19 180 0.19 0.10 0.08
10 0.135 119 0.19 176 0.19 0.10 0.07
3/16 0.188 121 0.19 100 0.19 0.20 0.08
85 (25')
1/4 0.250 122 0.19 80 0.19 0.30 0.08
90 (50')
3/8 0.375 124 0.19 50 0.19 0.50 0.09
1/2 0.500 132 0.19 26 0.19 0.75 0.10
5/8 0.625 135 0.19 19 Edge Start 0.10
3/4 0.750 136 0.19 14 Edge Start 0.08
1 1.000 150 0.19 6 Edge Start 0.11
Initial Kerf Width
Material Gas Pressure Torch Working Travel Pierce
Arc Voltage Piercing @ Rec.
Thickness (Air) Height Speed Delay
Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
1 115 4.8 7540 4.8 0 2.1
2 120 4.8 7015 4.0 0.10 1.9
3 118 4.8 4570 4.8 0.10 0.1
4 120 4.8 3650 4.8 0.20 1.9
5 121 4.8 2465 4.8 0.20 2.1
6 5.9 (7.6 m) 122 4.8 2145 4.8 0.30 2.0
8 123 4.8 1635 4.8 0.40 2.2
6.2 (15.2 m)
10 125 4.8 1180 4.8 0.60 2.4
12 130 4.8 795 4.8 0.75 2.4
15 134 4.8 530 Edge Start 2.4
20 138 4.8 325 Edge Start 2.2
25 149 4.8 165 Edge Start 2.7
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

4T-12 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Stainless Steel
60A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup

9-8218
9-8243 9-8210 9-8213 9-8232
9-8237

Torch Initial Kerf Width

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

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

16 0.063 119 0.19 350 0.20 0.00 0.05

14 0.078 116 0.19 300 0.20 0.10 0.07
11 0.125 123 0.19 150 0.20 0.10 0.07
10 0.141 118 0.19 125 0.20 0.10 0.08
3/16 0.188 85 (25') 122 0.19 90 0.20 0.20 0.08
1/4 0.250 90 (50') 123 0.19 65 0.20 0.30 0.09
3/8 0.375 130 0.19 30 0.20 0.50 0.09
1/2 0.500 132 0.19 21 0.20 0.90 0.08
5/8 0.625 132 0.19 14 Edge Start 0.11
3/4 0.750 135 0.19 10 Edge Start 0.10
Torch Initial Kerf Width
Material Arc Travel Pierce
Gas Pressure (Air) Working Piercing @ Rec.
Thickness Voltage Speed Delay
Height Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
1 124 4.8 10890 5.1 0.00 0.8
2 116 4.8 7560 5.1 0.10 1.7
3 122 4.8 4365 5.1 0.10 1.7
4 119 4.8 2865 5.1 0.20 2.1
5 122 4.8 2195 5.1 0.20 2.1
5.9 (7.6 m)
6 123 4.8 1790 5.1 0.30 2.2
8 6.2 (15.2 m) 127 4.8 1190 5.1 0.40 2.2
10 130 4.8 725 5.1 0.50 2.2
12 132 4.8 580 5.1 0.90 2.1
15 132 4.8 405 Edge Start 2.6
20 136 4.8 230 Edge Start 2.5
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-5119 OPERATION 4T-13

CUTMASTER A80, A120
Aluminum
60A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup

9-8218
9-8243 9-8210 9-8213 9-8232
9-8237

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
16 0.064 123 0.25 440 0.25 0.00 0.08
14 0.079 126 0.25 300 0.25 0.10 0.09
11 0.120 128 0.25 250 0.25 0.10 0.09
3/16 0.188 132 0.25 170 0.25 0.20 0.09
85 (25')
1/4 0.250 132 0.25 85 0.25 0.30 0.09
90 (50')
3/8 0.375 141 0.25 45 0.25 0.50 0.10
1/2 0.500 148 0.25 30 0.25 0.80 0.09
5/8 0.625 145 0.19 18 Edge Start 0.08
3/4 0.750 147 0.19 12 Edge Start 0.10
Torch Initial Kerf Width
Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

1 118 6.4 17010 6.4 0.00 1.8

2 126 6.4 7680 6.4 0.10 2.3
3 128 6.4 6410 6.4 0.10 2.3
4 130 6.4 5230 6.4 0.20 2.3
5 132 6.4 4010 6.4 0.20 2.4
5.9 (7.6 m)
6 132 6.4 2640 6.4 0.30 2.4
8 6.2 (15.2 m) 137 6.4 1630 6.4 0.40 2.4
10 142 6.4 1085 6.4 0.60 2.4
12 146 6.4 845 6.4 0.70 2.3
15 146 4.8 540 Edge Start 2.1
20 148 4.8 260 Edge Start 2.5

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

4T-14 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Mild Steel
80A
Air Plasma / Air Shield

Standard Shield Cup

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

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
16 0.060 110 0.19 320 0.20 0.00 0.06

11 0.120 113 0.19 230 0.20 0.10 0.07

10 0.135 110 0.19 180 0.20 0.20 0.07

3/16 0.188 110 0.19 136 0.20 0.30 0.07

1/4 0.250 85 (25') 115 0.19 100 0.20 0.40 0.09

3/8 0.375 125 0.19 42 0.20 0.50 0.09

90 (50')
1/2 0.500 123 0.19 40 0.20 0.60 0.09
5/8 0.625 133 0.19 18 0.20 0.75 0.10
3/4 0.750 140 0.25 18 Edge Start 0.11
7/8 0.875 150 0.25 10 Edge Start 0.11

1 1.000 152 0.25 8 Edge Start 0.13

Torch Initial Kerf Width
Material Arc Travel Pierce
Gas Pressure (Air) Working Piercing @ Rec.
Thickness Voltage Speed Delay
Height Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
1 109 4.8 8915 5.1 0.00 1.5
2 111 4.8 7415 5.1 0.10 1.7
3 113 4.8 5915 5.1 0.10 1.8
4 110 4.8 4095 5.1 0.30 1.7
5 111 4.8 3325 5.1 0.30 1.8
6 5.9 (7.6 m) 114 4.8 2745 5.1 0.40 2.2
8 120 4.8 1775 5.1 0.50 2.3
6.2 (15.2 m)
10 125 4.8 1060 5.1 0.50 2.3
12 123 4.8 1025 5.1 0.60 2.3
15 130 4.8 610 5.1 0.75 2.5
20 143 6.4 395 Edge Start 2.7
25 152 6.4 210 Edge Start 3.2

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

Manual 0-5119 OPERATION 4T-15

CUTMASTER A80, A120
Stainless Steel
80A
Air Plasma / Air Shield

Standard Shield Cup

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

Torch Initial Kerf Width

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

PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
16 0.063 110 0.19 340 0.25 0.00 0.06
11 0.125 115 .0.19 300 0.25 0.10 0.06
10 0.141 115 0.19 280 0.25 0.10 0.06
3/16 0.188 115 0.19 140 0.25 0.20 0.07
85 (25')
1/4 0.250 118 0.19 100 0.25 0.30 0.08
90 (50')
3/8 0.375 119 0.19 45 0.25 0.40 0.08
1/2 0.500 124 0.19 26 0.25 0.80 0.10
5/8 0.625 133 0.19 16 Edge Start 0.10
3/4 0.750 136 0.19 10 Edge Start 0.11
Torch Initial Kerf Width
Material Arc Travel Pierce
Gas Pressure (Air) Working Piercing @ Rec.
Thickness Voltage Speed Delay
Height Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
1 108 4.8 9020 6.4 0.00 1.5
2 111 4.8 8380 6.4 0.00 1.5
3 114 4.8 7730 6.4 0.10 1.5
4 115 4.8 5865 6.4 0.20 1.6
5 115 4.8 3410 6.4 0.20 1.8
5.9 (7.6 m)
6 117 4.8 2765 6.4 0.30 1.9
8 6.2 (15.2 m)
119 4.8 1815 6.4 0.40 2.0
10 120 4.8 1070 6.4 0.60 2.1
12 123 4.8 765 6.4 0.80 2.3
15 131 4.8 475 Edge Start 2.5
20 137 4.8 205 Edge Start 3.0
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

4T-16 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Aluminum
80A
Air Plasma / Air Shield

Standard Shield Cup

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

Torch Initial Kerf Width

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

PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
16 0.064 116 0.25 350 0.25 0.00 0.10
11 0.120 120 0.25 280 0.25 0.10 0.10
3/16 0.188 124 0.25 180 0.25 0.20 0.10

1/4 0.250 130 0.25 110 0.25 0.30 0.09

85 (25')
3/8 0.375 136 0.25 55 0.25 0.40 0.11
90 (50')
1/2 0.500 139 0.25 38 0.25 0.60 0.11
5/8 0.625 136 0.19 26 0.25 0.75 0.10
3/4 0.750 150 0.19 14 Edge Start 0.12
7/8 0.875 153 0.19 10 Edge Start 0.11
Torch Initial Kerf Width
Material Arc Travel Pierce
Gas Pressure (Air) Working Piercing @ Rec.
Thickness Voltage Speed Delay
Height Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

1 114 6.4 8890 6.4 0.00 2.4

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

Manual 0-5119 OPERATION 4T-17

CUTMASTER A80, A120
Mild Steel
100A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup
9-8218
9-8243
9-8237
9-8212 9-8213 9-8232

Torch Initial Kerf Width

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

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

1/4 0.250 110 0.18 85 0.20 0.10 0.09

3/8 0.375 112 0.18 75 0.20 0.20 0.09
1/2 0.500 115 0.18 45 0.20 0.40 0.10
75 (25')
5/8 0.625 118 0.18 30 0.20 0.60 0.11
75 (50')
3/4 0.750 120 0.18 20 0.20 1.20 0.12
1 1.000 123 0.18 15 Edge Start 0.12
1-1/4 1.250 128 0.18 8 Edge Start 0.13
Torch Initial Kerf Width
Material Travel Pierce
Gas Pressure (Air) Arc Voltage Working Piercing @ Rec.
Thickness Speed Delay
Height Height Speed

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
6 110 4.6 2200 5.1 0.10 2.3
8 111 4.6 2030 5.1 0.10 2.3
10 112 4.6 1790 5.1 0.20 2.3
12 5.2 (7.6 m) 114 4.6 1310 5.1 0.40 2.5
15 5.2 (15.2 m) 117 4.6 870 5.1 0.60 2.7
20 120 4.6 490 5.0 1.20 3.0
25 123 4.6 390 Edge Start 3.0
30 127 4.6 250 Edge Start 3.2
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

4T-18 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Stainless Steel
100A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup

9-8218
9-8243
9-8237
9-8212 9-8213 9-8232

Torch Initial Kerf Width

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

102 0.16 100 0.00 0.09

1/4 0.250 0.18
3/8 0.375 106 0.16 65 0.18 0.10 0.10
75 (25')
1/2 0.500 109 0.16 45 0.18 0.30 0.10

5/8 0.625 75 (50') 123 0.19 20 0.23 2.00 0.11

3/4 0.750 128 0.19 15 Edge Start 0.12

1 1.000 135 0.19 10 Edge Start 0.13

Torch Initial Kerf Width
Material Gas Pressure Travel
Arc Voltage Working Piercing Pierce Delay @ Rec.
Thickness (Air) Speed
Height Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
6 102 4.1 2630 4.6 0.00 2.3
8 104 4.1 2080 4.6 0.10 2.4
10 106 4.1 1575 4.6 0.20 2.4
5.2 (7.6 m)
12 108 4.1 1255 4.6 0.30 2.4
15 5.2 (15.2 m) 119 4.6 685 5.7 2.00 2.7
20 129 4.8 360 Edge Start 3.1

25 135 4.8 260 Edge Start 3.2

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

Manual 0-5119 OPERATION 4T-19

CUTMASTER A80, A120
Aluminum
100A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup

9-8218
9-8243 9-8212 9-8213 9-8232
9-8237

Torch Initial Kerf Width

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

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

1/4 0.250 110 0.19 100 0.20 0.00 0.09

3/8 0.375 124 0.19 65 0.20 0.20 0.10
1/2 0.500 75 (25') 128 0.19 45 0.20 0.30 0.11

5/8 0.625 75 (50') 132 0.19 35 0.20 0.50 0.11

3/4 0.750 135 0.19 20 0.20 2.00 0.13

1 1.000 140 0.19 10 Edge Start 0.13

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

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
6 109 4.8 2630 5.1 0.00 2.3
8 117 4.8 2080 5.1 0.10 2.5
10 125 4.8 1575 5.1 0.20 2.7
5.2 (7.6 m)
12 127 4.8 1255 5.1 0.30 2.7
15 5.2 (15.2 m) 131 4.8 960 5.1 0.50 2.8
20 136 4.8 470 6.0 2.00 3.3
25 140 4.8 270 Edge Start 3.4
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

4T-20 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Mild Steel
120A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup

9-8218
9-8243
9-8237
9-8233 9-8213 9-8232

Gas Torch Initial

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

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

1/4 0.250 134 0.19 150 0.25 0.10 0.11

3/8 0.375 141 0.19 85 0.25 0.30 0.11

1/2 0.500 141 0.19 70 0.25 0.80 0.12

5/8 0.625 146 0.19 45 0.25 1.00 0.12

80 (25')
3/4 0.750 150 0.19 30 0.25 1.20 0.12
80 (50')
7/8 0.875 160 0.25 25 Edge Start 0.14
1 1.000 163 0.25 19 Edge Start 0.14
1-1/4 1.250 168 0.25 12 Edge Start 0.15
1-1/2 1.500 172 0.25 8 Edge Start 0.16
Torch Initial
Material Gas Pressure Travel Pierce Kerf Width
Arc Voltage Working Piercing
Thickness (Air) Speed Delay @ Rec. Speed
Height Height
Bar
(mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm)
length)
6.0 133 4.8 3990 6.4 0.1 2.5
8.0 138 4.8 2950 6.4 0.2 2.7
10.0 141 4.8 2100 6.4 0.4 2.8
12.0 141 4.8 1860 6.4 0.6 2.9
15.0 5.5 (7.6 m) 145 4.8 1320 6.4 1.0 3.0
20.0 153 4.8 720 6.4 1.2 3.2
5.5 (15.2 m)
25.0 163 6.4 500 Edge Start 3.6
30.0 167 6.4 355 Edge Start 3.8
35.0 170 6.4 255 Edge Start 4.0

40.0 173 6.4 175 Edge Start 4.2

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

Manual 0-5119 OPERATION 4T-21

CUTMASTER A80, A120
Stainless Steel
120A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup

9-8218
9-8243
9-8237
9-8233 9-8213 9-8232

Torch Initial Kerf Width

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

1/4 0.250 133 0.19 180 0.25 0.20 0.10

3/8 0.375 136 0.19 100 0.25 0.40 0.11
1/2 0.500 140 0.19 60 0.25 0.80 0.11
80 (25')
5/8 0.625 152 0.25 40 0.30 1.20 0.13
80 (50')
3/4 0.750 154 0.25 26 Edge Start 0.14

1 1.000 159 0.25 16 Edge Start 0.14

1-1/4 1.250 167 0.25 8 Edge Start 0.14
Torch Initial Kerf Width
Material Travel
Gas Pressure (Air) Arc Voltage Working Piercing Pierce Delay @ Rec.
Thickness Speed
Height Height Speed

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
6 133 4.8 4800 6.4 0.2 2.6
8 135 4.8 3520 6.4 0.2 2.7
10 137 4.8 2390 6.4 0.5 2.8
12 5.5 (7.6 m) 139 4.8 1750 6.4 0.8 2.9
15 149 6.4 1160 7.6 1.2 3.4
5.5 (15.2 m)
20 155 6.4 625 Edge Start 3.6
25 159 6.4 425 Edge Start 3.6
30 165 6.4 260 Edge Start 3.6
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

4T-22 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Aluminum
120A
Air Plasma / Air Shield

Standard Shield Cup

Deflector Tip Starter Cartridge Electrode
Maximum Life Shield Cup
9-8218
9-8243
9-8237
9-8233 9-8213 9-8232

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
1/4 0.250 139 0.19 180 0.25 0.30 0.11
3/8 0.375 140 0.19 110 0.25 0.50 0.11
1/2 0.500 80 (25') 143 0.19 75 0.25 0.80 0.11

5/8 0.625 80 (50') 156 0.25 50 0.30 1.00 0.12

3/4 0.750 161 0.25 34 Edge Start 0.13

1 1.000 167 0.25 23 Edge Start 0.14

Torch Initial Kerf Width
Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
6 139 4.8 4770 6.4 0.2 2.8
8 140 4.8 3650 6.4 0.2 2.8
10 140 4.8 2660 6.4 0.5 2.8
5.5 (7.6 m)
12 142 4.8 2100 6.4 0.8 2.8
15 5.5 (15.2 m) 152 6.4 1445 7.6 1.2 3.0
20 162 6.4 820 Edge Start 3.4
25 167 6.4 600 Edge Start 3.4
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-5119 OPERATION 4T-23

CUTMASTER A80, A120
4T.09 Recommended Cutting Speeds for Machine and Automated Torches With
Shielded Tip

Mild Steel
40A CUTMASTER A120
Air Plasma / Air Shield
ONLY

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

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
20 0.036 107 0.16 130 0.16 0.0 0.06
16 0.060 113 0.16 120 0.16 0.0 0.06
14 0.075 108 0.16 90 0.16 0.1 0.06
12 0.105 111 0.16 75 0.16 0.2 0.06
75 (25')
10 0.135 114 0.16 65 0.16 0.3 0.07
80 (50')
3/16 0.188 115 0.16 65 0.16 0.4 0.07
1/4 0.250 118 0.16 45 0.16 0.5 0.07
3/8 0.375 123 0.16 23 0.16 1.2 0.08
1/2 0.500 128 0.16 18 0.16 2.0 0.08
Torch Initial Kerf Width
Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

1 108 4.1 3266 4.1 0.0 1.4

2 108 4.1 2239 4.1 0.0 1.5
3 112 4.1 1794 4.1 0.1 1.7
4 5.2 (7.6 m) 114 4.1 1651 4.1 0.2 1.7
5 115 4.1 1578 4.1 0.3 1.7
5.5 (15.2 m)
6 117 4.1 1256 4.1 0.4 1.7
8 121 4.1 853 4.1 0.5 1.7
10 124 4.1 565 4.1 1.2 1.8
12 127 4.1 485 4.1 2.0 1.9
BOLD TYPE indicates maximum piercing parameters.

4T-24 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Stainless Steel
40A
Air Plasma / Air Shield CUTMASTER A120
ONLY

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

Torch Initial Kerf Width

Material Gas Pressure Travel
Arc Voltage Working Piercing Pierce Delay @ Rec.
Thickness (Air) Speed
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
18 0.050 110 0.16 60 4.1 0.0 0.06
16 0.063 108 0.16 50 4.1 0.1 0.07
14 0.078 114 0.16 45 4.1 0.1 0.07
12 0.109 113 0.16 40 4.1 0.2 0.07
75 (25')
10 0.141 116 0.16 35 4.1 0.3 0.07
80 (50')
3/16 0.188 115 0.16 30 4.1 0.4 0.07
1/4 0.250 118 0.16 20 4.1 1.2 0.07
3/8 0.375 125 0.16 15 4.1 1.8 0.08
1/2 0.500 127 0.16 10 4.1 2.0 0.08
Torch Initial Kerf Width
Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

1 109 4.1 1670 4.1 0.0 1.7

2 114 4.1 1140 4.1 0.1 1.8
3 114 4.1 980 4.1 0.2 1.8
4 5.2 (7.6 m) 116 4.1 845 4.1 0.3 1.8
5 115 4.1 725 4.1 0.4 1.8
5.5 (15.2 m)
6 117 4.1 565 4.1 0.5 2.0
8 122 4.1 440 4.1 1.5 2.0
10 125 4.1 360 4.1 1.8 2.0
12 127 4.1 280 4.1 2.0 2.2
BOLD TYPE indicates maximum piercing parameters.

Manual 0-5119 OPERATION 4T-25

CUTMASTER A80, A120
Aluminum
40A
Air Plasma / Air Shield
CUTMASTER A120
ONLY

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

Torch Initial Kerf Width

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

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

20 0.040 110 0.19 300 0.20 0.0 0.06

16 0.063 113 0.19 170 0.20 0.1 0.07
12 0.097 120 0.19 100 0.20 0.2 0.07
11 0.125 75 (25') 125 0.19 90 0.20 0.3 0.07
9 0.160 80 (50') 126 0.19 85 0.20 0.4 0.07
3/16 0.188 128 0.19 70 0.20 0.5 0.07
1/4 0.250 137 0.19 30 0.20 1.0 0.08
3/8 0.375 145 0.19 10 0.20 2.0 0.09
Torch Initial Kerf Width
Material Travel Pierce
Gas Pressure (Air) Arc Voltage Working Piercing @ Rec.
Thickness Speed Delay
Height Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
1.0 110 4.8 7660 5.1 0.0 1.6
2.0 116 4.8 3490 5.1 0.2 1.8
3.0 124 4.8 2350 5.1 0.3 1.8
4.0 5.2 (7.6 m) 126 4.8 2170 5.1 0.4 1.8
5.0 5.5 (15.2 m) 129 4.8 1630 5.1 0.6 1.8
6.0 135 4.8 990 5.1 1.0 1.9
8.0 141 4.8 500 5.1 1.6 2.0
10.0 146 4.8 180 5.1 2.1 2.3
BOLD TYPE indicates maximum piercing parameters.

4T-26 OPERATION Manual 0-5119

 CUTMASTER A80, 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 9-8232

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
16 0.060 128 0.19 250 0.20 0.00 0.09
14 0.075 129 0.19 237 0.20 0.10 0.09
11 0.120 126 0.19 200 0.20 0.10 0.08
10 0.135 128 0.19 142 0.20 0.10 0.09
3/16 0.188 132 0.19 115 0.20 0.20 0.09
85 (25')
1/4 0.250 134 0.19 80 0.20 0.30 0.08
90 (50')
3/8 0.375 132 0.19 34 0.20 0.70 0.10
1/2 0.500 144 0.19 23 0.20 0.75 0.10
5/8 0.625 150 0.19 14 Edge Start 0.10
3/4 0.750 145 0.19 14 Edge Start 0.10
1 1.000 160 0.19 4 Edge Start 0.12
Torch Initial Kerf Width
Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) oltage Speed Delay
Height Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
1 127 4.8 6804 5.1 0 2.2
2 129 4.8 5942 5.1 0.10 2.2
3 126 4.8 5080 5.1 0.10 0.1
4 130 4.8 3316 5.1 0.20 2.3
5 132 4.8 2794 5.1 0.20 2.2
5.9 (7.6 m)
6 134 4.8 2230 5.1 0.30 2.1
8 6.2 (15.2 m) 133 4.8 1425 5.1 0.40 2.3
10 134 4.8 822 5.1 0.60 2.5
12 141 4.8 646 5.1 0.75 2.5
15 148 4.8 419 Edge Start 2.6
20 147 4.8 318 Edge Start 2.7
25 159 4.8 118 Edge Start 3.0
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-5119 OPERATION 4T-27

CUTMASTER A80, 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 9-8232

Torch Initial Kerf Width

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

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

16 0.063 110 0.13 165 0.20 0.00 0.06

14 0.078 116 0.13 155 0.20 0.10 0.07
11 0.125 118 0.13 125 0.20 0.10 0.07
10 0.141 126 0.13 80 0.20 0.10 0.09
3/16 0.188 85 (25') 125 0.13 75 0.20 0.20 0.09
1/4 0.250 90 (50') 127 0.13 60 0.20 0.30 0.08
3/8 0.375 134 0.13 28 0.20 0.50 0.08
1/2 0.500 136 0.19 17 0.25 0.75 0.09
5/8 0.625 131 0.13 14 Edge Start 0.08
3/4 0.750 142 0.19 10 Edge Start 0.11
Torch Initial Kerf Width
Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

1 101 3.3 4590 5.1 0.00 1.2

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

4T-28 OPERATION Manual 0-5119

 CUTMASTER A80, 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 9-8232

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
16 0.064 118 0.13 350 0.20 0.00 0.07
14 0.079 118 0.13 350 0.20 0.10 0.08
11 0.120 123 0.13 275 0.20 0.10 0.08
3/16 0.188 125 0.13 140 0.20 0.20 0.08
85 (25')
1/4 0.250 132 0.13 80 0.20 0.30 0.08
90 (50')
3/8 0.375 135 0.13 45 0.20 0.50 0.08
1/2 0.500 140 0.13 26 0.20 0.80 0.08
5/8 0.625 148 0.19 18 Edge start 0.10
3/4 0.750 155 0.19 12 Edge start 0.11
Torch Initial Kerf Width
Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
1 118 6.4 8890 6.4 0.00 2
2 118 6.4 8890 6.4 0.10 2.0
3 123 6.4 7070 6.4 0.10 2.1
4 124 6.4 5095 6.4 0.20 2.0
5 5.9 (7.6 m) 126 6.4 3335 6.4 0.20 2.0
6 130 6.4 2370 6.4 0.30 2.0
6.2 (15.2 m)
8 134 6.4 1570 6.4 0.40 2.0
10 136 6.4 1070 6.4 0.60 2.0
12 139 6.4 765 6.4 0.70 2.0
15 146 4.8 515 Edge start 2.4
20 157 4.8 260 Edge start 2.7
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-5119 OPERATION 4T-29

CUTMASTER A80, A120
Mild Steel
80A
Air Plasma / Air Shield

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

Torch Initial Kerf Width

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

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

16 0.060 115 0.13 280 0.20 0.00 0.06

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

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

1 116 3.3 7895 5.1 0.00 1.6

2 114 3.3 6395 5.1 0.10 1.6
3 112 3.3 4895 5.1 0.10 1.5
4 115 4.8 4025 5.1 0.30 1.7
5 123 4.8 3300 5.1 0.30 2.0
5.9 (7.6 m)
6 126 4.8 2735 5.1 0.40 2.2
8 6.2 (15.2 m) 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.

4T-30 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Stainless Steel
80A
Air Plasma / Air Shield

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

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
16 0.063 114 0.125 340 0.2 0.00 0.06
11 0.125 115 0.125 260 0.2 0.10 0.06
10 0.141 116 0.125 250 0.2 0.10 0.06
3/16 0.188 115 0.125 170 0.2 0.20 0.07
85 (25')
1/4 0.250 118 0.125 85 0.2 0.30 0.08
90 (50')
3/8 0.375 127 0.19 45 0.25 0.40 0.09
1/2 0.500 136 0.19 16 0.25 0.75 0.11
5/8 0.625 143 0.19 10 Edge Start 0.12
3/4 0.750 146 0.19 8 Edge Start 0.11
Torch Initial Kerf Width
Material Gas Pressure Travel Pierce
Arc Voltage Working Piercing @ Rec.
Thickness (Air) Speed Delay
Height Height Speed

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

Manual 0-5119 OPERATION 4T-31

CUTMASTER A80, A120
Aluminum
80A
Air Plasma / Air Shield

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

Torch Initial Kerf Width

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

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

16 0.064 115 0.13 320 0.2 0.00 0.09

11 0.120 120 0.13 240 0.2 0.10 0.08

3/16 0.188 122 0.13 165 0.2 0.20 0.08

0.250 85 (25') 0.10
1/4 124 0.13 100 0.2 0.30
3/8 0.375 90 (50') 140 0.19 60 0.2 0.40 0.09

1/2 0.500 142 0.19 36 0.2 0.60 0.11

5/8 0.625 148 0.19 26 0.2 0.75 0.11
3/4 0.750 155 0.19 16 Edge Start 0.12
Torch Initial Kerf Width
Material Travel Pierce
Gas Pressure (Air) Arc Voltage Working Piercing @ Rec.
Thickness Speed Delay
Height Height Speed

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
1 113 3.3 9020 5.1 0.00 2.4
2 116 3.3 7595 5.1 0.00 2.2
3 120 3.3 6165 5.1 0.10 2.0
4 121 3.3 5045 5.1 0.20 2.1
5 5.9 (7.6 m) 122 3.3 3955 5.1 0.20 2.2
6 124 3.3 2905 5.1 0.30 2.3
6.2 (15.2 m)
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.

4T-32 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Mild Steel
100A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode
9-8239 9-8237 9-8233 9-8213 9-8232

Torch Initial Kerf Width

Material Gas Pressure Travel Pierce
Arc Voltage Working Piercing @ Rec.
Thickness (Air) Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
1/4 0.250 114 0.16 85 0.18 0.00 0.08

3/8 0.375 112 0.16 70 0.18 0.20 0.09

1/2 0.500 115 0.16 40 0.18 0.30 0.10

75 (25')
5/8 0.625 123 0.16 30 0.18 0.40 0.10
75 (50')
3/4 0.750 127 0.16 20 0.18 0.80 0.11

1 1.000 133 0.16 12 Edge Start 0.12

1-1/4 1.250 135 0.16 8 Edge Start 0.12
Torch Initial Kerf Width
Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)
6 114 4.1 2210 4.6 0.00 2.0
8 113 4.1 1960 4.6 0.10 2.2
10 112 4.1 1665 4.6 0.20 2.3
12 5.2 (7.6 m) 114 4.1 1185 4.6 0.30 2.4
15 5.2 (15.2 m) 121 4.1 830 4.6 0.40 2.5
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.

Manual 0-5119 OPERATION 4T-33

CUTMASTER A80, A120
Stainless Steel
100A
Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode
9-8239 9-8237 9-8212 9-8213 9-8232

Torch Initial Kerf Width

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

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

1/4 0.250 114 0.16 110 0.18 0.00 0.08

3/8 0.375 116 0.16 70 0.18 0.10 0.09
1/2 0.500 75 (25') 119 0.16 45 0.18 0.30 0.10

5/8 0.625 75 (50') 130 0.19 20 0.23 2.00 0.11

3/4 0.750 135 0.19 15 0.23 2.80 0.11

1 1.000 140 0.19 10 Edge Start 0.11

Torch Initial Kerf Width

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

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

6 114 4.1 2900 4.6 0.00 2.0

8 115 4.1 2265 4.6 0.10 2.2
10 5.2 (7.6 m) 116 4.1 1685 4.6 0.20 2.4
12 118 4.1 1285 4.6 0.30 2.4
5.2 (15.2 m)
15 127 4.6 685 5.7 2.00 2.7
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.

4T-34 OPERATION Manual 0-5119

 CUTMASTER A80, 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 9-8232

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
1/4 0.250 121 0.18 110 0.19 0.00 0.10
3/8 0.375 129 0.18 60 0.19 0.20 0.10
1/2 0.500 75 (25') 135 0.18 45 0.19 0.30 0.11

5/8 0.625 75 (50') 133 0.18 32 0.19 0.60 0.11

3/4 0.750 138 0.18 25 0.19 2.00 0.11

1 1.000 143 0.18 15 Edge Start 0.14

Torch Initial Kerf Width

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

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

6 120 4.6 2920 4.8 0.00 2.5

8 125 4.6 2135 4.8 0.10 2.5
10 130 4.6 1470 4.8 0.20 2.6
5.2 (7.6 m)
12 134 4.6 1230 4.8 0.30 2.7
15 5.2 (15.2 m) 134 4.6 905 4.8 0.60 2.9
20 139 4.6 595 6.0 2.00 3.0
25 143 4.6 395 Edge Start 3.6
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Manual 0-5119 OPERATION 4T-35

CUTMASTER A80, A120
Mild Steel
120A CUTMASTER A120
Air Plasma / Air Shield
ONLY

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode
9-8256 9-8237 9-8233 9-8213 9-8232

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
1/4 0.250 139 0.125 160 0.20 0.20 0.11
3/8 0.375 140 0.125 85 0.20 0.20 0.11
1/2 0.500 142 0.125 75 0.20 0.50 0.10
5/8 0.625 144 0.125 45 0.20 0.70 0.11
80 (25')
3/4 0.750 150 0.125 30 0.25 1.50 0.12
80 (50')
7/8 0.875 158 0.175 25 Edge Start 0.13
1 1.000 160 0.175 22 Edge Start 0.14
1-1/4 1.250 165 0.175 15 Edge Start 0.17
1-1/2 1.500 171 0.175 8 Edge Start 0.15

Torch Initial Kerf Width

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

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

6 139 4.8 4270 5.08 0.20 2.8

8 140 4.8 3070 5.1 0.2 2.8
10 140 6.4 2120 5.08 0.30 2.8
12 142 6.4 1960 5.08 0.50 2.8
5.5 (7.6 m)
15 143 4.8 1355 5.08 0.70 2.8
20 5.5 (15.2 m) 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.

4T-36 OPERATION Manual 0-5119

 CUTMASTER A80, A120
Stainless Steel
120A CUTMASTER A120
Air Plasma / Air Shield
ONLY

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode
9-8256 9-8237 9-8233 9-8213 9-8232

Torch Initial Kerf Width

Material Gas Pressure Arc Travel Pierce
Working Piercing @ Rec.
Thickness (Air) Voltage Speed Delay
Height Height Speed
PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
1/4 0.250 140 0.13 180 0.20 0.30 0.11
3/8 0.375 140 0.13 100 0.20 0.40 0.12
1/2 0.500 142 0.15 65 0.25 0.80 0.12
80 (25')
5/8 0.625 152 0.15 40 0.25 1.00 0.12
80 (50')
3/4 0.750 150 0.15 26 Edge Start 0.13
1 1.000 155 0.15 16 Edge Start 0.13
1-1/4 1.250 165 0.15 8 Edge Start 0.13

Torch Initial Kerf Width

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

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

6 140 4.8 4800 5.1 0.3 2.8

8 140 4.8 3520 5.1 0.4 2.7

10 140 4.8 2410 5.1 0.6 3.0

5.5 (7.6 m)
12 142 4.8 1850 6.4 0.8 3.1
15 5.5 (15.2 m) 149 6.4 1190 6.4 1.0 3.1
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.

Manual 0-5119 OPERATION 4T-37

CUTMASTER A80, A120
Aluminum
120A CUTMASTER A120
Air Plasma / Air Shield ONLY

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode
9-8256 9-8237 9-8233 9-8213 9-8232

Torch Initial Kerf Width

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

PSI
(GA) (in) inch Volts (in) (ipm) (in) (sec) (in)
(torch lead length)
1/4 0.250 140 0.13 180 0.20 0.20 0.10
3/8 0.375 142 0.13 110 0.20 0.30 0.11
1/2 0.500 80 (25') 148 0.13 75 0.20 0.50 0.11
5/8 0.625 80 (50') 156 0.15 45 0.25 0.80 0.11
3/4 0.750 158 0.15 35 Edge Start 0.11
1 1.000 164 0.15 23 Edge Start 0.12

Torch Initial Kerf Width

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

Bar
(mm) Volts (mm) (mm/min) (mm) (sec) (mm)
(torch lead length)

6 140 4.8 4770 5.1 0.2 2.6

8 141 4.8 3650 5.1 0.3 2.6
10 5.5 (7.6 m) 143 4.8 2660 5.1 0.4 2.7
12 147 4.8 2100 5.1 0.5 2.8
5.5 (15.2 m)
15 154 4.8 1355 6.4 0.8 2.8
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.

4T-38 OPERATION Manual 0-5119

 CUTMASTER A80, 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
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
9-8233 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

Manual 0-5119 OPERATION 4T-39

CUTMASTER A80, A120
Plasma Cutting Torch Patents
The following parts are covered under U.S. and Foreign Patents as follows:
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

4T-40 OPERATION Manual 0-5119

 CUTMASTER A80, A120
SECTION 4 SYSTEM: 1 2 3 4

OPERATION
4.01 Front Panel Controls / Features
A
MIN MAX
PSI BAR

See Illustration for numbering Identification

MAX MAX

1. Output Current Control

MIN MIN

Sets the desired output current. Output settings

up to 60 Amps may be used for drag cutting, when !

hand torch is used and the torch tip contacting

the workpiece or higher for standoff cutting. For
automation current control settings greater than
45 Amps will stop the arc and remove the “OK to
Move” signal when the tip contacts the plate. For
currents below 45 Amps the cutting will continue Art# A-07886

even when the tip is in contact with the work. 5 6 7 8 9 10

2. Function Control
Function Control Knob, Used to select between 6. Temp Indicator
the different operating modes. Indicator is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Let
SET Used to purge the air through the unit the unit cool before continuing operation.
and torch and leads and to adjust gas pressure.

RUN Used for general cutting operations 7. Gas Indicator

RAPID AUTO RESTART Allows for faster re- Indicator is ON when minimum input gas pressure
starting of the Pilot Arc for uninterrupted cutting. for power supply operation is present. Minimum
pressure for power supply operation is not suf-
LATCH Used for longer hand held or ficient for torch operation.
mechanical cuts. This feature is disabled while
the automation torch is used, and is enabled when 8. DC Indicator
a hand torch is connected. Once a cutting arc is
established, the torch switch can be released. The Indicator is ON when DC output circuit is active.
cutting arc will remain ON until the torch is lifted
away from the work piece, the torch leaves the 9. ! Fault Error Indicator
edge of the work piece the torch switch is activated
again or if one of the system interlocks is activated. Indicator is ON when Fault circuit is active. See
section 5 for explanations of fault lights.
3. ON OFF Power Switch
10. Pressure Indicators
ON / OFF Switch controls input power to
the power supply. Up is ON, down is OFF. PSI BAR
MAX MAX

4. Air/Gas Pressure Control 90 6.3

85 5.9
The Pressure + Control is used in the
80 5.5
"SET" mode to adjust the air/gas pressure. Pull
the knob out to adjust and push in to lock. 75 5.2
Art # A-08170

70 4.8
5. AC Indicator
65 4.5
Steady light indicates power supply is ready for MIN MIN
operation. Blinking light indicates unit is in pro-
tective interlock mode. Shut unit OFF, shut OFF The Indicators will illuminate according to the
or disconnect input power, correct the fault, and pressure set by the Pressure Control Knob (num-
restart the unit. Refer to Section 5 for details. ber 4).

Manual 0-5119 OPERATION 4-1

CUTMASTER A80, A120
4.02 Preparations for Operation
Gas indicator turns ON if there is sufficient
At the start of each operating session: gas pressure for power supply operation and the
cooling fans turn ON.
NOTE
WARNING
Minimum pressure for power supply operation is
Disconnect primary power at the source before lower than minimum for torch operation.
assembling or disassembling power supply, The cooling fans will turn ON as soon as the
torch parts, or torch and leads assemblies. 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
Torch Parts Selection (Start Signal) is activated or if the unit is turned
Check the torch for proper assembly and appropri- OFF, then turned ON again. If an over tempera-
ate torch parts. The torch parts must correspond ture condition occurs, the fans will continue to
with the type of operation, and with the amperage run while the condition exists and for a ten (10)
output of this Power Supply (120 amps maximum). minute period once the condition is cleared.
Refer to Section 4T.07 and following for torch parts
selection. Set Operating Pressure
1. Place the Power Supply Function Control knob
Torch Connection
to the SET position. Gas will flow.
Check that the torch is properly connected. Only
Thermal Dynamics model SL100 / Manual or
SL100 / Mechanical Torches may be connected to 2. For Standoff cutting, adjust gas pressure from
this Power Supply. See Section 3T of this manual. 70 - 85 psi / 4.8 - 5.9 bar (LED's in center of
control panel). Refer to the Standoff chart for
Check Primary Input Power Source pressure setting details.

1. Check the power source for proper input volt-

1 2
age. Make sure the input power source meets
the power requirements for the unit per Section
2, Specifications.
2. Connect the input power cable (or close the
main disconnect switch) to supply power to MIN
A MAX
PSI BAR

the system.
MAX MAX

Air Source
MIN MIN

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 work- Art# A-07946
piece; do not connect to the part to be cut off.
STANDOFF
Gas Pressure Settings
SL100
Leads SL100 (Mechanized Torch)
Length (Hand Torch) SL100 SV
(Automation Torch)
Up to 50' 75 psi 75 psi
Art # A-04509 (7.6 m) 5.2 bar 5.2 bar

Power ON Each additional Add 5 psi Add 5 psi

Place the Power Supply ON / OFF switch to the 25' (7.6 m) 0.4 bar 0.4 bar
ON (up) position. AC indicator turns ON.

4-2 OPERATION Manual 0-5119

 CUTMASTER A80, A120
3. For Drag cutting (60 Amps and below), adjust Postflow
gas pressure from 75 - 95 psi / 5.2 - 6.5 bar
(LED's in center of control panel). Refer to the Release the trigger to stop the cutting arc. Gas
Drag Cutting chart for pressure setting details. continues to flow for approximately 20 seconds.
During post - flow, if the user moves the trigger
DRAG (60 amps or less) release to the rear and presses the trigger, the pilot
arc starts. The main arc transfers to the workpiece
Gas Preassure Settings
if the torch tip is within transfer distance to the
SL100 workpiece.
Leads Length (Hand Torch)
Up to 25' 80 psi Shutdown
(7.6 m) 5.5 bar
Each Additional Ad 5 psi Turn the ON / OFF switch to OFF
25' (7.6 m) 0.4 bar (down). All Power Supply indicators shut OFF.
Unplug the input power cord or disconnect input
Select Current Output Level power. Power is removed from the system.
1. Place the Function Control Knob in one of
the three operating positions available:

RUN ,

RAPID AUTO RESTART

or LATCH . Gas flow stops.

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

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 cut-
ting operations with the Function Control Knob
in the RUN position, there is a brief delay in re-
starting 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 op-
erator 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.

Manual 0-5119 OPERATION 4-3

CUTMASTER A80, A120

This Page Intentionally Blank

4-4 OPERATION Manual 0-5119

 CUTMASTER A80, A120

SECTION 5 SYSTEM:
SERVICE
5.01 General Maintenance
Maintain more often
Warning! if used under severe
Disconnect input power before maintaining. conditions

Each Use

Visual check of
torch tip and electrode

Weekly

Visually inspect the

cables and leads.
Visually inspect the torch body tip, Replace as needed
electrode, start cartridge and shield cup

3 Months

Replace all
Clean
broken parts
exterior
of power supply

6 Months

Visually check and

Carefully clean the
interior

Art # A-07938_AB

Manual 0-5119 SERVICE 5-1

CUTMASTER A80, A120
5.02 Maintenance Schedule 5.03 Common Faults
NOTE Problem - Symptom Common Cause
The actual frequency of maintenance may need Insufficient 1. Cutting speed too fast.
to be adjusted according to the operating envi- Penetration 2. Torch tilted too much.
ronment. 3. Metal too thick.
4. Worn torch parts
Daily Operational Checks or Every Six 5. Cutting current too low.
Cutting Hours: 6. Non - Genuine Thermal
Dynamics parts used
1. Check torch consumable parts, replace if dam- 7. Incorrect gas pressure
aged or worn.
Main Arc 1. Cutting speed too slow.
2. Check plasma and secondary supply and pres- Extinguishes 2. Torch standoff too high from
sure/flow. workpiece.
3. Cutting current too high.
3. Purge plasma gas line to remove any moisture 4. Work cable disconnected.
build-up. 5. Worn torch parts.
6. Non - Genuine Thermal
Weekly or Every 30 Cutting Hours: Dynamics parts used
1. Check fan for proper operation and adequate Excessive Dross 1. Cutting speed too slow.
air flow. Formation 2. Torch standoff too high from
2. Inspect torch for any cracks or exposed wires, workpiece.
replace if necessary. 3. Worn torch parts.
4. Improper cutting current.
3. Inspect input power cable for damage or ex- 5. Non - Genuine Thermal
posed wires, replace if necessary. Dynamics parts used
6. Incorrect gas pressure
Six Months or Every 720 Cutting Hours: Short Torch 1. Oil or moisture in air source.
1. Check the in-line air filter(s), clean or replace Parts Life 2. Exceeding system capability
as required (material too thick).
3. Excessive pilot arc time
2. Check cables and hoses for leaks or cracks, 4. Gas pressure too low.
replace if necessary. 5. Improperly assembled torch.
3. Check all contactor points for severe arcing or 6. Non - Genuine Thermal
pits, replace if necessary. Dynamics parts used
Difficult Starting 1. Worn torch parts.
4. Vacuum dust and dirt out of the entire machine.
2. Non - Genuine Thermal
Dynamics parts used.
3. Incorrect gas pressure.
CAUTION
Do not blow air into the power supply during
cleaning. Blowing air into the unit can cause
metal particles to interfere with sensitive electri-
cal components and cause damage to the unit.

5-2 SERVICE Manual 0-5119

 CUTMASTER A80, A120
5.04 Fault Indicator
At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used.
To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second
digit count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp
indicator and 76 psi indicators are ON indicating the version would be 2.3.

7
6
5 MIN
A
MAX
PSI
MAX
BAR
MAX

+
4
3
2
1 MIN MIN

0
!

Art# A-07988
1 2 3 4 5

When the ! "Fault" indicator is ON or blinking it will be accompanied by one of the pressure indicator
lights 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

NOTE
Fault explanations are covered in the following tables.

Manual 0-5119 SERVICE 5-3

CUTMASTER A80, 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 1. Primary power disconnect is in 1. Turn primary power disconnect switch to ON position.
is ON but the A/C OFF position.
Indicator does not 2. Primary fuses / breakers are 2. a) Have qualified person check primary fuses / breakers.
light blown or tripped. b) Connect unit to known good primary power receptacle
3. Units internal fuse blown. 3. a) Replace fuse.
b) If fuse blows again, return to authorized service center for
repair or replacement.
4. Faulty components in unit. 4. Return to authorized service center for repair or
replacement.
Fault indicator 1. INPUT VOLTAGE SELECTION 1. Set INPUT VOLTAGE SELECTION SWITCH to match primary
flashing, 65 PSI SWITCH set for incorrect input voltage.
indicator flashing voltage.
2. Primary input voltage problem. 2. Have qualified person check primary voltage to insure it
meets unit requirements see section 2.05.
3. Faulty components in unit. 3. Return to authorized service center for repair or
replacement.
TEMPERATURE 1. Air flow through or around the 1. Refer to clearance information – section 2.04
indicator ON. unit is obstructed.
FAULT indicator 2. Duty cycle of the unit has been 2. Allow unit to cool.
flashing. exceeded
3. Failed components in unit 3. Return to authorized service center for repair or
replacement.
GAS LED OFF, 1. Gas supply not connected to 1. Connect gas supply to unit.
FAULT and MIN unit.
pressure indicators 2. Gas supply not turned ON. 2. Turn gas supply ON.
flashing. 3. Gas supply pressure too low. 3. Set air supply inlet pressure to unit to 120 psi.
4. AIR PRESSURE CONTROL 4. Adjust regulator to set air pressure - see section 4.02.
regulator set too low.
5. Failed components in unit. 5. Return to authorized service center for repair or
replacement.
FAULT and 70 PSI 1. Shield Cup loose. 1. Hand tighten the shield cup until it is snug.
indicators flashing. 2. Torch not properly connected 2. Insure torch ATC is securely fastened to unit.
to power supply.
3. Problem in torch and leads PIP 3. Replace torch and leads or return to authorized service
circuit. center for repair or replacement.
4. Failed components in unit. 4. Return to authorized service center for repair or
replacement.

FAULT and 75 PSI 1. Start signal is active when 1. Start can be active for one of the following:
indicators flashing. ON/OFF SWITCH is turned to • Hand torch switch held closed
ON position. • Hand pendant switch held closed
• CNC START signal is active low Release the START signal
source
2. Problem in the torch and leads 2. Replace torch and leads or return to authorized service
switch circuit. center for repair or replacement.
3. Failed components in unit. 3. Return to authorized service center for repair or
replacement.

5-4 SERVICE Manual 0-5119

 CUTMASTER A80, 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. missing parts.
on and OFF. 3. Torch start cartridge is stuck. 3. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and start cartridge. Check start
cartridge lower end fitting for free movement. Replace if
fitting does not move freely.
4. Open conductor in torch leads. 4. Replace torch and leads or return to authorized service
center for repair or replacement.
5. Problem in the torch and leads 5. Replace torch and leads or return to authorized service
switch circuit. center for repair or replacement.
6. Failed components in unit. 6. Return to authorized service center for repair or
replacement.
Nothing happens 1. Problem in the torch and leads 1. Take Torch and Leads (Remote Pendant) to Authorized
when torch switch switch circuit (Remote pendant Repair Facility.
or remote switch switch circuit).
is closed (Or CNC 2. CNC Contoller device not 2. Contact Controller manufacturer.
START signal is providing Start signal.
active) No gas flow, 3. Failed components in unit. 3. Return to authorized service center for repair or
DC LED OFF. replacement.
FAULT and 85 PSI 1. Upper O-Ring on torch head is 1. Remove shield cup from torch; check upper O-Ring
indicators flashing. in wrong position. position; correct if necessary.
2. Torch starter cartridge is stuck. 2. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if
fitting does not move freely.
3. Worn or faulty torch parts. 3. Inspect torch consumable parts. Replace if necessary.
4. Shorted Torch. 4. Replace torch and leads or return to an authorized service
center for repair.
5. Temporary Short indicated by 5 5. Release torch switch and reactivate.
blinks per second.
6. Power Supply Failure (Standard 6. Return to authorized service center for repair or
rate of blinking) replacement.
No Fault lights ON, no 1. Failed components in unit. 1. Return to an authorized service center for repair.
arc in torch.
FAULT and 85 PSI 1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that
indicators flashing does not clear the fault, return to an authorized service
center for repair.
Pilot arc is ON but 1. Work cable not connected to 1. Connect work cable.
cutting arc will not work piece.
establish 2. Work cable/connector broken. 2. Replace work cable.
3. Failed components in unit. 3. Return to an authorized service center for repair.

Torch cutting is 1. Incorrect current setting. 1. Check and adjust to proper setting.
diminished 2. Worn torch consumables. 2. Check torch consumables and replace as needed.
3. Poor work cable connection to 3. Check the connection of the Work Lead to the work piece.
work piece.
4. Torch being moved too fast. 4. Reduce cutting speed.
5. Excessive oil or water in torch. 5. Refer to "Check air quality" in section 3 Torch.
6. Failed components in unit. 6. Return to an authorized service center for repair.

Manual 0-5119 SERVICE 5-5

CUTMASTER A80, A120
5.06 Power Supply Basic Parts C. Filter Element Assembly Replacement
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
! WARNING
5.02), and either cleaned or replaced.
1. Remove power from the power supply; turn
Disconnect primary power to the system before OFF the gas supply and bleed down the sys-
disassembling the torch, leads, or power supply. tem.
2. Remove the system cover. See "A Cover Re-
This section describes procedures for basic parts moval" in this section.
replacement. For more detailed parts replacement
procedures, refer to the Power Supply Service Manual. 3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
illustration.
A. Cover Removal
4. Hold a wrench or similar tool against the lock-
1. Remove the upper and lower screws which
ing ring on the filter assembly fitting, then pull
secure the cover to the main assembly. Do not
on the hose to release it. (Numbers 2 and 3 in
loosen the lower screws inside the cut out slots
the following illustration).
in the bottom of the cover.

Upper
Screws

Lower 1
Screws

Slots

Lower
Screws

Art # A-07989

Art # A-08429

2. Carefully pull the Cover up and away from the

unit.
3 4
B. Cover Installation 5
1. Reconnect the ground wire, if necessary.
2. Place the cover onto the power supply so that 6mm
slots in the bottom edges of the cover engage
the lower screws.
3. Tighten lower screws. 5. Remove the fitting from the filter element as-
sembly by inserting a 6 mm hex wrench into
4. Reinstall and tighten the upper screws. the internal hex fitting and turning it counter
clock-wise (left). Numbers 4 and 5 in the previ-
ous illustration.
6. Disconnect the input line from the filter ele-
ment assembly.

5-6 SERVICE Manual 0-5119

 CUTMASTER A80, A120
7. Remove the filter element assembly through
the rear opening.
Housing
NOTE
If replacing or cleaning just the filter element
refer to the following illustration for disassembly.
Filter
Element
(Cat. No. 9-7741)

Spring

O-ring
Filter Element (Cat. No. 9-7743) Assembled Filter

Cover

Barbed
Fitting Art # A-02476

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing

and set Element aside to dry.
Art # A-07990

8. Install the new or cleaned assembly by revers- 6. Wipe inside of housing clean, then insert the
ing these procedures. replacement Filter Element open side first.

9. Turn ON the air supply and check for leaks 7. Replace Housing on Cover.
before reinstalling the cover. 8. Reattach gas supply.

Optional Single-Stage Filter Element NOTE

Replacement If unit leaks between housing and cover, inspect
the O-Ring for cuts or other damage.
These instructions apply to power supplies where the
optional Single-Stage Filter has been installed.
Optional Two-Stage Filter Element
The Power Supply shuts down automatically when Replacement
the Filter Element becomes completely saturated. The
Filter Element can be removed from its housing, dried, The Two-Stage Air Filter has two Filter Elements.
and reused. Allow 24 hours for Element to dry. Refer When the Filter Elements become dirty the Power
to Section 6, Parts List, for replacement filter element Supply will continue to operate but cut quality may
catalog number. become unacceptable. Refer to Section 6, Parts List,
for replacement filter element catalog number.
1. Remove power from power supply.
1. Shut OFF primary input power.
2. Shut OFF air supply and bleed down system
before disassembling Filter to change Filter 2. Shut OFF air supply and bleed down system.
Element.
3. Disconnect gas supply hose. ! WARNING
4. Turn the Filter Housing Cover counter-
clockwise and remove it. The Filter Element Always turn OFF the air supply and bleed the
is located inside the Housing. system before disassembling the Filter Assembly
as injury could result.

3. Loosen the two bolts on the top of the Filter

Assembly enough to allow the Filter Elements
to move freely.
4. Note the location and orientation of the old
Filter Elements.

Manual 0-5119 SERVICE 5-7

CUTMASTER A80, A120
5. Slide out the old Filter Elements.

First & Second

Stage
Cartridges
(as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

6. Slide the replacement Filter Elements into the

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

5-8 SERVICE Manual 0-5119

 CUTMASTER A80, A120

SECTION 5 TORCH:
SERVICE
5T.01 General Maintenance
NOTE
Refer to Previous "Section 5 System" for common
and fault indicator descriptions. Upper Groove
with Vent Holes
Cleaning Torch Must Remain Open

Even if precautions are taken to use only clean Upper O-Ring

air with a torch, eventually the inside of the torch in Correct Groove
becomes coated with residue. This buildup can
affect the pilot arc initiation and the overall cut Threads
quality of the torch. Lower O-Ring Art # A-03725

Torch Head O-Ring

WARNING

Disconnect primary power to the system before ATC Male Connector

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

The inside of the torch should be cleaned with elec-

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

Gas Fitting
CAUTION
Dry the torch thoroughly before reinstalling.

O-Ring Lubrication
An o-ring on the Torch Head and ATC Male Con-
nector requires lubrication on a scheduled basis.
This will allow the o-rings to remain pliable and Art #A-03791 O-Ring
provide a proper seal. The o-rings will dry out,
becoming hard and cracked if the lubricant is not ATC O-Ring
used on a regular basis. This can lead to potential
performance problems. NOTE
It is recommended to apply a very light film of DO NOT use other lubricants or grease,
o-ring lubricant (Catalog # 8-4025) to the o-rings they may not be designed to operate within
on a weekly basis. high temperatures or may contain “unknown
elements” that may react with the atmosphere.
This reaction can leave contaminants inside
the torch. Either of these conditions can lead
to inconsistent performance or poor parts life.

Manual 0-5119 SERVICE 5T-1

CUTMASTER A80, A120
5T.02 Inspection and Replacement of 4. Remove the tip. Check for excessive wear (in-
dicated by an elongated or oversized orifice).
Consumable Torch Parts Clean or replace the tip if necessary.

Good Tip Worn Tip

WARNING

Disconnect primary power to the system before

disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the A-03406
AC indicator light of the Power Supply is ON.
Example of Tip Wear
Remove the consumable torch parts as follows:
5. Remove the starter cartridge. Check for exces-
NOTE sive wear, plugged gas holes, or discoloration.
The shield cup holds the tip and starter cartridge Check the lower end fitting for free motion.
in place. Position the torch with the shield cup Replace if necessary.
facing upward to prevent these parts from falling
out when the cup is removed. Spring-Loaded Spring-Loaded
Lower End Fitting Lower End Fitting at Reset /
1. Unscrew and remove the shield cup from the Full Compression Full Extension
torch.
NOTE
Slag built up on the shield cup that cannot be re-
moved may effect the performance of the system.
2. Inspect the cup for damage. Wipe it clean or
Art # A-08064_AC
replace if damaged.
6. Pull the Electrode straight out of the Torch
Head. Check the face of the electrode for exces-
sive wear. Refer to the following figure.

Art # A-08067
New Electrode
Shield Cups

3. On torches with a shield cup body and a shield

cap or deflector, ensure that the cap or deflector
Worn Electrode
is threaded snugly against the shield cup body. Art # A-03284

In shielded drag cutting operations (only), Electrode Wear

there may be an O-ring between the shield cup
body and drag shield cap. Do not lubricate the
O-ring. 7. Reinstall the Electrode by pushing it straight
into the torch head until it clicks.
Drag
Shield Cap 8. Reinstall the desired starter cartridge and tip
into the torch head.
9. Hand tighten the shield cup until it is seated
Shield Cap, on the torch head. If resistance is felt when
Machine installing the cup, check the threads before
Shield
proceeding.
Cup Body This completes the parts replacement procedures.
Shield Cap,
Deflector
Shield
Cup
Art # A-08742

5T-2 SERVICE Manual 0-5119

 CUTMASTER A80, A120
SECTION 6:
PARTS LISTS
6.01 Introduction

A. Parts List Breakdown

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

Section "6.03 Power Supply Replacement"

Section "6.04 Replacement Power Supply Parts"
Section "6.05 Options and Accessories"
Section "6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)"
Section "6.07 Torch Consumable Parts (SL100)"
Section "6.08 Replacement Parts for Hand Torch"

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

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

6.02 Ordering Information

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

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable,
gas pressure regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster A80 400VAC, Non CE Power Supply
With 400V, 3 Phase input power cable 3-1334-3
1 CutMaster A120 400VAC, Non CE Power Supply
With 400V, 3 Phase input power cable 3-1734-3
1 CutMaster A80 400VAC, CE Power Supply
With 400V, 3 Phase input power cable 3-1334-4
1 CutMaster A120 400VAC, CE Power Supply
With 400V, 3 Phase input power cable 3-1734-4

Manual 0-5119 PARTS LIST 6-1

CUTMASTER A80, A120
6.04 Replacement Power Supply Parts
Qty Description Catalog #
1 Regulator 9-0115
1 Filter Assembly Replacement Element 9-0116
1 Input Power Cord for 400 V Power Supply 9-0216

6.05 Options and Accessories

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

Housing

Filter
Element
(Cat. No. 9-7741)

Spring

O-ring
(Cat. No. 9-7743) Assembled Filter First & Second
Stage
Cover Cartridges
(as marked)
Barbed
Fitting Art # A-02476 Art # A-02942

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

6-2 PARTS LIST Manual 0-5119

 CUTMASTER A80, A120

This Page Intentionally Blank

Manual 0-5119 PARTS LIST 6-3

CUTMASTER A80, A120
6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)
Item No. Qty Description Catalog #
1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O-Ring 8-3487
3 1 Small O-Ring 8-3486
4 1 PIP Switch Kit 9-7036
5 1 PIP Plunger and Return Spring Kit 9-7045
6 Automated Leads Assemblies with ATC connectors
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-3058
1 35 - foot / 10.6 m Leads Assembly with ATC connector 4-3059
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-3060
7 1 Rack 9-9448
8 1 Mounting Tube 9-9445
9 1 End Cap Assembly 9-7044
10 2 Body, Mounting, Pinch Block 9-4513
11 1 Pin, Mounting, Pinch Block 9-4521
12 1 Torch Holder Sleeve 7-2896
13 1 Pinion Assembly (does not include positioning tube) 7-2827
14 1 Torch Holder Sleeve 7-2896
15 1 Pinion Gear-Short 8-6074
16 1 Handwheel (Torch Holder) 9-4514
17 1 Low Profile Torch Holder (1 3/8 Dia) w/o Hardware 9-4515
18 1 Calibrated Torch Holder Bushing 9-4366
19 1 5/32 Dia x 5/8 Lg Slotted Spring Pin See Note 1
20 1 3/8-24 x 3/8 Soc Hd Set Screw, Cup Point See Note 1
21 2 1/4-20 x 5/8 Hex Socket Head Screw See Note 1
22 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point See Note 1
23 1 Solenoid Assembly 9-9447
24 1 Solenoid Cover 9-9446

NOTE
Purchase these parts locally.

6-4 PARTS LIST Manual 0-5119

 CUTMASTER A80, A120

24 23

10
7

13

21
20
21
19
10 16

1
2 11

3
12
4
17
5 15

22
18

14

Art # A-07113

Manual 0-5119 PARTS LIST 6-5

CUTMASTER A80, A120
6.07 Torch Consumable Parts (SL100)

Ohmic Clip
Automation Torch
Ohmic Clip 9-8224
Manual Torch
9-8259

20-40A Tip:
Shield
Cup Body, Shield Cap, Machine
STANDOFF 40A 9-8245
9-8237
CUTTING

20A 9-8205 Shield Cup Shield Cap, Deflector

30A 9-8206 9-8218 9-8243
40A 9-8208

Drag Shield Cup

9-8235

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

50-55A 9-8209 Shield Cup

60A 9-8210 9-8218 Shield Cap, Deflector
9-8243

Drag Shield Cup

70-100A 9-8236
Electrode Starter Heavy Duty
Auto 9-8232 Cartridge Starter Cartridge Tips: Shield Drag Shield Cup
Manual 9-8215 9-8213 Non HF Only 9-8277 Cup Body, 120A 9-8258
9-8237
Shield Cap, Machine
70-100A 9-8239
70-120A 70A 9-8231
STANDOFF 80A 9-8211 Shield Cup Shield Cap, Machine
CUTTING 90/100A 9-8212 9-8218 120A 9-8256
120A Auto 9-8233
120A Manual 9-8253
Shield Cap, Deflector
9-8243

40-120A
GOUGING Shield
Cup Body,
9-8237
Tips:

Tip A 9-8225 (40 Amps Max.) Shield Cup, Gouging

9-8241
Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Art # A-08066_AG Tip E 9-8254 (60 - 120 Amps)

6-6 PARTS LIST Manual 0-5119

 CUTMASTER A80, A120
6.08 Replacement Parts for Hand Torch
Item # Qty Description Catalog #
1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
2 1 Trigger Assembly Replacement Kit 9-7034
3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O-Ring 8-3487
6 1 Small O-Ring 8-3486
7 Leads Assemblies with ATC connectors (includes switch assemblies)
1 SL100, 20 - foot Leads Assembly with ATC connector 4-7836
1 SL100, 50 - foot Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031
10 1 Torch Control Cable Adapter (includes item # 11) 7-3447
11 1 Through - Hole Protector 9-8103

5
6
3

Art # A-07993_AB

Manual 0-5119 PARTS LIST 6-7

CUTMASTER A80, A120

This Page Intentionally Blank

6-8 PARTS LIST Manual 0-5119

 CUTMASTER A80, A120
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION: ACTION: ACTION: ACTION:
ON / OFF switch to ON RUN / Rapid Auto Restart /
Close external RUN / SET / LATCH
disconnect switch. Rapid Auto Restart /
RESULT: switch to RUN
RESULT: SET / LATCH switch
AC indicator ON. to SET (for most applications)
Power to system. or to
GAS indicator ON Rapid Auto Restart
when input RESULT:
pressure is adequate (for gouging, trimming,
for power supply operation. Gas flows to set or expanded metal
pressure. applications)
Power circuit ready.
or to
LATCH

is used for specific applications

(torch switch can be released
after main arc transfer).

ACTION: RESULT: Gas flow stops.

Connect work cable to workpiece.

Set output amperage. ACTION:
RESULT:
Torch moved away from work (while
System is ready still activated).
for operation.
RESULT:

Main arc stops.

Pilot arc automatically
ACTION:
restarts.
Protect eyes and activate
Torch switch (START) PILOT ARC
RESULT:
Fans turn on. Gas flows briefly, ACTION:
then stops.Gas restarts.
Torch moved within
DC indicator ON transfer distance of workpiece.
Pilot arc established.
RESULT:

Main arc transfers.

Pilot arc off.
ACTION:
Release Torch switch.
RESULT: ACTION:
ACTION:
Main arc stops. Unplug input
Gas flow stops after post - flow. ON / OFF switch power cord or
to OFF open external
(Fans will continue to run for disconnect.
10 minutes after the Torch switch RESULT:
[START] is removed) RESULT:
All indicators off. No power to system.
Power supply fans shut off.
Art #A-07979_AB

Manual 0-5119 A-1 APPENDIX

CUTMASTER A80, A120

APPENDIX 2: DATA TAG INFORMATION

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

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

Output Current Type Duty Cycle Factor

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

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

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

APPENDIX A-2 Manual 0-5119

 CUTMASTER A80, A120
APPENDIX 3: TORCH PIN - OUT DIAGRAMS
A. Automation SL100SV Torch Pin - Out Diagram
ATC Male Connector - ATC Female Receptacle -
Front View Front View

Negative / Plasma Negative / Plasma

4 - Not Used
8 - Open
4- Open 8 - Open

7 - Green / 7 - Torch 3 - Not Used

8 4
3 - Open 4 8 - Torch Solenoid
Solenoid 7 3
3 7 6 2
2 6 2 - PIP Circuit
6 - Open 6 - Open 5 1
2 - Orange / 1 5
PIP
5 - White / 5 - Torch 1 - PIP Circuit
1 - Black / - Torch Solenoid
PIP Solenoid Pilot
Pilot
Art # A-07114

B. Machine SL100 Torch Pin - Out Diagram

ATC Male Connector UNSHIELDED MACHINE TORCH ATC Female Receptacle
Front View Front View
Negative / Plasma
Negative / Plasma
8 - Green -
4- Black -
Pendant
Pendant
Connector 8 - Ground 4 - Switch
Connector
Ground
3 - White -
4 8 7 - Green / 3 - Switch
Pendant 7 - Open 8 4
3 7 Not Used
Connector 7 3
2 6 6 2
6 - Open
2 - Orange / 1 5 5 1
6 - Open 2 - PIP
PIP

5 - White / 1 - PIP
1 - Black / 5 - Open
Not Used
PIP
Pilot Pilot

Art # A-03799

C. Hand Torch Pin - Out Diagram

ATC Male Connector ATC Female Receptacle
Negative / Front View Front View Negative /
Plasma Plasma

4 - Green / 8 - Open 8 - Ground

Switch 4 - Switch

7 - Open 7 - Open 3 - Switch

3 - White / 4 8 8 4
Switch 3 7 7 3
2 6 6 - Open 6 2
2- Orange / 6 - Open
1 5 5 1 2 - PIP
PIP
5 - Open 5 - Open
1 - PIP
1 - Black /
PIP Pilot
Pilot A-03701

Manual 0-5119 A-3 APPENDIX

CUTMASTER A80, A120

APPENDIX 4: TORCH CONNECTION DIAGRAMS

A. Automation (SL100SV) Torch Connection Diagram
Automated CutMaster Power Supply with ATC Torch Receptacle,
Automated SL100SV Torch (w/ Solenoid on Positioning Tube), Torch Lead with ATC Connector
ATC Male ATC Female
Torch Leads Connector Torch Receptacle

Torch Head Torch Leads Power Supply

Socket
Pin No.s No.s
PIP Black 1 1 Main PC Board
Switch Orange 2 2 Main PC Board

White 5 5 Main PC Board

4 4
Not Connected
3 3
Green 7 7 Main PC Board
6 6 Not Connected
Solenoid 8 8
Negative / Plasma Lead

Pilot Lead

Art # A-07115

B. Machine (SL100) Torch Connection Diagram

Torch: Unshielded Mechanized SL100 Machine Torch
Leads: Leads with ATC Connector and
Remote Pendant Connector To Remote Control
Power Supply: with ATC Female Receptacle
Remote
Male ATC Female
Pendant
ATC Leads Receptacle
Connector
Connector
Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
White 5 5
6 6
Not Black 4 4 To Power Supply
Used
White 3 3 Circuitry
Green 8 8
Green 7 7
Negative / Plasma Lead Negative / Plasma
Pilot Lead
Pilot

Art # A-03798

APPENDIX A-4 Manual 0-5119

 CUTMASTER A80, A120

C. Hand Torch Connection Diagram

Torch: SL60 / SL100 Hand Torch

Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle Male
ATC Leads ATC Female
Connector Receptacle Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
5 5
6 6
Torch Green 4 4 To Power Supply
Switch White 3 3 Circuitry
8 8
7 7
Negative / Plasma Negative / Plasma
Pilot
Pilot

Art # A-03797

Manual 0-5119 A-5 APPENDIX

 CUTMASTER A80, A120

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

T1

SW1 J1 PRI 3 PRI 4

1 3 1 C D
2 BIAS
3 SUPPLY
2 4
4 B
5 PRI 2 PRI 2

INRUSH A
+12VDC RESISTORS PRI 1 PRI 1

+ TP2 MTH1 MTH2 TP1 +

K1

Q1

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

* CM102 & A80

TP8 MTH7 C7 & C10 not installed
MTH4 TP5

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

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

SW2 J3
* 1 460_IN
BUSS BARS/JUMPERS
2

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

5 24VAC
J6

W1 1
2 24VAC RET
_
6
J14
J4
SYNC
1 3.3VDC
2 TXD
SERIAL PORT 3 RXD
1 /OVERTEMP +12VDC
4 2 /FAN_ON
5 D
3 /CSR
4 CUR_SET
5 MAIN_PCB_ID PCB1
/230
/460

K1,K2 MAIN PCB ASSY

6 COMMON

K5,K6
J13 J12
1
2
3
4
5
6

3
2
1

T2
J1 K3,K4

1
2
3
FERRITE
FILTER +12VDC
J2

1
2

J4 J3
1
2
3
4
5
6
7
8
9
10

1
2

PRI 1 PRI 2 PRI 3 PRI 4

+12VDC
MOT2 +12VDC A B C D
+

J1
FAN 1 J9
2 /FAN
SYNC +
-

AC1 40A_AC1
MOT3 Q1
+

J2
FAN AC2 40A_AC2
1
2
AC3 40A_AC3
-

PMTH1 PMTH1
+
C16-17 +

D1
PMTH2 PMTH2

PMTH3 PMTH3

PCB2 INPUT CAPACITOR PCB

Q2
C12-13
+

PMTH4 PMTH4

PCB5 40/50 AMP PCB

A-09132_AC

APPENDIX A-6 Manual 0-5119

 CUTMASTER A80, A120

A120 ONLY
1TORCH
TS1
PIP SWITCH

L1
TORCH SWITCH
J11
1
2

SEC1 SEC2 CHOKE1

+12VDC

ATC CONNECTOR
J1
1 1 AUTOMATION
TEMP /OVERTEMP 2 2
CIRCUIT TORCH SOLENOID
3 3
4 4
5 5
6 6
NTC 7 7
8 8
-V OUT 1

-
E64
ELECTRODE1

+
D3 TIP1 E35
Q5

PILOT IGBT

WORK1
WORK

J9
78
/PIP 1
79
2 80
/START 3
81
4
24VAC RETURN 82
5
6 CNC INTERFACE STANDARD ON A80 & A120 UNITS
83
24VAC SUPPLY 7 CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS

J2

J10 P10 14

1 1
13
12
} OK TO MOVE
CNC PINOUT
OK-TO-MOVE 2 2 11
(5A @ 250VAC / 30VDC) 3 3 10 3 1
4 4 9
5 5 8 7 4
+12VDC
6 6 7 11 8
7 7 6 14 12
8 8 5
4
3
} /START / STOP
2
1

J2

40 PIN RIBBON CABLE SIGNALS FULL FEATURED AUTOMATION INTERFACE PCB OPTION
TEST POINTS 1 -V_OUT_SIGNAL M-L
D59 PCR 2 /TIP_VOLTS M-L *
GND1 COMMON 3 /TIP_SENSE M-L * To configure DIVIDED ARC VOLTS signal output
GND2 COMMON 4 /460V_IN L-M No jumper installed for ARC VOLTS / 16.67
+12V1 +12 VDC SUPPLY 5 /230V_IN L-M Jumper pins 1 & 2 for ARC VOLTS / 30
48V1 +48 VDC SUPPLY 6 CUR_SET L-M Jumper pins 2 & 3 for ARC VOLTS / 50

1
2
3
D78 CSR I_DMD_1 CURRENT DEMAND To -V OUT 1 P1
7 /RAR (RAPID AUTO RESTART) L-M
TIP_SEN TIP DRAG SENSE on PCB1
8 /INRUSH L-M
E1 J1
9 /W1_ON L-M
10 SHDN L-M 1
11 /TORCH_SOLENOID L-M 2
12 /SOLENOID_ON L-M 3
13 /OK_TO_MOVE L-M
P10 P2 +12VDC
4
} /START / STOP
} (+) *DIVIDED
14 /FAN_ON L-M 1 1 1 5 (-)
15 /LATCH_ACTIVE ARC VOLTS
L-M 2 2 2 6
16 /TORCH_SWITCH M-L 3 3 3 K1 7 (-)
17
18
/PIP
AC_ON
M-L
M-L
4
5
4
5
4
5
8
9
} (+) ARC VOLTS
(W/ 100K IN SERIES (2))
19 CSR M-L 6 6 6 10
FERRITE
FILTER
20 /TORCH_SOLENOID_DETECT M-L 7 7 7 PCB4 11
21 /OVERTEMP M-L 8 8 8 12
22 V_IN M-L AUTOMATION K1 13 } OK-TO-MOVE
23 +12VDC M-L INTERFACE PCB 14
24 +12VDC M-L
25 COMMON M-L
26 COMMON M-L
29 MAIN_PCB_ID M-L
34 460_IN M-L
35 +3.3VDC L-M
36 TXD M-L
37 RXD M-L
38 COMMON L-M
39 D M-L

L2

J1

SEC1 SEC2 CHOKE1

ERROR IND FAULT

AC MAX
MAX OVER PRESSURE
90 INTERNAL ERROR
85 SHORTED TORCH
OVERTEMP 80 CONSUMABLES MISSING 90
75 START ERROR
70 PARTS IN PLACE
65 INPUT POWER
GAS MIN UNDER PRESSURE 85

TEST POINTS
DC 80
TP1 GND
TP2 +12 VDC
TP3 +5 VDC
D2 ERROR TP4 3.3 VDC 75 GAS CONTROL
TP5 0.v - 5.0 VDC / 0-100PSI
TP6 1.8 VDC
REGULATOR
TP7 CURRENT DEMAND
70
SOLENOID
VALVE ATC
Current Control
NTC TEMP +12VDC 65 FILTER
/OVERTEMP
CIRCUIT AIR
INLET
LATCH D1
MIN PRESSURE
SET TRANSDUCER

RUN J3
+5VDC
1
2
3

+OUT_1 RAR 3
0-100PSI / 0-4.5VDC 2
1
PCB3 LOGIC PCB

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

Manual 0-5119 A-7 APPENDIX

CUTMASTER A80, A120

APPENDIX 6: SYSTEM SCHEMATIC, 380V/400V-600V

UNITS
5 4

T1

SW1 J1 PRI 3 PRI 4

1 3 1 C D
2 BIAS
3 SUPPLY
2 4
4 B
5 PRI 2 PRI 2

D
INRUSH A
+12VDC RESISTORS PRI 1 PRI 1

+ TP2 MTH1 MTH2 TP1 +

K1

Q1

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

* CEONLY
UNITS

TP8 MTH7
MTH4 TP5

*FILTER
EMI
W1
_ AC1 80A_AC1
7
L1 1 1
L1 T1
AC2 80A_AC2
L2 2 2
L2 T2
8

9
L3 3 3
L3 T3
AC3 80A_AC3

GND 4 4 L4 T4
7A

380/400/415V
OR 600V
3 PH AC INPUT
PRIMARY POWER CONNECTIONS:
USE L1, L2, L3 & GND MTH8 TP4

+12VDC
MOT1 J7 TP3
C MTH6
1
+ FAN - 2 /FAN
Q2

C5,C6,C9,C10*
+
J5

SOL 1 1
2
3 /SOLENOID

5 24VAC
J6

W1 1
2 24VAC RET
_
6
J14
J4
SYNC
1 3.3VDC
2 TXD
SERIAL PORT 3 RXD
1 /OVERTEMP
4 2 /FAN_ON
5 D
3 /CSR
4 CUR_SET
5 MAIN_PCB_ID PCB1 MAIN PCB ASSY
6 COMMON

J13
1
2
3
4
5
6

T2

FERRITE
FILTER +12VDC
J2
B
1
2

J4 J3
1
2
3
4
5
6
7
8
9
10

1
2

PRI 1 PRI 2 PRI 3 PRI 4

+12VDC
MOT2 +12VDC A B C D
+

J1
FAN 1 J9
2 /FAN
SYNC +
-

AC1 40A_AC1
MOT3 Q1
+

J2
FAN AC2 40A_AC2
1
2
AC3 40A_AC3
-

PMTH1 PMTH1
+
C16-17 +

D1
PMTH2 PMTH2

PMTH3 PMTH3

PCB2 INPUT CAPACITOR PCB

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

PMTH4 PMTH4

PCB5 40/50 AMP PCB

A-09130_AD
5 4

APPENDIX A-8 Manual 0-5119

 CUTMASTER A80, A120

3 2 1

1TORCH
TS1
PIP SWITCH

L1
TORCH SWITCH
J11
1
2

SEC1 SEC2 CHOKE1

+12VDC

ATC CONNECTOR
J1
1 1 AUTOMATION
TEMP /OVERTEMP 2 2
CIRCUIT TORCH SOLENOID
3 3
4 4 D
5 5
6 6
NTC 7 7
8 8
-V OUT 1

-
E64
ELECTRODE1

+
D3 TIP1 E35
Q5

PILOT IGBT

WORK1
WORK

J9
78
/PIP 1
79
2 80
/START 3
81
4
24VAC RETURN 82
5
6 83 CNC INTERFACE STANDARD ON A80 & A120 UNITS
24VAC SUPPLY 7 CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS

J2

J10 P10 14

1 1
13
12
} OK TO MOVE
CNC PINOUT
OK-TO-MOVE 2 2 11
(5A @ 250VAC / 30VDC) 3 3 10 3 1
4 4 9
5 5 8 7 4
+12VDC
6 6 7 11 8
7 7 6 14 12
8 8 5
4
3
} /START / STOP
2
1

J2
C

40 PIN RIBBON CABLE SIGNALS FULL FEATURED AUTOMATION INTERFACE PCB OPTION
TEST POINTS 1 -V_OUT_SIGNAL M-L
D59 PCR 2 /TIP_VOLTS M-L *
GND1 COMMON 3 /TIP_SENSE M-L * To configure DIVIDED ARC VOLTS signal output
GND2 COMMON 4 /460V_IN L-M No jumper installed for ARC VOLTS / 16.67
+12V1 +12 VDC SUPPLY 5 /230V_IN L-M Jumper pins 1 & 2 for ARC VOLTS / 30
48V1 +48 VDC SUPPLY 6 CUR_SET L-M Jumper pins 2 & 3 for ARC VOLTS / 50

1
2
3
D78 CSR I_DMD_1 CURRENT DEMAND To -V OUT 1 P1
7 /RAR (RAPID AUTO RESTART) L-M
TIP_SEN TIP DRAG SENSE on PCB1
8 /INRUSH L-M
E1 J1
9 /W1_ON L-M
10 SHDN L-M 1
11 /TORCH_SOLENOID L-M 2
12 /SOLENOID_ON L-M 3
13 /OK_TO_MOVE L-M
P10 P2 +12VDC
4
} /START / STOP
} (+) *DIVIDED
14 /FAN_ON L-M 1 1 1 5 (-)
15 /LATCH_ACTIVE ARC VOLTS
L-M 2 2 2 6
16 /TORCH_SWITCH M-L 3 3 3 K1 7 (-)
17
18
/PIP
AC_ON
M-L
M-L
4
5
4
5
4
5
8
9
} (+) ARC VOLTS
(W/ 100K IN SERIES (2))
19 CSR M-L 6 6 6 10
FERRITE
FILTER
20 /TORCH_SOLENOID_DETECT M-L 7 7 7 PCB4 11
21 /OVERTEMP M-L 8 8 8 12
22 V_IN M-L AUTOMATION K1 13 } OK-TO-MOVE
23 +12VDC M-L INTERFACE PCB 14
24 +12VDC M-L
25 COMMON M-L
26 COMMON M-L
29 MAIN_PCB_ID M-L
34 460_IN M-L
35 +3.3VDC L-M
36 TXD M-L
37 RXD M-L
38 COMMON L-M
39 D M-L

L2

J1

SEC1 SEC2 CHOKE1

ERROR IND FAULT

AC MAX
MAX OVER PRESSURE
90 INTERNAL ERROR
85 SHORTED TORCH
OVERTEMP 80 CONSUMABLES MISSING 90
75 START ERROR
70 PARTS IN PLACE
65 INPUT POWER
GAS MIN UNDER PRESSURE 85

TEST POINTS
DC 80
TP1 GND
TP2 +12 VDC
TP3 +5 VDC
D2 ERROR TP4 3.3 VDC 75 GAS CONTROL
TP5 0.v - 5.0 VDC / 0-100PSI
TP6 1.8 VDC
REGULATOR
TP7 CURRENT DEMAND
70
SOLENOID
VALVE ATC
Current Control
NTC TEMP +12VDC 65 FILTER
/OVERTEMP
CIRCUIT AIR
INLET
LATCH D1
MIN PRESSURE
SET TRANSDUCER

RUN J3
+5VDC
1
2
3

+OUT_1 RAR 3
0-100PSI / 0-4.5VDC 2
1
PCB3 LOGIC PCB

A-09130_AD
Rev Revisions By Date PCB No:
VICTOR TECHNOLOGIES
AA INTRO ECO B1357 RWH 03/31/09 16052 Swingley Ridge Road Assy No:
Suite 300 Scale Supersedes
AB ECO B1399 RWH 05/05/09
St Louis MO 63017 USA
AB ECO B1611 RWH 05/05/09
Date:
Information Proprietary to THERMAL DYNAMICS CORPORATION. MARCH 30, 2009
Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: References
NOTE: RWH
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF) Chk: App: Sheet
1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Friday, December 11, 2009 09:02:19
D
CM102/152/35mm/40mm/A80/A120 380/400/415/600V 42X1330
3 2 1

Manual 0-5119 A-9 APPENDIX

CUTMASTER A80, A120

APPENDIX 7: RAW ARC VOLTAGE

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

1. Disconnect the power from the power supply.

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

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

Art # A-10286

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

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

WORK 1
-V OUT 1
WORK 1

-V OUT 1

J10

Art # A-10287

APPENDIX A-10 Manual 0-5119

 CUTMASTER A80, A120

Art # A-10288

-V out (-) Polarity Work1 (+) Polarity

5. Tighten the strain relief.

6. Replace the cover.

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

Manual 0-5119 A-11 APPENDIX

CUTMASTER A80, A120

APPENDIX 8: PUBLICATION HISTORY

Cover Date Rev. Change(s)

Dec. 10, 2008 AA Manual released.

May 29, 2009 AB Updated 400V/600V schematic in appendix per ECOB1399 and updated
230/460V schematic per ECOB1357. Corrected part numbers in section 6 per
ECOB1201.
Oct. 20, 2009 AC Updated Tip and Electrode part numbers per ECOB1494 changing 9-8215 to 9-
8232 and 9-8253 to 9-8233.
Jan. 7, 2010 AD Updated "Power Supply Input Cable Wiring Requirements" with metric power
cable sizes in Section 2. Updated torch consumables art section 4T and 6.
Updated automation interface and harness descriptions and part numbers per
ECOB1282.
Feb. 25, 2010 AE Updated CNC cable part numbers in section 6 per ECOB1637.
Mar. 14, 2011 AF Updated power cord part number in section 6 per ECOB1234.
June 23, 2011 AG Added Appendix 7: Raw Arc Voltage
Mar. 20, 2012 AH Updated ART A-08066 and changed COO text, per ECOB2149.
Sept. 25, 2015 AJ Revised to Victor trade dress standards. Updated DoC. ECO-B2695.
Feb. 11, 2015 AK Added jumper information to section 3T per ECOB2673.

APPENDIX A-12 Manual 0-5119

This Page Intentionally Blank
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