Specifications

ManualsBrandsVictor ManualsIndustrialCUTMASTER

380-

400

Art # A-08955_AB

460

600

AUTOMATED PLASMA

CUTTING SYSTEM

A120

CUTMASTER

™

Rev. AO Date: Dec. 7, 2012 Manual # 0-4989

Operating Features:

Operating Manual

Summary of content (128 pages)

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A120 CUTMASTER ™ Automated PLASMA CUTTING SYSTEM Art # A-08955_AB Operating Manual Rev. AO Date: Dec.
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WE APPRECIATE YOUR BUSINESS! Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800426-1888, or visit us on the web at www.thermal-dynamics.com.
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! WARNING Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster™ A120 SL100 1Torch™ Operating Manual Number 0-4989 Published by: Victor Technologies International, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.
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This Page Intentionally Blank
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TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION............................................................................................1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings......................................................................................1-1 Important Safety Precautions........................................................................................1-1 Publications.............................................................................
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TABLE OF CONTENTS PATENT INFORMATION................................................................................................................4T-58 SECTION 5 SYSTEM: SERVICE........................................................................................................5-1 5.01 5.02 5.03 5.04 5.05 5.06 General Maintenance....................................................................................................5-1 Maintenance Schedule...................................................
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CUTMASTER A120 SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. • Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. • The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes.
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CUTMASTER A120 • Ventilate all flammable or explosive vapors from the workplace. • Do not cut or weld on containers that may have held combustibles. • Provide a fire watch when working in an area where fire hazards may exist. • Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated.
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CUTMASTER A120 1.04 Note, Attention et Avertissement Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit : NOTE Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.
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CUTMASTER A120 • Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page 5, article 9.) • Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation. Lisez et respectez toutes les consignes du Manuel de consignes. • Courant Arc Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma.
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CUTMASTER A120 1.06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. Norme ANSI Z49.
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CUTMASTER A120 1.07 Declaration of Conformity Manufacturer: Address: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
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CUTMASTER A120 1.08 Statement of Warranty LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship.
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CUTMASTER A120 This Page Intentionally Blank GENERAL INFORMATION 1-8 Manual 0-4989
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CUTMASTER A120 SECTION 2 SYSTEM: INTRODUCTION 2.01 How To Use This Manual This Owner’s Manual applies to just specification or part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
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CUTMASTER A120 2.04 Power Supply Specifications CutMaster A120 Power Supply Specifications Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz 230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 400 VAC (360 - 440 VAC), Three Phase, 50 Hz 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz 600 VAC (540 - 630), Three Phase, 60 Hz Input Power Cable Power Supply includes input cable.
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CUTMASTER A120 2.05 Input Wiring Specifications CutMaster A120 Power Supply Input Cable Wiring Requirements Input Freq Power Suggested Sizes voltage Input Volts Hz kVA I max I eff Fuse Flexible Cord Flexible Cord (amps) (Min. AWG) (Min. mm2) 1 Phase 208 60 26.2 126 98 150 4 Type W 25 Type W 230 60 27.6 118 95 125 4 Type W 25 Type W 460 60 35 76 68 100 4 25 3 Phase 208 60 21.6 60 55 60 4 25 230 60 22.3 56 50 60 4 25 380 50 23 35 32 40 8 10 400 50 23.6 34 31 40 8 10 460 60 29.5 37 33 40 8 10 600 60 29.
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CUTMASTER A120 2.
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CUTMASTER A120 SECTION 2 TORCH: INTRODUCTION 2T.03Specifications A. Torch Configurations 1. Automation Torch, Model 2T.01Scope of Manual This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL100/Manual and SL100/Mechanized Plasma Cutting Torches.
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CUTMASTER A120 C. Torch Parts H. Direct Contact Hazard Starter Cartridge, Electrode, Tip, Shield Cup For standoff tip the recommended standoff is 3/16 inches / 4.7 mm. D. Parts - In - Place (PIP) Torch Head has built - in switch 2T.04Options And Accessories 12 VDC circuit rating For options and accessories, see section 6. 2T.05Introduction to Plasma E. Type Cooling Combination of ambient air and gas stream through torch. A. Plasma Gas Flow F.
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CUTMASTER A120 By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration of heat to a small area. The stiff, constricted plasma arc is shown in Zone C. Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration. E. Parts - In - Place (PIP) The torch includes a 'Parts - In - Place' (PIP) circuit. When the shield cup is properly installed, it closes a switch. The torch will not operate if this switch is open.
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CUTMASTER A120 This Page Intentionally Blank INTRODUCTION 2T-4 Manual 0-4989
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CUTMASTER A120 mounting the power supply. Choose one that allows for free movement of torch leads, complies with ventilation per section 2.04 and provides a safe firm surface where the unit can be secured. 2. Place the unit in the desired position and mark where the four keyway holes SECTION 3 SYSTEM: INSTALLATION 3.01 Unpacking 1. Use the packing lists to identify and account for each item. 2. Inspect each item for possible shipping damage.
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CUTMASTER A120 3.05 Primary Input Power Connections Upper Screws Lower Screws CAUTION Check your power source for correct voltage before plugging in or connecting the unit. Check the Voltage Selector at the rear of the unit for correct setting before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2.
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CUTMASTER A120 D. Quick Guide to Phase Wiring The following illustration and directions are for changing phase of the power supply. CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2). Input Power Cable Connections Three-Phase (3ø) L1 L1 L2 L2 L3 L3 L4 L4 GND 6. Connect the wires as follows.
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CUTMASTER A120 Filter Assembly CAUTION Inlet Port The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2). Hose Clamp 6. Connect the wires as follows. • Wires to L1, L2 and L3 input. It does not matter what order these wires are attached. See previous illustration and on label in the power supply. • Green / Yellow wire to Ground. 7.
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CUTMASTER A120 Installing Optional Two - Stage Air Filter Kit Filter Assembly Inlet Port This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns. Connect the air supply as follows: 1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the filter assembly.
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CUTMASTER A120 Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: 1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any dust which may be present. 3.
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CUTMASTER A120 SECTION 3 TORCH: INSTALLATION Check Air Quality To test the quality of air: 1. Put the ON / OFF switch in the ON (up) position. 2. Put the Function Control switch in the SET 3T.01Torch Connections If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL100SV / Automation, SL100 / Mechanical or SL100 / Manual Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions. position. 3.
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CUTMASTER 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.
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CUTMASTER A120 SECTION 4 SYSTEM: OPERATION 1 4.01 Front Panel Controls / Features MIN 2 A MAX 3 PSI BAR MAX MAX MIN MIN 4 + See Illustration for numbering Identification 1. Output Current Control Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or higher for standoff cutting. ! 2. Function Control Function Control Knob, Used to select between the different operating modes. RUN 6.
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CUTMASTER A120 4.02 Preparations for Operation Power ON Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns ON. At the start of each operating session: WARNING Gas indicator turns ON if there is sufficient gas pressure for power supply operation and the cooling fans turn ON. Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.
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CUTMASTER A120 Cutting Operation STANDOFF When the torch leaves the workpiece during cutting operations with the Function Control Knob in the RUN position, there is a brief delay in restarting the pilot arc. With the knob in the RAPID AUTO RESTART position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arc contacts the workpiece.
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CUTMASTER A120 SECTION 4 TORCH: OPERATION For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer. 4T.01Machine and Automated Torch Operation Travel speed also affects the bevel angle of a cut.
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CUTMASTER A120 4T.02Automation Torch Parts Selection Torch Head Art # A-04173_AB Electrode Check the torch for proper consumable parts. The parts supplied in the torch may not be correct for the operator’s chosen amperage level. The torch parts must correspond with the type of operation. Start Cartridge Tip Torch parts: Ohmic Clip (If installed) Shield Cup, Cutting Tip, Electrode and Starter Cartridge NOTE Shield Cup Body Refer to Sections 4T.
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CUTMASTER A120 Change the torch parts for a different operation as follows: 4T.04Cut Quality NOTE WARNING Disconnect primary power at the source before assembling or disassembling torch parts, or torch and leads assemblies. NOTE The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed. 1. Unscrew and remove the shield cup assembly from the torch head. 2.
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CUTMASTER A120 Bottom Dross Buildup Edge Starting Molten material which is not blown out of the cut area and resolidifies on the plate. Excessive dross may require secondary cleanup operations after cutting. For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touching) the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to "reach" for the edge of the metal.
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CUTMASTER A120 3. Hold the torch away from your body. 4. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start. 4T.06Hand Torch Operation Standoff Cutting With Hand Torch NOTE For best performance and parts life, always use the correct parts for the type of operation. 1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle.
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CUTMASTER A120 8. For a consistent standoff height from the workpiece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece. 2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle.
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CUTMASTER A120 9. Follow normal recommended cutting practices as provided in the power supply operator's manual. 6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF. NOTE NOTE When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap.
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CUTMASTER A120 4T.07Gouging ! Lead Angle The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.
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CUTMASTER A120 This Page Intentionally Blank Manual 0-4989 4T-9 OPERATION
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CutMaster A120 4T.08Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip Mild Steel 40A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 1.6 112 3.6 1345 4.6 0.4 1.6 116 3.6 1100 4.6 0.5 1.7 8 118 3.6 815 4.6 1.0 1.7 10 119 3.6 595 4.6 1.5 1.
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CutMaster A120 Stainless Steel 40A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 18 0.050 110 0.19 60 0.20 0.00 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 1.8 111 4.8 715 5.1 0.4 1.8 118 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.
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CutMaster A120 Aluminum 40A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 20 0.040 95 0.16 300 0.16 0.0 0.06 16 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 (7.6m) 113 4.6 2170 4.6 0.4 1.7 5.0 5.2 (15.2m) 118 4.6 1740 4.6 0.5 1.8 125 4.6 1015 4.6 0.8 1.9 8.0 139 4.6 500 Edge Start 2.
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CutMaster A120 Mild Steel 60A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.060 118 0.19 290 0.19 0.00 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 5.9 (7.6m) 122 4.8 2145 4.8 0.30 2.0 6.2 (15.2m) 123 4.8 1635 4.8 0.40 2.2 125 4.
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CutMaster A120 Stainless Steel 60A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.063 119 0.19 350 0.20 0.00 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 2.1 122 4.8 2195 5.1 0.20 2.1 123 4.8 1790 5.1 0.30 2.2 127 4.8 1190 5.1 0.40 2.2 10 130 4.8 725 5.1 0.50 2.
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CutMaster A120 Aluminum 60A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.064 123 0.25 440 0.25 0.00 0.08 14 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 2.3 132 6.4 4010 6.4 0.20 2.4 132 6.4 2640 6.4 0.30 2.4 137 6.4 1630 6.4 0.40 2.4 10 142 6.4 1085 6.4 0.60 2.
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CutMaster A120 Mild Steel 80A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.060 110 0.19 320 0.20 0.00 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 1.8 114 4.8 2745 5.1 0.40 2.2 120 4.8 1775 5.1 0.50 2.3 125 4.8 1060 5.1 0.50 2.
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CutMaster A120 Stainless Steel 80A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.063 110 0.19 340 0.25 0.00 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 1.6 115 4.8 3410 6.4 0.20 1.8 117 4.8 2765 6.4 0.30 1.9 119 4.8 1815 6.4 0.40 2.0 10 120 4.8 1070 6.4 0.60 2.
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CutMaster A120 Aluminum 80A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.064 116 0.25 350 0.25 0.00 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 2.5 125 6.4 4315 6.4 0.20 2.5 129 6.4 3190 6.4 0.30 2.4 133 6.4 2070 6.4 0.40 2.5 136 6.4 1330 6.4 0.50 2.7 2.
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CutMaster A120 Mild Steel 100A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip 9-8243 9-8218 9-8237 9-8212 Material Thickness (GA) Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8213 9-8232 9-8277 Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 110 0.18 85 0.20 0.10 0.
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cutmaster A120 Stainless Steel 100A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8212 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 102 0.16 100 0.00 0.09 106 0.16 65 0.18 0.
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CutMaster A120 Aluminum 100A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8212 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 110 0.19 100 0.20 0.00 0.
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CutMaster A120 Mild Steel 120A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8233 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 134 0.19 150 0.25 0.10 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 2.9 145 4.8 1320 6.4 1.0 3.0 153 4.8 720 6.4 1.2 3.2 163 6.4 500 Edge Start 3.6 30.0 167 6.
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CutMaster A120 Stainless Steel 120A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8233 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 133 0.19 180 0.25 0.20 0.
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cutmaster A120 Aluminum 120A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8233 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 139 0.19 180 0.25 0.30 0.
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CutMaster A120 4T.09Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip Mild Steel 40A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec.
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cutmaster A120 Stainless Steel 40A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 18 0.050 110 0.16 60 4.1 0.0 0.06 16 0.063 108 0.16 50 4.
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CutMaster A120 Aluminum 40A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 20 0.040 110 0.19 300 0.20 0.0 0.06 16 0.063 113 0.19 170 0.
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CutMaster A120 Mild Steel 60A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.060 128 0.19 250 0.20 0.00 0.09 14 0.075 129 0.19 237 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 2.3 132 4.8 2794 5.1 0.20 2.2 134 4.8 2230 5.1 0.30 2.1 5 5.9 (7.6m) 6 6.2 (15.2m) 8 133 4.8 1425 5.1 0.40 2.
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CutMaster A120 Stainless Steel 60A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.063 110 0.13 165 0.20 0.00 0.06 14 0.078 116 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 2.2 125 3.3 1850 5.1 0.20 2.1 127 3.3 1605 5.1 0.30 2.1 5 5.9 (7.6m) 6 6.2 (15.2m) 8 131 3.3 1100 5.1 0.40 2.
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CutMaster A120 Aluminum 60A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.064 118 0.13 350 0.20 0.00 0.07 14 0.079 118 0.13 350 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 2.0 126 6.4 3335 6.4 0.20 2.0 130 6.4 2370 6.4 0.30 2.0 134 6.4 1570 6.4 0.40 2.0 10 136 6.4 1070 6.4 0.60 2.
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CutMaster A120 Mild Steel 80A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) Initial Piercing Pierce Delay Height Kerf Width @ Rec. Speed 16 0.060 115 0.13 280 0.20 0.00 0.06 11 0.120 112 0.13 190 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 1.7 123 4.8 3300 5.1 0.30 2.0 126 4.8 2735 5.1 0.40 2.2 131 4.8 1745 5.1 0.50 2.5 5 5.9 (7.6m) 6 6.2 (15.2m) 8 Initial Piercing Pierce Delay Height Kerf Width @ Rec.
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CutMaster A120 Stainless Steel 80A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) Initial Piercing Pierce Delay Height Kerf Width @ Rec. Speed 16 0.063 114 0.125 340 0.2 0.00 0.06 11 0.125 115 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 1.5 115 3.2 4010 5.1 0.20 1.8 117 3.2 2640 5.1 0.30 2.0 123 4.8 1630 6.4 0.40 2.1 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.
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CutMaster A120 Aluminum 80A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.064 115 0.13 320 0.2 0.00 0.09 11 0.120 120 0.13 240 0.
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cutmaster A120 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 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 2.1 122 3.3 3955 5.1 0.20 2.2 124 3.3 2905 5.1 0.30 2.3 132 4.8 2010 5.1 0.40 2.3 10 140 4.8 1430 5.1 0.50 2.
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CutMaster A120 Mild Steel 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8233 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 114 0.16 85 0.18 0.00 0.08 3/8 0.375 112 0.
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cutmaster A120 Stainless Steel 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8212 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch 1/4 0.250 3/8 0.375 Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 114 0.16 110 0.18 0.00 0.08 116 0.
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CutMaster A120 Aluminum 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8212 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 121 0.18 110 0.19 0.00 0.10 3/8 0.375 129 0.18 60 0.
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cutmaster A120 Mild Steel 120A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8256 9-8237 9-8233 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 139 0.125 160 0.20 0.20 0.11 3/8 0.375 140 0.
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CutMaster A120 Stainless Steel 120A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8256 9-8237 9-8233 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 140 0.13 180 0.20 0.30 0.11 3/8 0.375 140 0.
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cutmaster A120 Aluminum 120A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8256 9-8237 9-8233 9-8213 9-8277 9-8232 Material Thickness (GA) Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) (in) inch 1/4 0.250 140 0.13 180 0.20 0.20 0.10 3/8 0.375 142 0.
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CUTMASTER A120 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S.
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CUTMASTER A120 Catalog # Description Patent(s) 9-8239 Shield Cap 9-8244 Shield Cap 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending US Pat No(s) 6914211; D505309 Other Pat(s) Pending US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No.
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CUTMASTER A120 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Warning! Disconnect input power before maintaining. Maintain more often if used under severe conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the torch body tip, electrode, start cartridge and shield cup Visually inspect the cables and leads.
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CUTMASTER A120 5.02 Maintenance Schedule 5.03 Common Faults Problem - Symptom NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment. Insufficient Penetration 1. Cutting speed too fast. 2. Torch tilted too much. 3. Metal too thick. 4. Worn torch parts 5. Cutting current too low. 6. Non - Genuine Thermal Dynamics parts used 7. Incorrect gas pressure Main Arc Extinguishes 1. Cutting speed too slow. 2. Torch standoff too high from workpiece. 3.
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CUTMASTER A120 5.04 Fault Indicator At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator and 76 psi indicators are ON indicating the version would be 2.3.
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CUTMASTER A120 5.05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Problem - Symptom Possible Cause Recommended Action ON / OFF Switch is ON but the A/C Indicator does not light 1. Primary power disconnect is in 1. Turn primary power disconnect switch to ON position. OFF position. 2.
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CUTMASTER A120 Problem - Symptom FAULT & 80 PSI indicators flashing. Gas flow is cycling ON and OFF. Possible Cause 1. Torch shield cup is loose. 2. Torch tip, electrode or starter cartridge missing. 3. Torch start cartridge is stuck. 4. Open conductor in torch leads. Recommended Action 1. Tighten shield cup by hand. Do not overtighten. 2. Turn OFF power supply. Remove shield cup. Install missing parts. 3. Turn OFF power supply. Bleed down system pressure. Remove shield cup, tip and start cartridge.
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CUTMASTER A120 5.06 Power Supply Basic Parts Replacement WARNING C. Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be checked per the Maintenance Schedule (Subsection 5.02), and either cleaned or replaced. Disconnect primary power to the system before disassembling the torch, leads, or power supply. This section describes procedures for basic parts replacement.
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CUTMASTER A120 Remove the fitting from the filter element assembly by inserting a 6 mm hex wrench into the internal hex fitting and turning it counter clock-wise (left). Numbers 4 and 5 in the previous illustration. Optional Single-Stage Filter Element Replacement 6. Disconnect the input line from the filter element assembly. 7. Remove the filter element assembly through the rear opening. The Power Supply shuts down automatically when the Filter Element becomes completely saturated.
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CUTMASTER A120 Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog number. 1. Shut OFF primary input power. 2. Shut OFF air supply and bleed down system.
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CUTMASTER A120 SECTION 5 TORCH: SERVICE Upper Groove with Vent Holes Must Remain Open 5T.01General Maintenance NOTE Upper O-Ring in Correct Groove Refer to Previous "Section 5 System" for common and fault indicator descriptions. Threads Lower O-Ring Cleaning Torch Art # A-03725 Torch Head O-Ring Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue.
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CUTMASTER A120 5T.02Inspection and Replacement of Consumable Torch Parts 4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary. Worn Tip Good Tip WARNING Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON. A-03406 Example of Tip Wear 5.
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CUTMASTER 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.
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CUTMASTER A120 6.04 Replacement Power Supply Parts Qty Description 1 Regulator 1 Filter Assembly Replacement Element 1 Input Power Cord for 208 / 230 V Power Supply 1 Input Power Cord for 400 V Power Supply Catalog # 9-0115 9-0116 9-0191 9-0216 6.
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CUTMASTER A120 6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) Item No. Qty Description Catalog No. 1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 2 1 Large O-Ring 8-3487 3 1 Small O-Ring 8-3486 4 1 PIP Switch Kit 9-7036 5 1 PIP Plunger and Return Spring Kit 9-7045 6 Automated Leads Assemblies with ATC connectors 1 25 - foot / 7.6m Leads Assembly with ATC connector 4-3058 1 35 - foot / 10.
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CUTMASTER A120 23 24 9 10 7 8 13 19 21 16 10 1 21 20 11 2 3 4 12 17 5 15 22 18 14 6 Art # A-07113 Manual 0-4989 6-5 PARTS LIST
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CUTMASTER A120 6.
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CUTMASTER A120 6.08 Replacement Parts for Hand Torch Item # Qty Description Catalog # 1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 2 1 Trigger Assembly Replacement Kit 3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 4 1 Torch Head Assembly Replacement Kit (includes items No.
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CUTMASTER A120 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: Close external disconnect switch. RESULT: Power to system. ACTION: ON / OFF switch to ON RESULT: AC indicator ON. RUN / Rapid Auto Restart / SET / LATCH switch to SET GAS indicator ON when input pressure is adequate for power supply operation. Power circuit ready. RESULT: Gas flows to set pressure.
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CUTMASTER A120 APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Model : Dat e of Mf r : Type of Power Supply (Note 1) 1/ 3 f1 S/N Made in USA Regulatory Standard Covering This Type of Power Supply f2 Output Current Type Duty Cycle Factor Output Range (Amperage/ Voltage) Plasma Cutting Symbol X U0 = Rated NoLoad Voltage Duty Cycle Data (Note 3) I U2 Conventional Load Voltage Rated Maximum Supply Current Input Power Symbol U1 I 1max 3Ø 1 1Ø 1 1Ø I 1eff 3Ø Input Power Specif
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CUTMASTER A120 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram 8 - Open 4 - Green / Switch 3 - White / Switch Negative / Plasma 8 - Ground 4 - Switch 4 3 2- Orange / PIP 1 - Black / PIP ATC Female Receptacle Front View ATC Male Connector Front View Negative / Plasma 6 5 2 1 8 7 7 - Open 7 - Open 6 - Open 6 - Open 8 7 6 5 2 1 2 - PIP 5 - Open 5 - Open 3 - Switch 4 3 1 - PIP Pilot Pilot A-03701 B.
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CUTMASTER A120 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Torch Head Male ATC Leads Connector ATC Female Receptacle Power Supply Torch Leads Black PIP Switch Orange Green Torch Switch White 1 1 2 2 5 5 6 6 4 4 3 3 8 8 7 7 Negative / Plasma To Power Supply Circuitry To Power Supply Circuitry Negative / Plasma Pilot Pilot Art # A-03797 B.
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CUTMASTER A120 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS T1 3 C 1 2 3 4 5 4 2 PRI 4 PRI 3 J1 SW1 1 BIAS SUPPLY PRI 2 INRUSH RESISTORS +12VDC PRI 1 + TP2 MTH1 B A D PRI 2 PRI 1 + MTH2 TP1 K1 Q1 /INRUSH +12VDC BIAS SUPPLY D1 + TP8 PRIMARY AC INPUT _ W1 L1 L2 L3 GND L1 T1 L2 T2 L3 T3 L4 T4 AC1 80A_AC1 AC2 80A_AC2 AC3 80A_AC3 MTH4 TP5 7 8 9 K1 K2 K3 K4 K5 K6 7A SW2 J3 * 460_IN 1 2 BUSS BARS/JUMPERS *PRIMARY POWER C3,C4,C7,C8* * CM102 & A80 C7 & C1
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CUTMASTER A120 A120 ONLY 1TORCH TS1 PIP SWITCH L1 TORCH SWITCH 1 2 J11 SEC1 SEC2 +12VDC CHOKE1 ATC CONNECTOR J1 TEMP CIRCUIT 1 2 3 4 5 6 7 8 /OVERTEMP NTC -V OUT 1 1 2 3 4 5 6 7 8 E64 - E35 + AUTOMATION TORCH SOLENOID ELECTRODE1 D3 TIP1 Q5 PILOT IGBT WORK1 WORK J9 /PIP 1 2 3 4 5 6 7 /START 24VAC RETURN 24VAC SUPPLY 78 79 80 81 82 CNC INTERFACE STANDARD ON A80 & A120 UNITS CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS 83 J2 J10 1 2 3 4 5 6 7 8 OK-TO-MOVE (5A @ 250VAC / 30VDC)
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CUTMASTER A120 APPENDIX 6: SYSTEM SCHEMATIC, 400/600V UNITS 5 4 T1 3 2 C 1 2 3 4 5 4 PRI 4 PRI 3 J1 SW1 1 BIAS SUPPLY PRI 2 D INRUSH RESISTORS +12VDC PRI 1 + TP2 MTH1 B A D PRI 2 PRI 1 + MTH2 TP1 K1 Q1 EMI *CHOKE /INRUSH +12VDC BIAS SUPPLY D1 + C3,C4,C7,C8* UNITS * CEONLY TP8 EMI *FILTER L1 1 1 L2 2 2 L3 3 3 GND 4 4 _ W1 MTH7 AC1 80A_AC1 AC2 80A_AC2 AC3 80A_AC3 MTH4 TP5 7 L1 T1 L2 T2 8 9 L3 T3 L4 T4 7A 380/400/415V OR 600V 3 PH AC INPUT PRIMAR
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CUTMASTER A120 3 2 1 1TORCH TS1 PIP SWITCH L1 TORCH SWITCH 1 2 J11 SEC1 SEC2 +12VDC CHOKE1 ATC CONNECTOR J1 TEMP CIRCUIT 1 2 3 4 5 6 7 8 /OVERTEMP NTC -V OUT 1 1 2 3 4 5 6 7 8 E64 - E35 + AUTOMATION TORCH SOLENOID D ELECTRODE1 D3 TIP1 Q5 PILOT IGBT WORK1 WORK J9 /PIP 1 2 3 4 5 6 7 /START 24VAC RETURN 24VAC SUPPLY 78 79 80 81 82 CNC INTERFACE STANDARD ON A80 & A120 UNITS CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS 83 J2 J10 1 2 3 4 5 6 7 8 OK-TO-MOVE (5A @ 250VAC / 30VDC)
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CUTMASTER A120 APPENDIX 7: RAW ARC VOLTAGE If raw arc voltage is necessary for the torch height control, the customer must supply an 18 AWG (1.0 mm2), single pair, unshielded cable rated for 300V or greater. All work must be performed following applicable local and national codes. 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.
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CUTMASTER A120 Art # A-10288 Work1 (+) Polarity -V out (-) Polarity 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control .
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CutMaster A120 APPENDIX 8: PUBLICATION HISTORY Cover Date Rev. Change(s) June 30, 2008 AA Manual released. Sept. 19, 2008 AB Added CE information Per ECOB. Jan. 27, 2009 AC Updated art in section 3 to show all the information for the two stage filter per ECOB1248. Updated power supply and input wiring specs per ECOB1197 Apr. 1, 2009 AD Updated Cover, system specs and input wiring specs in section 2, system catalog number in section 6 and Appendix with 600V schematic info per ECOB1346.
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THE AMERICAS Denton, TX USA U.S.