ESAB A-12786 User manual

120
380/400V
Art # A-12786
esab.com
ESAB Cutmaster®120
Plasma Cutting System
SL100 1TorchTM
Operating
Manual
Revision: AC Issue Date: July 6, 2015 Manual No.: 0-5389

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our cus-
tomer and will strive to provide you with the best service and reliability in the industry.
This product is backed by our extensive warranty and world-wide service network. To
locate your nearest distributor or service agency, visit us on the web at www.esab.com
This Operating Manual has been designed to instruct you on the correct use and op-
eration of your ESAB product. Your satisfaction with this product and its safe opera-
tion is our ultimate concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid potential hazards that
may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable
products that have stood the test of time. We pride ourselves on technical innovation,
competitive prices, excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to
achieve a safer working environment within the welding industry.

!
WARNING
Read and understand this entire Manual and your employer’s safety practices before install-
ing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judge-
ment, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
ESAB Cutmaster®120 with SL100 1Torch™
Operating Manual Number 0-5389
Published by:
ESAB
2800 Airport Rd.
Denton, Texas 76207
www.esab.com
Copyright © 2015 by
ESAB
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of
the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party
for any loss or damage caused by any error or omission in this Manual, whether
such error results from negligence, accident, or any other cause.
Original Publication Date: January 15, 2015
Revision Date: July 6, 2015
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________
Purchase Date:__________________________________ __________
Power Supply Serial #:___________________________ __________
Torch Serial #:___________________________________ __________
i

Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully
familiar with the principles of operation and safe practices for arc welding
and cutting equipment, we urge you to read our booklet, “Precautions and
Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do
NOT permit untrained persons to install, operate, or maintain this equip-
ment. Do NOT attempt to install or operate this equipment until you have
read and fully understand these instructions. If you do not fully understand
these instructions, contact your supplier for further information. Be sure to
read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance
with the instructions provided. This equipment must be checked periodically. Malfunctioning or
poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted
or contaminated should be replaced immediately. Should such repair or replacement become
necessary, the manufacturer recommends that a telephone or written request for service advice
be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the
manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which
results from improper use, faulty maintenance, damage, improper repair or alteration by anyone
other than the manufacturer or a service facility designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS
SECTION 1: SAFETY............................................................................................................................ 1-1
1.0 Safety Precautions.......................................................................................... 1-1
SECTION 2 SYSTEM:
INTRODUCTION ......................................................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Power Supply Specifications .......................................................................... 2-2
2.05 Input Wiring Specifications............................................................................. 2-3
2.06 Power Supply Features ................................................................................... 2-4
SECTION 2 TORCH:
INTRODUCTION ........................................................................................................................2T-1
2T.01 Scope of Manual............................................................................................2T-1
2T.02 General Description .......................................................................................2T-1
2T.03 Specifications ...............................................................................................2T-1
2T.04 Options And Accessories ...............................................................................2T-2
2T.05 Introduction to Plasma ..................................................................................2T-2
SECTION 3 SYSTEM:
INSTALLATION .......................................................................................................................... 3-1
3.01 Unpacking....................................................................................................... 3-1
3.02 Lifting Options ................................................................................................ 3-1
3.03 Primary Input Power Connections .................................................................. 3-1
3.04 Gas Connections............................................................................................. 3-2
SECTION 3 TORCH:
INSTALLATION ..........................................................................................................................3T-1
3T.01 Torch Connections .........................................................................................3T-1
3T.02 Setting Up Mechanical Torch .........................................................................3T-1
SECTION 4 SYSTEM:
OPERATION ............................................................................................................................... 4-1
4.01 Front Panel Controls / Features....................................................................... 4-1
4.02 Preparations for Operation.............................................................................. 4-2
SECTION 4 TORCH:
OPERATION...............................................................................................................................4T-1
4T.01 Torch Parts Selection.....................................................................................4T-1
4T.02 Cut Quality .....................................................................................................4T-2
4T.03 General Cutting Information...........................................................................4T-3
4T.04 Hand Torch Operation....................................................................................4T-4
4T.05 Gouging .........................................................................................................4T-7
4T.06 Mechanized Torch Operation..........................................................................4T-8
4T.07 Parts Selection for SL100 Torch Cutting........................................................4T-9
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip ....4T-10
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip ....4T-15
PATENT INFORMATION ....................................................................................................................4T-20

TABLE OF CONTENTS
SECTION 5 SYSTEM:
SERVICE..................................................................................................................................... 5-1
5.01 General Maintenance ...................................................................................... 5-1
5.02 Maintenance Schedule.................................................................................... 5-2
5.03 Common Faults............................................................................................... 5-2
5.04 Fault Indicator................................................................................................. 5-3
5.05 Basic Troubleshooting Guide .......................................................................... 5-4
5.06 Power Supply Basic Parts Replacement ......................................................... 5-6
SECTION 5 TORCH:
SERVICE....................................................................................................................................5T-1
5T.01 General Maintenance .....................................................................................5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts..............................5T-2
SECTION 6:
PARTS LISTS.............................................................................................................................. 6-1
6.01 Introduction.................................................................................................... 6-1
6.02 Ordering Information ...................................................................................... 6-1
6.03 Power Supply Replacement ............................................................................ 6-1
6.04 Replacement Power Supply Parts................................................................... 6-2
6.05 Options and Accessories ................................................................................ 6-2
6.06 Replacement Parts for Hand Torch ................................................................ 6-3
6.07 Replacement Parts - for Machine Torches with Unshielded Leads.................. 6-4
6.08 Replacement Shielded Machine Torch Leads Assemblies .............................. 6-6
6.09 Torch Consumable Parts (SL100)................................................................... 6-7
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM) .................................................................................................................... A-1
APPENDIX 2: DATA TAG INFORMATION .............................................................................................A-2
APPENDIX 3: TORCH PIN - OUT DIAGRAMS ......................................................................................A-3
APPENDIX 4: TORCH CONNECTION DIAGRAMS ................................................................................A-4
APPENDIX 5: SYSTEM SCHEMATIC, 380/400V UNITS.......................................................................A-6
APPENDIX 6: PUBLICATION HISTORY................................................................................................ A-8

ESAB CUTMASTER 120
Manual 0-5389 SAFETY 1-1
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding or plasma cutting equipment. The following
recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or
plasma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which
can result in injury to the operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, ame proof
clothing, safety gloves.
- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualied electrician.
- Appropriate re extinguishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in
accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of
at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary cutting protection and accessories.
SECTION 1: SAFETY

ESAB CUTMASTER 120
SAFETY Manual 0-5389
1-2
Arc welding and cutting can be injurious to yourself and others.
Take precautions when welding and cutting. Ask for your employer's
safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
WARNING
This product is solely intended for plasma cutting. Any other use may
result in personal injury and / or equipment damage.
CAUTION
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be poten-
tial diculties in ensuring electromagnetic compat-
ibility of class A equipment in those locations, due to
conducted as well as radiated disturbances.
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
Do not use the power source for thawing frozen pipes.
WARNING
!

ESAB CUTMASTER 120
Manual 0-5389 INTRODUCTION 2-1
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, CAU-
TION, and NOTE may appear. Pay particular attention
to the information provided under these headings.
These special annotations are easily recognized as
follows:
NOTE!
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful in ecient operation of the system.
!
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
!
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operat-
ing 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 ESAB at the address and phone num-
ber in your area listed on back cover of this manual.
Include the Owner’s Manual number and equipment
identification numbers.
Electronic copies of this manual can also be down-
loaded at no charge in Acrobat PDF format by going
to the ESAB web site listed below
http://www.esab.com
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear
on a data tag attached to the rear panel. Equipment
which does not have a data tag such as torch and
cable assemblies are identified only by the specifica-
tion or part number printed on loosely attached card
or the shipping container. Record these numbers on
the bottom of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If
there is any damage, notify the carrier immediately to
file a claim. Furnish complete information concerning
damage claims or shipping errors to the location in
your area listed in the inside back cover of this manual.
Include all equipment identification numbers as
described above along with a full description of the
parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-
crate the unit.

ESAB CUTMASTER 120
INTRODUCTION Manual 0-5389
2-2
2.04 Power Supply Specifications
ESAB Cutmaster®120 Power Supply Specifications
Input Power 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 120 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability Particulates to 5 Microns
ESAB Cutmaster®120 Power Supply Duty Cycle *
Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
All Units
Duty Cycle 80% 100%
Rating IEC IEC
Current 120A 110A
DC Voltage 128 124
* NOTE: The duty cycle will be reduced if the primary input power (AC) is
low or the output voltage (DC) is higher than shown in this chart.
NOTE!
IEC Rating is determined as specied by the International Electro-Technical Commission. These specications include
calculating an output voltage based upon power supply rated current. To facilitate comparison between power supplies, all
manufacturers use this output voltage to determine duty cycle.
Power Supply Dimensions & Weight Ventilation Clearance Requirements
30.5"
774.7 mm
63 lb / 28.6 kg
10.75"
273 mm
16.375"
416 mm
Art # A-08358_AB
6"
150 mm
24"
610 mm
6"
150 mm
6"
150 mm
Art # A-07925_AB

ESAB CUTMASTER 120
Manual 0-5389 INTRODUCTION 2-3
2.05 Input Wiring Specifications
ESAB Cutmaster®120 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I 1max I1eff Fuse (amps)
Flexible Cord
(Min. AWG)
Flexible Cord
(Min. mm2)
3 phase 380 50 23 35 32 40 10# 6
400 50 23.6 34 31 40 10# 6
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on US Electric Code and Canadian Electric Code
NOTE!
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
I1max is taken at rated minimum duty cycle.
I1e is taken at 100% rated duty cycle.

ESAB CUTMASTER 120
INTRODUCTION Manual 0-5389
2-4
2.06 Power Supply Features
Handle and Leads Wrap
To rch Leads Receptacl
e
Control Panel
Ar
t # A-08359
Work Cable
and Clamp
Art # A-08547
Input Power Cord
Port for Optional Automation
Interface Cable
Gas Inlet
Port
Filter Assembly

ESAB CUTMASTER 120
Manual 0-5389 INTRODUCTION 2T-1
SECTION 2 TORCH:
INTRODUCTION
2T.01 Scope of Manual
This manual contains descriptions, operating instruc-
tions and maintenance procedures for the 1Torch
Models SL100/Manual and SL100/Mechanized
Plasma Cutting Torches. Service of this equipment
is restricted to properly trained personnel; unqualified
personnel are strictly cautioned against attempting
repairs or adjustments not covered in this manual, at
the risk of voiding the Warranty.
Read this manual thoroughly. A complete under-
standing of the characteristics and capabilities of this
equipment will assure the dependable operation for
which it was designed.
2T.02 General Description
Plasma torches are similar in design to the automotive
spark plug. They consist of negative and positive sec-
tions separated by a center insulator. Inside the torch,
the pilot arc starts in the gap between the negatively
charged electrode and the positively charged tip.
Once the pilot arc has ionized the plasma gas, the
superheated column of gas flows through the small
orifice in the torch tip, which is focused on the metal
to be cut.
A single torch lead provides gas from a single source
to be used as both the plasma and secondary gas.
The air flow is divided inside the torch head. Single
- gas operation provides a smaller sized torch and
inexpensive operation.
NOTE!
An operation,Refer to Section "2T.05 Introduction to
Plasma", for a more detailed description of plasma
torch operation.
Refer to the Appendix Pages for additional speci-
cations as related to the Power Supply used.
2T.03 Specifications
A. Torch Configurations
1. Hand/Manual Torch, Models
The hand torch head is at 75° to the torch
handle. The hand torches include a torch
handle and torch trigger assembly.
10.125" (257 mm)
3.75"
(95 mm)
1.17" (29 mm)
Art # A-03322_AB
2. Mechanized Torch, Model
The standard machine torch has a positioning
tube with rack & pinch block assembly.
Ar
t # A-02998
1.75" /
44.5 mm
1.375" / 35 mm
15.875" / 403 mm
0.625" /
16 mm
4.95" / 126 mm
1.175" / 30 mm
9.285" / 236 mm
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20ft/6.1m,withATCconnectors
• 50ft/15.2m,withATCconnectors
Machine Torches are available as follows:
• 5foot/1.5m,withATCconnectors
• 10foot/3.05m,withATCconnectors
• 25foot/7.6m,withATCconnectors
• 50foot/15.2m,withATCconnectors
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch Head has built - in switch
12 VDC circuit rating
E. Type Cooling
Combination of ambient air and gas stream
through torch.

ESAB CUTMASTER 120
INTRODUCTION Manual 0-5389
2T-2
F. Torch Ratings
Manual Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum Current 120 Amps
Voltage (Vpeak)500V
Arc Striking Voltage 7kV
Mechanized Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum Current 120 Amps
Voltage (Vpeak)500V
Arc Striking Voltage 7kV
G. Gas Requirements
Manual and Mechanized Torch Gas Specifications
Gas (Plasma and Secondary) Compressed Air
Operating Pressure
Refer to NOTE
60 - 95 psi
4.1 - 6.5 bar
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow (Cutting and Gouging) 300 - 500 scfh
142 - 235 lpm
!
WARNING
This torch is not to be used with oxygen (O2).
NOTE!
Operating pressure varies with torch model, oper-
ating amperage, and torch leads length. Refer to
gas pressure settings charts for each model.
H. Direct Contact Hazard
Forstandofftiptherecommendedstandoffis3/16
inches / 4.7 mm.
2T.04 Options And Accessories
Foroptionsandaccessories,seeSection6.
2T.05 Introduction to Plasma
A. Plasma Gas Flow
Plasma is a gas which has been heated to an
extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma
to transfer an electrical arc to the workpiece. The
metal to be cut or removed is melted by the heat
of the arc and then blown away.
While the goal of plasma arc cutting is separation
of the material, plasma arc gouging is used to
remove metals to a controlled depth and width.
In a Plasma Cutting Torch a cool gas enters Zone
B, where a pilot arc between the electrode and
the torch tip heats and ionizes the gas. The main
cutting arc then transfers to the workpiece through
the column of plasma gas in Zone C.
A-00002
Workpiece
Power
Supply
+
_
C
B
A
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.

ESAB CUTMASTER 120
Manual 0-5389 INTRODUCTION 2T-3
B. Gas Distribution
The single gas used is internally split into plasma
and secondary gases.
The plasma gas flows into the torch through
the negative lead, through the starter cartridge,
around the electrode, and out through the tip
orifice.
The secondary gas flows down around the outside
of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot
arc creates a path for the main arc to transfer to
the work.
D. Main Cutting Arc
DC power is also used for the main cutting arc.
The negative output is connected to the torch
electrode through the torch lead. The positive
output is connected to the workpiece via the work
cable and to the torch through a pilot wire.
E. Parts - In - Place (PIP)
The torch includes a 'Parts - In - Place' (PIP) cir-
cuit. When the shield cup is properly installed, it
closes a switch. The torch will not operate if this
switch is open.
A-02997
Torch Trigge
r
PIP Switch Shield Cup
To Control
Cable Wiring
Torch Switch
Parts - In - Place Circuit Diagram for Hand Torch
PIP Sw itch Sh ield C
up
To
AT C
CNC Start
PIP Sw itch Sh ield C
up
PIP Sw itch Sh ield C
up
Remote Pendant
Automation To rch
To AT C
To AT C
Art # A-08168
Parts - In - Place Circuit Diagram for Machine Torch

ESAB CUTMASTER 120
INTRODUCTION Manual 0-5389
2T-4
This Page Intentionally Blank

ESAB CUTMASTER 120
Manual 0-5389 INSTALLATION 3-1
SECTION 3 SYSTEM:
INSTALLATION
3.01 Unpacking
1. Use the packing lists to identify and account
for each item.
2. Inspect each item for possible shipping
damage. If damage is evident, contact your
distributor and / or shipping company before
proceeding with the installation.
3. Record Power Supply and Torch model and
serial numbers, purchase date and vendor
name, in the information block at the front of
this manual.
3.02 Lifting Options
The Power Supply includes a handle for hand lifting
only. Be sure unit is lifted and transported safely and
securely.
WARNING
Do not touch live electrical parts.
Disconnect input power cord before moving unit.
!
WARNING
FALLING EQUIPMENT can cause serious personal
injury and can damage equipment.
HANDLE is not for mechanical lifting.
• Only persons of adequate physical strength
should lift the unit.
• Liftunitbythehandles,usingtwohands.Do
not use straps for lifting.
• Useoptionalcartorsimilardeviceofadequate
capacity to move unit.
• Placeunitonaproperskidandsecureinplace
before transporting with a fork lift or other ve-
hicle.
3.03 Primary Input Power Connections
!
CAUTION
Check your power source for correct voltage 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 require-
ments as specied in Section 2..
Connect three-phase input power cable as shown in
the illustration below.
Art # A-08548
Input Power Cable Connections
Three-Phase (3ø)
GND
L1
L2
L3
L4
Three Phase Input Power Wiring
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 400 VAC Power Supply to Three
- Phase input power.
1. Remove the Power Supply cover per instruc-
tions found in Section 5.
2. Disconnect the original input power cable
from the main input contactor and the chassis
ground connection.
3. Loosen the through - hole protector on the
back panel of the power supply. Pull the
original power cable out of the power supply.
4. Using a customer supplied four - conductor
input power cable for the voltage desired, strip
back the insulation on the individual wires.
5. Pass the cable being used through the access
opening in the back panel of the power supply.
Refer to Section 2 for power cable specifica-
tions.
!
CAUTION
The primary power source and power cable must
conform to local electrical code and the recom-
mended circuit protection and wiring requirements
(refer to table in Section 2).

ESAB CUTMASTER 120
INSTALLATION Manual 0-5389
3-2
6. Connectthewiresasfollows.
• WiringtoL1,L2andL3input.Seetheprevi-
ous illustration and power label. It does not
matter what order these wires are attached.
• Green/YellowwiretoGround.
7. With a little slack in the wires, tighten the
through - hole protector to secure the power
cable.
8. Reinstall the Power Supply cover per instruc-
tions found in Section 5.
9. Connect the opposite end of individual wires to
a customer supplied plug or main disconnect.
10.Connect the input power cable (or close the
main disconnect switch) to supply power.
3.04 Gas Connections
Connecting Gas Supply to Unit
The connection is the same for compressed air or
high pressure cylinders. Refer to the following two
subsections if an optional air line filter is to be installed.
1. Connect the air line to the inlet port. The il-
lustration shows typical fittings as an example.
NOTE!
For a secure seal, apply thread sealant to the tting
threads, according to manufacturer's instructions.
Do not use Teon tape as a thread sealer, as small
particles of the tape may break o and block the
small air passages in the torch.
Art # A-07943
Hose Clamp
Regulator/Filter
Assembly
Inlet Port
Gas Supply
Hose
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.
NOTE!
For a secure seal, apply thread sealant to the tting
threads, according to manufacturer's instructions.
Do not use Teon tape as a thread sealer, as small
particles of the tape may break o and block the
small air passages in the torch.
Ar
t # A-07944
Hose Clam
p
1/4 NPT to 1/4"
(6mm) Fitting
Regulator/Filter
Assembly
Inlet Port
Gas Supply
Hose
Optional Single - Stage Filter Installation

ESAB CUTMASTER 120
Manual 0-5389 INSTALLATION 3-3
Installing Optional Two - Stage Air Filter Kit
This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture
and contaminants to at least 5 microns.
Connect the air supply as follows:
1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the
filter assembly.
NOTE!
For a secure seal, apply thread sealant to the tting threads, according to manufacturer's instructions. Do not use Teon
tape as a thread sealer, as small particles of the tape may break o 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
Input
Gas Supply
Hose
1/4 NPT to 1/4”
(6mm) Fitting
Regulator/Filter
Assembly 2-Stage Filter
Inlet Port (IN)
Outlet Port
(OUT)
T
wo Stage
Filter
Assembly
Art # A-07945_AC
Hose Clamp
Optional Two - Stage Filter Installation
Using High Pressure Air Cylinders
When using high pressure air cylinders as the air supply:
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pres-
sure regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material.
Briefly open each cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures
upto100psi(6.9bar)maximumandowsofatleast300scfh(141.5lpm).
4. Connect supply hose to the cylinder.
NOTE!
Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the tting threads, according to manufacturer's instructions. Do Not use Teon
tape as a thread sealer, as small particles of the tape may break o and block the small air passages in the torch.

ESAB CUTMASTER 120
INSTALLATION Manual 0-5389
3-4
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