ESAB A120 User manual

CUTMASTER®A120
AUTOMATED PLASMA CUTTING SYSTEM
Art # A-12879
120
OUTPUT MAX OUTPUT INPUT POWER VOLTAGEVOLTAGEVOLTAGE INPUT POWER VOLTAGE
PHASE PHASE
AMPS
380-400V208-230V
600V460V
Revision: AA Issue Date: August 30, 2015 Manual No.: 0-5430
Operating
Manual
esab.eu

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer
and will strive to provide you with the best service and reliability in the industry. This prod-
uct is backed by our extensive warranty and world-wide service network. To locate your
nearest distributor or service agency, visit us on the web at www.esab.eu.
This Operating Manual has been designed to instruct you on the correct use and opera-
tion of your ESAB product. Your satisfaction with this product and its safe operation is
our ultimate concern. Therefore please take the time to read the entire manual, especially
the Safety Precautions. They will help you to avoid potential hazards that may exist when
working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
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 judgement,
the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
Cutmaster®A120
SL100 1Torch™
Operating Manual Number 0-5430
Published by:
ESAB Group Inc.
2800 Airport Rd.
Denton, TX 76208
[phone]
www.esab.eu
Copyright 2015 by ESAB
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or
damage caused by any error or omission in this Manual, whether such error results from negli-
gence, accident, or any other cause.
For Printing Material Specification refer to document 47x1909
Original Publication Date: August 30, 2015
Revision Date:
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 equip-
ment, 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 equipment. 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 manu-
facturer. 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 manufac-
turer 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 Power Supply location and Mounting ........................................................3-1
3.04 Opening the Contactor Cover ....................................................................3-1
3.05 Primary Input Power Connections..............................................................3-1
3.06 Gas Connections ........................................................................................3-3
SECTION 3 TORCH: INSTALLATION ................................................................................. 3T-1
3T.01 Torch Connections ...................................................................................3T-1
3T.02 CNC Connection.......................................................................................3T-1
3T.03 Automation Interface PCB with Ohmic Sense..........................................3T-2
3T.04 Setting Up Automation or Machine Torch................................................3T-3
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-1
4T.03 Machine and Hand Torch Parts Selection................................................4T-2
4T.04 Cut Quality................................................................................................4T-3
4T.05 General Cutting Information .....................................................................4T-3
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-8
4T.09 Recommended Cutting Speeds for Machine and
Automated Torches With Shielded Tip...................................................4T-40

TABLE OF CONTENTS
PATENT INFORMATION.................................................................................................... 4T-70
SECTION 5 SYSTEM: SERVICE .............................................................................................5-1
5.01 General Maintenance..................................................................................5-1
5.02 Maintenance Schedule ...............................................................................5-2
5.03 Common Faults ..........................................................................................5-2
5.04 Fault Indicator.............................................................................................5-3
5.05 Basic Troubleshooting Guide .....................................................................5-4
5.06 Power Supply Basic Parts Replacement....................................................5-6
SECTION 5 TORCH: SERVICE............................................................................................ 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-4
APPENDIX 4: TORCH CONNECTION DIAGRAMS ............................................................. A-6
APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS ..................................................... A-8
APPENDIX 6: SYSTEM SCHEMATIC, 400/600V UNITS ................................................... A-10
APPENDIX 7: RAW ARC VOLTAGE .................................................................................. A-12
Revision History................................................................................................................... A-14

CUTMASTER A120
0-5430 GENERAL INFORMATION 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, flame proof
clothing, safety gloves.
- Do not wear loose fitting 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 qualified electrician.
- Appropriate fire 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 col-
lection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary cutting protection and accessories.
SECTION 1: SAFETY

CUTMASTER A120
GENERAL INFORMATION 0-5430
1-2
WARNING 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 filter
lens and wear protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable
materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmuffs 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 Do not use the power source for thawing frozen pipes.
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 potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those lo-
cations, due to conducted as well as radiated disturbances.
CAUTION This product is solely intended for metal removal. Any other use
may result in personal injury and / or equipment damage.
CAUTION Read and understand the instruction manual before
installing or operating.
!

CUTMASTER A120
0-5430 INTRODUCTION 2-1
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specication or part
numbers listed on page i.
To ensure safe operation, read the entire manual, in-
cluding the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAU-
TION, DANGER and NOTE may appear. Pay par-
ticular attention to the information provided under these
headings. These special annotations are easily recog-
nized as follows:
NOTE!
An operation, procedure, or back-
ground information which requires
additional emphasis or is helpful in
ef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 operating
area.
WARNING
Gives information regarding possible
electrical shock injury. Warnings
will be enclosed in a box such as
this.
!
DANGER
Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.
Additional copies of this manual may be purchased by
contacting ESAB at the address and phone number in
your area listed on back cover of this manual. Include
the Owner’s Manual number and equipment identica-
tion numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the ESAB
web site listed below
http://www.esab.eu
2.02 EquipmentIdentication
The unit’s identication number (specication or part
number), model, and serial number usually appear on
a data tag attached to the rear panel. Equipment which
does not have a data tag such as torch and cable as-
semblies are identied only by the specication or part
number printed on loosely attached card or the shipping
container. Record these numbers on the bottom of page
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 le a
claim. Furnish complete information concerning dam-
age claims or shipping errors to the location in your area
listed in the inside back cover of this manual.
Include all equipment identication numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.