Victor CUTMASTER A80 User manual

VictorThermalDynamics.com
CUTMASTER®A80, A120
AUTOMATED PLASMA CUTTING SYSTEM
Operating
Manual
Revision: AJ Issue Date: April 9, 2014 Manual No.: 0-5119
380-
V
400
80 120
A80 A120

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Radnor/Victor 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 1-800-426-1888, or visit us on the web at www.thermal-
dynamics.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your
Radnor/Victor Thermal Dynamics 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.
Victor Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products
for Victor Technologies, Inc.
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 plasma and 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.
i
Plasma Cutting Power Supply
CutMaster™ A80 SL100SV Torch™ Operating Manual No.: 0-5119
CutMaster™ A120SL100SV Torch™ Operating Manual No.: 0-5119
Published by:
Victor Technologies, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.victorthermaldynamics.com
Copyright 2008, 2009, 2010, 2012 by
Victor Technologies International, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or
damage caused by any error or omission in this Manual, whether such error results from negli-
gence, accident, or any other cause.
Original Publication Date: December 10, 2008
Revision Date: April 9, 2014
Record the following information for Warranty purposes:
Where Purchased:_________________________________________________
Purchase Date:____________________________________________________
Power Supply Serial #:_____________________________________________
Torch Serial #:_____________________________________________________

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION .......................................................................................................1-1
1.01 Notes, Cautions and Warnings.....................................................................................1-1
1.02 Important Safety Precautions .......................................................................................1-1
1.03 Publications ..................................................................................................................1-2
1.04 Note, Attention et Avertissement ..................................................................................1-3
1.05 Precautions De Securite Importantes...........................................................................1-3
1.06 Documents De Reference ............................................................................................1-5
1.07 Declaration of Conformity .............................................................................................1-6
1.08 Statement of Warranty..................................................................................................1-7
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 ...........................................................................................2-4
2.06 Power Supply Features ................................................................................................2-5
SECTION 2 TORCH:
INTRODUCTION ....................................................................................................................2T-1
2T.01 Scope of Manual.........................................................................................................2T-1
2T.02 General Description....................................................................................................2T-1
2T.03 Specifications ............................................................................................................2T-1
2T.04 Options and Accessories............................................................................................2T-2
2T.05 Introduction to Plasma................................................................................................2T-2
SECTION 3 SYSTEM:
INSTALLATION ........................................................................................................................3-1
3.01 Unpacking 3-1
3.02 Lifting Options...............................................................................................................3-1
3.03 Power Supply location and Mounting ...........................................................................3-1
3.04 Primary Input Power Connections ................................................................................3-1
3.05 Gas Connections..........................................................................................................3-3
SECTION 3 TORCH:
INSTALLATION ......................................................................................................................3T-1
3T.01 Torch Connections .....................................................................................................3T-1
3T.02 CNC Connection.........................................................................................................3T-1
SECTION 4 SYSTEM:
OPERATION ............................................................................................................................4-1
4.01 Front Panel Controls / Features ...................................................................................4-1
4.02 Preparations for Operation ...........................................................................................4-2

TABLE OF CONTENTS
SECTION 4 TORCH:
OPERATION ...........................................................................................................................4T-1
4T.01 Machine and Automated Torch Operation..................................................................4T-1
4T.02 Automation Torch Parts Selection ..............................................................................4T-2
4T.03 Machine and Hand Torch Parts Selection ..................................................................4T-2
4T.04 Cut Quality..................................................................................................................4T-3
4T.05 General Cutting Information .......................................................................................4T-4
4T.06 Hand Torch Operation................................................................................................4T-4
4T.07 Gouging ..................................................................................................................4T-7
4T.08 Recommended Cutting Speeds for Machine and Automated Torches
With Exposed Tip .......................................................................................................4T-9
4T.09 Recommended Cutting Speeds for Machine and Automated Torches
With Shielded Tip .....................................................................................................4T-24
PATENT INFORMATION...............................................................................................................4T-39
SECTION 5 SYSTEM:
SERVICE...................................................................................................................................5-1
5.01 General Maintenance ...................................................................................................5-1
5.02 Maintenance Schedule.................................................................................................5-2
5.03 Common Faults ............................................................................................................5-2
5.04 Fault Indicator...............................................................................................................5-3
5.05 Basic Troubleshooting Guide .......................................................................................5-4
5.06 Power Supply Basic Parts Replacement ......................................................................5-6
SECTION 5 TORCH:
SERVICE.................................................................................................................................5T-1
5T.01 General Maintenance .................................................................................................5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts .........................................5T-2
SECTION 6:
PARTS LISTS............................................................................................................................6-1
6.01 Introduction...................................................................................................................6-1
6.02 Ordering Information.....................................................................................................6-1
6.03 Power Supply Replacement .........................................................................................6-1
6.04 Replacement Power Supply Parts................................................................................6-2
6.05 Options and Accessories..............................................................................................6-2
6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)............6-4
6.07 Torch Consumable Parts (SL100) ................................................................................6-6
6.08 Replacement Parts for Hand Torch .............................................................................6-7
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM) ................................................................................................................. A-1
APPENDIX 2: DATA TAG INFORMATION...................................................................................... A-2
APPENDIX 3: TORCH PIN - OUT DIAGRAMS ............................................................................... A-3
APPENDIX 4: TORCH CONNECTION DIAGRAMS........................................................................ A-4
APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS................................................................ A-6
APPENDIX 6: SYSTEM SCHEMATIC, 380V/400V-600V UNITS.................................................... A-8
APPENDIX 7: RAW ARC VOLTAGE ............................................................................................ A-10
APPENDIX 8: PUBLICATION HISTORY ....................................................................................... A-12

This Page Intentionally Blank

CUTMASTER A80, A120
Manual 0-5119 GENERAL INFORMATION 1-1
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warn-
ings are used to highlight important information.
These highlights are categorized as follows:
NOTE
An operation, procedure, or background infor-
mation which requires additional emphasis or
is helpful 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 operating area.
WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a
box such as this.
1.02 Important Safety Precautions
!
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE
DANGEROUS AND HAZARDOUS TO
YOUR HEALTH.
Plasma arc cuing produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hear-
ing aids, or other electronic health equipment.
Persons who work near plasma arc cuing ap-
plications should consult their medical health
professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand
and follow all warnings, safety precautions and
instructions before using the equipment. Call
1-603-298-5711 or your local distributor if you
have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cut-
ting process can be dangerous and hazardous to your
health.
• 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. You
mustbeverycarefulwhencuttingorwelding
any metals which may contain one or more of
the following:
Antimony Chromium Mercury
 Arsenic Cobalt  Nickel
Barium Copper Selenium
 Beryllium Lead  Silver 
Cadmium Manganese Vanadium
• AlwaysreadtheMaterialSafetyData Sheets
(MSDS)thatshouldbesuppliedwiththematerial
youareusing.TheseMSDSswillgiveyouthe
informationregardingthekindandamountof
fumes and gases that may be dangerous to your
health.
• Forinformationon howtotestforfumes and
gasesinyourworkplace,refertoitem1inSub-
section 1.03, Publications in this manual.
• Usespecialequipment,suchaswaterordown
draft cutting tables, to capture fumes and gases.
• Donotusetheplasmatorchinanareawhere
combustibleorexplosivegasesormaterialsare
located.
• Phosgene,atoxicgas,isgeneratedfromthe
vaporsofchlorinatedsolventsandcleansers.
Removeallsourcesofthesevapors.
• WARNING: This product contains chemicals,
includinglead,knowntotheStateofCalifornia
tocausebirthdefectsandotherreproductive
harm. Wash hands after handling.
ELECTRIC SHOCK
ElectricShockcaninjureorkill.Theplasmaarcprocess
usesandproduceshighvoltageelectricalenergy.This
electricenergycancausesevereorfatalshocktothe
operatororothersintheworkplace.
SECTION 1:
GENERAL INFORMATION

CUTMASTER A80, A120
GENERAL INFORMATION Manual 0-5119
1-2
• Nevertouchanypartsthatareelectrically“live”
or“hot.”
• Weardryglovesandclothing.Insulateyourself
fromtheworkpieceorotherpartsofthewelding
circuit.
• Repairorreplaceallwornordamagedparts.
• Extracaremustbetakenwhentheworkplaceis
moist or damp.
• Installandmaintainequipmentaccordingto
NEC code, refer to item 9 in Subsection 1.03,
Publications.
• Disconnectpowersourcebeforeperformingany
serviceorrepairs.
• ReadandfollowalltheinstructionsintheOper-
ating Manual.
FIRE AND EXPLOSION
Fireandexplosioncanbecausedbyhotslag,sparks,
or the plasma arc.
• Besurethereisnocombustibleorammable
materialintheworkplace. Anymaterialthat
cannotberemovedmustbeprotected.
• Ventilateallammableorexplosivevaporsfrom
theworkplace.
• Donotcutorweldoncontainersthatmayhave
held combustibles.
• Providearewatchwhenworkinginanarea
whererehazardsmayexist.
• Hydrogengasmaybeformedandtrappedunder
aluminumworkpieceswhentheyarecutunder-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or
dissipated. Trapped hydrogen gas that is ignited
will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc
processescancausenoiselevelstoexceedsafelimits.
Youmustprotectyourearsfromloudnoisetoprevent
permanent loss of hearing.
• Toprotectyourhearingfromloudnoise,wear
protectiveearplugsand/orearmuffs.Protect
othersintheworkplace.
• Noiselevelsshouldbemeasuredtobesurethe
decibels(sound)donotexceedsafelevels.
• Forinformationonhowtotestfornoise,seeitem
1 in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
PlasmaArcRayscaninjureyoureyesandburnyour
skin.Theplasmaarcprocessproducesverybright
ultravioletandinfraredlight.Thesearcrayswill
damageyoureyesandburnyourskinifyouarenot
properly protected.
• Toprotectyoureyes,alwayswearawelding
helmet or shield. Also always wear safety glasses
withsideshields,gogglesorotherprotectiveeye
wear.
• Wearweldingglovesandsuitableclothingto
protectyourskinfromthearcraysandsparks.
• Keephelmetandsafetyglassesingoodcondi-
tion.Replacelenseswhencracked,chippedor
dirty.
• Protectothersintheworkareafromthearcrays.
Useprotectivebooths,screensorshields.
• Usetheshadeoflensassuggestedinthefollow-
ingperANSI/ASCZ49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
 300-400* 9 12
 400-800* 10 14
* These values apply where the actual arc is
clearly seen. Experience has shown that lighter
lters may be used when the arc is hidden by
the workpiece.
LEAD WARNING
WARNING: This product contains chemicals, includ-
inglead,knowntotheStateofCaliforniatocausebirth
defectsandotherreproductiveharm.Wash hands
after handling.
1.03 Publications
Refertothefollowingstandardsortheirlatestrevi-
sions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent
ofDocuments,U.S.GovernmentPrintingOfce,
Washington,D.C.20402
2. ANSIStandardZ49.1,SAFETYINWELDINGAND
CUTTING,obtainablefromtheAmericanWelding
Society,550N.W.LeJeuneRd.,Miami,FL33126
3. NIOSH,SAFETYANDHEALTHINARCWELDING
ANDGASWELDINGANDCUTTING,obtainable
fromtheSuperintendentofDocuments,U.S.Govern-
mentPrintingOfce,Washington,D.C.20402
4. ANSIStandardZ87.1,SAFEPRACTICESFOROC-
CUPATIONANDEDUCATIONALEYEANDFACE
PROTECTION,obtainablefromAmericanNational
StandardsInstitute,1430Broadway,NewYork,NY
10018

CUTMASTER A80, A120
Manual 0-5119 INFORMATIONS GÉNÉRALES 1-3
5. ANSIStandardZ41.1,STANDARDFORMEN’S
SAFETY-TOEFOOTWEAR, obtainablefromthe
AmericanNationalStandardsInstitute,1430Broad-
way,NewYork,NY10018
6. ANSIStandardZ49.2,FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainablefromAmericanNationalStandardsInsti-
tute,1430Broadway,NewYork,NY10018
7. AWSStandardA6.0,WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES,obtainablefromAmericanWeldingSociety,
550N.W.LeJeuneRd.,Miami,FL33126
8. NFPAStandard51,OXYGEN-FUELGASSYSTEMS
FORWELDING,CUTTINGANDALLIEDPRO-
CESSES,obtainablefromtheNationalFireProtection
Association,BatterymarchPark,Quincy,MA02269
9. NFPAStandard70,NATIONALELECTRICALCODE,
obtainablefromtheNationalFireProtectionAssocia-
tion,BatterymarchPark,Quincy,MA02269
10.NFPA Standard51B,CUTTINGANDWELDING
PROCESSES,obtainablefromtheNationalFirePro-
tectionAssociation,BatterymarchPark,Quincy,MA
02269
11.CGAPamphletP-1,SAFE HANDLINGOFCOM-
PRESSEDGASESINCYLINDERS,obtainablefrom
theCompressedGasAssociation,1235JeffersonDavis
Highway,Suite501,Arlington,VA22202
12.CSAStandardW117.2,CODEFORSAFETYIN
WELDINGANDCUTTING, obtainablefromthe
CanadianStandardsAssociation,StandardsSales,178
RexdaleBoulevard,Rexdale,Ontario,CanadaM9W
1R3
13.NWSAbooklet,WELDINGSAFETYBIBLIOGRAPHY
obtainablefromtheNationalWeldingSupplyAssocia-
tion, 1900 Arch Street, Philadelphia, PA 19103
14.AmericanWeldingSocietyStandardAWSF4.1,
RECOMMENDEDSAFEPRACTICESFORTHE
PREPARATIONFORWELDINGANDCUTTING
OFCONTAINERSANDPIPINGTHATHAVEHELD
HAZARDOUSSUBSTANCES,obtainablefromthe
AmericanWeldingSociety,550N.W.LeJeuneRd,
Miami,FL33126
15.ANSIStandardZ88.2,PRACTICEFORRESPIRA-
TORYPROTECTION, obtainablefromAmerican
NationalStandardsInstitute,1430Broadway, New
York,NY10018
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classiéescommesuit:
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’ecacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter l’endomma-
gement du matériel en cas de non-respect de la
procédure en question.
!
AVERTISSEMENT
Toute procédure pouvant provoquer des bles-
sures de l’opérateur ou des autres personnes se
trouvant dans la zone de travail en cas de non-
respect de la procédure en question.
AVERTISSEMENT
Fournit l'information concernant des dommages
possibles de choc électrique. Des avertissements
seront enfermés dans une boîte de ce type.
1.05 Precautions De Securite
Importantes
!
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de
l’énergie électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc
au jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier
de matériel de santé pour déterminer s’il existe
des risques de santé.
Il faut communiquer aux opérateurs et au per-
sonnel TOUS les dangers possibles. An d’éviter
les blessures possibles, lisez, comprenez et suivez
tous les avertissements, toutes les précautions de
sécurité et toutes les consignes avant d’utiliser le
matériel. Composez le + 603-298-5711 ou votre
distributeur local si vous avez des questions.
FUMÉE et GAZ
Lafuméeetlesgazproduitsparleprocédédejetde
plasmapeuventprésenterdesrisquesetdesdangers
desanté.
• Eloigneztoutefuméeetgazdevotrezonederespi-
ration.Gardezvotretêtehorsdelaplumedefumée
provenantduchalumeau.
• Utilisezunappareilrespiratoireàalimentationen
airsil’aérationfournienepermetpasd’éliminerla
fuméeetlesgaz.

CUTMASTER A80, A120
INFORMATIONS GÉNÉRALES Manual 0-5119
1-4
• Lessortesdegazetdefuméeprovenantdel’arcde
plasmadépendentdugenredemétalutilisé,des
revêtementssetrouvantsurlemétaletdesdifférents
procédés.Vousdevezprendresoinlorsquevous
coupezousoudeztoutmétalpouvantcontenirun
ouplusieursdesélémentssuivants:
antimoine cadmium mercure
 argent chrome nickel
arsenic cobalt plomb
 baryum cuivre  sélénium
 béryllium manganèse vanadium
• Liseztoujoursleschesdedonnéessurlasécurité
desmatières(sigleaméricain“MSDS”);celles-ci
devraientêtrefourniesaveclematérielquevous
utilisez.LesMSDScontiennentdesrenseignements
quantàlaquantitéetlanaturedelafuméeetdes
gazpouvantposerdesdangersdesanté.
• Pourdesinformationssurlamanièredetesterla
fuméeetlesgazdevotrelieudetravail,consultez
l’article1etlesdocumentscitésàlapage5.
• Utilisezunéquipementspécialtelquedestablesde
coupeàdébitd’eauouàcourantdescendantpour
capterlafuméeetlesgaz.
• N’utilisezpaslechalumeauaujetdeplasmadans
unezoneoùsetrouventdesmatièresoudesgaz
combustibles ou explosifs.
• Lephosgène,ungaztoxique,estgénéréparlafumée
provenantdessolvantsetdesproduitsdenettoyage
chlorés.Elimineztoutesourcedetellefumée.
• AVERTISSEMENT: Ce produit contient des pro-
duits chimiques, notamment du plomb, reconnu par
l'État de la Californie pour causer des malforma-
tionscongénitalesetd'autresdommagestouchant
le système reproductif. Se laver les mains après
manipulation.
CHOC ELECTRIQUE
Leschocsélectriquespeuventblesseroumêmetuer.Le
procédéaujetdeplasmarequiertetproduitdel’éner-
gieélectriquehautetension.Cetteénergieélectrique
peutproduiredeschocsgraves,voiremortels,pour
l’opérateuretlesautrespersonnessurlelieudetravail.
• Netouchez jamaisunepièce“soustension” ou
“vive”;portezdesgantsetdesvêtementssecs.Iso-
lez-vousdelapiècedetravailoudesautresparties
du circuit de soudage.
• Réparezouremplaceztoutepièceuséeouendom-
magée.
• Prenezdessoinsparticulierslorsquelazonede
travailesthumideoumoite.
• 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.
INCENDIE ET EXPLOSION
Lesincendiesetlesexplosionspeuventrésulterdes
scorieschaudes,desétincellesoudel’arcdeplasma.
Leprocédéà l’arcde plasmaproduitdumétal,des
étincelles,desscorieschaudespouvantmettrelefeu
auxmatièrescombustiblesouprovoquerl’explosion
defuméesinammables.
• Soyezcertainqu’aucunematièrecombustible ou
inammablenesetrouvesurle lieudetravail.
Protégeztoutetellematièrequ’ilestimpossiblede
retirerdelazonedetravail.
• Procurezunebonneaérationdetouteslesfumées
inammablesouexplosives.
• Necoupezpasetnesoudezpaslesconteneursayant
pu renfermer des matières combustibles.
• Prévoyezuneveilled’incendielorsdetouttravail
dansunezoneprésentantdesdangersd’incendie.
• Legashydrogènepeutseformerous’accumuler
souslespiècesdetravailenaluminiumlorsqu’elles
sontcoupéessousl’eauousurunetabled’eau.NE
PAScouperlesalliagesenaluminiumsousl’eauou
surunetabled’eauàmoinsquelegashydrogène
peuts’échapperousedissiper.Legashydrogène
accumuléexploserasienammé.
RAYONS D’ARC DE PLASMA
Lesrayonsprovenantdel’arcdeplasmapeuventbles-
servosyeuxetbrûlervotrepeau.Leprocédéàl’arcde
plasma produit une lumière infra-rouge et des rayons
ultra-violetstrèsforts.Cesrayonsd’arcnuirontàvos
yeuxetbrûlerontvotrepeausivousnevousprotégez
pas correctement.
• Pourprotégervosyeux,portez toujoursuncas-
queouunécrandesoudeur.Porteztoujoursdes
lunettesdesécuritémuniesdeparoislatéralesou
des lunettes de protection ou une autre sorte de
protection oculaire.
• Portezdesgantsdesoudeuretunvêtementprotec-
teurappropriépourprotégervotrepeaucontreles
étincellesetlesrayonsdel’arc.
• Maintenezvotrecasqueetvoslunettesdeprotec-
tionenbonétat.Remplaceztoutelentillesaleou
comportantssureourognure.
• Protégezlesautrespersonnessetrouvantsurlazone
detravailcontrelesrayonsdel’arcenfournissant
descabinesoudesécransdeprotection.

CUTMASTER A80, A120
Manual 0-5119 INFORMATIONS GÉNÉRALES 1-5
• Utilisezlanuancedelentillequiestsuggèréedans
lerecommendationquisuiventANSI/ASCZ49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
 300-400* 9 12
 400-800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est
observé clairement. L’experience a démontrer
que les ltres moins foncés peuvent être utilisés
quand l’arc est caché par moiceau de travail.
BRUIT
Lebruitpeutprovoquerunepertepermanentede
l’ouïe.Lesprocédésdesoudageàl’arcdeplasma
peuventprovoquerdesniveauxsonoressupérieurs
auxlimitesnormalementacceptables.Vousdú4ezvous
protégerlesoreillescontrelesbruitsfortsand’éviter
unepertepermanentedel’ouïe.
• Pourprotégervotreouïecontrelesbruitsforts,
portezdestamponsprotecteurset/oudesprotec-
tionsauriculaires.Protégezégalementlesautres
personnessetrouvantsurlelieudetravail.
• Ilfautmesurerlesniveauxsonoresand’assurer
quelesdécibels(lebruit)nedépassentpasles
niveauxsûrs.
• Pourdesrenseignementssurlamanièredetester
lebruit,consultezl’article1,page5.
PLOMB AVERTISSEMENT
AVERTISSEMENT: Ce produit contient des produits
chimiques, notamment du plomb, reconnu par l'État
delaCaliforniepourcauserdesmalformationscongé-
nitales et d'autres dommages touchant le système
reproductif. Se laver les mains après manipulation.
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.Govern-
mentPrintingOfce,Washington,D.C.20402
2. NormeANSIZ49.1,LASÉCURITÉDESOPÉRATIONS
DECOUPE ETDESOUDAGE,disponibleauprèsde
laSociétéAméricainedeSoudage(AmericanWelding
Society),550N.W.LeJeuneRd.,Miami,FL33126
3. NIOSH,LASÉCURITÉETLASANTÉLORSDESOPÉ-
RATIONSDECOUPEETDESOUDAGEÀL’ARCET
AUGAZ,disponibleauprèsduSuperintendentofDocu-
ments,U.S. GovernmentPrintingOfce,Washington,
D.C.20402
4. NormeANSIZ87.1,PRATIQUESSURESPOURLAPRO-
TECTIONDESYEUXETDUVISAGEAUTRAVAILET
DANSLESECOLES,disponibledel’InstitutAméricain
des Normes Nationales (American National Standards
Institute),1430Broadway,NewYork,NY10018
5. NormeANSIZ41.1,NORMESPOURLESCHAUSSU-
RESPROTECTRICES,disponibleauprèsdel’American
NationalStandardsInstitute,1430Broadway,NewYork,
NY 10018
6. NormeANSI Z49.2, PRÉVENTION DES INCENDIES
LORSDEL’EMPLOIDEPROCÉDÉSDECOUPEETDE
SOUDAGE,disponibleauprèsdel’AmericanNational
StandardsInstitute,1430Broadway,NewYork,NY10018
7. NormeA6.0 de l’AssociationAméricaineduSoudage
(AWS),LESOUDAGEETLACOUPEDECONTENEURS
AYANTRENFERMÉDESPRODUITSCOMBUSTIBLES,
disponibleauprèsdelaAmericanWeldingSociety,550
N.W.LeJeuneRd.,Miami,FL33126
8. Norme51del’AssociationAméricainepourlaProtec-
tioncontrelesIncendies(NFPA),LESSYSTEMESÀ
GAZAVECALIMENTATIONENOXYGENEPOURLE
SOUDAGE,LACOUPEETLESPROCÉDÉSASSOCIÉS,
disponibleauprèsdelaNationalFireProtectionAssocia-
tion,BatterymarchPark,Quincy,MA02269
9. Norme70delaNFPA,CODEELECTRIQUENATIONAL,
disponibleauprèsdelaNationalFireProtectionAssocia-
tion,BatterymarchPark,Quincy,MA02269
10. Norme51BdelaNFPA,LESPROCÉDÉSDECOUPEET
DESOUDAGE, disponible auprèsdelaNational Fire
ProtectionAssociation,BatterymarchPark,Quincy,MA
02269
11. BrochureGCAP-1,LAMANIPULATIONSANSRISQUE
DESGAZ COMPRIMÉSENCYLINDRES,disponible
auprèsdel’AssociationdesGazComprimés(Compressed
GasAssociation),1235JeffersonDavisHighway,Suite
501, Arlington, VA 22202
12. NormeCSA W117.2,CODEDE SÉCURITÉPOUR LE
SOUDAGEETLACOUPE,disponibleauprèsdel’Asso-
ciationdesNormesCanadiennes,StandardsSales,178
RexdaleBoulevard,Rexdale,Ontario,Canada,M9W1R3
13. LivretNWSA,BIBLIOGRAPHIESURLASÉCURITÉDU
SOUDAGE,disponibleauprèsdel’AssociationNationale
deFournituresdeSoudage(NationalWeldingSupply
Association),1900ArchStreet,Philadelphia,PA19103
14. NormeAWSF4.1del’AssociationAméricainedeSoudage,
RECOMMANDATIONSDEPRATIQUESSURESPOUR
LAPRÉPARATIONÀ LACOUPEETAUSOUDAGE
DECONTENEURSETTUYAUXAYANTRENFERMÉ
DESPRODUITSDANGEREUX,disponibleauprèsdela
AmericanWeldingSociety,550N.W.LeJeuneRd.,Miami,
FL33126
15. NormeANSIZ88.2,PRATIQUESDEPROTECTIONRES-
PIRATOIRE,disponibleauprèsdel’AmericanNational
StandardsInstitute,1430Broadway,NewYork,NY10018

CUTMASTER A80, A120
GENERAL INFORMATION Manual 0-5119
1-6
1.07 Declaration of Conformity
Manufacturer: ThermalDynamicsCorporation
Address: 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’(2006/95EC)andtotheNationallegislationfortheenforcementofthisDirective.
Theequipmentdescribedinthismanualconformstoallapplicableaspectsandregulationsofthe"EMCDirective"
(EuropeanCouncilDirective89/336/EEC)andtotheNationallegislationfortheenforcementofthisDirective.
Serialnumbersareuniquewitheachindividualpieceofequipmentanddetailsdescription,partsusedtomanufacture
a unit and date of manufacture.
National Standard and Technical Specications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
*UL(UnderwritersLaboratory)rating94VOammabilitytestingforallprinted-circuitboardsused.
*Forenvironmentswithincreasedhazardofelectricalshock,PowerSuppliesbearingthe"S"markconform
toEN50192whenusedinconjunctionwithhandtorcheswithexposedcuttingtips,ifequippedwith
properly installed standoff guides.
*Extensiveproductdesignvericationisconductedatthemanufacturingfacilityaspartoftheroutinedesign
and manufacturing process. This is to ensure the product is safe, when used according to instructions in this
manualandrelatedindustrystandards,andperformsasspecied.Rigoroustestingisincorporatedinto
themanufacturingprocesstoensurethemanufacturedproductmeetsorexceedsalldesignspecications.
ThermalDynamicshasbeenmanufacturingproductsformorethan30years,andwillcontinuetoachieveexcellence
in our area of manufacture.
Manufacturersresponsiblerepresentative: SteveWard
OperationsDirector
Thermadyne Europe
Europa Building
    ChorleyNIndustrialPark
Chorley, Lancashire,
    EnglandPR67BX

CUTMASTER A80, A120
Manual 0-5119 GENERAL INFORMATION 1-7
1.08 Statement of Warranty
LIMITED WARRANTY: Subjecttothetermsandconditionsestablishedbelow,VictorTechnologies,Inc.warrantstotheoriginal
retailpurchaserthatnewVictorThermalDynamicsCUTMASTER™plasmacuttingsystemssoldaftertheeffectivedateofthis
warrantyarefreeofdefectsinmaterialandworkmanship.Shouldanyfailuretoconformtothiswarrantyappearwithinthe
applicableperiodstatedbelow,VictorTechnologies,Inc.shall,uponnoticationthereofandsubstantiationthattheproducthas
beenstoredoperatedandmaintainedinaccordancewithVictorThermalDynamics’specications,instructions,recommendations
and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or tness for a particular purpose.
VictorThermalDynamicswillrepairorreplace,atitsdiscretion,anywarrantedpartsorcomponentsthatfailduetodefectsin
materialorworkmanshipwithinthetimeperiodssetoutbelow.VictorTechnologies,Inc.mustbenotiedwithin30daysofany
failure,atwhichtimeVictorTechnologies,Inc.willprovideinstructionsonthewarrantyprocedurestobeimplemented.
VictorTechnologies,Inc.willhonorwarrantyclaimssubmittedwithinthewarrantyperiodslistedbelow.Allwarrantyperiods
beginonthedateofsaleoftheproducttotheoriginalretailcustomeror1yearaftersaletoanauthorizedVictorThermalDynamics
Distributor.
LIMITED WARRANTY PERIOD
Product Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
U.S. Non U.S.
CUTMASTER™ A40 4 Years 3 Years 1 Year
CUTMASTER™ A60 4 Years 3 Years 1 Year
CUTMASTER™ A80 4 Years 3 Years 1 Year
CUTMASTER™ A120 4 Years 3 Years 1 Year
This warranty does not apply to:
1. ConsumableParts,suchastips,electrodes,shieldcups,o-rings,startercartridges,gasdistributors,fuses,lters.
2. Equipmentthathasbeenmodiedbyanunauthorizedparty,improperlyinstalled,improperlyoperatedormisusedbased
upon industry standards.
Intheeventofaclaimunderthiswarranty,theremediesshallbe,atthediscretionofVictorTechnologies,Inc.
 1. Repairofthedefectiveproduct.
 2. Replacementofthedefectiveproduct.
 3. ReimbursementofreasonablecostsofrepairwhenauthorizedinadvancebyVictorThermalDynamics.
 4. Paymentofcredituptothepurchasepricelessreasonabledepreciationbasedonactualuse.
TheseremediesmaybeauthorizedbyVictorThermalDynamicsandareFOBWestLebanon,NHoranauthorizedVictorThermal
Dynamicsservicestation.Productreturnedforserviceisattheowner’sexpenseandnoreimbursementoftravelortransportation
is authorized.
LIMITATION OF LIABILITY: VictorThermalDynamicsshallnotunderanycircumstancesbeliableforspecialorconsequential
damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors
(hereinafter“Purchaser”)forserviceinterruption.TheremediesofthePurchasersetforthhereinareexclusiveandtheliabilityof
VictorThermalDynamicswithrespecttoanycontract,oranythingdoneinconnectiontherewithsuchastheperformanceorbreach
thereof,orfromthemanufacture,sale,delivery,resale,oruseofthegoodscoveredbyorfurnishedbyVictorThermalDynamics
whetherarisingoutofcontract,negligence,stricttort,orunderanywarranty,orotherwise,shallnot,exceptasexpresslyprovided
herein, exceed the price of the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any
Victor Thermal Dynamics product.
This warranty is invalid if the Victor Thermal Dynamics product is sold by non - authorized persons.
EffectiveSeptember4,2007

CUTMASTER A80, A120
GENERAL INFORMATION Manual 0-5119
1-8
This Page Intentionally Blank

CUTMASTER A80, A120
Manual 0-5119 INTRODUCTION 2-1
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 warn-
ings.
Throughout this manual, the words WARNING,
CAUTION, 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 infor-
mation which requires additional emphasis or
is helpful 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 operating area.
WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a
box such as this.
Additional copies of this manual may be purchased by
contactingVictorThermalDynamicsattheaddressand
phonenumberinyourarealistedintheinsideback
coverofthismanual.IncludetheOwner’sManual
numberandequipmentidenticationnumbers.
Electronic copies of this manual can also be download-
edatnochargeinAcrobatPDFformatbygoingtothe
VictorThermalDynamicswebsitelistedbelowand
clickingontheLiteraturelink:
http://www.victorthermaldynamics.com
2.02 Equipment Identification
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
assemblies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 1 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
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.
SECTION 2 SYSTEM:
INTRODUCTION

CUTMASTER A80, A120
INTRODUCTION Manual 0-5119
2-2
2.04 Power Supply Specifications
CutMaster A80 Power Supply Specications
Input Power 380 VAC (360 - 480 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 480 VAC), Three Phase, 50 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 100 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability Particulates to 5 Microns
CutMaster A80 Power Supply Duty Cycle *
Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
All Units
Duty Cycle 60% 80% 100%
Current 100 80 70
IEC IEC IEC
DC Voltage 120 112 108
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low
or the output voltage (DC) is higher than shown in this chart.
CutMaster A120 Power Supply Specications
Input Power 380 VAC (360 - 480 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 480 VAC), Three Phase, 50 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 120 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability Particulates to 5 Microns
CutMaster A120 Power Supply Duty Cycle *
Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
All Units
Duty Cycle 60% 80%** 100%
Current 120 120 100
IEC IEC IEC
DC Voltage 128 128 120
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output
voltage (DC) is higher than shown in this chart.
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications
include calculating an output voltage based upon power supply rated current. To facilitate comparison between
power supplies, all manufacturers use this output voltage to determine duty cycle.

CUTMASTER A80, A120
Manual 0-5119 INTRODUCTION 2-3
Power Supply Dimensions & Weight Ventilation Clearance Requirements
26.3"
0.668 m
63 lb / 28.6 kg
10"
254 mm
13.78"
350 mm
Art # A-08459
6"
150 mm
24"
610 mm
6"
150 mm
6"
150 mm
Art # A-07925_AB
2.05 Input Wiring Specifications
CutMaster A80 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I1max I1eff Fuse (amps)
Flexible Cord
(mm2)
Flexible Cord
(AWG)
3 Phase 380 50 18.4 28 25 35 10 8
400 50 18.7 27 24 35 10 8
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
CutMaster A120 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I1max I1eff Fuse (amps)
Flexible Cord
(mm2)
Flexible Cord
(AWG)
3 Phase 380 60 23 35 32 35 6 10
400 50 23.6 34 31 35 6 10
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTE
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.
I1max is taken at TDC rated minimum duty cycle.
I1eff is taken at TDC 100% rated duty cycle

CUTMASTER A80, A120
INTRODUCTION Manual 0-5119
2-4
2.06 Power Supply Features
Art # A-08460
Mounting Rails
Torch Leads
Receptacle
Control Panel
Work Cable
and Clamp
Input Power Cord
Automation Interface
Cable Port
Gas Inlet Port
Filter Assembly
Input Power Selection
Art # A-08461

CUTMASTER A80, A120
Manual 0-5119 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SL100SV/ManualandSL100SV/Mechanized
PlasmaCuttingTorches.Serviceofthisequipmentis
restrictedtoproperlytrainedpersonnel;unqualied
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 super-
heatedcolumnofgasowsthroughthesmallorice
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owisdividedinsidethetorchhead.Single-gas
operationprovidesasmallersizedtorchandinexpen-
siveoperation.
NOTE
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-
fications as related to the Power Supply used.
2T.03 Specifications
A. Torch Configurations
1. Automation Torch, Model
The standard automation torch has a positioning
tubewithrack&pinchblockassemblyanda
solenoidvalve.
Art # A-07402_AC
1.75" /
44.5 mm
1.375" / 35 mm
18.875" / 479 mm
0.625" /
16 mm
4.95" / 126 mm 1.175" / 30 mm
12.285" / 312 mm
2.875” /
73 mm
2. Machine Torch, Model
The standard machine torch has a positioning
tubewithrack&pinchblockassembly.
Art # 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
3. Hand/ManualTorch,Models
Thehandtorchheadisat75°tothetorchhan-
dle. 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
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/Automation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

CUTMASTER A80, A120
INTRODUCTION Manual 0-5119
2T-2
E. Type Cooling
Combination of ambient air and gas stream
through torch.
F. Torch Ratings
Automated / Machine Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 100 Amps @ 400 scfh
80% @ 120 Amps @ 400 scfh
Maximum
Current 120 Amps
Voltage (Vpeak)500V
Arc Striking
Voltage 7kV
Manual Torch Ratings
CUTMASTER A80
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum
Current 120 Amps
Voltage (Vpeak) 500V
Arc Striking
Voltage 7kV
Manual Torch Ratings
CUTMASTER A120
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 120 Amps @ 400 scfh
Maximum
Current 120 Amps
Voltage (Vpeak) 500V
Arc Striking
Voltage 7kV
G.Gas Requirements
Automated, Manual and Machine Torch Gas
Specications
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, op-
erating 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 ex-
tremely 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 cut-
tingarcthentransferstotheworkpiecethrough
thecolumnofplasmagasinZoneC.