ESAB Cutmaster 120 Operating Manual

208/230V 400V 460V Revision: AB Issue Date: April 15, 2015 Manual No.: 0-5380 ESAB Cutmaster® 120 PLASMA CUTTING SYSTEM SL100 1Torch™ Operating Manual esab.com.br

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 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.br. This Operating Manual has been designed to instruct you on the correct use and operation 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.

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 ESAB Cutmaster® 120 with SL100 1Torch™ Operating Manual Number 0-5380 Published by: ESAB 2800 Airport Rd. Denton, TX 76208 www.esab.com.br Copyright 2015 by ESAB All rights reserved. Reproduction of this work, in whole or in part, without written permission of the pub- lisher 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: April 15, 2015 Revision Date: April 15, 2015 Record the following information for Warranty purposes: Where Purchased:_______________________________ ________________ Purchase Date:__________________________________ ________________ Power Supply Serial #:___________________________ ________________ Torch Serial #:___________________________________ ________________ i

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 AN D OTHERS!

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 Opening the Contactor Cover .....................................................................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 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-1 4T.03 General Cutting Information ......................................................................4T-2 4T.04 Hand Torch Operation ..............................................................................4T-3 4T.05 Gouging ....................................................................................................4T-6 4T.06 Mechanized Torch Operation ...................................................................4T-7 4T.07 Parts Selection for SL100 Torch Cutting ..................................................4T-9 4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip ......4T-10 4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip ......4T-14 PATENT INFORMATION .....................................................................................................4T-20

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, 208/460V UNITS ....................................................... A-6 Revision History .................................................................................................................... A-8

Manual 0-5380 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

GENERAL INFORMATION Manual 0-5380 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 appli- cable 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 mate- rials 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 loca- tions, 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. !

Manual 0-5380 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, includ- ing 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 information which requires additional emphasis or is helpful in efficient 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 electri- cal 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 identifica- 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.com.br 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 as- semblies are identified only by the specification 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 de- scribed 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.

INTRODUCTION Manual 0-5380 2-2 2.04 Power Supply Specifications ESAB Cutmaster® 120 Power Supply Specifications Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz 230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 400 VAC (360 - 440 VAC), Three Phase, 50 Hz 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz 600 VAC (540 - 630), Three Phase, 60 Hz Input Power Cable Power Supply includes input cable. 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 **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. **60% at 208/230V 1 Phase input ONLY NOTE! IEC Rating is determined as specified by the International Electro-Technical Commission. These specifica- tions 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

Manual 0-5380 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 max I eff Fuse (amps) Flexible Cord (Min. AWG) 1 Phase 208 60 26.2 126 98 150 4 Type W 230 60 27.6 118 95 125 4 Type W 460 60 35 76 68 100 4 3 Phase 208 60 21.6 60 55 60 4 230 60 22.3 56 50 60 4 380 50 23 35 32 40 8 400 50 23.6 34 31 40 8 460 60 29.5 37 33 40 8 600 60 29.0 28 25 30 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.

INTRODUCTION Manual 0-5380 2-4 2.06 Power Supply Features Handle and Leads Wrap Torch Leads Receptacle Control Panel Art # A-08359 Work Cable and Clamp Art # A-08360 Input Power Cord Port for Optional Automation Interface Cable Gas Inlet Port Filter Assembly Input Power Selection

Manual 0-5380 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 adjust- ments not covered in this manual, at the risk of voiding the Warranty. Read this manual thoroughly. A complete understanding 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 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 specifications as related to the Power Sup- ply 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. 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 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.

INTRODUCTION Manual 0-5380 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, operating 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 cut- ting 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 al- lowing for a fast, slag - free cut.

Manual 0-5380 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 con- nected 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) circuit. When the shield cup is properly installed, it closes a switch. The torch will not operate if this switch is open. A-02997 Torch Trigger PIP Switch Shield Cup To Control Cable Wiring Torch Switch Parts - In - Place Circuit Diagram for Hand Torch PIP Switch Shield Cup To ATC CNC Start PIP Switch Shield Cup PIP Switch Shield Cup Remote Pendant Automation Torch To ATC To ATC Art # A-08168 Parts - In - Place Circuit Diagram for Machine Torch

Manual 0-5380 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 dam- age 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 per- sonal 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�trans- porting with a fork lift or other vehicle. 3.03 Opening the Contactor Cover The input power cord is connected to the main contactor, the contactor is located inside a box with a snap on cover. The cover is held in place with two or more snap lock tabs. To remove the cover release the front latch and tilt the cover up about ½ inch. Then squeeze both sides of the cover and lift it straight up. See the Primary Input Power Connections section for the necessary changes to the Contactor. Remember to replace the Contactor Cover when the changes are complete. Art# A-11478 1 2 2 1 Contactor cover 3.04 Primary Input Power Connections ! CAUTION Check your power source for correct volt- age before plugging in or connecting the unit. Check the Voltage Selector at the rear of the unit for correct setting before plug- ging 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 protec- tion and wiring requirements as specified in Section 2. The following illustration and directions are for changing phase of the power supply. Art # A-08493 Input Power Cable Connections Three-Phase (3ø) Store copper jumpers on base plate Single-Phase (1ø) and Jumper Settings GND L1 L2 L3 L4 GND L1 L2 L3 L4 Single and Three Phase Input Power Wiring NOTE! There are two jumpers used for the single phase 230V setting and none for three phase.

INSTALLATION Manual 0-5380 3-2 B. Connections to Three Phase Input Power WARNING Disconnect input power from the power supply and input cable before attempting this procedure. These instructions are for changing the input power and or cable on the 208/230, 400, 460 VAC Power Supply to Three - Phase input power. 1. Remove the Power Supply cover per instructions 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 specifications. ! CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Sec- tion 2). 6. Connect the wires as follows. •� Wires�to�L1,�L2�and�L3�input.��It�does�not�matter�what� order these wires are attached. See previous illustra- tion and on label in the power supply. •� 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 instructions 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 discon- nect switch) to supply power. A. Connections to Single Phase Input Power WARNING Disconnect input power from the power supply and input cable before attempting this procedure. These instructions are for changing the input power and or cable on the 208/230, 400, 460 VAC Power Supply to Single - Phase input power. 1. Remove the Power Supply cover per instructions 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. If the power cable being used is not the factory - sup- plied cable, use a three - conductor input power cable for the voltage desired and 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 specifications. ! CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Sec- tion 2). 6. Connect the wires as follows. •� Connect�Bus�Bar�Jumpers�on�the�contactor�as�shown� in prior illustration and on label in the power supply. •� Green�/�Yellow�wire�to�Ground. 7. Reinstall the Power Supply cover per instructions found in section 5. 8. Connect the opposite end of individual wires to a customer supplied plug or main disconnect. 9. Connect the input power cable (or close the main discon- nect switch) to supply power.

Manual 0-5380 INSTALLATION 3-3 3.05 Gas Connections Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders. Refer to the following two subsections if an optional air line filter is to be installed. 1. Connect the air line to the inlet port. The illustration shows typical fittings as an example. NOTE! For a secure seal, apply thread sealant to the fitting threads, according to manufac- turer's instructions. Do not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch. 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 illustration shows typical fittings as an example. NOTE! For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air pas- sages in the torch. Connect as follows: Art # A-07944 Hose Clamp 1/4 NPT to 1/4" (6mm) Fitting Regulator/Filter Assembly Inlet Port Gas Supply Hose Optional Single - Stage Filter Installation

INSTALLATION Manual 0-5380 3-4 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 fitting threads according to manufacturer's instructions. Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch. 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) Two 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 pressure regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any dust which may be present. 3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100 psi (6.9 bar) maximum and flows 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 fitting threads, according to manufacturer's instructions. Do Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

Manual 0-5380 INSTALLATION 3T-1 SECTION 3 TORCH: INSTALLATION 3T.01 Torch Connections If necessary, connect the torch to the Power Supply. Connect only the ESAB model SL100 / Manual or SL100 / Mechanical Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including exten- sions. WARNING Disconnect primary power at the source before connecting the torch. 1. Align the ATC male connector (on the torch lead) with the female receptacle. Push the male con- nector into the female receptacle. The connec- tors should push together with a small amount of pressure. 2. Secure the connection by turning the locking nut clockwise until it clicks. DO NOT use the locking nut to pull the connection together. Do not use tools to secure the connection. 1 2 Art # A-07885 Connecting the Torch to the Power Supply 3. The system is ready for operation. Check Air Quality To test the quality of air: 1. Put the ON / OFF switch in the ON (up) position. 2. Put the Function Control switch in the SET position. 3. Place a welding filter lens in front of the torch and turn ON the air. Do not start an arc! Any oil or moisture in the air will be visible on the lens. 3T.02 Setting Up Mechanical Torch NOTE! An adapter is required to be installed in the power supply if converting a hand torch sys- tem to operate a machine torch. WARNING Disconnect primary power at the source be- fore disassembling the torch or torch leads The mechanical torch includes a positioning tube with rack and pinch block assembly. 1. Mount the torch assembly on the cutting table. 2. To obtain a clean vertical cut, use a square to align the torch perpendicular to the surface of the workpiece. A-02585 Workpiece Square Pinch Block Assembly Mechanical Torch Set - Up 3. The proper torch parts (shield cup, tip, start cartridge, and electrode) must be installed for the type of operation. Refer to Section 4T.07, Torch Parts Selection for details.

Manual 0-5380 OPERATION 4-1 SECTION 4 SYSTEM: OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification 1. Output Current Control Sets the desired output current. Output settings up�to�60�Amps�may�be�used�for�drag�cutting�(with� the torch tip contacting the workpiece) or higher for standoff cutting. 2. Function Control Function Control Knob, Used to select between the different operating modes. SET Used to purge the air through the unit and torch and leads and to adjust gas pressure. RUN Used for general cutting operations RAPID AUTO RESTART Allows for faster restarting of the Pilot Arc for uninterrupted cutting. LATCH Used for longer hand held cuts. Once a cutting arc is established, the torch switch can be released. The cutting arc will remain ON until the torch is lifted away from the work piece, the torch leaves the edge of the work piece the torch switch is activated again or if one of the system interlocks is activated. 3. ON OFF Power Switch ON / OFF Switch controls input power to the power supply. Up is ON, down is OFF. 4. Air/Gas Pressure Control The Pressure Control is used in the "SET" mode to adjust the air/gas pressure. Pull the knob out to adjust and push in to lock. 5. AC Indicator Steady light indicates power supply is ready for operation. Blinking light indicates unit is in protec- tive interlock mode. Shut unit OFF, shut OFF or disconnect input power, correct the fault, and restart the unit. Refer to Section 5 for details. A + PSI BAR MAX MAX MIN MIN ! 1 2 3 4 5 6 7 8 9 Art# A-07886 MIN MAX 10 6. Temp Indicator Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Let the unit cool before continuing operation. 7. Gas Indicator Indicator is ON when minimum input gas pressure for power supply operation is present. Minimum pressure for power supply operation is not sufficient for torch operation. 8. DC Indicator Indicator is ON when DC output circuit is active. 9. ! Fault Error Indicator Indicator is ON when Fault circuit is active. See section 5 for explanations of fault lights. 10. Pressure Indicators PSI BAR MAX MAX MIN MIN 80 75 70 65 5.5 85 5.9 90 6.3 5.2 4.8 4.5 Art # A-08170 The Indicators will illuminate according to the pres- sure set by the Pressure Control Knob (number 4).

OPERATION Manual 0-5380 4-2 4.02 Preparations for Operation At the start of each operating session: WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads as- semblies. Torch Parts Selection Check the torch for proper assembly and appropri- ate torch parts. The torch parts must correspond with the type of operation, and with the amperage output of this Power Supply (120 amps maximum). Refer to Section 4T.07 and following for torch parts selection. Torch Connection Check that the torch is properly connected. Only ESAB model SL100 / Manual or SL100 / Mechanical Torches may be connected to this Power Supply. See Section 3T of this manual. Check Primary Input Power Source 1. Check the power source for proper input volt- age. Make sure the input power source meets the power requirements for the unit per Section 2, Specifications. 2. Connect the input power cable (or close the main disconnect switch) to supply power to the system. Air Source Ensure source meets requirements (refer to Section 2). Check connections and turn air supply ON. Connect Work Cable Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off. Art # A-04509 Power ON Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns ON. Gas indicator turns ON if there is sufficient gas pressure for power supply operation and the cool- ing fans turn ON. NOTE! Minimum pressure for power supply operation is lower than minimum for torch operation. The cooling fans will turn ON as soon as the unit is turned ON. After the unit is idle for ten (10) minutes the fans will turn OFF. The fans will come back ON as soon as the torch switch (Start Signal) is activated or if the unit is turned off, then turned ON again. If an over temperature condition occurs, the fans will continue to run while the condition exists and for a ten (10) minute period once the condition is cleared. Set Operating Pressure 1. Place the Power Supply Function Control knob to the SET position. Gas will flow. 2. For Standoff cutting, adjust gas pressure from 70�-�85�psi�/�4.8�-�5.9�bar�(LED's�in�center�of� control panel). Refer to the Standoff chart for pressure setting details.

Manual 0-5380 OPERATION 4-3 A + PSI BAR MAX MAX MIN MIN ! 1 2 Art# A-07946 MIN MAX STANDOFF ESAB Cutmaster® 120 Gas Pressure Settings Leads Length SL100 (Hand Torch) SL100 (Mechanized Torch) Up to 50' (7.6�m) 75 psi 5.2 bar 75 psi 5.2 bar Each additional 25'��(7.6�m) Add 5 psi 0.4 bar Add 5 psi 0.4 bar 3.� For�Drag�cutting�(60�Amps�or�below),�adjust�gas� pressure�from�75�-�95�psi�/�5.2�-�6.5�bar�(LED's� in center of control panel). Refer to the Drag Cutting chart for pressure setting details. DRAG (60 amps or less) ESAB Cutmaster® 120 Gas Pressure Settings Leads Length SL100 (Hand Torch) Up to 25' (7.6�m) 80 psi 5.5 bar Each additional 25'��(7.6�m) Add 5 psi 0.4 bar Select Current Output Level 1. Place the Function Control Knob in one of the three operating positions available: RUN , RAPID AUTO RESTART or LATCH . Gas flow stops. 2. Set the output current to desired amperage with the Output Current Control Knob. Cutting Operation When the torch leaves the workpiece during cut- ting operations with the Function Control Knob in the RUN position, there is a brief delay in restarting the pilot arc. With the knob in the RAPID AUTO RESTART position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arc con- tacts the workpiece. (Use the 'Rapid Auto Restart' position when cutting expanded metal or gratings, or in gouging or trimming operations when an un- interrupted restart is desired). And with the knob in the LATCH position the main cutting arc will be maintained after the torch switch is released. Typical Cutting Speeds Cutting speeds vary according to torch output am- perage, the type of material being cut, and opera- tor skill. Refer to Section 4T.08 and following for greater details. Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, or using a template or cutting guide while still producing cuts of excellent quality. Postflow Release the trigger to stop the cutting arc. Gas con- tinues to flow for approximately 20 seconds. During post - flow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece. Shutdown Turn the ON / OFF switch to OFF (down). All Power Supply indicators shut OFF. Unplug the input power cord or disconnect input power. Power is removed from the system.

Manual 0-5380 OPERATION 4T-1 SECTION 4 TORCH: OPERATION 4T.01 Torch Parts Selection Depending on the type of operation to be done deter- mines the torch parts to be used. Type of operation: Drag cutting, standoff cutting or gouging Torch parts: Shield Cup, Cutting Tip, Electrode and Starter Cartridge NOTE! Refer to Section 4T.07 and following for ad- ditional information on torch parts. Change the torch parts for a different operation as fol- lows: WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads as- semblies. NOTE! The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed. 1. Unscrew and remove the shield cup assembly from the torch head. 2. Remove the Electrode by pulling it straight out of the Torch Head. A-03510_AB Electrode Start Cartridge Tip Shield Cup Torch Head Torch Parts (Drag Shield Cap & Shield Cup Body Shown) 3. Install the replacement Electrode by pushing it straight into the torch head until it clicks. 4. Install the starter cartridge and desired tip for the operation into the torch head. 5. Hand tighten the shield cup assembly until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding. 4T.02 Cut Quality NOTE! Cut quality depends heavily on setup and parameters such as torch standoff, align- ment with the workpiece, cutting speed, gas pressures, and operator ability. Cut quality requirements differ depending on applica- tion. For instance, nitride build - up and bevel angle may be major factors when the surface will be welded after cutting. Dross - free cutting is important when fin- ish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in the following figure: Kerf Width Cut Surface Bevel Angle Top Edge Rounding Cut Surface Drag Lines Dross Build-Up Top Spatter A-00007 Cut Quality Characteristics Cut Surface The desired or specified condition (smooth or rough) of the face of the cut. Nitride Build - Up Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream. These buildups may create difficulties if the material is to be welded after the cutting process.

OPERATION Manual 0-5380 4T-2 Bevel Angle The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle. Top - Edge Rounding Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece. Bottom Dross Buildup Molten material which is not blown out of the cut area and resolidifies on the plate. Excessive dross may require secondary cleanup operations after cutting. Kerf Width The width of the cut (or the width of material re- moved during the cut). Top Spatter (Dross) Top spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip whose orifice has become elongated. 4T.03 General Cutting Information ! WARNING Disconnect primary power at the source be- fore disassembling the power supply, torch, or torch leads. Frequently review the Important Safety Pre- cautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated. ! CAUTION Sparks from the cutting process can cause damage to coated, painted, and other sur- faces such as glass, plastic and metal. NOTE! Handle torch leads with care and protect them from damage. Piloting Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life. Torch Standoff Improper standoff (the distance between the torch tip and workpiece) can adversely affect tip life as well as shield cup life. Standoff may also signifi- cantly affect the bevel angle. Reducing standoff will generally result in a more square cut. Edge Starting For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touch- ing) the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to "reach" for the edge of the metal. Establish the cutting arc as quickly as possible. Direction of Cut In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left. Right Side Cut Angle Left Side Cut Angle A-00512 Side Characteristics Of Cut To make a square - edged cut along an inside diameter of a circle, the torch should move coun- terclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Manual 0-5380 OPERATION 4T-3 Dross When dross is present on carbon steel, it is com- monly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate dis- tance. "Top dross" is normally very easy to remove and can often be wiped off with a welding glove. "Slow speed dross" is normally present on the bot- tom edge of the plate. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily scraped off. "High speed dross" usually forms a narrow bead along the bot- tom of the cut edge and is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be ac- complished by scraping, not grinding. 4T.04 Hand Torch Operation Standoff Cutting With Hand Torch NOTE! For best performance and parts life, always use the correct parts for the type of opera- tion. 1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfort- able and allows good control and movement. NOTE! The tip should never come in contact with the workpiece except during drag cutting operations. 2. Depending on the cutting operation, do one of the following: a. For edge starts, hold the torch perpendicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start. b. For standoff cutting, hold the torch 1/8 - 3/8 in�(3-9�mm)�from�the�workpiece�as�shown� below. A-00024_AB Shield Cup Torch Standoff Distance 1/8" - 3/8" (3 - 9mm) Standoff Distance 3. Hold the torch away from your body. 4. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start. A-02986 Trigger Trigger Release 5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF. NOTE! The gas preflow and postflow are a char- acteristic of the power supply and not a function of the torch.

OPERATION Manual 0-5380 4T-4 3 4 Art # A-03383 Trigger 2 1 Trigger Release 6.� Cut�as�usual.��Simply�release�the�trigger�assem- bly to stop cutting. 7. Follow normal recommended cutting practices as provided in the power supply operator's manual. NOTE! When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components. 8. For a consistent standoff height from the work- piece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece. Shield Cup Workpiece Standoff Guide Art # A-04034 Torch Tip Shield Cup With Straight Edge The drag shield cup can be used with a non conduc- tive straight edge to make straight cuts by hand. WARNING The straight edge must be non-conductive. A-03539 Non-Conductive Straight Edge Cutting Guide Using Drag Shield Cup With Straight Edge The crown shield cup functions best when cutting 3/16�inch�(4.7�mm)�solid�metal�with�relatively�smooth� surface. Drag Cutting With a Hand Torch Drag�cutting�works�best�on�metal�1/4"�(6�mm)�thick� or less. NOTE! Drag cutting can only be performed at 60 amps or less. For best parts performance and life, always use the correct parts for the type of opera- tion. 1. Install the drag cutting tip and set the output current. 2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfort- able and allows good control and movement. 3. Keep the torch in contact with the workpiece during the cutting cycle. 4. Hold the torch away from your body.

Manual 0-5380 OPERATION 4T-5 5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start. A-02986 Trigger Trigger Release 6.� Bring�the�torch�within�transfer�distance�to�the� work. The main arc will transfer to the work, and the pilot arc will shut OFF. NOTE! The gas preflow and postflow are a char- acteristic of the power supply and not a function of the torch. 3 4 Art # A-03383 Trigger 2 1 Trigger Release 7. Cut as usual. Simply release the trigger assem- bly to stop cutting. 8. Follow normal recommended cutting practices as provided in the power supply operator's manual. NOTE! When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components. Piercing With Hand Torch 1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement. NOTE! The tip should never come in contact with the workpiece except during drag cutting operations. 2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete. 3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete. 4. Hold the torch away from your body. 5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start. A-02986 Trigger Trigger Release 6.� Bring�the�torch�within�transfer�distance�to�the� work. The main arc will transfer to the work, and the pilot arc will shut OFF. NOTE! The gas preflow and postflow are a char- acteristic of the power supply and not a function of the torch. When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.

OPERATION Manual 0-5380 4T-6 7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it. Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance: •� Torch�parts�wear •� Air�quality •� Line�voltage�fluctuations •� Torch�standoff�height •� Proper�work�cable�connection 4T.05 Gouging ! WARNING Be sure the operator is equipped with proper gloves, clothing, eye and ear protec- tion and that all safety precautions at the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch is activated. Disconnect primary power to the system before disassembling the torch, leads, or power supply. ! CAUTION Sparks from plasma gouging can cause damage to coated, painted or other sur- faces such as glass, plastic, and metal. Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 4T.07, Torch Parts Selection. Gouging Parameters Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff). ! CAUTION Touching the torch tip or shield cup to the work surface will cause excessive parts wear. Torch Travel Speed NOTE! Refer to Appendix Pages for additional information as related to the Power Supply used. Optimum torch travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch). Current Setting Current settings depend on torch travel speed, mode of operation (hand or machine torch), and the amount of material to be removed. Pressure Setting Even though the setting is within the specified range, if the torch does not pilot well the pressure may need to be reduced. Lead Angle The angle between the torch and workpiece de- pends on the output current setting and torch travel speed. The recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, re- quiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable. 35° Workpiece Torch Head Standoff Height A-00941_AB Gouging Angle and Standoff Distance Standoff Distance The tip to work distance affects gouge quality and depth.��Standoff�distance�of�1/8�-�1/4�inch�(3�-�6� mm) allows for smooth, consistent metal removal. Smaller standoff distances may result in a severance cut rather than a gouge. Standoff distances greater than�1/4�inch�(6�mm)�may�result�in�minimal�metal� removal or loss of transferred main arc.

Manual 0-5380 OPERATION 4T-7 Slag Buildup Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels, can be removed easily in most cases. Slag does not obstruct the gouging process if it accumulates to the side of the gouge path. However, slag build - up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc. The build - up is most often a result of improper travel speed, lead angle, or standoff height. 4T.06 Mechanized Torch Operation Cutting With Mechanized Torch The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC. 1. To start a cut at the plate edge, position the center of the torch along the edge of the plate. Travel Speed Proper travel speed is indicated by the trail of the arc which is seen below the plate. The arc can be one of the following: 1. Straight Arc A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cut using air plasma on stainless or aluminum. 2. Leading Arc The leading arc is directed in the same direction as torch travel. A five degree leading arc is generally rec- ommended for air plasma on mild steel. 3. Trailing Arc The trailing arc is directed in the opposite direction as torch travel.

OPERATION Manual 0-5380 4T-8 Standoff Distance Straight Arc Trailing Arc Leading Arc Direction of Torch Travel A-02586 Mechanized Torch Operation For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer. Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required. Piercing With Machine Torch To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow back onto the front end of the torch. When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled until the arc penetrates the bottom of the plate. As motion begins, torch standoff should be reduced to the recommended�1/8�-�1/4�inch�(3-6�mm)�distance�for�optimum�speed�and�cut�quality.��Clean�spatter�and�scale� from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti - spatter com- pound will minimize the amount of scale which adheres to it.

Manual 0-5380 OPERATION 4T-9 4T.07 Parts Selection for SL100 Torch Cutting Starter Cartridge 9-8213 Electrode Auto 9-8232 Manual 9-8215 50-55A 9-8209 60A 9-8210 70A 9-8231 80A 9-8211 90/100A 9-8212 120A Auto 9-8233 120A Manual 9-8253 Tips: Tips: Tip A 9-8225 (40 Amps Max.) Tip B 9-8226 (50 - 120 Amps) Tip C 9-8227 (60 - 120 Amps) Tip D 9-8228 (60 - 120 Amps) Tip E 9-8254 (60 - 120 Amps) Shield Cup, Gouging 9-8241 Shield Cup Body, 9-8237 Tips: 40-120A GOUGING Shield Cup Body, 9-8237 Shield Cup 9-8218 Shield Cap, Deflector 9-8243 Shield Cup Body, 9-8237 Shield Cup 9-8218 Shield Cap, Machine 50-60A 9-8238 Drag Shield Cup 9-8235 Drag Shield Cup 70-100A 9-8236 Drag Shield Cup 120A 9-8258 Shield Cap, Machine 70-100A 9-8239 Shield Cap, Machine 120A 9-8256 Art # A-08066_AG CUTTING STANDOFF 70-120A CUTTING STANDOFF 20-40A Shield Cap, Deflector 9-8243 50-60A CUTTING STANDOFF Heavy Duty Starter Cartridge Non HF Only 9-8277 Shield Cap, Deflector 9-8243 Shield Cap, Machine 40A 9-8245 20A 9-8205 30A 9-8206 40A 9-8208 Shield Cup Body, 9-8237 Shield Cup 9-8218 Tip: Ohmic Clip Automation Torch 9-8224 Ohmic Clip Manual Torch 9-8259

OPERATION Manual 0-5380 4T-10 4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.036 0.9 9-8208 104 40 340 8.64 0.19 4.8 65 4.5 55 170 0.00 0.2 5.1 0.06 1.5 9-8208 108 40 250 6.35 0.19 4.8 65 4.5 55 170 0.10 0.2 5.1 0.075 1.9 9-8208 108 40 190 4.83 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1 0.135 3.4 9-8208 110 40 105 2.67 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1 0.188 4.8 9-8208 113 40 60 1.52 0.19 4.8 65 4.5 55 170 0.60 0.2 5.1 0.25 6.4 9-8208 111 40 40 1.02 0.19 4.8 65 4.5 55 170 1.00 0.2 5.1 0.375 9.5 9-8208 124 40 21 0.53 0.19 4.8 65 4.5 55 170 NR NR NR 0.500 12.7 9-8208 123 40 11 0.28 0.19 4.8 65 4.5 55 170 NR NR NR 0.625 15.9 9-8208 137 40 7 0.18 0.19 4.8 65 4.5 55 170 NR NR NR Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.036 0.9 9-8208 103 40 355 9.02 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1 0.05 1.3 9-8208 98 40 310 7.87 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1 0.06 1.5 9-8208 98 40 240 6.10 0.125 3.2 65 4.5 55 170 0.10 0.2 5.1 0.078 2.0 9-8208 100 40 125 3.18 0.125 3.2 65 4.5 55 170 0.30 0.2 5.1 0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 65 4.5 55 170 0.40 0.2 5.1 0.188 4.8 9-8208 124 40 20 0.51 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1 0.25 6.4 9-8208 122 40 15 0.38 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1 0.375 9.5 9-8208 126 40 10 0.25 0.187 4.8 65 4.5 55 170 NR NR NR Type Torch: SL100 With Exposed Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.032 0.8 9-8208 110 40 440 11.18 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1 0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1 0.064 1.6 9-8208 112 40 250 6.35 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1 0.079 2.0 9-8208 112 40 200 5.08 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1 0.125 3.2 9-8208 118 40 100 2.54 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1 0.188 4.8 9-8208 120 40 98 2.49 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1 0.250 6.4 9-8208 123 40 50 1.27 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1 0.375 9.5 9-8208 134 40 16 0.41 0.187 4.8 65 4.5 55 170 NR NR NR

Manual 0-5380 OPERATION 4T-11 Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8 70 4.8 90 245 0.00 0.19 4.8 0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8 0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8 0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8 0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 70 4.8 90 245 0.20 0.19 4.8 0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.19 4.8 0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 70 4.8 90 245 0.50 0.19 4.8 0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 70 4.8 90 245 0.75 0.19 4.8 0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR 0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR 1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 70 4.8 90 245 NR NR NR Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8 70 4.8 90 245 0.00 0.20 5.1 0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1 0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1 0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1 0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 70 4.8 90 245 0.20 0.20 5.1 0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1 0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1 0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1 0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR 0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 70 4.8 90 245 NR NR NR Type Torch: SL100 With Exposed Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.00 0.25 6.4 0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4 0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4 0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 70 4.8 90 245 0.20 0.25 6.4 0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 70 4.8 90 245 0.30 0.25 6.4 0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 70 4.8 90 245 0.50 0.25 6.4 0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 70 4.8 90 245 0.80 0.25 6.4 0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 70 4.8 90 245 NR NR NR 0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 70 4.8 90 245 NR NR NR

OPERATION Manual 0-5380 4T-12 Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8211 113 80 320 8.13 0.19 4.8 65 4.5 115 340 0.00 0.19 4.8 0.120 3.0 9-8211 113 80 230 5.84 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8 0.135 3.4 9-8211 115 80 180 4.57 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8 0.188 4.8 9-8211 114 80 140 3.56 0.19 4.8 65 4.5 115 340 0.20 0.19 4.8 0.250 6.4 9-8211 114 80 100 2.54 0.19 4.8 65 4.5 115 340 0.30 0.19 4.8 0.375 9.5 9-8211 117 80 42 1.07 0.19 4.8 65 4.5 115 340 0.40 0.19 4.8 0.500 12.7 9-8211 120 80 33 0.84 0.19 4.8 65 4.5 115 340 0.60 0.19 4.8 0.625 15.9 9-8211 133 80 22 0.56 0.19 4.8 65 4.5 115 340 0.75 0.19 4.8 0.750 19.1 9-8211 128 80 18 0.46 0.19 4.8 65 4.5 115 340 NR NR NR 0.875 22.2 9-8211 133 80 10 0.25 0.19 4.8 65 4.5 115 340 NR NR NR 1.000 25.4 9-8211 132 80 9 0.23 0.19 4.8 65 4.5 115 340 NR NR NR Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8211 120 80 340 8.64 0.25 6.4 65 4.5 115 340 0.00 0.25 6.4 0.120 3.0 9-8211 120 80 300 7.62 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4 0.135 3.4 9-8211 120 80 280 7.11 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4 0.188 4.8 9-8211 120 80 140 3.56 0.25 6.4 65 4.5 115 340 0.20 0.25 6.4 0.250 6.4 9-8211 120 80 100 2.54 0.25 6.4 65 4.5 115 340 0.30 0.25 6.4 0.375 9.5 9-8211 126 80 50 1.27 0.25 6.4 65 4.5 115 340 0.40 0.25 6.4 0.500 12.7 9-8211 129 80 28 0.71 0.25 6.4 65 4.5 115 340 0.80 0.25 6.4 0.625 15.9 9-8211 135 80 20 0.51 0.25 6.4 65 4.5 115 340 1.00 0.25 6.4 0.750 19.1 9-8211 143 80 10 0.25 0.25 6.4 65 4.5 115 340 NR NR NR 0.875 22.2 9-8211 143 80 9 0.23 0.25 6.4 65 4.5 115 340 NR NR NR 1.000 25.4 9-8211 146 80 8 0.20 0.25 6.4 65 4.5 115 340 NR NR NR Type Torch: SL100 with Exposed Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.06 1.5 9-8211 120 80 350 8.89 0.25 6.4 65 4.5 115 340 0.00 0.25 6.4 0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4 0.188 4.8 9-8211 124 80 180 4.57 0.25 6.4 65 4.5 115 340 0.20 0.25 6.4 0.250 6.4 9-8211 128 80 110 2.79 0.25 6.4 65 4.5 115 340 0.30 0.25 6.4 0.375 9.5 9-8211 136 80 55 1.40 0.25 6.4 65 4.5 115 340 0.40 0.25 6.4 0.500 12.7 9-8211 139 80 38 0.97 0.25 6.4 65 4.5 115 340 0.60 0.25 6.4 0.625 15.9 9-8211 142 80 26 0.66 0.25 6.4 65 4.5 115 340 0.75 0.25 6.4 0.750 19.1 9-8211 145 80 24 0.61 0.25 6.4 65 4.5 115 340 NR NR NR 0.875 22.2 9-8211 153 80 10 0.25 0.25 6.4 65 4.5 115 340 NR NR NR 1.000 25.4 9-8211 162 80 6 0.15 0.25 6.4 65 4.5 115 340 NR NR NR

Manual 0-5380 OPERATION 4T-13 Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8212 110 100 105 2.65 0.190 4.8 75 5.2 130 390 0.4 0.200 5.1 0.375 9.5 9-8212 117 100 70 1.75 0.190 4.8 75 5.2 130 390 0.5 0.200 5.1 0.500 12.7 9-8212 120 100 50 1.25 0.190 4.8 75 5.2 130 390 0.6 0.200 5.1 0.625 15.9 9-8212 125 100 35 0.90 0.190 4.8 75 5.2 130 390 1.0 0.200 5.1 0.750 19.0 9-8212 131 100 18 0.45 0.190 4.8 75 5.2 130 390 2.0 0.250 6.4 1.000 25.4 9-8212 135 100 10 0.25 0.190 4.8 75 5.2 130 390 NR NR NR Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8212 118 100 90 2.30 0.190 4.8 75 5.2 130 390 0.5 0.250 6.4 0.375 9.5 9-8212 122 100 55 1.40 0.190 4.8 75 5.2 130 390 0.8 0.250 6.4 0.500 12.7 9-8212 126 100 30 0.75 0.190 4.8 75 5.2 130 390 1.0 0.250 6.4 0.625 15.9 9-8212 133 100 20 0.50 0.190 4.8 75 5.2 130 390 1.5 0.250 6.4 0.750 19.0 9-8212 138 100 15 0.40 0.190 4.8 75 5.2 130 390 NR NR NR 1.000 25.4 9-8212 139 100 10 0.25 0.190 4.8 75 5.2 130 390 NR NR NR Type Torch: SL100 with Exposed Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8212 108 100 120 3.05 0.190 4.8 65 4.5 120 360 0.2 0.225 5.7 0.375 9.5 9-8212 117 100 65 1.65 0.190 4.8 65 4.5 120 360 0.4 0.225 5.7 0.500 12.7 9-8212 120 100 45 1.15 0.190 4.8 65 4.5 120 360 0.5 0.225 5.7 0.625 15.9 9-8212 125 100 30 0.75 0.190 4.8 65 4.5 120 360 0.8 0.225 5.7 0.750 19.0 9-8212 131 100 25 0.65 0.190 4.8 65 4.5 120 360 1.0 0.225 5.7 1.000 25.4 9-8212 140 100 10 0.25 0.190 4.8 65 4.5 120 360 NR NR NR Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8253 138 120 150 3.81 0.19 4.8 75 5.2 180 360 0.10 0.25 6.4 0.375 9.5 9-8253 140 120 85 2.16 0.19 4.8 75 5.2 180 360 0.30 0.25 6.4 0.500 12.7 9-8253 144 120 70 1.78 0.19 4.8 75 5.2 180 360 0.50 0.25 6.4 0.625 15.9 9-8253 152 120 45 1.14 0.19 4.8 75 5.2 180 360 0.70 0.25 6.4 0.750 19.0 9-8253 155 120 30 0.76 0.19 4.8 75 5.2 180 360 0.90 0.25 6.4 0.875 22.2 9-8253 160 120 25 0.64 0.25 6.4 75 5.2 180 360 NR NR NR 1.000 25.4 9-8253 164 120 20 0.51 0.25 6.4 75 5.2 180 360 NR NR NR 1.250 31.8 9-8253 170 120 12 0.30 0.25 6.4 75 5.2 180 360 NR NR NR 1.500 38.1 9-8253 180 120 8 0.20 0.25 6.4 75 5.2 180 360 NR NR NR

OPERATION Manual 0-5380 4T-14 Type Torch: SL100 With Exposed Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8253 135 120 180 4.57 0.19 4.8 75 5.2 180 360 0.20 0.25 6.4 0.375 9.5 9-8253 144 120 100 2.54 0.19 4.8 75 5.2 180 360 0.40 0.25 6.4 0.500 12.7 9-8253 146 120 60 1.52 0.19 4.8 75 5.2 180 360 0.80 0.25 6.4 0.625 15.9 9-8253 155 120 40 1.02 0.25 6.4 75 5.2 180 360 1.20 0.28 7.0 0.750 19.0 9-8253 164 120 26 0.66 0.25 6.4 75 5.2 180 360 NR NR NR 1.000 25.4 9-8253 164 120 18 0.46 0.25 6.4 75 5.2 180 360 NR NR NR 1.250 31.8 9-8253 170 120 9 0.23 0.25 6.4 75 5.2 180 360 NR NR NR Type Torch: SL100 with Exposed Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8253 142 120 190 4.83 0.19 4.8 75 5.2 180 360 0.30 0.25 6.4 0.375 9.5 9-8253 145 120 120 3.05 0.19 4.8 75 5.2 180 360 0.50 0.25 6.4 0.500 12.7 9-8253 151 120 70 1.78 0.19 4.8 75 5.2 180 360 0.80 0.25 6.4 0.625 15.9 9-8253 162 120 50 1.27 0.25 6.4 75 5.2 180 360 1.00 0.28 7.0 0.750 19.0 9-8253 164 120 34 0.86 0.25 6.4 75 5.2 180 360 NR NR NR 1.000 25.4 9-8253 170 120 20 0.51 0.25 6.4 75 5.2 180 360 NR NR NR NOTE! * Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pres- sure to 70 psi / 4.8 bar. ** Total flow rate includes plasma and secondary gas flow. 4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.036 0.9 9-8208 114 40 170 4.32 0.19 4.8 65 4.5 55 170 0.00 0.2 5.1 0.06 1.5 9-8208 120 40 90 2.29 0.19 4.8 65 4.5 55 170 0.10 0.2 5.1 0.075 1.9 9-8208 121 40 80 2.03 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1 0.135 3.4 9-8208 122 40 75 1.91 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1 0.188 4.8 9-8208 123 40 30 0.76 0.19 4.8 65 4.5 55 170 0.60 0.2 5.1 0.25 6.4 9-8208 125 40 25 0.64 0.19 4.8 65 4.5 55 170 1.00 0.2 5.1 0.375 9.5 9-8208 138 40 11 0.28 0.19 4.8 65 4.5 55 170 NR NR NR 0.500 12.7 9-8208 142 40 7 0.18 0.19 4.8 65 4.5 55 170 NR NR NR 0.625 15.9 9-8208 152 40 3 0.08 0.19 4.8 65 4.5 55 170 NR NR NR

Manual 0-5380 OPERATION 4T-15 Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.036 0.9 9-8208 109 40 180 4.57 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1 0.05 1.3 9-8208 105 40 165 4.19 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1 0.06 1.5 9-8208 115 40 120 3.05 0.125 3.2 65 4.5 55 170 0.10 0.2 5.1 0.078 2.0 9-8208 120 40 65 1.65 0.187 4.8 65 4.5 55 170 0.30 0.2 5.1 0.135 3.4 9-8208 125 40 25 0.64 0.187 4.8 65 4.5 55 170 0.40 0.2 5.1 0.188 4.8 9-8208 132 40 20 0.51 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1 0.25 6.4 9-8208 130 40 15 0.38 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1 0.375 9.5 9-8208 130 40 10 0.25 0.187 4.8 65 4.5 55 170 NR NR NR Type Torch: SL100 With Shielded Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.032 0.8 9-8208 116 40 220 5.59 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1 0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1 0.064 1.6 9-8208 118 40 180 4.57 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1 0.079 2.0 9-8208 116 40 150 3.81 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1 0.125 3.2 9-8208 130 40 75 1.91 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1 0.188 4.8 9-8208 132 40 60 1.52 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1 0.250 6.4 9-8208 134 40 28 0.71 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1 0.375 9.5 9-8208 143 40 11 0.28 0.187 4.8 65 4.5 55 170 NR NR NR Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 70 4.8 90 245 0.00 0.2 5.1 0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1 0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1 0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1 0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 70 4.8 90 245 0.20 0.2 5.1 0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.2 5.1 0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 70 4.8 90 245 0.50 0.2 5.1 0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 70 4.8 90 245 0.75 0.2 5.1 0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR 0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR 1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 70 4.8 90 245 NR NR NR

OPERATION Manual 0-5380 4T-16 Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.06 1.5 9-8210 110 60 165 4.19 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1 0.075 1.9 9-8210 116 60 155 3.94 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1 0.120 3.0 9-8210 115 60 125 3.18 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1 0.135 3.4 9-8210 118 60 80 2.03 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1 0.188 4.8 9-8210 120 60 75 1.91 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1 0.250 6.4 9-8210 121 60 60 1.52 0.13 3.2 70 4.8 90 245 0.30 0.20 5.1 0.375 9.5 9-8210 129 60 28 0.71 0.13 3.2 70 4.8 90 245 0.50 0.20 5.1 0.500 12.7 9-8210 135 60 17 0.43 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1 0.625 15.9 9-8210 135 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR 0.750 19.1 9-8210 142 60 10 0.25 0.19 4.8 70 4.8 90 245 NR NR NR Type Torch: SL100 With Shielded Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1 0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1 0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1 0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1 0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1 0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1 0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 70 4.8 90 245 0.80 0.20 5.1 0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR 0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8211 128 80 280 7.11 0.19 4.8 65 4.5 115 340 0.00 0.2 5.1 0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1 0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1 0.188 4.8 9-8211 128 80 137 3.48 0.19 4.8 65 4.5 115 340 0.20 0.2 5.1 0.250 6.4 9-8211 131 80 100 2.54 0.19 4.8 65 4.5 115 340 0.30 0.2 5.1 0.375 9.5 9-8211 134 80 40 1.02 0.19 4.8 65 4.5 115 340 0.50 0.2 5.1 0.500 12.7 9-8211 136 80 36 0.91 0.19 4.8 65 4.5 115 340 0.60 0.2 5.1 0.625 15.9 9-8211 145 80 21 0.53 0.19 4.8 65 4.5 115 340 0.75 0.2 5.1 0.750 19.1 9-8211 144 80 14 0.36 0.19 4.8 65 4.5 115 340 NR NR NR 0.875 22.2 9-8211 149 80 11 0.28 0.19 4.8 65 4.5 115 340 NR NR NR 1.000 25.4 9-8211 162 80 8 0.20 0.19 4.8 65 4.5 115 340 NR NR NR

Manual 0-5380 OPERATION 4T-17 Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8211 110 80 340 8.50 0.125 3.2 65 4.5 115 340 0.00 0.2 5.1 0.120 3.0 9-8211 115 80 260 6.50 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1 0.135 3.4 9-8211 113 80 250 6.25 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1 0.188 4.8 9-8211 114 80 170 4.25 0.125 3.2 65 4.5 115 340 0.20 0.2 5.1 0.250 6.4 9-8211 116 80 85 2.13 0.125 3.2 65 4.5 115 340 0.30 0.2 5.1 0.375 9.5 9-8211 123 80 45 1.13 0.125 3.2 65 4.5 115 340 0.40 0.25 6.4 0.500 12.7 9-8211 133 80 18 0.45 0.125 3.2 65 4.5 115 340 0.75 0.25 6.4 0.625 15.9 9-8211 135 80 16 0.40 0.125 3.2 65 4.5 115 340 1.00 0.25 6.4 0.750 19.1 9-8211 144 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR 0.875 22.2 9-8211 137 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR 1.000 25.4 9-8211 140 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR Type Torch: SL100 With Shielded Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.06 1.5 9-8211 115 80 320 8.13 0.13 3.2 65 4.5 115 340 0.00 0.25 6.4 0.12 3.0 9-8211 120 80 240 6.10 0.13 3.2 65 4.5 115 340 0.10 0.25 6.4 0.188 4.8 9-8211 120 80 165 4.19 0.13 3.2 65 4.5 115 340 0.20 0.25 6.4 0.250 6.4 9-8211 124 80 100 2.54 0.13 3.2 65 4.5 115 340 0.30 0.25 6.4 0.375 9.5 9-8211 138 80 60 1.52 0.19 4.8 65 4.5 115 340 0.40 0.25 6.4 0.500 12.7 9-8211 141 80 36 0.91 0.19 4.8 65 4.5 115 340 0.60 0.25 6.4 0.625 15.9 9-8211 142 80 26 0.66 0.19 4.8 65 4.5 115 340 0.75 0.25 6.4 0.750 19.1 9-8211 150 80 18 0.46 0.19 4.8 65 4.5 115 340 NR NR NR 0.875 22.2 9-8211 156 80 8 0.20 0.19 4.8 65 4.5 115 340 NR NR NR 1.000 25.4 9-8211 164 80 6 0.15 0.19 4.8 65 4.5 115 340 NR NR NR Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8212 124 100 110 2.80 0.180 4.6 75 5.2 130 390 0.4 0.200 5.1 0.375 9.5 9-8212 127 100 75 1.90 0.180 4.6 75 5.2 130 390 0.5 0.200 5.1 0.500 12.7 9-8212 132 100 50 1.30 0.180 4.6 75 5.2 130 390 0.6 0.200 5.1 0.625 15.9 9-8212 136 100 30 0.75 0.180 4.6 75 5.2 130 390 0.8 0.200 5.1 0.750 19.0 9-8212 140 100 18 0.45 0.190 4.8 75 5.2 130 390 2.0 0.225 5.7 1.000 25.4 9-8212 147 100 10 0.25 0.190 4.8 75 5.2 130 390 NR NR NR

OPERATION Manual 0-5380 4T-18 Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8212 121 100 110 2.80 0.125 3.2 75 5.2 130 390 0.5 0.200 5.1 0.375 9.5 9-8212 125 100 60 1.50 0.150 3.8 75 5.2 130 390 0.8 0.200 5.1 0.500 12.7 9-8212 132 100 35 0.90 0.150 3.8 75 5.2 130 390 1.0 0.200 5.1 0.625 15.9 9-8212 137 100 20 0.50 0.150 3.8 75 5.2 130 390 2.0 0.225 5.7 0.750 19.0 9-8212 144 100 15 0.40 0.190 4.8 75 5.2 130 390 NR NR NR 1.000 25.4 9-8212 154 100 8 0.20 0.190 4.8 75 5.2 130 390 NR NR NR Type Torch: SL100 With Shielded Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8212 120 100 120 3.05 0.180 65 4.5 105 360 0.2 0.225 5.7 0.375 9.5 9-8212 128 100 65 1.65 0.180 65 4.5 105 360 0.4 0.225 5.7 0.500 12.7 9-8212 130 100 45 1.15 0.180 65 4.5 105 360 0.5 0.225 5.7 0.625 15.9 9-8212 135 100 30 0.75 0.180 65 4.5 105 360 0.8 0.225 5.7 0.750 19.0 9-8212 140 100 25 0.65 0.180 65 4.5 105 360 1.0 0.225 5.7 1.000 25.4 9-8212 148 100 10 0.25 0.190 65 4.5 105 360 NR NR NR Type Torch: SL100 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8253 140 120 165 4.19 0.125 3.2 75 5.2 180 360 0.20 0.20 5.1 0.375 9.5 9-8253 142 120 85 2.16 0.125 3.2 75 5.2 180 360 0.50 0.20 5.1 0.500 12.7 9-8253 144 120 75 1.91 0.125 3.2 75 5.2 180 360 0.70 0.20 5.1 0.625 15.9 9-8253 150 120 50 1.27 0.125 3.2 75 5.2 180 360 0.80 0.20 5.1 0.750 19.0 9-8253 154 120 30 0.76 0.150 3.8 75 5.2 180 360 1.50 0.20 5.1 0.875 22.2 9-8253 158 120 25 0.64 0.150 3.8 75 5.2 180 360 NR NR NR 1.000 25.4 9-8253 160 120 20 0.51 0.150 3.8 75 5.2 180 360 NR NR NR 1.250 31.8 9-8253 170 120 13 0.33 0.175 4.4 75 5.2 180 360 NR NR NR 1.500 38.1 9-8253 176 120 8 0.20 0.175 4.4 75 5.2 180 360 NR NR NR

Manual 0-5380 OPERATION 4T-19 Type Torch: SL100 With Shielded Tip Type Material: Stainless Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8253 136 120 180 4.57 0.13 3.2 75 5.2 180 360 0.20 0.20 5.1 0.375 9.5 9-8253 144 120 100 2.54 0.13 3.2 75 5.2 180 360 0.40 0.20 5.1 0.500 12.7 9-8253 149 120 60 1.52 0.13 3.2 75 5.2 180 360 0.80 0.20 5.1 0.625 15.9 9-8253 153 120 40 1.02 0.15 3.8 75 5.2 180 360 1.20 0.20 5.1 0.750 19.1 9-8253 157 120 30 0.76 0.15 3.8 75 5.2 180 360 NR NR NR 1.000 25.4 9-8253 162 120 20 0.51 0.15 3.8 75 5.2 180 360 NR NR NR 1.250 31.8 9-8253 165 120 10 0.25 0.15 3.8 75 5.2 180 360 NR NR NR Type Torch: SL100 With Shielded Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8253 144 120 190 4.83 0.13 3.2 75 5.2 180 360 0.20 0.20 5.1 0.375 9.5 9-8253 148 120 120 3.05 0.13 3.2 75 5.2 180 360 0.50 0.20 5.1 0.500 12.7 9-8253 152 120 75 1.91 0.15 3.8 75 5.2 180 360 0.70 0.20 5.1 0.625 15.9 9-8253 162 120 45 1.14 0.15 3.8 75 5.2 180 360 1.00 0.20 5.1 0.750 19.1 9-8253 163 120 35 0.89 0.15 3.8 75 5.2 180 360 NR NR NR 1.000 25.4 9-8253 168 120 20 0.51 0.15 3.8 75 5.2 180 360 NR NR NR NOTE! * Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pres- sure to 70 psi / 4.8 bar. ** Total flow rate includes plasma and secondary gas flow.

OPERATION Manual 0-5380 4T-20 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S. and Foreign Patents as follows: Catalog # Description Patent(s) � 9-8215� Electrode� US�Pat�No(s)�6163008;�6987238 Other Pat(s) Pending � 9-8213� Cartridge� US�Pat�No(s)�6903301;�6717096;�6936786;�� � � � 6703581;�D496842;�D511280;�D492709;�� � � � D499620;�D504142�Other�Pat(s)�Pending � 9-8205� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8206� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8207� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8252� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8208� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8209� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8210� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8231� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8211� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8212� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8253� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8225� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8226� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8227� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8228� Tip� US�Pat�No(s)�6774336;�7145099;�6933461 Other Pat(s) Pending � 9-8241� Shield�Cap� US�Pat�No(s)�6914211;�D505309 Other Pat(s) Pending � 9-8243� Shield�Cap� US�Pat�No(s)�6914211;�D493183 Other Pat(s) Pending � 9-8235� Shield�Cap� US�Pat�No(s)�6914211;�D505309 Other Pat(s) Pending � 9-8236� Shield�Cap� US�Pat�No(s)�6914211;�D505309 Other Pat(s) Pending � 9-8237� Shield�Cup� US�Pat�No(s)�6914211;�D501632;�D511633 Other Pat(s) Pending � 9-8238� Shield�Cap� US�Pat�No(s)�6914211;�D496951 Other Pat(s) Pending � 9-8239� Shield�Cap� US�Pat�No(s)�6914211;�D496951 Other Pat(s) Pending � 9-8244� Shield�Cap� US�Pat�No(s)�6914211;�D505309 Other Pat(s) Pending

Manual 0-5380 OPERATION 4T-21 Catalog # Description Patent(s) � 9-8245� Shield�Cap� US�Pat�No(s)�6914211;�D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No. 5, 120, 930 and 5, 132, 512: Catalog # Description 9-8235� � Shield�Cap 9-8236� � Shield�Cap 9-8237� � Shield�Cup 9-8238� � Shield�Cap 9-8239� � Shield�Cap 9-8244� � Shield�Cap 9-8245� � Shield�Cap

Manual 0-5380 SERVICE 5-1 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Warning! Disconnect input power before maintaining. Each Use Visual check of torch tip and electrode Weekly Visually inspect the torch body tip, electrode, start cartridge and shield cup Visually inspect the cables and leads. Replace as needed 3 Months Clean exterior of power supply 6 Months Replace all broken parts Visually check and Carefully clean the interior Maintain more often if used under severe conditions Art # A-07938_AB

SERVICE Manual 0-5380 5-2 5.02 Maintenance Schedule NOTE! The actual frequency of maintenance may need to be adjusted according to the oper- ating environment. Daily Operational Checks or Every Six Cutting Hours: 1. Check torch consumable parts, replace if dam- aged or worn. 2. Check plasma and secondary supply and pres- sure/flow. 3. Purge plasma gas line to remove any moisture build-up. Weekly or Every 30 Cutting Hours: 1. Check fan for proper operation and adequate air flow. 2. Inspect torch for any cracks or exposed wires, replace if necessary. 3. Inspect input power cable for damage or ex- posed wires, replace if necessary. Six Months or Every 720 Cutting Hours: 1. Check the in-line air filter(s), clean or replace as required. 2. Check cables and hoses for leaks or cracks, replace if necessary. 3. Check all contactor points for severe arcing or pits, replace if necessary. 4. Vacuum dust and dirt out of the entire machine. ! CAUTION Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit. 5.03 Common Faults Problem - Symptom Common Cause Insufficient Penetration1. Cutting speed too fast. 2. Torch tilted too much. 3. Metal too thick. 4. Worn torch parts 5. Cutting current too low. 6. Non - Genuine ESAB parts used 7. Incorrect gas pressure Main Arc Extinguishes 1. Cutting speed too slow. 2. Torch standoff too high from workpiece. 3. Cutting current too high. 4. Work cable disconnected. 5. Worn torch parts. 6. Non - Genuine ESAB parts used Excessive Dross Formation 1. Cutting speed too slow. 2. Torch standoff too high from workpiece. 3. Worn torch parts. 4. Improper cutting current. 5. Non - Genuine ESAB parts used 6. Incorrect gas pressure Short Torch Parts Life 1. Oil or moisture in air source. 2. Exceeding system capability (material too thick). 3. Excessive pilot arc time 4. Gas pressure too low. 5. Improperly assembled torch. 6. Non - Genuine ESAB parts used Difficult Starting 1. Worn torch parts. 2. Non - Genuine ESAB parts used. 3. Incorrect gas pressure.

Manual 0-5380 SERVICE 5-3 5.04 Fault Indicator At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator and 75 psi indicators are ON indicating the version would be 2.3. A + PSI BAR MAX MAX MIN MIN ! 1 2 3 4 Art# A-07988 MIN MAX 0 1 2 3 4 5 6 7 5 When the ! "Fault" indicator is ON or blinking it will be accompanied by one of the pressure indicator lights depending on what the Fault is. The following table explains each of those Faults. Pressure Indicator Fault Max Over Pressure 90 Internal Error 85 Check Consumables 80 Consumables Missing 75 Start Error 70 Parts in Place 65 Input Power Min Under Pressure NOTE! Fault explanations are covered in the following tables.

SERVICE Manual 0-5380 5-4 5.05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Problem - Symptom Possible Cause Recommended Action ON / OFF Switch is ON but the A/C Indicator does not light 1. Primary power disconnect is in OFF position. 2. Primary fuses / breakers are blown or tripped. 3. Units internal fuse blown. 4. Faulty components in unit. 1. Turn primary power disconnect switch to ON position. 2. a) Have qualified person check primary fuses / breakers. b) Connect unit to known good primary power receptacle 3. a) Replace fuse. b) If fuse blows again, return to authorized service center for repair or replacement. 4. Return to authorized service center for repair or replacement. Fault indicator flashing, 65 PSI indicator flashing 1. INPUT VOLTAGE SELECTION SWITCH set for incorrect voltage. 2. Primary input voltage problem. 3. Faulty components in unit. 1. Set INPUT VOLTAGE SELECTION SWITCH to match primary input voltage. 2. Have qualified person check primary voltage to insure it meets unit requirements see section 2.05. 3. Return to authorized service center for repair or replacement. TEMPERATURE indicator ON. FAULT indicator flashing. 1. Air flow through or around the unit is obstructed. 2. Duty cycle of the unit has been exceeded 3. Failed components in unit 1. Refer to clearance information – section 2.04 2. Allow unit to cool. 3. Return to authorized service center for repair or replacement. GAS LED OFF, FAULT and MIN pressure indicators flashing. 1. Gas supply not connected to unit. 2. Gas supply not turned ON. 3. Gas supply pressure too low. 4. AIR PRESSURE CONTROL regulator set too low. 5. Failed components in unit. 1. Connect gas supply to unit. 2. Turn gas supply ON. 3. Set air supply inlet pressure to unit to 120 psi. 4. Adjust regulator to set air pressure - see section 4.02. 5. Return to authorized service center for repair or replacement. FAULT and 70 PSI indicators flashing. 1. Shield Cup loose. 2. Torch not properly connected to power supply. 3. Problem in torch and leads PIP circuit. 4. Failed components in unit. 1. Hand tighten the shield cup until it is snug. 2. Insure torch ATC is securely fastened to unit. 3. Replace torch and leads or return to authorized service center for repair or replacement. 4. Return to authorized service center for repair or replacement. FAULT and 75 PSI indicators flashing. 1. Start signal is active when ON/OFF SWITCH is turned to ON position. 2. Problem in the torch and leads switch circuit. 3. Failed components in unit. 1. Start can be active for one of the following: ��•�Hand�torch�switch�held�closed� ��•�Hand�pendant�switch�held�closed ��•�CNC�START�signal�is�active�low Release the START signal source 2. Replace torch and leads or return to authorized service center for repair or replacement. 3. Return to authorized service center for repair or replacement.

Manual 0-5380 SERVICE 5-5 Problem - Symptom Possible Cause Recommended Action FAULT & 80 PSI indicators flashing. Gas flow is cycling ON and OFF. 1. Torch shield cup is loose. 2. Torch tip, electrode or starter cartridge missing. 3. Torch starter cartridge is stuck. 4. Open conductor in torch leads. 5. Problem in the torch and leads switch circuit. 6. Failed components in unit. 1. Tighten shield cup by hand. Do not overtighten. 2. Turn OFF power supply. Remove shield cup. Install missing parts. 3. Turn OFF power supply. Bleed down system pressure. Remove shield cup, tip and starter cartridge. Check starter cartridge lower end fitting for free movement. Replace if fitting does not move freely. 4. Replace torch and leads or return to authorized service center for repair or replacement. 5. Replace torch and leads or return to authorized service center for repair or replacement. 6. Return to authorized service center for repair or replacement. Nothing happens when torch switch or remote switch is closed (Or CNC START signal is active) No gas flow, DC LED OFF. 1. Problem in the torch and leads switch circuit (Remote pendant switch circuit). 2. CNC Controller device not providing Start signal. 3. Failed components in unit. 1. Take Torch and Leads (Remote Pendant) to Authorized Repair Facility. 2. Contact Controller manufacturer. 3. Return to authorized service center for repair or replacement. FAULT and 85 PSI indicators flashing. 1. Upper O-Ring on torch head is in wrong position. 2. Torch starter cartridge is stuck. 3. Worn or faulty torch parts. 4. Shorted Torch. 5. Temporary Short indicated by 5 blinks per second. 6. Power Supply Failure (Standard rate of blinking) 1. Remove shield cup from torch; check upper O-Ring position; correct if necessary. 2. Turn OFF power supply. Bleed down system pressure. Remove shield cup, tip and starter cartridge. Check starter cartridge lower end fitting for free movement. Replace if fitting does not move freely. 3. Inspect torch consumable parts. Replace if necessary. 4. Replace torch and leads or return to an authorized service center for repair. 5. Release torch switch and reactivate. 6. Return to authorized service center for repair or replacement. No Fault lights ON, no arc in torch. 1. Failed components in unit. 1. Return to an authorized service center for repair. Fault and 90 PSI indicators flashing 1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that does not clear the fault, return to an authorized service center for repair. Pilot arc is ON but cutting arc will not establish 1. Work cable not connected to work piece. 2. Work cable/connector broken. 3. Failed components in unit. 1. Connect work cable. 2. Replace work cable. 3. Return to an authorized service center for repair. Torch cutting is diminished 1. Incorrect current setting. 2. Worn torch consumables. 3. Poor work cable connection to work piece. 4. Torch being moved too fast. 5. Excessive oil or water in torch. 6. Failed components in unit. 1. Check and adjust to proper setting. 2. Check torch consumables and replace as needed. 3. Check the connection of the Work Lead to the work piece. 4. Reduce cutting speed. 5. Refer to "Check air quality" in section 3 Torch. 6. Return to an authorized service center for repair.

SERVICE Manual 0-5380 5-6 5.06 Power Supply Basic Parts Replacement ! WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply. This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual. A. Cover Removal 1. Remove the upper and lower screws which secure the cover to the main assembly. Do not loosen the lower screws inside the cut out slots in the bottom of the cover. Art # A-08429 Lower Screws Lower Screws Slots Upper Screws 2. Carefully pull the Cover up and away from the unit. B. Cover Installation 1. Reconnect the ground wire, if necessary. 2. Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws. 3. Tighten lower screws. 4. Reinstall and tighten the upper screws. C. Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be checked per the Maintenance Schedule (Subsection 5.02), and either cleaned or replaced. 1. Remove power from the power supply; turn OFF the gas supply and bleed down the system. 2. Remove the system cover. See "A Cover Re- moval" in this section. 3. Locate the internal air line and the fitting from the filter assembly. Number 1 in the following illustration. 4. Hold a wrench or similar tool against the locking ring on the filter assembly fitting, then pull on the hose to release it. (Numbers 2 and 3 in the following illustration). Art # A-07989 1 2 3 4 5 6mm

Manual 0-5380 SERVICE 5-7 5. Remove the fitting from the filter element as- sembly�by�inserting�a�6�mm�hex�wrench�into� the internal hex fitting and turning it counter clock-wise (left). Numbers 4 and 5 in the previ- ous illustration. 6.� Disconnect�the�input�line�from�the�filter�element� assembly. 7. Remove the filter element assembly through the rear opening. NOTE! If replacing or cleaning just the filter ele- ment refer to the following illustration for disassembly. Art # A-07990 Filter Element 8. Install the new or cleaned assembly by reversing these procedures. 9.� Turn�ON�the�air�supply�and�check�for�leaks�before� reinstalling the cover. Optional Single-Stage Filter Element Replacement These instructions apply to power supplies where the optional Single-Stage Filter has been installed. The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to�Section�6,�Parts�List,�for�replacement�filter�element� catalog number. 1. Remove power from power supply. 2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter Ele- ment. 3. Disconnect gas supply hose. 4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located inside the Housing. Art # A-02476 Filter Element (Cat. No. 9-7741) Housing Cover Barbed Fitting Spring Assembled Filter O-ring (Cat. No. 9-7743) Optional Single-Stage Filter Element Replacement 5. Remove the Filter Element from the Housing and set Element aside to dry. 6.� Wipe�inside�of�housing�clean,�then�insert�the� replacement Filter Element open side first. 7. Replace Housing on Cover. 8. Reattach gas supply. NOTE! If unit leaks between housing and cover, inspect the O-ring for cuts or other damage.

SERVICE Manual 0-5380 5-8 Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue�to�operate�but�cut�quality�may�become�unacceptable.��Refer�to�Section�6,�Parts�List,�for�replacement� filter element catalog number. 1. Shut OFF primary input power. 2. Shut OFF air supply and bleed down system. ! WARNING Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could result. 3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely. 4. Note the location and orientation of the old Filter Elements. 5. Slide out the old Filter Elements. First & Second Stage Cartridges (as marked) Art # A-02942 Optional Two-Stage Filter Replacement 6.� Slide�the�replacement�Filter�Elements�into�the�Filter�Assembly,�with�the�same�orientation�as�noted�in�Step� 4 above. 7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may damage the gasket. 8. Slowly apply air pressure to the assembly, checking for leaks. NOTE! A small amount of air leakage from the bottom fitting is normal. This completes the parts replacement procedures.

Manual 0-5380 SERVICE 5T-1 SECTION 5 TORCH: SERVICE 5T.01 General Maintenance NOTE! Refer to Previous "Section 5: System" for common and fault indicator descriptions. Cleaning Torch Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch be- comes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch. WARNING Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON. The inside of the torch should be cleaned with elec- trical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air. ! CAUTION Dry the torch thoroughly before reinstalling. O-Ring Lubrication An o-ring on the Torch Head and ATC Male Con- nector requires lubrication on a scheduled basis. This will allow the o-rings to remain pliable and provide a proper seal. The o-rings will dry out, becoming hard and cracked if the lubricant is not used on a regular basis. This can lead to potential performance problems. It is recommended to apply a very light film of o- ring lubricant (Catalog # 8-4025) to the o-rings on a weekly basis. Upper Groove with Vent Holes Must Remain Open Threads Upper O-Ring in Correct Groove Lower O-Ring Art # A-03725 Torch Head O-Ring ATC Male Connector Art #A-03791 Gas Fitting O-Ring ATC O-Ring NOTE! DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.

SERVICE Manual 0-5380 5T-2 5T.02 Inspection and Replacement of Consumable Torch Parts WARNING Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON. Remove the consumable torch parts as follows: NOTE! The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed. 1. Unscrew and remove the shield cup from the torch. NOTE! Slag built up on the shield cup that cannot be removed may effect the performance of the system. 2. Inspect the cup for damage. Wipe it clean or replace if damaged. Art # A-08067 Shield Cups 3. On torches with a shield cup body and a shield cap or deflector, ensure that the cap or deflector is threaded snugly against the shield cup body. In shielded drag cutting operations (only), there may be an O-ring between the shield cup body and drag shield cap. Do not lubricate the O-ring. Drag Shield Cap Shield Cup Body O-Ring No. 8-3488 Art # A-03878 4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary. Good Tip Worn Tip A-03406 Example of Tip Wear 5. Remove the starter cartridge. Check for exces- sive wear, plugged gas holes, or discoloration. Check the lower end fitting for free motion. Replace if necessary. Art # A-08064_AC Spring-Loaded Lower End Fitting Full Compression Spring-Loaded Lower End Fitting at Reset / Full Extension 6.� Pull�the�Electrode�straight�out�of�the�Torch�Head.� Check the face of the electrode for excessive wear. Refer to the following figure. Worn Electrode New Electrode Art # A-03284 Electrode Wear 7. Reinstall the Electrode by pushing it straight into the torch head until it clicks. 8. Reinstall the desired starter cartridge and tip into the torch head. 9.� Hand�tighten�the�shield�cup�until�it�is�seated�on� the torch head. If resistance is felt when install- ing the cup, check the threads before proceed- ing. This completes the parts replacement procedures.

Manual 0-5380 PARTS LIST 6-1 SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows: Section "6.03 Power Supply Replacement" Section "6.04 Replacement Power Supply Parts" Section "6.05 Options and Accessories" Section "6.06 Replacement Parts for Hand Torch" Section "6.07 Replacement Parts - for Machine Torches with Unshielded Leads" Section "6.08 Replacement Shielded Machine Torch Leads Assemblies" Section "6.09 Torch Consumable Parts (SL100)" NOTE! Parts listed without item numbers are not shown, but may be ordered by the catalog number shown. B. Returns If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted. 6.02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for each type item. Also include the model and serial number of the power supply. Address all inquiries to your authorized distributor. 6.03 Power Supply Replacement The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / filter, and operating manual. Qty Description Catalog # 1 ESAB Cutmaster® 120 Power Supply with 400VAC, 3 phase input power cable 0559317302

PARTS LIST Manual 0-5380 6-2 6.04 Replacement Power Supply Parts Qty Description Catalog # 1 Regulator 9-0115 1 Filter Assembly Replacement Element 9-0116 1 Input Power Cord for 208 / 230 V Power Supply 9-0191 1 460/600V Power Supply 9-0209 6.05 Options and Accessories Qty Description Catalog # 1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507 1 Replacement Filter Body 9-7740 1 Replacement Filter Hose (not shown) 9-7742 2 Replacement Filter Element 9-7741 1 Two - Stage Filter Kit (includes Hose & Mounting Screws 9-9387 Bracket, Filter Mounting (not shown) 9-9386 1 Two - Stage Air Filter Assembly 9-7527 1 First Stage Cartridge 9-1021 1 Second Stage Cartridge 9-1022 1 Extended Work Cable (50 ft / 15.2 m) with Clamp 9-8529 1 Automation Interface Kit 9-8311 1 Automation Harness 9-9385 1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008 1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010 1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011 Art # A-02476 Filter Element (Cat. No. 9-7741) Housing Cover Barbed Fitting Spring Assembled Filter O-ring (Cat. No. 9-7743) First & Second Stage Cartridges (as marked) Art # A-02942 Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

Manual 0-5380 PARTS LIST 6-3 6.06 Replacement Parts for Hand Torch Item # Qty Description Catalog # 1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 2 1 Trigger Assembly Replacement Kit 9-7034 3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219 5 1 Large O-ring 8-3487 6 1 Small O-ring 8-3486 7 Leads Assemblies with ATC connectors (includes switch assemblies) 1 SL100, 20 - foot Leads Assembly with ATC connector 4-7836 1 SL100, 50 - foot Leads Assembly with ATC connector 4-7837 8 1 Switch Kit 9-7031 10 1 Torch Control Cable Adapter (includes item # 11) 7-3447 11 1 Through - Hole Protector 9-8103 7 5 6 3 4 2 Art # A-07993_AB 1 8

PARTS LIST Manual 0-5380 6-4 6.07 Replacement Parts - for Machine Torches with Unshielded Leads Item No. Qty Description Catalog No. 1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 2 1 Large O-ring 8-3487 3 1 Small O-ring 8-3486 4 1 PIP Switch Kit 9-7036 5 Unshielded Automated Leads Assemblies with ATC connectors 1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850 1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851 1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852 1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853 6 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842 1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843 1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844 1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845 7 1 11” / 279 mm Rack 9-7041 8 1 11” / 279 mm Mounting Tube 9-7043 9 1 End Cap Assembly 9-7044 10 2 Body, Mounting, Pinch Block 9-4513 11 1 Pin, Mounting, Pinch Block 9-4521 12 1 Torch Holder Sleeve 7-2896 13 1 PIP Plunger and Return Spring Kit 9-7045 1 Pinion Assembly (Not shown) 7-2827 1 5” / 126 mm Positioning Tube (Not shown) 9-7042 NOTE! * Does not include Control Cable Adapter or Through - Hole Protector. Refer to Section 6.09 for Replacement Shielded Leads Assemblies.

PARTS LIST Manual 0-5380 6-6 6.08 Replacement Shielded Machine Torch Leads Assemblies Item No. Qty Description Catalog No. 1 Mechanized Shielded Leads Assemblies with ATC Connectors 1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846 1 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847 1 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848 1 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849 A-03684 1 Torch Continuity ('PIP') Switch Remote Pendant Adapter is present on Mechanized leads only.

Manual 0-5380 PARTS LIST 6-7 6.09 Torch Consumable Parts (SL100) Starter Cartridge 9-8213 Electrode Auto 9-8232 Manual 9-8215 50-55A 9-8209 60A 9-8210 70A 9-8231 80A 9-8211 90/100A 9-8212 120A Auto 9-8233 120A Manual 9-8253 Tips: Tips: Tip A 9-8225 (40 Amps Max.) Tip B 9-8226 (50 - 120 Amps) Tip C 9-8227 (60 - 120 Amps) Tip D 9-8228 (60 - 120 Amps) Tip E 9-8254 (60 - 120 Amps) Shield Cup, Gouging 9-8241 Shield Cup Body, 9-8237 Tips: 40-120A GOUGING Shield Cup Body, 9-8237 Shield Cup 9-8218 Shield Cap, Deflector 9-8243 Shield Cup Body, 9-8237 Shield Cup 9-8218 Shield Cap, Machine 50-60A 9-8238 Drag Shield Cup 9-8235 Drag Shield Cup 70-100A 9-8236 Drag Shield Cup 120A 9-8258 Shield Cap, Machine 70-100A 9-8239 Shield Cap, Machine 120A 9-8256 Art # A-08066_AG CUTTING STANDOFF 70-120A CUTTING STANDOFF 20-40A Shield Cap, Deflector 9-8243 50-60A CUTTING STANDOFF Heavy Duty Starter Cartridge Non HF Only 9-8277 Shield Cap, Deflector 9-8243 Shield Cap, Machine 40A 9-8245 20A 9-8205 30A 9-8206 40A 9-8208 Shield Cup Body, 9-8237 Shield Cup 9-8218 Tip: Ohmic Clip Automation Torch 9-8224 Ohmic Clip Manual Torch 9-8259

Manual 0-5380 APPENDIX A-1 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ON / OFF switch to ON RESULT: AC indicator ON. GAS indicator ON when input pressure is adequate for power supply operation. Power circuit ready. ACTION: Protect eyes and activate Torch switch (START) RESULT: Fans turn on. Gas flows briefly, then stops.Gas restarts. DC indicator ON Pilot arc established. ACTION: Unplug input power cord or open external disconnect. RESULT: No power to system. ACTION: Connect work cable to workpiece. Set output amperage. RESULT: System is ready for operation. ACTION: RUN / Rapid Auto Restart / SET / LATCH switch to SET RESULT: Gas flows to set pressure. ACTION: RUN / Rapid Auto Restart / SET / LATCH switch to RUN (for most applications) or to Rapid Auto Restart (for gouging, trimming, or expanded metal applications) or to LATCH is used for specific applications (torch switch can be released after main arc transfer). RESULT: Gas flow stops. ACTION: Release Torch switch. RESULT: Main arc stops. Gas flow stops after post - flow. (Fans will continue to run for 10 minutes after the Torch switch [START] is removed) ACTION: ON / OFF switch to OFF RESULT: All indicators off. Power supply fans shut off. ACTION: Close external disconnect switch. RESULT: Power to system. ACTION: Torch moved within transfer distance of workpiece. RESULT: Main arc transfers. Pilot arc off. PILOT ARC ACTION: Torch moved away from work (while still activated). RESULT: Main arc stops. Pilot arc automatically restarts. Art #A-07979_AB

APPENDIX Manual 0-5380 A-2 1/ 3 f 1f 2 Model : U1 1 1 1max 1eff I I U2 3Ø 3Ø 1Ø 1Ø S/N U0 = X Standard Symbols Ø AC DC Phase NOTES: 1. Symbol shown indicates single- or three-phase AC input, static frequency converter-transformer-rectifier, DC output. 2. Indicates input voltages for this power supply. Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built. 3. Top row: Duty cycle values. IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission. Duty cycle value is determined under the power supply manufacturer's test procedures. Second row: Rated cutting current values. Third row: Conventional load voltage values. 4. Sections of the Data Tag may be applied to separate areas of the power supply. I Art # A-12765_AA Dat e of Mf r : Output Range (Amperage/ Voltage) Type of Power Supply (Note 1) Output Current Type Rated No- Load Voltage Plasma Cutting Symbol Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code Conventional Load Voltage Regulatory Standard Covering This Type of Power Supply Duty Cycle Data (Note 3) Duty Cycle Factor Input Power Specifications (Phase, AC or DC Hertz Rating) Input Power Symbol Rated Supply Voltage (Note 2) Rated Maximum Supply Current Maximum Effective Supply Current Degree of Protection Manufacturer's Electrical Schematic File Number and Revision Level APPENDIX 2: DATA TAG INFORMATION

Manual 0-5380 APPENDIX A-3 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram 1 2 3 4 5 6 7 8 5 6 7 8 1 2 3 4 ATC Female Receptacle Front View Pilot Pilot 6 - Open 7 - Open 8 - Open 5 - Open Negative / Plasma 6 - Open 7 - Open 5 - Open 2 - PIP 3 - Switch 4 - Switch 1 - PIP 4 - Green / Switch 2- Orange / PIP 3 - White / Switch 1 - Black / PIP Negative / Plasma 8 - Ground ATC Male Connector Front View A-03701 B. Mechanized (Machine) Torch Pin - Out Diagram ATC Female Receptacle Front View ATC Male Connector Front View Negative / Plasma 3 - White - Pendant Connector 4- Black - Pendant Connector 2 - Orange / PIP 1 - Black / PIP Pilot 2 - PIP 1 - PIP 6 - Open 7 - Open 5 - Open 8 - Ground 8 - Green - Pendant Connector Ground 5 - White / Not Used 7 - Green / Not Used 6 - Open UNSHIELDED MACHINE TORCH 3 - Switch 4 - Switch Art # A-03799 Negative / Plasma Pilot 1 2 3 4 5 6 7 8 5 6 8 1 2 3 4 7

APPENDIX Manual 0-5380 A-4 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Pilot Negative / Plasma Power Supply PIP Switch Male ATC Leads Connector ATC Female Receptacle Pilot Negative / Plasma Black Orange Torch Leads Torch Head To Power Supply Circuitry Art # A-03797 1 2 5 6 4 3 8 7 1 2 5 6 4 3 8 7 Torch Switch Green White To Power Supply Circuitry B. Mechanized Torch Connection Diagram Torch: Unshielded Mechanized SL100 Machine Torch Leads: Leads with ATC Connector and Remote Pendant Connector Power Supply: with ATC Female Receptacle Pilot Negative / Plasma Power Supply To Remote Control Remote Pendant Connector PIP Switch Not Used Male ATC Leads Connector ATC Female Receptacle Pilot Lead Negative / Plasma Lead Torch Leads Torch Head Art # A-03798 1 2 5 6 4 3 8 7 To Power Supply Circuitry Green To Power Supply Circuitry 1 2 5 6 4 3 8 7 Black White Green Black Orange White

APPENDIX Manual 0-5380 A-6 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS A-09130_AD 5 5 4 4 D C B A +12VDC +12VDC +12VDC +12VDC +12VDC 24VAC _ INRUSH RESISTORS 3.3VDC TXD RXD Q2 D SERIAL PORT _ PCB1 + + + + Q1 /SOLENOID MAIN PCB ASSY /INRUSH D1 C D B A _ Q2 _ B A PCB5 40/50 AMP PCB PCB2 Q1 FAN /FAN FAN D1 C D INPUT CAPACITOR PCB 1 /OVERTEMP 2 /FAN_ON 3 /CSR 4 CUR_SET 5 MAIN_PCB_ID 6 COMMON SYNC SYNC FAN 9 8 7A PRIMARY POWER CONNECTIONS: USE L1, L2, L3 & GND L1 L2 L4 L3 T2 T1 T4 T3 24VAC RET 5 6 7 L2 L1 GND L3 /FAN BIAS SUPPLY +12VDC BIAS SUPPLY FERRITE FILTER * EMI CHOKE EMI FILTER 1 2 3 4 1 2 3 4 * * 380/400/415V OR 600V 3 PH AC INPUT CE UNITS ONLY MTH4 MTH4 TP3 TP3 AC3 AC3 J2 J2 1 2 J9 J9 AC2 AC2 MTH7 MTH7 MOT3 MOT3 + - + C3,C4,C7,C8* + C3,C4,C7,C8* SOL 1 SOL 1 MTH6 MTH6 J14 J14 PRI 2 PRI 2 80A_AC2 80A_AC2 J13 J13 1 2 3 4 5 6 PRI 3 PRI 3 80A_AC3 80A_AC3 PMTH2 PMTH2 + C16-17 + C16-17 MTH8 MTH8 J4 J4 1 2 3 4 5 AC1 AC1 PRI 2 PRI 2 K1 K1 PRI 4 PRI 4 J7 J7 1 2 T1 T1 MTH2 MTH2 SW1 SW1 1 3 2 4 MOT1 MOT1 + - PMTH1 PMTH1 PRI 1 PRI 1 PMTH3 PMTH3 J4 J4 1 2 3 4 5 6 7 8 9 10 W1 W1 J1 J1 1 2 AC2 AC2 40A_AC2 40A_AC2 MOT2 MOT2 + - AC1 AC1 W1 W1 PMTH1 PMTH1 J5 J5 1 2 3 + C12-13 + C12-13 TP4 TP4 PRI 1 PRI 1 J6 J6 1 2 80A_AC1 80A_AC1 J1 J1 1 2 3 4 5 PMTH4 PMTH4 AC3 AC3 PRI 4 PRI 4 TP2 TP2 PRI 3 PRI 3 40A_AC3 40A_AC3 TP5 TP5 PRI 1 PRI 1 T2 T2 PMTH4 PMTH4 MTH1 MTH1 PRI 2 PRI 2 TP1 TP1 + C5,C6,C9,C10* + C5,C6,C9,C10* TP8 TP8 40A_AC1 40A_AC1 J3 J3 1 2 PMTH3 PMTH3 PMTH2 PMTH2 J2 J2 1 2

Manual 0-5380 APPENDIX A-7 A-12771_AB 3 3 2 2 1 1 D C B A +12VDC +12VDC +12VDC +5VDC +12VDC DWG No: Sheet of Supersedes Scale Date: Drawn: References Date By Revisions Rev PCB No: Assy No: Not For Release, Reproduction, or Distribution without Written Consent. NOTE: Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. Capacitors are in Microfarads (UF) Chk: App: TITLE: Last Modified: Size SCHEMATIC, 42X1330 1 1 09:02:19 D DWG No: Sheet of Supersedes Scale Date: Drawn: References Date By Revisions Rev PCB No: Assy No: Not For Release, Reproduction, or Distribution without Written Consent. NOTE: Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. Capacitors are in Microfarads (UF) Chk: App: TITLE: Last Modified: Size SCHEMATIC, 42X1330 Friday, December 11, 2009 1 1 09:02:19 D DWG No: Sheet of Supersedes Scale Date: Drawn: References Date By Revisions Rev PCB No: Assy No: Information Proprietary to ESAB Not For Release, Reproduction, or Distribution without Written Consent. NOTE: Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. Capacitors are in Microfarads (UF) Chk: App: TITLE: Last Modified: Size SCHEMATIC, 42X1330 1 1 09:02:19 CM102/152/35mm/40mm/A80/A120 380/400/415/600V D OVER PRESSURE INTERNAL ERROR SHORTED TORCH CONSUMABLES MISSING START ERROR PARTS IN PLACE INPUT POWER UNDER PRESSURE ERROR IND FAULT PCB3 LATCH SET RUN RAR MAX 90 85 80 75 70 65 MIN TP1 TP2 TP3 TP4 TP5 TP6 TP7 LOGIC PCB GND +12 VDC +5 VDC 3.3 VDC 0.v - 5.0 VDC / 0-100PSI 1.8 VDC CURRENT DEMAND TEST POINTS TEMP CIRCUIT 80 81 82 83 E64 E35 78 79 - + ATC CONNECTOR GND1 GND2 +12V1 48V1 I_DMD_1 TIP_SEN COMMON COMMON +12 VDC SUPPLY +48 VDC SUPPLY CURRENT DEMAND TIP DRAG SENSE TEST POINTS J2 J1 CNC PINOUT 1 3 4 7 8 11 12 14 OK-TO-MOVE /PIP /START 24VAC RETURN 24VAC SUPPLY /OVERTEMP TEMP CIRCUIT PRESSURE TRANSDUCER AIR INLET FILTER REGULATOR SOLENOID VALVE ATC GAS CONTROL 0-100PSI / 0-4.5VDC /OVERTEMP D3 (5A @ 250VAC / 30VDC) 1TORCH AUTOMATION TORCH SOLENOID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 29 34 35 36 37 38 39 -V_OUT_SIGNAL /TIP_VOLTS /TIP_SENSE /460V_IN /230V_IN CUR_SET /RAR (RAPID AUTO RESTART) /INRUSH /W1_ON SHDN /TORCH_SOLENOID /SOLENOID_ON /OK_TO_MOVE /FAN_ON /LATCH_ACTIVE /TORCH_SWITCH /PIP AC_ON CSR /TORCH_SOLENOID_DETECT /OVERTEMP V_IN +12VDC +12VDC COMMON COMMON MAIN_PCB_ID 460_IN +3.3VDC TXD RXD COMMON D M-L M-L M-L L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L L-M M-L M-L L-M M-L 40 PIN RIBBON CABLE SIGNALS D2 MARCH 30, 2009 } OK-TO-MOVE OK TO MOVE } } PCB4 AUTOMATION INTERFACE PCB FULL FEATURED AUTOMATION INTERFACE PCB OPTION (+) } To configure DIVIDED ARC VOLTS signal output No jumper installed for ARC VOLTS / 16.67 Jumper pins 1 & 2 for ARC VOLTS / 30 Jumper pins 2 & 3 for ARC VOLTS / 50 K1 To -V OUT 1 on PCB1 } /START / STOP * * } DIVIDED ARC VOLTS /START / STOP (+) (-) (W/ 100K IN SERIES (2)) (-) * ARC VOLTS AA INTRO ECO B1357 FERRITE FILTER RWH RWH 03/31/09 AB ECO B1399 RWH 05/05/09 WORK1 WORK1 -V OUT 1 -V OUT 1 NTC NTC AC AC J2 J2 2 3 4 5 6 7 8 9 10 11 12 13 14 1 90 90 CHOKE1 CHOKE1 J1 J1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 SEC1 SEC1 J3 J3 3 2 1 Q5 PILOT IGBT Q5 PILOT IGBT J10 J10 1 2 3 4 5 6 7 8 SEC1 SEC1 TS1 TS1 85 85 L2 L2 ERROR ERROR NTC NTC TIP1 TIP1 70 70 MIN MIN D78 CSR D78 CSR 1 2 3 TORCH SWITCH TORCH SWITCH ELECTRODE1 ELECTRODE1 SEC2 SEC2 P2 P2 1 2 3 4 5 6 7 8 SEC2 SEC2 Current Control Current Control DC DC CHOKE1 CHOKE1 MAX MAX J11 J11 1 2 GAS GAS 65 65 J1 J1 1 2 3 4 5 6 7 8 P1 P1 1 2 3 L1 L1 OVERTEMP OVERTEMP P10 P10 1 2 3 4 5 6 7 8 +OUT_1 +OUT_1 D1 D1 80 80 1 2 3 4 5 6 7 8 75 75 PIP SWITCH PIP SWITCH K1 K1 D59 PCR D59 PCR E1 E1 J9 J9 1 2 3 4 5 6 7 WORK WORK P10 P10 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 AB ECO B1611 RWH 05/05/09 SEE A-09130

APPENDIX Manual 0-5380 A-8 Revision History Date Rev Description 01/15/2015 AA Manual release 05/22/2015 AB Miscellaneous corrections and updates

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