wilkinsonstar.com
Cut 45P
Air Plasma Cutting machine
Order code ! JP-45P
OPERATOR MANUAL
Your new product
Thank you for selecting this Jasic Technology, Wilkinson Star product.
This product manual has been designed to ensure that you get the most from your new product. Please ensure that you are fully
conversant with the information provided paying particular attention to the safety precautions. The information will help protect
yourself and others against the potential hazards that you may come across.
Please ensure that you carry out daily and periodic maintenance checks to ensure years of reliable and trouble free operation.
Wilkinson Star Limited are a leading supplier of equipment in the UK and our products are supported by our extensive service
network. Call your distributor in the unlikely event of a problem occurring. Please record below the details from your product as
these will be required for warranty purposes and to ensure you get the correct information should you require assistance or
spare parts.
Date purchased
_____________________________________________________
From where _____________________________________________________
Serial Number
_____________________________________________________
(The serial number will normally be located on the equipment data plate on the underside of the machine or on the rear panel)
Please note products are subject to continual development and may be subject to change without notice
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Safety Precautions
These general safety norms cover both arc welding
machines and plasma cutting machines unless
otherwise noted.
The equipment must only be used for the purpose it was
Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact
with the work ground.
Never touch the electrode if you are in contact with the work
ground, or another electrode from a different machine.
designed for. Using it in any other way could result in
damage or injury and in breach of the safety rules.
Only suitably trained and competent persons should use the
equipment. Operators should
respect the safety of other
persons.
Prevention against electric shock
The equipment should be installed by a qualified person and
in accordance with current standards in operation.It is the
users responsibility to ensure that the equipment is
connected to a suitable power supply. Consult with your
utility supplier if required
If earth grounding of the work piece is required, ground it
directly with a separate cable.
Do not use the equipment with the covers removed.
Do not touch live electrical parts or parts which are
electrically charged.
Turn off all equipment when not in use.
Cables (both primary supply and welding) should be
regularly checked for damage and overheating. Do not use
worn, damaged, under sized, or poorly jointed cables.
Ensure that you wear the correct protective clothing, gloves,
head and eye protection.
Do not wrap cables over your body.
Ensure that you take additional safety precautions when you
are welding in electrically hazardous conditions such as
damp environments, wearing wet clothing, and metal
structures. Try to avoid welding in cramped or restricted
positions.
Ensure that the equipment is well maintained. Repair or
replace damaged or defective parts immediately. Carry out
any regular maintenance in accordance with the
manufacturers instructions.
Safety against fumes and welding gases
Locate the equipment in a well-ventilated position.
Keep your head out of the fumes. Do not breathe the fumes.
Ensure the welding zone is in a well-ventilated area. If this is
not possible provision should be made for suitable fume
extraction.
If ventilation is poor, wear an approved respirator.
Read and understand the Material Safety Data Sheets
(MSDS’s) and the manufacturer’s instructions for metals,
consumable, coatings, cleaners, and de-greasers.
Do not weld in locations near any de-greasing, cleaning, or
spraying operations. Be aware that heat and rays of the arc
can react with vapours to form highly toxic and irritating
gases.
2
Do not weld on coated metals, unless the coating is
removed from the weld area, the area is well ventilated, and
while wearing an air-supplied respirator. The coatings on
many metals can give off toxic fumes if welded.
Prevention against burns and radiation
Arc rays from the welding process produce intense, visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin.
Wear an approved welding helmet fitted with a proper shade
of filter lens to protect your face and eyes when welding or
watching
Replace the coverings and protections and close all doors
when the intervention is finished, and before starting the
equipment.
Take care to avoid getting fingers trapped when loading and
feeding wire during set up and operation.
When feeding wire be careful to avoid pointing it at other
people or toward your body.
Always ensure machine covers and protective devices are in
operation.
Precautions against fire and explosion
Wear approved safety glasses with side shields under your
helmet.
Avoid causing fires due to sparks and hot waste or molten
metal
Never use broken or faulty welding helmets.
Ensure that appropriate fire safety devices are available near
the cutting / welding area.
Always ensure there are adequate protective screens or
barriers to protect others from flash, glare and sparks from
the welding area. Ensure that there are adequate warnings
that welding or cutting is taking place.
Remove all flammable and combustible materials from the
cutting / welding zone and surrounding areas
Wear suitable protective flame resistant clothing.
Do not cut/weld fuel and lubricant containers, even if empty.
These must be carefully cleaned before they can be cut/
welded.
The sparks and spatter from welding, hot work pieces, and
hot equipment can cause fires and burns
Welding on closed containers, such as tanks, drums, or
pipes, can cause them to explode.
Accidental contact of electrode to metal objects can cause
arcs, explosion, overheating, or fire.
Check and be sure the area is safe and clear of inflammable
material before carrying out any welding.
Protection against noise
Some welding and cutting operations may produce noise.
Always allow the cut/welded material to cool before touching
it or placing it in contact with combustible or flammable
material.
Do not work in atmospheres with high concentrations of
combustible fumes, flammable gases and dust.
Always check the work area half an hour after cutting to
make sure that no fires have begun.
Risks due to magnetic fields
The magnetic fields created by high currents may affect the
operation of pacemakers or electronically controlled medical
equipment.
Wear safety ear protection to protect your hearing.
Protection from moving parts
When the machine is in operation keep away from moving
parts such as motors and fans. Moving parts, such as the
fan, may cut fingers and hands and snag garments.
Wearers of vital electronic equipment should consult their
physician before beginning any arc welding, cutting, gouging
or spot welding operations.
Do not go near welding equipment with any sensitive
electronic equipment as the magnetic fields may cause
damage.
Protections and coverings may be removed for maintenance
and controls only by qualified personnel, after first
disconnecting the power supply cable.
3
RF Declaration
Equipment that complies with directive 2004/108/EC
concerning electromagnetic compatibility (EMC) and the
technical requirements of EN60974-10 is designed for use in
industrial buildings and not those for domestic use where
electricity is provided via the low voltage public distribution
system. Difficulties may arise in assuring class A
electromagnetic compatibility for systems installed in
domestic locations due to conducted and radiated
emissions.
Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
Always secure the cylinder safely
Never deface or alter any cylinder
In the case of electromagnetic problems, it is the
responsibility of the user to resolve the situation. It may be
necessary to shield the equipment and fit suitable filters on
the mains supply.
LF Declaration
Consult the data plate on the equipment for the power
supply requirements.
Due to the elevated absorbance of the primary current from
the power supply network, high power systems affect the
quality of power provided by the network. Consequently,
connection restrictions or maximum impedance
requirements permitted by the network at the public network
connection point must be applied to these systems.
In this case the installer or the user is responsible for
ensuring the equipment can be connected, consulting the
electricity provider if necessary.
Materials and their disposal
The equipment is manufactured with materials, which do not
contain any toxic or poisonous materials dangerous to the
operator.
When the equipment is scrapped, it should be dismantled
separating components according to the type of materials.
Do not dispose of the equipment with normal waste. The
European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment states the electrical equipment that
has reached its end of life must be collected separately and
returned to an environmentally compatible recycling facility.
Handling of Compressed gas cylinders and
regulators
All cylinders and pressure regulators used in welding
operations should be handled with care.
Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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2
Product Overview
This is a digital plasma cutting machine with high
performance and using advanced technology. The CUT45P
is an ultra-portable plasma cutting system suitable for a
variety of application requirements. It can be used in
handheld cutting or with automated cutting systems. The
CUT45P can cut conductive metal, such as low carbon
steel, stainless steel and aluminium etc.
The modern design concept of this machine and the
application of a large number of advanced and mature
technologies ensure the user’s investment for the future.
Advanced digital control mode
The CUT45P adopts intelligent digital control technology,
and all its major functions are performed using this
advanced software. It is this digital control which has lead
to improvements in both and performance when compared
with the traditional plasma cutting machines.
Powerful cutting performance
This machine is economical and practical since it can cut
metals by using compressed air as the plasma gas source.
The cutting speed is increased by 1.8 times when compared
with oxy-acetylene cutting.
It can cut steel, stainless steel, copper, cast iron and
aluminium conveniently and quickly.
It has an easy start ignition mode, and a post-flow cooling
function is available.
Its simple operation and high cutting speed, gives excellent
cut quality.
Both contact and non-contact mode is available for
successful arc ignition.
With PWM technology and high power IGBT components, it
inverts the DC voltage, which is rectified from 50Hz/60Hz
input AC voltage, to 30K~100KHz AC high voltage. Then the
voltage is dropped and rectified to output the high power
DC power supply for cutting.
The machine adopts switching power supply inverter
technology, greatly reducing the volume and weight of the
plasma cutter, and obviously enhancing the power
efficiency. The switching frequency is beyond audio range,
which almost eliminates the noise pollution.
High consistency and stable performance
Generally speaking, for a cutting machine with analogue
circuit control, the performance characteristics are
determined by the parameters of various components.
Cutting performance of the machines differ as a result of the
inconsistent parameters of the components, so even for the
cutting machines of the same brand, their parameters often
differ from each other. In addition, cutting performance of
the machine may change, since parameters of the
components may vary according to the environment such
as temperature and humidity, etc.
One of the characteristics of digital control is that it is not
sensitive to the change of parameters;the performance of
cutting machine will not be affected by the change of the
parameters of certain parts. Therefore, the consistency and
stability of digital control cutter is better than that of
traditional cutter.
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Technical data
MODEL
Rated input voltage (V)
CUT45P
230V AC±15%
Rated input frequency (Hz)
50/60
Rated input capacity (KVA)
5.1
Recommended supply fuse (A)
20
Compressed air requirement
No load voltage
Cutting current (A)
Rated output voltage (V)
Rated duty cycle (%)
0.45Mpa; 170L/Min.
280V DC
20-45
98
45A @ 35%
Efficiency (%)
85
Power factor
0.99
Insulation class
F
Protection class
IP21S
Arc ignition
Without HF
Maximum cutting thickness (mm)
19
Weight (kg)
9.2
Overall size (mm) (L×W×H) without handle
439*165*328
Tested at the environment temperature of 400 C
Product design may vary due to customer requirements.
Cutting speed guide - Quality cut
12 mm at 500 mm/min
19 mm at 250 mm/min
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Controls
PANEL LAYOUT
FRONT
REAR
1
AIR PRESSURE GUAGE
5
MAINS INPUT CABLE
2
WORK RETURN CONNECTOR
6
MAINS ON/OFF SWITCH
3
TORCH CONNECTOR
7
AIR INLET CONNECTION
4
CURRENT CONTROL KNOB
7
Front panel of CUT45P
No.
Symbol
Function
1
Power indicator: It illuminates when the machine is powered on, and it flashes
after arc is successfully ignited.
2
Overheating indicator: It illuminates when the working temperature of the IGBT is
too high. When in this state, the machine stops working.
3
Torch protection indicator: It illuminates when the consumable parts of the
machine are incorrectly fitted or the torch head is shorted. When in this state, the
machine stops working.
4
2T indicator: It illuminates when the machine is in 2T status.
5
4T indicator: It illuminates when the machine is in 4T status.
6
Gas-check indicator: It illuminates when the machine is in gas-check status. At
this moment, the machine cannot cut.
7
Metal mesh cutting indicator: The machine can cut metal mesh when this indicator
illuminates.
8
The machine is under normal cutting status when neither of the indicators
illuminates.
5
Installation
Unpacking
Check the packaging for any signs of damage.
Carefully remove the machine and retain the packaging until
the installation is complete.
Connection of cutting torch
Connect the central connection plug on the cutting torch to
the central connection socket of the power supply, and
tighten It clockwise to avoid gas leakage.
Location
The machine should be located in a suitable position and
environment. Care should be taken to avoid moisture, dust,
steam, oil or corrosive gases
Place on a secure level surface and ensure that there is
adequate clearance around the machine to ensure natural
airflow.
Input connection
Before connecting the machine you should ensure that the
correct supply is available. Details of the machine
requirements can be found on the data plate of the machine
or in the technical parameters shown in the manual.
The equipment should be connected by a suitably qualified
competent person. Always ensure the equipment has a
proper grounding.
Never connect the machine to the mains supply with the
panels removed.
Connection of work cable
Installation of the cutting torch
1)
Screw the end of the electrode with screw thread into
the torch head, and tighten it.
2)
Insert the other end of the electrode into the
distributor.
3)
Connect the nozzle with the electrode and distributor.
4)
Connect the protective sleeve with the nozzle, screw
it into the torch head, and tighten it.
Note: Screw the electrode into the torch with an inner
hexagon spanner, and tighten it. Otherwise, the inner thread
of the electrode will be burned.
Insert the quick plug on the work cable into the quick socket
at the bottom of the front panel of the machine, and tighten
it clockwise. Clamp the workpiece with the work clamp at
the other end of the earth cable.
9
Operation of the reducer valve
current or inner temperature exceeds the set standard, the
machine will stop automatically. However, excessive use
(e.g. too high voltage) of machine may also damage the
machine:
Embedded filter reducer
The embedded filter reducer is correctly set when leaving
factory, and users do not need to set it themselves in
general.
If users need to set the embedded filter reducer, the machine
cover should be opened as shown in the above figure.
Ensure the mains supply is disconnected whilst
removing the cover.
Reconnect the mains supply but take care to avoid any
contact with live electrical components.
Switch on the machine.
Start the gas flow
Lift the pressure control knob upward.
Adjust the gas pressure to the desired value by rotating the
knob (rotate to “+” direction to increase gas pressure; rotate
to “-” direction to reduce gas pressure).
Press down the pressure control knob to lock the adjusting
knob.
Any water will be drained automatically via the auto-drain
function in the embedded filter reducer.
Ensure the mains supply is disconnected whilst
replacing the cover.
Over current / over voltage / overheating protection
circuit
An over current / over voltage / overheating protection circuit
is installed in this machine. When the mains voltage, output
10
Operation
Before starting any cutting activity ensure that you have
suitable eye protection and protective clothing. Also take
the necessary steps to protect any persons within the
area.
Check that all connections have been made as shown above
Check the following before starting the machine.
1)
Check if the machine is reliably grounded according
to the relevant standard.
2)
Check that there are no bad contacts.
3)
Check if the power cord is connected to the correct
input voltage.
3)
It is recommended to initiate the cutting from the
edge of workpiece, unless penetration is needed.
4)
Ensure spatter comes from the bottom of workpiece
while cutting. If spatter comes upward from the top of
workpiece, it indicates that the workpiece has not been fully
cut through. This could be due to not enough power or the
cutting torch is moved too fast.
5)
For cutting a round workpiece or to meet precise
cutting requirement, a stencil board or other tools are
needed.
7)
It is recommended to pull the cutting torch while
cutting.
Operation
8)
Keep the nozzle of cutting torch upright over the
workpiece, and check if the arc is moving with the cutting
line. Do not bend the cable too much, step on or press upon
the cable to avoid restricting the air flow. The cutting torch
may be burned if the air flow is too low. Keep the cutting
cable away from sharp edges.
1)
Turn on the power switch on the back panel of the
machine, and the power LED is on.
9)
When the workpiece is nearly cut off, slow down the
cutting speed and release the torch trigger to stop cutting.
2)
Select the working mode and function. There are two
working modes available on the machine panel: 2T and 4T.
There are two functions available: normal cutting and metal
mesh cutting. The electrode and nozzle wear is increased in
metal mesh cutting.
10) Maintain the torch consumables frequently to prolong
the life
4)
Check if the connecting cables and gas hoses are in
good condition and are not twisted.
6) Always ensure the correct consumables are fitted in the
torch. Incorrect items may cause damage to the torch or
machine
3)
Set cutting current according to the thickness of
workpiece.
4) Bring the copper nozzle of the cutting torch at a distance
of about 2mm between the copper nozzle of the torch and
the workpiece.), and then push the torch trigger. After the
arc is ignited and cutting starts.
For welder training please visit our Academy website at
www.wilkinson-welding-academy.com
5) It is recommended that a torch of maximum length of 4
metres is used. If the torch cable is too long, the
performance of this cutting machine such as arc ignition
will possibly be affected due to the fact that the inner
resistance of the cable will reduce the output voltage.
Notes for cutting operation
1)
Do not touch the hot workpiece with bare hands to
avoid burning.
2)
It is recommended not to ignite the arc in the air if not
necessary, for it will shorten the lifespan of the electrode and
nozzle of the torch.
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6
Maintenance and troubleshooting
The following operation requires sufficient professional
knowledge on electric aspects and comprehensive
safety knowledge. Make sure the input cable of the
machine is disconnected from the electricity supply and
Troubleshooting
Before arc cutting machines are dispatched from the factory,
they have already been checked thoroughly. The machine
should not be tampered with or altered.
wait for 5 minutes before removing the machine covers.
In order to guarantee that the arc welding machine works
efficiently and in safety, it must be maintained regularly.
Operators should understand the maintenance methods and
means of arc welding machine operation. This guide should
enable customers to carry on simple examination and
safeguarding by oneself, try to reduce the fault rate and
repair times of the arc welding machine, so as to lengthen
Maintenance must be carried out carefully. If any wire
becomes loose or is misplaced, it maybe potential danger to
user!
Only professional maintenance personnel should repair the
machine!
Ensure the power is disconnected before working on the
machine. Always wait 5 minutes after power switch off
before opening the case.
service life of arc welding machine
Period
Daily
examination
Monthly
examination
Yearly
examination
Maintenance item
Carry out a full visual inspection. Check
for any damage to the machine, leads,
cables and connections. Replace where
necessary.
Switch on the machine and check for any
warning Led’s and general operation
Using the dry compressed air to clean the
inside of arc welding machine. Especially
check for build up of dust / debris on
intake grills, main voltage transformer,
inductance, IGBT modules, the fast
recover diode and PCB, etc. Take care
when blowing electronic components and
do not dislodge any wiring connections
Check the security of output connections
and plugs. Replace if signs of overheating.
Carry out an annual service. Check earth
continuity and insulation resistance of the
machine at the relevant points.
PLEASE NOTE THIS WORK SHOULD
BE CARRIED OUT BY A TRAINED
COMPETENT PERSON.
Malfunction
Cause and solution
Turn on the machine, the
power indicator illuminates,
The machine crashes: Shut
the control PCB keys do not
down the machine, and
function, and there is no
restart it.
response when pushing the
torch trigger.
Turn on the machine, the
power indicator illuminates,
the control PCB keys work
normally, but there is no
response when pushing the
torch trigger.
1) The LED1 on the main
board is on: The control
PCB is damaged.
2) The LED1 on the main
board is off: Check the torch
trigger and torch trigger
wire.
Turn on the machine, the
power indicator illuminates,
and the fan works. When
pushing the torch trigger, the
solenoid valve functions, but
there is no HF discharge.
The arc ignition part fails:
1) T h e i n n e r e l e c t ro d e
distance of the discharge
nozzle is too long.
2) There is leakage of the
HF capacitor 102/10KV.
3) The relay is damaged.
4) The input voltage is too
low.
Arc can not be ignited.
The air pressure is too high
or too low.
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7
Electrical schematic
13
8
Parts list
Cut 45P - (JP-45P)
14
No.
Part no
Description
No.
Part no
Description
1
10004949
Mains switch
20
10048680
Rear panel
2
10048390
Filter
21
10041723
Gas connection
3
10048683
Mid section plate
22
10041446
Fan
4
10041724
Handle
23
10048677
Heatsink
5
10048647
Control PCB
24
10007251
IGBT
6
10048679
Front panel
25
10048675
Heatsink
7
10048684
Cover
26
10048628
Thermal switch
8
10048681
Display panel
27
10037075
Insulating strip
9
10007295
Pressure guage
28
10050319
Main PCB
10
10041712
Jasic ident
29
10050326
Insulation
11
10037152
Quick connector socket
30
10037028
Support
12
10043926
Blanking plate
31
10048706
Base plate
13
10048633
Central connector
32
10006256
Rectifier
14
10050205
PFC inductance
33
10043394
Diode
15
10048682
Base panel
34
10050257
Heatsink
16
10048661
Bracket
35
10029693
IGBT
17
10048389
Solenoid valve
36
10006646
Diode
18
10050312
EMC board
37
10050258
Heatsink
19
10041861
Quick coupling
38
10048678
Fan cover
15
JP-45P AIR PLASMA CUTTING MACHINE
Order code ! JP-45P
© Wilkinson Star Limited
Issue 1 November 2014
Product is subject to change without notice
xvi
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