wilkinsonstar.com
Plasma 25C
Air Plasma Cutting machine
Order code ! JP-25C
OPERATOR MANUAL
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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
1
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
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.
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.
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 r e g u l ar ma i n t e n an c e in accordanc e 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
Wear approved safety glasses with side shields under your
helmet.
Never use broken or faulty welding helmets.
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.
Wear suitable protective flame resistant clothing.
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.
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.
Protections and coverings may be removed for maintenance
and controls only by qualified personnel, after first
disconnecting the power supply cable.
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
Avoid causing fires due to sparks and hot waste or molten
metal
Ensure that appropriate fire safety devices are available near
the cutting / welding area.
Remove all flammable and combustible materials from the
cutting / welding zone and surrounding areas
Do not cut/weld fuel and lubricant containers, even if empty.
These must be carefully cleaned before they can be cut/
welded.
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.
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.
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.
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.
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
4
Product Overview
2
CUT25 is a plasma cutting machine model developed from
the original CUT series plasma cutting machines. It inherits
the mature and stable inverter technology of CUT series:
With PWM technology and high-power MOSFET switching
devices, it converts the DC voltage, which is rectified from
50Hz/60Hz input AC voltage, to 100KHz AC high voltage.
Then, the voltage is dropped and rectified, providing a highpower DC cutting is output.
The CUT series uses a non-HF arc ignition with pilot arc.
This reduce EMI emissions during the arc start. Therefore,
non-HF arc ignition with pilot arc should be used when
higher requirement on electromagnetic environment is
needed, e.g. in CNC cutting.The CUT25 is designed for
such high-end application. In addition, CUT25 adopts a
single PCB structure. An external air source connection is
unnecessary, since it is equipped with an internal air
compressor. Both contact and non-contact mode is
available for successful arc ignition, and the 3s pilot arc
time auto control inside the machine effectively reduces the
wear of torch nozzle. The machine has such advantages as
simple internal structure, small size, easy to ignite arc and
convenient to use.
Product functions
•
Internal air compressor is equipped, and external air
source connection is unnecessary.
•
Fixed current output
Product performance characteristics
Economical and practical 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 thin steel plate conveniently and quickly.
•
Easy to ignite arc, pre-flow and post-flow function
available.
•
It has a wide range of use, especially for cutting stainless
steel, copper, cast iron and aluminum, etc.
•
Simple operation
•
Excellent cut quality
•
Both contact and non-contact mode is available for
successful arc ignition.
5
Technical data
3
Tested at the environment temperature of 400 C
Product design may vary due to customer requirements.
6
MODEL
CUT25
Rated input voltage (V)
230V AC±10%
Rated input frequency (Hz)
50/60
Rated input capacity (KVA)
3.5
No-load voltage (V)
230±15
Cutting current (A)
25
Rated output voltage (V)
90
Rated duty cycle (%)
35
Efficiency (%)
85
Power factor
0.7
Insulation class
F
Protection class
IP21S
Arc ignition
Contact/non-contact ignition
Maximum cutting thickness (mm)
8
Weight (kg)
18
Overall size (mm) (L×W×H)
430×199×335
Cutting speed guide
Cutting speed {m/mm)
7
Cutting thickness (mm)
1234568
Mild steel
7
1.4
0.3
0.2
Galvanised
7
1.4
0.3
0.2
Stainless steel
7
1.4
0.3
0.2
Aluminium
5
1.2
0.2
Brass
0.7
0.2
Copper
0.7
0.2
Controls
4
1.! ! Input cable
2.! ! Work return cable socket
3.! ! Torch connection.
4! ! Mains switch-
5! ! Power led - It indicates that the input power is normal.
6.! ! Overheat led.- This indicator will turn on when the machine is overheated due to overload or over
! ! current and the output has been disabled. Leave the machine on to allow the internal components
! ! to cool. When the indicator turns off, normal operation is again possible.
7, 8, 9! Warning indicator legends.
! ! ! ! Front ! ! ! ! ! ! ! ! ! ! Rear
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Installation
5
Unpacking
Check the packaging for any signs of damage.
Carefully remove the machine and retain the packaging until
the installation is complete.
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
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.
Connection of cutting torch
The cutting torch of this machine is fixed into the machine,
and users do not need to connect it for themselves.
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.
9
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.
4)! Check if the connecting cables and gas hoses are in
good condition and are not twisted.
Operation
1)! Turn on the power switch on the back panel of the
machine, and the power LED is on.
2)! Press the control button on the cutting torch: The
solenoid valve will operate, the air compressor starts, and
there is plasma arc output from the nozzle of the cutting
torch.
3)! Non-contact arc ignition: Keep a distance of about
1~2mm between the copper nozzle of the cutting torch and
the workpiece, and then press the control button on the
cutting torch. After arc is ignited, cutting can be carried out.%
Contact arc ignition: Bring the copper nozzle of the cutting
torch into contact with the workpiece, and then press the
control button on the cutting torch. After arc is ignited,
decline the cutting torch to the position about 1~2mm above
the workpiece. And then, cutting can be carried out.
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
be possibly 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.
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)! Keep the nozzle slightly touching the workpiece when
starting or keep a short distance between the nozzle and
workpiece. If the torch is pressed against the workpiece, the
nozzle may stick to the workpiece, and smooth cutting is
unavailable.
6)! 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.
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.
9)! When the workpiece is nearly cut off, slow down the
cutting speed and release the torch trigger to stop cutting.
10) Maintain the torch consumables frequently to prolong the
life
11) Always ensure the correct consumables are fitted in the
torch. Incorrect items may cause damage to the torch or
machine
For welder training please visit our Academy website at
www.wilkinson-welding-academy.com
10
Maintenance and troubleshooting
6
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
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
service life of arc welding machine
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.
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.
11
Period
Maintenance item
Daily
examination
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
Monthly
examination
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, Mosfet 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.
Yearly
examination
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
phenomena
Cause and solution
Turn on the machine, the
power LED is on, but the fan
does not w or k, an d t he
co ntr o l b u tto n d o es n ot
function.
Over voltage protection occurs: Check if
the mains voltage is identical with the
working voltage of the machine.
Turn on the machine, the
power LED is on, and the fan
works. When pressing the
control button of the cutting
torch, the solenoid valve
functions, and the red LED
inside the machine is on or
the yellow LED on the front
panel is on.
Over current protection occurs:
1) The MOSFET on the top PCB is
damaged. (The drive module is
damaged.)
2) The control module is damaged.
Overheating protection occurs: It is
unnecessary to shut down the machine,
and it will recover after a few minutes.
Turn on the machine, the
power LED is on, and the fan
works. When pressing the
control button of the cutting
torch, the solenoid valve
functions, the red LED inside
the machine is off, but there
is no arc ignition.
The arc ignition part fails:
1) The a ir compresso r inside the
machine is damaged or not well
connected.
2) Check the electrode and nozzle of
the cutting torch.
3) T h e arc m a i n t a ining re l a y is
damaged.
Turn on the machine, the
power LED is on, and the fan
works. When pressing the
control button of the cutting
torch,
1) The protective sleeve of the cutting
torch head is not well installed.
2) T h e c u t t in g to rc h tr i g g er is
damaged.
Electrical schematic
7
12
Parts list
8
Cut 25 - (JP-25C)
13
14
No.
Part no
Description
No.
Part no
Description
1
10027491
Handle
13
10021916
Spring Line button
2
10046083
Machine Cover
14
10043261
Air compressor
3
10046082
Central insulation board
15
10046113
Shock absorber
4
10001873
Fan1610016489
Foot510046115
Clamp
17
10046058
Bottom panel
6
10020602
EMC board
18
10007278
Solenoid valve
7
10046084
Insulation Board
19
10044457
Filter
8
10044437
Main Board
20
10046076
Gas elbow
9
10022874
Steel stud bolts
21
10007331
Fan grill
10
10046056
Front Panel
22
10004886
Cable gland
11
10006368
Indicator lamp
23
10004946
Mains switch
12
10004637
Quick socket
JP-25C AIR PLASMA CUTTING MACHINE
Order code ! JP-25C
© Wilkinson Star Limited
Issue 1 January 2014
Product is subject to change without notice
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