Operator Manual
www.jasic.co.uk
Plasma Cut Series
| Plasma Cut 60 (JP-60) | Plasma Cut 80 (JP-80) |
| Plasma Cut 100 (JP-100) |
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
i
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 a r maintenance in accordance w ith t h e
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 or cut 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
sy stem . Diffic ulti es may a rise in a ssuring c lass 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,
co n ne c t i on re s tr i ct i o n s o r m a x im u m imp e d a nc e
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
The CUT series are inverter cutting machines using
advanced inverter technology.
They are products with stable performance.
With PWM technology and high power component
MOSFETs (or IGBTs), 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 required for cutting. The machine
uses a switching power supply inverter technology,
greatly reducing the volume and weight of the
cutter, and obviously enhancing the power
conversion efficiency by 30%.
Features of CUT series
Economic and practical using compressed air as
the plasma gas source.
They can cut thick steel plate conveniently and
quickly.
It has an easy to ignite arc, and post-flow function
is available.
It has a wide range of uses, especially for cutting
stainless steel, copper, cast iron and aluminium,
etc.
With simple operation and high cutting speed,
smooth cutting surface can be obtained, and
cleaning is often unnecessary.
The Cut 60 and Cut 80 use a non HF arc ignition
mode.The Cut 100 uses HF ignition.
Application
Economic and practical using compressed air as
the plasma gas source. The plasma cutter has a
wide range of uses, especially for cutting metal
plates of carbon steel, alloy steel, stainless steel,
galvanised steel, copper and aluminium, etc.
It can be widely used in various industries involving
metal cutting such as boiler and pressure vessel
manufacturing, chemical container manufacturing,
power plant installation and construction industry,
metallurgy, chemical engineering, aerospace,
automobile and engineering vehicles manufacturing
and construction, etc.
5
Technical data
3
6
Model
CUT60
CUT80
Cut 100
Rated input voltage
AC400V±15%(3 phases) , 50/60Hz
Rated output
60A/104V
80A/112V
100A/120V
Rated input capacity (KVA)
71214.3
Rated input current(A)
152221.7
Cutting current range (A)
20-60
20-80
20-100
No-load voltage (V)
290
290
315
Duty cycle Imax (40℃)
40%
40%
60%
Efficiency (%)8585
90
Power factor
0.7
0.7
0.93
Protection class
IP21S
IP21S
IP 21
Insulation classFF
F
Overall size (mm) ( L×W×H )
540×250×380
540×250×380
555×238×415
Weight (kg)
14.5
15
23
Ignition method
Non HF
Non HF
HF
Controls
4
PANEL LAYOUT
! ! ! ! FRONT ! ! ! ! ! ! ! REAR
7
1
2 3
4
5
6
7
1
CONTROL PANEL
5
FAN2WORK RETURN SOCKET
6
MAINS SWITCH
3
TORCH CONNECTION SOCKET
7
MAINS CABLE
4
AIR REGULATOR
1
DIGITAL METER
4
CUTTING CURRENT ADJUSTER
2
2T/4T (AUTOMATIC OPERATION)
5
OVER TEMPERATURE ALARM
3
PURGE - RUN SWITCH
6
MAINS INDICATOR
1
DIGITAL METER
4
CURRENT ADJUSTMENT
2
2T/4T (AUTOMATION)
5
ALARM INDICATOR
3
PURGE - RUN SWITCH
6
MAINS INDICATOR
CONTROL PANEL
AIR REGULATOR AND GUAGE
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 (at
least 20cm) 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
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.
9
Connection of the air supply
The unit should be connected to a suitable, clean
and dry air supply. If there is oil or water in the air a
suitable three stage filter should be connected.
If the quality of air is poor, the cutting speed will
decrease, the cutting quality will lower, the cutting
thickness will reduce, and the service life of wearing
parts will be shortened. In order to obtain the
optimal performance, the maximum particle size of
air should be 0.1μm, the maximum concentration of
air should be 0.1mg/m3, the maximum dew point of
air should be -40℃, the maximum oil concentration
should be 0.1mg/m3.
The air supply pressure should not exceed 8 bar
and normal cutting pressure will be around 6 bar.
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.
Introduction of the cutting torch
The plasma cutter CUT100 uses the P150 plasma
cutting torch for its standard configuration.
The plasma cutters CUT60 and Cut 80 use the
PT100 plasma cutting torch for its standard
configuration
The frequency of replacing the wearing parts of the
cutting torch depends on the aspects below:
The thickness of the metal to be cut.
The average cutting length.
Whether it is used for automatic cutting or it is used
for handheld cutting.
Air quality (whether there is oil, water or other
contaminants)
Whether it is used to punch on the metal or it is
used to cut from the metal edge.
Whether the distance between the cutting torch and
the workpiece is appropriate when cutting with
wearing parts without protective sleeves.
Whether the cutting height is appropriate.
The quality of the wearing parts used.
Under normal circumstances, the nozzle will wear
out first in hand-held cutting.
The general rule is: The wearing parts will expire
after the practical “arc discharge” time reaches 1~2
hours when it is used for handheld cutting. The
specific time depends on the above factors. The
wearing parts will expire after the practical “arc
discharge” time reaches 3~5 hours when it is used
for automatic cutting. Selecting wearing parts
WARNING: Plasma arc may cause burns or scalds
during the instantaneous start of cutting torch.
The Plasma arc will be produced at the moment
after the cutting torch is started, so make sure that
the power is cut off before replacing the wearing
parts.
10
Air inlet
Pressure adjuster
Pressure gauge
PT-100 Plasma Cutting Torch
Current: 30-120 Amps • Duty Cycle: 120 Amps @ 60 % • Gas: Air /N2 • Gas Pressure: 70-80 psi (4.6-5.0 Bar) • Gas Flow: 420scfh (200 lpm)
Item No Description
09721/LG 6mtr Cable Central Connection
TORCH PACKAGE
MAIN CONSUMABLES & SPARE PARTS
Item Part Description Pack
No No Qty
1•09700 PT100 Torch Head 1
1A • 51190.41 'O' Ring 5
2•09705 Handle c/w Switch 1
3•09700.48 Cooling Tube 1
4•52556 Electrode - Back Striking 5
5 60025 Gas Distributor 30-70A 1
6•60026 Gas Distributor 80-120A 1
7 51245.09 Tip Contact Cutting 0.9mm 30-40A Back Striking 10
8 51246.10 Tip Cutting 1.0mm 40-50A Back Striking 10
51246.11 Tip Cutting 1.1mm 50-60A Back Striking 10
51246.12 Tip Cutting 1.2mm 60-70A Back Striking 10
9 51248.14 Tip Cutting 1.4mm 80-90A Back Striking 10
51248.15 Tip Cutting 1.5mm 100-110A Back Striking 10
• 51248.16 Tip Cutting 1.6mm 110-120A Back Striking 10
10 60500 Retaining Cap 30-70A 1
11 • 60501 Retaining Cap 80-120A 1
12 • 60444 Double Pointed Spacer (For use with items 8 & 9 Only) 1
13 51864 Circle Cutting Attachment (Not Illustrated) 1
•
Denotes Standard Set Up
1A
2
3
5
6
8
9
4
7
11
12
10
1
P150LT COMPATIBLE CEBORA
Gas: Single • Air Flow: 220 Litres Per Min • Rating: 150 Amp @ 60% Duty Cycle • Cutting Capacity: 35mm Most Materials
TORCH PACKAGES
Item No
Description List Price Each £
C1576LT Hand Torch 6mt Central Fitting 670.55
C1578LT Hand Torch 12mt Central Fitting 792.15
C1577 Machine Torch 6mt Central Fitting 709.34
C1579 Machine Torch 12mt Central Fitting 831.47
MAIN CONSUMABLES
Item
Part Description Pack List Price
No No
Qty
Each £
16 C1007 Spring Holder Protection Nut 1 5.96
17 C1008 Spacer Springs for C1007 5 1.51
18 C1009 Gouging Spacer 1 6.95
19 C1010 Spacer for Contact Cutting - Hand 1 6.69
Use with items 8, 15 & 24
C1011 Spacer for Contact Cutting - Hand 1 9.53
Use with items 10, 15 & 24
C1394 Spacer for Contact Cutting - Hand 1 9.45
Use with items 10, 15 & 24
20 C1012 Spacer - Machine 1 8.36
Use with items 8, 15 & 24
C1013 Spacer - Machine 1 8.36
Use with items 10, 15 & 24
21 C1014 Shield Cup - Hand Max 50 Amp 1 7.23
22 C1015 Spacer for Contact Cutting - Hand 1 7.73
23 C1020 Spacer for Extended Tips High Amp 1 10.99
24 C1016 Locking Nut 1 4.59
25 C1004 Spacer c/w Springs 1 9.04
26 C1005 Spacer Springs 5 0.66
27 C1386 Stand Off Spring 5 1.34
28 C1408 Double Pointed Spacer 1 10.39
29 C1409 Crown Spacer 1 10.87
30 C1406 Gouging Spacer 1 9.45
31 C1509 Extractor for Swirl Ring 1 9.62
32 09706 Handle c/w Micro Switch - Hand Torch 1
33 07301.20 Switch 1 14.75
34 C3055623 Handle Machine Torch 1 32.77
35 C3045012 Wrench for Electrode 1 6.23
36 C970 6mt Cable Assy Hand Torch 1 268.26
C980 12mt Cable Assy Hand Torch 1 425.56
C04320 6mt Cable Assy Machine Torch 1 268.00
C04330 12mt Cable Assy Machine Torch 1 425.00
37 C534-JP Central Connector 1 39.33
MAIN CONSUMABLES
Item
Part Description Pack List Price
No No
Qty
Each £
1 02001 Torch Head 1 224.12
2 C1354 Torch Head - Macine Torch 1 268.33
3 C3160067 'O' Ring - Torch Head 10 0.53
4 C1378 Diffuser 1 4.50
5 C1017 Front Insulator - Vespel 1 32.71
6 C1376 Electrode Hafnium 5 3.15
7 C1377 Swirl Ring Vespel 1 19.66
8 C1371 Cutting Tip 1.1 10 2.45
C1372 Cutting Tip 1.35 10 2.45
C1373 Cutting Tip 1.6 10 2.45
C1374 Cutting Tip 1.8 10 2.45
C1375 Gouging Tip 3.0 10 2.45
9 C1389 Nozzle Retaining Cap 1 24.29
10 C1390 Contact Cutting Tip 1.35 10 3.15
C1391 Contact Cutting Tip 1.6 10 3.15
C1392 Contact Cutting Tip 1.8 10 3.15
11 C1018 Extended Diffuser 1 6.55
12 C1517 Extended Electrode 5 7.02
13 C1369 Extended Contact Cutting Tip- 50 Amp 5 6.32
14 C1001 Extended Tip 1.35 - 90 Amp 5 6.32
C1002 Extended Tip 1.6 - 120 Amp 5 6.32
C1003 Extended Tip 1.8 - 150 Amp 5 6.32
15 C1393 Contact Nozzle Retaining Cap 1 30.74
C1006 Contact Nozzle Ret cap - Long Life 1 42.60
SECONDARY CONSUMABLES
37
19
29
30
28
27
25
18
26
17
16
15
9
13
14
12
11
4
3
5
1
6
7
8
10
35
31
36
32
36
34
2
3
5
23
22
24
21
20
© WILKINSON STAR LTD
33
Operation
6
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) Select the working mode and function.
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.
5) It is recommended that a torch of maximum length of 6
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.
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.
6)! It is recommended to pull the cutting torch while
cutting.
7)! 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.
8)! When the workpiece is nearly cut off, slow down the
cutting speed and release the torch trigger to stop cutting.
9)! Maintain the torch consumables frequently to prolong
the life
10)! Always ensure the correct consumables are fitted in
the torch. Incorrect items may cause damage to the torch or
machine
Cutting parameters tables
Cutting speed (m/min) when cutting current is 40A
13
Cutting speed (m/min) when cutting current is 60A
Cutting speed (m/min) when cutting current is 100A
For welder training please visit our Academy website at
www.wilkinson-welding-academy.com
Precautions
1)! Make sure the place to install the machine can bear
the weight of the cutting machine.
2)! Do not install the machine at places where water may
splash, such as near water pipes.
3)! Cutting should be carried out in dry environment with
humidity of 90% or less.
4)! The temperature of the working environment should
be between -10℃ and 40℃.
5)! Avoid cutting in the open air unless sheltered from
sunlight and rain. Keep it dry at all times and do not place it
on wet ground or in puddles.
6)! Avoid cutting in dusty area or environment with
corrosive chemical gas.
7)! Do not carry out cutting with the cutting machine
placed on a platform with a pitch greater than 15°.
Overcurrent/overvoltage/overheating protection circuit is
installed in this machine. When the mains voltage, output
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, so please note:
Good ventilation&
This cutting machine can create powerful cutting current and
has strict cooling requirements that cannot be met with
natural ventilation. Therefore the built-in fan is very important
in enabling the machine to work stable with effective cooling.
The operator should make sure that the louvers be
uncovered and unblocked. The minimum distance between
the machine and nearby objects should be 30cm.
Overvoltage&
This machine is of automatic mains voltage compensation,
which ensures that the cutting current varies within the given
range. In case that the input mains voltage exceeds the
tolerance value, it would possibly damage the machine. The
operator should understand this circumstance fully and
adopt relevant precautions.
Overload.&
Remember to observe the max load current at any time (refer
to the corresponding duty cycle). Make sure that the cutting
current should not exceed the maximum load current.
Overload could obviously shorten the machine's lifespan, or
even damage the machine.&
A sudden halt may occur with the yellow LED on the front
panel on while the machine is of over-load status. Under this
circumstance, it is unnecessary to restart the machine. Keep
the built-in fan working to lower the temperature inside the
machine. Cutting can be continued after the inner
temperature falls into the standard range and the yellow LED
is off.
14
Maintenance and troubleshooting
7
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.
15
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, 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.
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.
Fault symptom
Possible cause
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Parts List
8
Cut 60 /80
16
!
17
No.
Part number
Description
No.
Part number
Description
1
10052709
Digital display board
19
10035518
Relief valve
2
10004944
Transform switch
20
10046002
IGBT
3
10040930
Knob
21
10004887
Cable clip
4
10047358
Front panel blinds
22
10021936
Power switch
5
10004637
Quick socket
23
10049874
Column
6
10051490
Front panel
24
10006256
Rectifier
7
10053206
Plasma center socket & wires
25
10049894
heat sink
8
10046932
Left plastic
26
10043995
EMC board
9
10049887
Base plate
27
10049741
rectifier bridge & wires
10
10046933
Right plastic
28
10052876
Control board
11
10028470
Gas connector
29
10046896
Handle
12
10048389
Solenoid value
30
10052518
Arc striking board
13
10049735
Reactor
31
10047357
trimming
10049829
CUT60 main transformer
10052906
CUT60 Rectifier board
14
10049736
CUT80 main transformer
32
10053198
CUT80 Rectifier board
15
10049893
Radiator
33
10051645
middle clapboard
10052907
CUT60 inverter board
10053196
CUT60 filter board
16
10052907
CUT80 inverter board
34
10053581
CUT80 filter board
Cut 100
18
No.
Part number
Description
No.
Part number
Description
1
10046896
Handle
16
10048690
Arc striking board
2
10046712
Digital display
17
10035518
Relief valve
3
10004917
Knob
18
10021936
Power switch
4
10004944
2T / 4T switch
19
10004886
Cable clip
5
10047339
Front grill
20
10022274
Switch Angle support
6
10004637
Quick connector
21
10043995
EMC board
7
10004622
Torch connector
22
10049050
Power transfer board
8
10006525
AC contactor
23
10049048
Arc starting control board
9
10035516
Reactor
24
10049105
Silicon bridge and wire
10
10046491
Solenoid valve
25
10052794
Power transformer and wire
11
10049042
Rectifier board
26
10049046
Control board
12
10006636
Fast Recovery Diode
27
10005040
Resistor
13
10007246
IGBT
28
10035607
Main transformer
14
10049044
Inverter board
29
15
10001855
Fan & wires
30
!
CUT 60/80/100 AIR PLASMA CUTTING MACHINE
Order codes !JP-60, JP-80, JP-100
© Wilkinson Star Limited
Issue 1 June 2015
Product is subject to change without notice
xix
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