Unimig KUPJR55, CUT105, KUPJR105, CUT 55 Operating Manual

1

Please read and understand this instruction manual carefully
before the installation and operation of this equipment.

OPERATING MANUAL

KUPJR55

©

Welding Guns Of Australia PTY LTD 2013

YEARS Warranty

(Power Source)

2

2

WARRANTY

• 2 Years from date of purchase.

• Welding Guns of Australia Pty Ltd Ltd warranties all goods as specified by the manufacturer
of those goods.

• This Warranty does not cover freight or goods that have been interfered with.

• All goods in question must be repaired by an authorised repair agent as appointed by this
company.

• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.

• New product will not be supplied unless Welding Guns of Australia Pty Ltd has inspected
product returned for warranty and agree’s to replace product.

• Product will only be replaced if repair is not possible

• Please view full Warranty term and conditions supplied with machine or at
www.unimig.com.au/warranty.asp or at the back of this manual.

Thank you for your purchase of your UNIMIG Plasma Cutting Machine.

We are proud of our range of plasma cutting and welding equipment that has a proven track record of
innovation, performance and reliability. Our product range represents the latest developments in Inverter
technology put together by our professional team of highly skilled engineers. The expertise gained from
our long involvement with inverter technology has proven to be invaluable towards the evolution and future
development of our equipment range. This experience gives us the inside knowledge on what the arc
characteristics, performance and interface between man and machine should be. Within our team are
specialist welders that have a proven history of welding knowledge and expertise, giving vital input towards
ensuring that our machines deliver control and performance to the utmost professional level.
We employ an expert team of professional sales, marketing and technical personnel that provide us with
market trends, market feedback and customer comments and requirements. Secondly they provide a
customer support service that is second to none, thus ensuring our customers have confidence that they
will be well satisfied both now and in the future.

UNIMIG welders and plasma cutters are manufactured to be compliant with - AS/NZ 60974-1,
guaranteeing you electrical safety and performance.

3

CONTENTS PAGE

Warranty 2

Safety - Pre Cautions 4-6

Air Plasma Cutting Technology 7

Technical Data, Product Information 8

Machine Layout & Descriptions 9

Set Up and Operating Procedure 10-12

Plasma Cutting Procedure & Techniques 13-15

T-100 & T-150 Plasma Torch Parts Breakdown 16-19

KUPJR55 Machine spare parts 20-21

Trouble Shooting 22

Warranty terms 23-25

4

SAFETY

IMPORTANT: BEFORE INSTALLING, OPERATING OR CARRYING OUT

MAINTENANCE ON THE PLASMA CUTTER, READ THE CONTENTS OF THIS
MANUAL CAREFULLY, WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL
USERS FOR THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.

PAY PARTICULAR ATTENTION TO THE SAFETY RULES.
THIS EQUIPMENT MUST BE USED SOLELY FOR PLASMA CUTTING.

Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe
burns. The plasma nozzle and work circuit is electrically live whenever the output is on.
The input power circuit and internal machine circuits are also live when power is on.
Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing.
Incorrectly installed or improperly grounded equipment is dangerous.

• Connect the primary input cable according to Australian and New Zealand standards and regulations.

• Disconnect power source before performing any service or repairs.

• Avoid all contact with live electrical parts of the welding circuit, torch nozzle and work piece with bare
hands. The operator must wear dry welding gloves while he/she performs the plasma cutting task.

• Isolate yourselves from both the earth and the work piece.

• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,
bare wiring is dangerous and can kill.

• Do not use damaged, under sized, or badly joined cables.

• Do not drape cables over your body.

• We recommend (RCD) safety switch is used with this equipment to detect any leakage of current to earth.

Fumes and gases are dangerous. Plasma cutting produces fumes and gases. Harmful
fumes and metallic powders are produced during the cutting operation. Metals which are
painted or coated or which contain mercury, zinc, lead and graphite may produce harmful
concentrations of toxic fumes during cutting. Breathing these fumes and gases can be

hazardous to your health.

• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes

• Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.

• In confined or heavy fume environments always wear an approved air-supplied respirator.
Cutting fumes and gases can displace air and lower the oxygen level causing injury or death.
Be sure the breathing air is safe.

• Do not cut in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc
can react with vapours to form highly toxic and irritating gases.

• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic
fumes when cuttung. Do not cut these materials unless the area is very well ventilated, and or wearing
an air supplied respirator.

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are
using.These MSDSs will give you the information regarding the kind and amount of fumes and gases that
may be dangerous to your health.

MACHINE OPERATING SAFETY

Plasma cutting equipment can be dangerous to both the operator and people in or near the surrounding
working area, if the equipment is not correctly operated. Equipment must only be used under the strict and
comprehensive observance of all relevant safety regulations. Read and understand this instruction manual
carefully before the installation and operation of this equipment.

5

Fire hazard. Plasma cutting on closed containers, such as tanks,drums, or pipes, can cause them to

explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns.
Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check
and be sure the area is safe before doing any cutting.

• The cutting sparks may cause fire, therefore remove any flammable materials well away from the working
area. Cover flammable materials and containers with approved covers if unable to be
moved from the welding area.

•Do not Plasma Cut closed containers such as tanks, drums, or pipes, unless they are
properly prepared according to the required Safety Standards to insure that flammable
or toxic vapors and substances are totally removed, these can cause an explosion even
though the vessel has been “cleaned”. Vent hollow castings or containers before heating,

cutting or welding. They may explode.

• Do not cut where the atmosphere may contain flammable dust, gas, or liquid vapours (such as petrol)

• Have a fire extinguisher nearby and know how to use it. Be alert that cutting sparks and hot materials

from cutting can easily go through small cracks and openings to adjacent areas. Be aware that cutting

on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

Gas Cylinders. Do not cut in the vicinity of pressurised gas cylinders or in the presence of
explosive dust, gases or fumes. Gas cylinders contain gas under high pressure. If damaged,
a cylinder can explode. Because gas cylinders are normally part of the welding process, be
sure to treat them carefully. CYLINDERS can explode if damaged.

• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames,

sparks, and arcs.

• Insure cylinders are held secure and upright to prevent tipping or falling over.

• Never allow the plasma nozzle or earth clamp to touch the gas cylinder, do not drape welding cables

over the cylinder.

• Never plasma cut on a pressurised gas cylinder, it will explode and kill you.

• Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.

Electronic magnetic fields. The magnetic fields created by the high currents generated by
plasma cutting may affect the operation of pacemakers and other vital electronic medical
equipment.

• Wearers of Pacemakers and other Implanted Medical Devices should keep away.

• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going

near any electric welding, cutting or heating operation.

Noise can damage hearing. Noise from some processes or equipment can damage hearing.
This machine does not directly produce noise exceeding 80dB. The plasma cutting/welding
procedure may produce noise levels beyond said limit; users must therefore implement all
precautions required by law. Wear approved ear protection if noise level is high.

Hot parts. Items being plasma cut generate and hold high heat and can cause severe burns.
Do not touch hot parts with bare hands. Allow a cooling period before working on the plasma
torch. Use insulated welding gloves and clothing to handle hot parts and prevent burns.

Arc rays: harmful to people’s eyes and skin. Arc rays from the plasma cutting process
produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.
Protect your eyes with welding masks or goggles fitted with filtered lenses, and protect your
body with appropriate safety garments. Protect others by installing adequate shields or
curtains.

• Always wear a helmet or goggles with correct shade of filter lens and suitable protective clothing including
welding gloves, appron, leg and foot protection whilst the plasma cutting operation is performed.

• Measures should be taken to protect people in or near the surrounding working area. Use protective
screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

6

CAUTION

1. Working Environment.

1.1 The environment in which this Plasma Cutter equipment is installed must be free of grinding dust,

corrosive chemicals, flammable gas or materials etc, and at no more than maximum of 80% humidity.

1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;
the temperature of working environment should be maintained within -10°C to +40°C.

1.3 Keep this equipment 30cm distant from the wall.

1.4 Ensure the working environment is well ventilated.

2. Safety Tips.

2.1 Ventilation

This equipment is small-sized, compact in structure, and of excellent performance in amperage output.
The fan is used to dissipate heat generated by this equipment during the welding operation.
Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between
this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is
of critical importance for the normal performance and service life of this equipment.

2.2

Thermal Overload protection.

Should the machine be used to an excessive level, or in high temperature environment, poorly
ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the
machine will cease to operate. Under this circumstance, leave the machine switched on to keep the
built-in fan working to bring down the temperature inside the equipment. The machine will be ready for
use again when the internal temperature reaches safe level.

2.3

Over-Voltage Supply

Regarding the power supply voltage range of the machine, please refer to “Main parameter” table.
This equipment is of automatic voltage compensation, which enables the maintaining of the voltage
range within the given range. In case that the voltage of input power supply amperage exceeds the
stipulated value, it is possible to cause damage to the components of this equipment. Please ensure
your primary power supply is correct.

2.4 Do not come into contact with the output terminals while the machine is in operation. An electric shock
may possibly occur.

MAINTENANCE

Exposure to extremely dusty, damp, or corrosive air is damaging to this plasma cutter. In order to prevent
any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and dry
compressed air of required pressure.

Please note that: lack of maintenance can result in the cancellation of the warranty; the warranty of this
plasma cuting equipment will be void if the machine has been modified, an attempt to take apart the
machine or open the factory-made sealing of the machine without the consent of an authorized
representative of the manufacturer.

TROUBLE SHOOTING

Caution: Only qualified technicians are authorized to undertake the repair of this Plasma cutter equipment.
For your safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed in this manual.

Note:

• Our equipment as described in this manual conforms to all applicable rules and regulations of the
‘LowVoltage Directive’ (European Council Directive 73/23/EEC) as set out and amended by Council
Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

• Our equipment as described in this manual conforms to all applicable rules and regulations of the
European Council Directive 89/336/EEC, (EMC Directive) and to the National legislation for he
enforcement of this Directive.

7

Plasma cutters work by passing an electric arc through a gas that is passing through a constricted opening. The gas
can be air, nitrogen, argon, oxygen. etc. The electric arc elevates the temperature of the gas to the point that it enters a
4th state of matter. We all are familiar with the first three: i.e., Solid, liquid, and gas. Scientists call this additional state
plasma. As the metal being cut is part of the circuit, the electrical conductivity of the plasma causes the arc to transfer to
the work. The restricted opening (nozzle) the gas passes through causes it to squeeze by at a high speed, like air passing
through a venturi in a carburettor. This high speed gas cuts through the molten metal.

Plasma cutting was invented as the result of trying to develop a better welding process. Many improvements then led to
making this technology what it is today. Plasma cutters provide the best combination of accuracy, speed, and afford ability
for producing a variety of flat metal shapes. They can cut much finer, and faster than oxy-acetylene torches.

How a plasma cutter works:

Basic plasma cutters use electricity to superheat air into plasma (the 4th state of matter), which is then blown through the
metal to be cut. Plasma cutters require a compressed air supply and AC power to operate.

Operation:

1. When the trigger is squeezed, DC current flows through the torch lead into the nozzle.

2. Next, compressed air flows through the torch head, through the air diffuser that spirals the air flow around the
electrode and through the hole of the cutting nozzle.

3. A fixed gap is established between the electrode and the nozzle. (The power supply increases voltage in order to
maintain a constant current through the joint.) Electrons arc across the gap, ionizing and super heating the air
creating a plasma stream.

4. Finally, the regulated DC current is switched so that it no longer flows to the nozzle but instead flows from the
electrode to the work piece. Current and airflow continue until cutting is stopped.

Notes:

The nozzle and electrode require periodic replacement. The electrode has an insert of tough high conductive material
such as hafnium and cerium. This insert erodes with use, also the nozzle orifice will erode with use. Quality of the air
used is paramount to longer life of electrodes and nozzles, in short clean dry air gives longer parts life, the cleaner and
dryer the better. We recommend use of a Plasma Air Filter.

What kinds of materials can the plasma cut?

Virtually any metal can be plasma cut including steel, stainless steel, aluminium, brass, copper, etc. Any thickness from
30 gauge through 30mm can be cut, depending on the power of the plasma cutter used.

How Does Plasma Cutting Compare to Oxy-fuel (gas) cutting?

Plasma cutting can be performed on any type of conductive metal - mild steel, aluminium and stainless are some
examples. With mild steel, operators will experience faster, thicker cuts than with alloys. Oxy-fuel cuts by burning, or
oxidizing the metal it is severing. It is therefore limited to steel and other ferrous metals which support the oxidizing
process. Metals like aluminium and stainless steel form an oxide that inhibits further oxidization, making conventional
oxy-fuel cutting impossible. Plasma cutting however does not rely on oxidation to work and thus it can cut aluminium,
stainless and any other conductive material. While different gasses can be used for plasma cutting, most people today
use compressed air for the plasma gas. In most shops, compressed air is readily available, and thus plasma does not
require fuel gas and compressed oxygen for operation. Plasma cutting is typically easier for the novice to master, and on
thinner materials, plasma cutting is much faster than oxy-fuel cutting. However, for heavy sections of steel (25mm and
greater), oxy-fuel is still preferred since oxy-fuel is typically faster and, for heavier plate applications high powered plasma
machines are required for plasma cutting applications.

What are the limitations to Plasma Cutting? Where is Oxyfuel preferred?

The plasma cutting machines are typically more expensive than oxy/acetylene. Also, oxy/acetylene does not require
access to electrical power or compressed air which may make it a more convenient method for some users. Oxyfuel can
generally cut thicker sections (>25mm) of steel more quickly than plasma

Electrode

Air Diffuser

Nozzle

Plasma Stream

Electrode Insert

Shield Cup

AIR PLASMA CUTTING TECHNOLOGY

8

R

a

z

o

r

w

e

l

d

•

2

Y

e

a

r

s

W

a

r

r

a

n

t

y

U

N

I

M

I

G

W

A

R

R

A

N

T

Y

(

P

o

w

e

r

S

o

u

r

c

e

o

n

l

y

)

Product Code: KUPJR55

Standard option includes: CUT55 Machine, T150 Plasma Torch 6m,

Earth Lead 25mm x 4m and Air Regulator.

Technical Data

Power Supply / Phases (V-Ph) 415 - 3 +/- 15%
Duty Cycle @ 40°c as per AS/NZ60974-1 30% @ 55Amps
Rated Power (KVA) 11.0
No Load Voltage (V) 270
Output Current Range (A) Plasma 20-55
Rated Output Voltage (V) 104
Air Flow Draw Off (l/min) 150-220
Air Flow Pressure (Bar) 5-6 (70-87 psi)
Efficiency (%) 85
Power Factor 0.93
Insulation Class F
Protection Class IP21S
Plasma Arc Starting HF
Cutting Thickness - Clean (mm) 20
Cutting Thickness - Severance (mm) 22
Dimensions (mm) 540x220x370
Weight (kg) 21
Warranty 2 years machine only
Certification Approval AS/NZ60974-1

Overview

The CUT55 is an inverter-based Plasma cutting machine produced using the latest in IGBT technology. Low cost and portable this
machine is reliable, robust and stacked with features that you can expect from a quality Plasma cutter. The CUT55 produces a high
temperature plasma stream enabling effortless cutting of all electrically conductive materials including steel, cast Iron, stainless steel,
copper, aluminium brass etc. The CUT55 is equipped with a high quality Plasma torch developed specifically to enhance and improve
the cut quality of the CUT55 machine. Connection of the T150 Plasma torch provides powerful, fast and accurate cutting performance,
additional benefit is the T150 longer life cycle consumable electrodes and cutting tips. The HF start function allows effortless and clean
cut start and stand off cutting, contact cutting is possible by installing the contact cutting torch parts. The CUT55 is an exceptional
machine that is suitable for a wide range of applications including general engineering, fabrication, site work, agricultural, repair and
maintenance services. The CUT55 is packaged with a tough T150 Plasma torch, earth lead and air regulator. The CUT55 gives you the
power and performance to get the job done. Built to our specification and manufactured in compliance to AS/NZ60974-1

Features

• Latest Inverter Technology

• Industrial application

• Safe Euro style torch connection

• Strong metal housing

• Auto protection of over-voltage and over current supply

• Auto protection of short air pressure and thermal overload

• Tolerant to variable power supply

• Suitable to cut all electrically conductive materials

• HF Start

UNIMIG CUT 55

Plasma - 55 Amp Inverter Plasma Cutter

Cuts: Steels, Stainless, Cast Iron, Brass, Copper. Aluminium

55 Amp - 20mm Cut on Steel
415v Inverter Plasma Cutter
Industrial Rated, Lightweight and Portable

51851

Circle Cutting Kit

Option

50505-48

Sub-Micronic Cartridge

Option

50500-12

Sub-Micronic Air Filter

Option

04151/CS TORCH

Plasma Torch 12 meter Option

9

Front & Rear Panel Layout

Front Panel Layout Rear Panel Layout

8

5

4

3

2

1

9

6

7

(1) Digital Display
(2) Over Current - Thermal Overload LED

a. Abnormal or over current supply - LED ON
b. Overheating of the machine - LED ON

(3) Amperage Control Dial
(4) Torch connection (DC-)
(5) Output connector (DC+) connect to the work piece
(6) Regulator bracket mounts
(7) Primary power input cable
(8) On/Off switch
(9) Air supply connector inlet connection

(Note: the air regulator must be set to 5-6 Bar and the air compressor you are using must
be able to continually supply this pressure and a flow rate of 150-220 litres/min)