Jasic Cut 61 User manual

Wilkinson Star Technical
Jasic Cut 61
PT100 Plasma Hand Torch Manual

2
Contents Page
Before starng any cung acvity thoroughly read the operang manual rst to familiarize yourself with the safe and correct
operaon of your Jasic plasma machine. Always ensure that you have suitable eye protecon and protecve clothing. Also take
the necessary steps to protect any persons within the cung area.
Index Page Number
Jasic Cut 61 with PT100 Plasma Torch Overview 3
PT100 Consumable Breakdowns 4
PT100 Torch Informaon 7
Safety Informaon 8
General Plasma Cung Informaon 9
Stand-o Cung 10
Drag Cung 11
Piercing 12
Bevelling 12
Gouging 13
Tips and Techniques 14
Plasma Machine Gas Supply - Compressed Air 15
Contact Details 16

3
Jasic Cut 61 Plasma Cung Machine
with PT100 6m Plasma Hand Torch
Wilkinson Star Technical
PT100 (Pt No 09721/LG) - Torch Specicaons
Duty Cycle : 100 Amps at 60%
Gas Air Pressure - Cung : 70-80 PSI (4.6 - 5.0 bar)
Gas Air Flow : 420 SCFH (200 lpm)
Pilot Arc Ignion : NON HF

4
Jasic Cut 61 Plasma with PT100 6m Hand Torch
Item No Part Number Descripon Pack Qty
109700 PT100 Torch Head 1
1a 51190.41 Torch Head 'O' Ring 5
1b 09700.48 Cooling Tube 1
1c 60368 Wrench for Electrode 1
209705 Handle c/w Switch 1
352556 Electrode - Back Striking 1
460025 Gas Distributor (Swirl Ring) 30-70A 1
560026 Gas Distributor (Swirl Ring) 80A 1
651245.09 Contact Cung Tip (0.9mm) 30-40A Back Striking 10
751246.10 Cung Tip (1.0mm) 40-50A Back Striking 10
751246.11 Cung Tip (1.1mm) 50-60A Back Striking 10
751246.12 Cung Tip (1.2mm) 60-70A Back Striking 10
851248.14 Cung Tip (1.4mm) 80-90A Back Striking 10
960500 Retaining Cap 30-70A 1
10 60501 Retaining Cap 80A 1
11 60444 Double Pointed Spacer (use with items 7 & 8 only) 1
12 51276.10 Contact Tip (1.0mm) 40-50A 10
12 51276.11 Contact Tip (1.1mm) 50-60A 10
12 51276.12 Contact Tip (1.2mm) 60-70A 10
13 51276.14 Contact Tip (1.4mm) 80A 10
15 60502 Shield Cup Body 1
16 60504 Shield Cap 40-70A 1
17 60505 Shield Cap 80A 1
19 52556L Extended Electrode 1
20 51276L.10 Extended Shielded Tip 1.0mm 40-50A 10
20 51276L.11 Extended Shielded Tip 1.1mm 50-60A 10
20 51276L.12 Extended Shielded Tip 1.2mm 60-70A 10
21 51276L.14 Extended Shielded Tip 1.4mm 80A 10
22 60504L Extended Shield Cap 40-70A 1
23 60505L Extended Shield Cap 80A 1
Wilkinson Star Technical Please Note: Only use the above conguraon for the Jasic Cut 61 model

5
Jasic Cut 61 with PT100 Plasma Hand Torch
Stand o and exposed contact p cung setup
Wilkinson Star Tech-
Item No Part Number Descripon Pack Qty
109700 PT100 Torch Head 1
1a 51190.41 Torch Head 'O' Ring 5
1b 09700.48 Cooling Tube 1
1c 60368 Wrench for Electrode 1
209705 Handle c/w Switch 1
352556 Electrode - Back Striking 1
460025 Gas Distributor (Swirl Ring) 30-70A 1
651245.09 Contact Cung Tip (0.9mm) 30-40A Back Striking 10
751246.10 Cung Tip (1.0mm) 40-50A Back Striking 10
751246.11 Cung Tip (1.1mm) 50-60A Back Striking 10
960500 Retaining Cap 30-70A 1
11 60444 Double Pointed Spacer (use with item 7 only) 1

6
Jasic Cut 61 with PT100 Plasma Hand Torch
Drag cung (enclosed p) setup
Wilkinson Star Technical
Item No Part Number Descripon Pack Qty
109700 PT100 Torch Head 1
1a 51190.41 Torch Head 'O' Ring 5
1b 09700.48 Cooling Tube 1
1c 60368 Wrench for Electrode 1
209705 Handle c/w Switch 1
352556 Electrode - Back Striking 1
460025 Gas Distributor (Swirl Ring) 30-70A 1
12 51276.10 Contact Tip (1.0mm) 40-50A 10
12 51276.11 Contact Tip (1.1mm) 50-60A 10
12 51276.12 Contact Tip (1.2mm) 60-70A 10
15 60502 Shield Cup Body 1
16 60504 Shield Cap 40-70A 1
19 52556L Extended Electrode 1
20 51276L.10 Extended Shielded Tip (1.0mm) 40-50A 10
20 51276L.11 Extended Shielded Tip (1.1mm) 50-60A 10
20 51276L.12 Extended Shielded Tip (1.2mm) 60-70A 10
22 60504L Extended Shield Cap 40-70A 1

7
PT100 Plasma Hand Torch
The PT100 plasma torch supplied has the ‘euro style’ power/gas connecon, pilot cable and switch pins
connecons.
All Jasic plasma cung systems and torches supplied incorporate a safety circuit to prevent operator injury when
changing consumables etc. This is a simple ring circuit that breaks the electrical torch switching as soon as the
retaining cap is removed prevenng machine operaon. Without such a protecon circuit as previously menoned
the open circuit voltage could be as high as 350V DC at the torch head.
The torch head encompasses a full set of consumables as shown right, these consumables are made
up of a cooling tube, torch electrode, swirl ring for gas distribuon, cung p, retaining cap and if
required a stand o device to ensure the same distance between p and material being cut.
Fing the PT100 plasma torch
On the Jasic Cut 61 plasma machine, the below torch ng instrucons
will need to be observed.
• Locate plasma torch plug into euro connector socket as shown in
image 1 below
• Push the torch (image 1) whilst at the same me rotate the locking
nut on torch clockwise unl fully connected and ght as in image 2
below
Image 1 Image 2
Wilkinson Star Technical
Plasma Torch Connecon Diagram

8
Plasma Cung Safe Working Pracce
Safety glasses must be worn at all times in addition to welding mask Long and loose hair must be contained
Oil free leather gloves and spats must be worn Sturdy footwear with rubber soles must be worn
Close fitting/protective clothing to cover arms and legs must be worn A welding mask with shade number 11 protective filters must be worn
Respiratory protection devices may be required Hearing protection may be required when cutting thick material
PRE-OPERATIONAL SAFETY CHECKS
• Locate and ensure you are familiar with all machine operaons and controls.
• Ensure material to be cut poses no hazard. Consult the manufacturers' Material Safety Data Sheets (MSDS) for specic technical data and precauonary measures for any materials or
coangs on materials cut with this equipment.
• Check workspaces and walkways to ensure no slip/trip hazards are present, ensure the work leads and hoses do not create a trip hazard.
• Ensure the work area is clean and clear of grease, oil and any ammable materials.
• Keep the equipment, work area and your gloves dry to avoid electric shocks.
• Ensure the gloves, handpiece and work leads are in good condion.
• Ensure other people are protected from ashes by closing the curtain to the welding bay or erecng screens.
• Start the fume extracon unit before beginning cung operaon. Ensure machine is used in a well-venlated area if not used in a welding bay.
OPERATIONAL SAFETY CHECKS
• Ensure machine is correctly set up for current and airow.
• Ensure work return earth cables make rm contact to provide a good electrical connecon.
ENDING OPERATIONS AND CLEANING UP
• Switch o the machine and fume extracon unit when work completed.
• Turn o the air supply and hang up handpiece, hose and welding cables.
• Leave the work area in a safe, clean and dy state.
DON’T
• Do not use faulty equipment. Immediately report suspect equipment.
• Do not weld or cut containers that have held combusble liquids or gases.
• Do not heat or cut metals coated with or containing materials that emit toxic fumes, unless coang is removed from the work surface.
• Never leave the machine running unaended.
This safety page does not necessarily cover all possible hazards associated with plasma equipment safety and should be used in conjuncon with the operang manual along
with other references such as risk assessments. It is designed as a reminder to users prior to equipment use and as a guide to be used to compliment operator training.
POTENTIAL HAZARDS AND INJURIES
 Electric shock
 Noise
 Body burns
 Compressed air
 Radiaon burns
 Fumes
 Noxious gas
 Flying sparks and falling slag
Wilkinson Star Technical

9
Wilkinson Star Technical
General Plasma Cung Informaon
Before starting any welding or cutting activity ensure that you have suitable eye protection and
protective clothing. Also take the necessary steps to protect any persons within the welding area.
Notes for cung operaon
 Do not touch the hot workpiece with bare hands to avoid burning.
 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.
 It is recommended to iniate the cung from the edge of the workpiece unless penetraon is needed.
 Ensure spaer comes from the boom of workpiece while cung. If spaer comes upwards 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 cung torch is moved too fast.
 For cung a round or shaped piece or to meet precise cung requirement, a stencil board or other tools are needed.
 It is recommended to pull the cung torch while cung.
 Keep the nozzle of the cung torch upright over the workpiece and check if the arc is moving with the cung line. Do not bend the cable too
much, step on or press upon the cable to avoid restricng the air ow. The cung torch may be burned if the air ow is too low. Keep the cung
cable away from sharp edges.
 When the workpiece is nearly cut o, slow down the cung speed and release the torch trigger to stop cung.
 Check the torch consumables frequently to prolong the life.
 Always ensure the correct consumables are ed in the torch. Incorrect items may cause damage to the torch or machine.
 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 cung machine
such as arc ignion will possibly be aected due to the fact that the inner resistance of the cable will reduce the output voltage.
Please Note:
• Your air supply must be free of moisture, water, oil or any other contaminants. Excessive water or oil may cause double arcing, excessive
electrode/p wear or even torch head failure. Contaminants will also cause poor cut quality.
• When starng the arc, ensure you keep the pilot arc me to a minimum to avoid excessive wear on the cung p.
• Do not overghten the electrode when ng a new set of consumables. Over ghtening may cause damage to the internal torch head thread
so that the cung p will not seat correctly.
• Only use the supplied or recommended ’O’ ring lubricant or grease for your plasma torch head, using the wrong lubricant that cannot
withstand high temperatures could cause damage to the plasma torch head.

10
Stand-O Cung
The stand-o cung technique is the process of holding the p of the torch
between 3-4mm from the workpiece to achieve the opmum cut.
Stand-o cung requires a cung p that you need to ensure that the plasma
machines output amperage is matched to the amperage with the p.
Depending on the applicaon the operator may choose to hold the torch ‘free
hand’ away from the plate or could choose to use a stand-o guide to help hold the
torch away from the plate at a xed height, also available are roller guides and
circle cung guide kits which can be very helpful in creang the cuts you want.
To begin cung you would place the torch above the work piece of about 3-4mm,
and begin drawing the p across the workpiece.
You should always start with the torch placed at farthest point from you and then
cut by pulling the torch towards you.
Make sure to keep the torch upright to the material being cut throughout the
cung process.
As you are cung ensure you maintain a smooth and consistent travel speed to
make a clean and precise cut.
There are 3 main reasons why plasma machine operators prefer to use the stand-o
technique rather than drag p cung
 It allows for a smoother movement of the torch above the material being cut
without any part of the torch touching the material.
 You can comfortably stand the torch while making the contouring process or
following a certain paern.
 Because the cung p is not touching the material, this helps to prevent any
blowback of molten material.
Descripon of Stand-o Cung
FREE HAND STAND-OFF CUTTING
STAND-OFF GUIDE CUTTING Wilkinson Star Technical

11
Drag Tip Cung
Drag p cung is the process of dragging the p of the torch along the workpiece to cut the metal.
This is oen the easiest way to cut while minimizing heat input but usually only on cung currents
of 40amps and below. This technique works best when the material being cut is 5mm or less.
Drag p cung does require a ‘drag’ cung p and you need to ensure that the plasma machines
output amperage is matched to the amperage with the cung p.
It can oen be helpful to use a non-conducve straight edge to help maintain a straight cut.
Drag Shield Cap Cung
The drag shield cap opon allows the same technique to be used but having the cung p
insulated (shielded) from the material being cut. Using a drag shield cap allows you to rest the torch
(via the drag cap) on the workpiece while maintaining an opmal 2-3mm stando without touching
the cung p to the material for amperages 40amps and above. (When cung at above 40amps,
touching the p to the work material will adversely aect your cut quality and consumable life).
When you start to drag cut, you would place the p/cap of the torch on the workpiece and begin
dragging (moving) the torch across the workpiece.
You should always start with the torch placed at the farthest point from you and then cut by pulling
the torch towards you while making sure to keep the torch upright to the material being cut
throughout the cung process.
As you are drag cung ensure you maintain a smooth and consistent travel speed to make a clean,
precise cut.
The main benets of drag cung is:
 Much easier for the operator because you don't need to maintain a distance between the
cung p and the workpiece. You can simply drag the end of the plasma torch along a
template or a straight edge. This process usually ensures a more accurate cut.
 Drag cung produces less spaer and blow back and improves the life of the front end torch
parts.
 Best cut quality for material of 5mm or less.
Descripon of Drag Cung
DRAG TIP CUTTING
DRAG SHIELD CAP CUTTING Wilkinson Star Technical

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Piercing
Piercing is the process in which a quick hole is made in the workpiece. Piercing is oen just a starng hole that will be used to make a
circular cut within the workpiece.
You can use standard cung ps for piercing although ensure the plasma machines output amperage matches the cung ps amperage
rang. No accessories are required when piercing.
The thickness of the material to be pierced will need to fall in the proper amperage range for the machine and p you will be using. There
are two dierent techniques for piercing depending on the thickness of the workpiece. If the work piece is less than 2mm sheet metal, the
torch should be held at a 15°-30° angle with the cung p touching the workpiece.
Begin by establishing the pilot arc, as soon as the pilot arc penetrates the workpiece, use a smooth, rolling moon to move the torch to a 90°
(perpendicular) angle. At this point, the pierce has been created in the workpiece allowing you to begin the cung process. If the materi-
al being cut is thicker than 2mm the torch should be held at a 90° (perpendicular) angle approximately 12mm or more above the workpiece.
Begin by establishing the pilot arc and slowly move the torch towards the workpiece unl the cung arc transfers.
Once the transfer has occurred, hold the torch sll unl the arc exits the boom of the workpiece. Once the pierce has been made, the torch
can be lowered to normal cung height and the cung process can begin.
Bevelling
Bevelling allows you to angle the edge of a at plate or pipe to allow for deeper weld penetraon.
This process is normally used for materials that are 9mm or thicker. You can ulize standard cung ps for bevelling, again you need to
ensure you ulize the correct plasma machine amperage to match the cung ps used.
Ensure that the thickness of the material to be bevelled falls in the amperage range of the plasma machine and cung p that you will be
using. If bevelling by hand, a roller and/or angle guide can be helpful in maintaining the consistent bevel face and the desired angle which is
usually determined by the weld joint design.
The industry standard angle ranges are from 15°-45°. The cung p would normally be between 3–6mm from the workpiece.
Plasma Cung Techniques
Wilkinson Star Technical

13
Gouging
Gouging creates a smooth, clean concaved groove within the material being gouged which is oen weld ready. This process is primarily used
for weld removal or back gouging.
Gouging has specic consumables and sengs depending on the gouge you need to produce which include the gouging p, shield cup and
gas distributor that would be specic to gouging.
To begin the gouging process, hold the p of the torch approximately 12mm from the workpiece angling the torch approximately 20°-40° to
the surface, engage the pilot arc and once established slowly move the p closer to the work piece unl the main arc has transferred. Once
the main arc is established, retract the p unl the distance from the work piece to the p is approximately 15mm.
Make sure that you keep the p of the torch angled approximately 20°-40° during this enre gouging process.
To create a narrow u-groove in the workpiece, the operator should maintain a constant, smooth travel speed.
With this technique the gouge created will be approximately 6mm wide by 6mm deep but this may depend on the gouging p prole.
To create a wider groove, you can oscillate the plasma torch side to side in a half-moon sequence while maintaining a constant, smooth
travel speed. The gouge created will be wider but not as deep. Due to the nature of the gouging process, lead covers, gouging deectors
and torch covers are some accessories that will help to protect the equipment used in the gouging process.
Gouging can be done on all conducve materials.
Before you start gouging, check the torch, consumables, and cables for excessive wear and damage. If the electrode, swirl ring or the cung
p orice shows signs of wear and tear, replace it with a new component that is sized correctly for your unit and applicaon. Cung or
gouging with worn-out consumables only leads to poor cung/gouging performance.
Use clean, dry workshop air (install a lter if necessary) and match pressure and ow requirements to those of the plasma cuer. Adjust the
gas pressure on the machine according to the owner’s manual. For torch leads longer than 6m, add 4 PSI for each addional 6m. Seng the
pressure when the air is owing through the torch will ensure that you have proper pressure and airow while cung.
Plasma Cung Techniques
Wilkinson Star Technical

14
The below is just a few ps on how to get the best cut performance out of your Jasic plasma machine.
Before cung always check the torch, consumables and cables for excessive wear and tear. If the electrode, air distributor or the cung p ori-
ce shows signs of wear and tear then replace it with new consumables sized correctly for your Jasic plasma machine and applicaon your about
to undertake. Cung with worn-out consumables will only lead to poor cut quality.
Only use clean, dry compressed air (always ensure a air lter is installed), ensure you match the air pressure and air ow requirements to those
of your Jasic plasma machine. Adjust the gas pressure on the machine according to the owner’s manual.
Always set the air pressure when the air is owing through the torch, this will ensure that you have proper pressure and airow while cung.
For torch leads longer than 12m, it is common to increase the air pressure by approximately 10 PSI.
Always use the right p for your amperage seng. A lower amperage p has a smaller orice which maintains a narrow plasma stream at lower
sengs. Using a 40-amp p at an 80-amp seng will distort the p orice and will reduce consumable life. Using an 80-amp p on the lower
sengs will not focus the plasma stream as well and lead to a wider kerf.
Use extended ps to reach out further for cung in corners, using paerns or in ght areas.
It is generally best to start a cut from the edge of the plate, hold the torch at 90° to the edge of the workpiece. Press the trigger and pause at the
edge unl the cung arc has completely cut through the material being cut.
When pierce cung, start the pierce just o the cung line in the area of unwanted metal. Angle the torch slightly to direct blowback
molten material away from the torch p (which will greatly extends p life). Once the arc pierces the metal, return the torch to the
perpendicular posion and start moving the torch.
When possible, pull the torch toward you rather than pushing it away from you. On thicker materials it is common to lt the torch back (away
from the cung direcon) about 5°-10° to help minimize dross build up.
When you are cung at the correct speed, the plasma arc under the workpiece should trail the torch at a 5°-10° degree angle. An arc that trails
straight up and down can indicate that your travel speed is too slow, which can produce a cut that is wider than desired, along with an increase
amount of excess dross. An arc with a shallow trail indicates you’re moving too quickly and most likely you will not be severing the metal cleanly.
For straight line cung, use a non-metallic straight edge. Using a piece of mild steel for example as a straight edge can pull the arc towards it
oering a poor cut quality or possibly causing double arcing. A roller guide can prevent this.
Plasma Cung Tips and Techniques
Wilkinson Star Technical

15
Only use compressed air with the Jasic plasma machines
Please Note: NEVER USE OXYGEN
Compressed Air Supplies
Sizing the appropriate compressor to use with your plasma cung machine is as important as supplying
the correct mains power supply.
To get the best out of your plasma cuer you need to supply it with an adequate air supply. The below
are suggested quesons that need to be considered when specifying an air compressor.
• What is the maximum required operang pressure of the plasma cuer?
• What is the maximum required CFM usage of the plasma cuer?
• Does the machine need to be portable or staonary?
• What type of drive do you require? Electric motor or diesel engine?
• What receiver tank size will be needed?
• Generally 3 phase compressors are considered a beer opon than single phase compressors.
The accessories used with the compressor are also important, providing the correct air pressure, air ow which is moisture and oil free is
crucial in ensuring that your plasma will give you quality cuts.
Air Hose: Remember to select the correct bore size, considering demand and length.
Filters: Remove contaminants e.g. water and oil thus prolonging plasma torch consumable life.
Dryers: Refrigerant dryers, high eciency heat exchangers.
Regulators: Allow adjustment to opmum pressure for ecient use of your plasma cuer. Regulate your system to the pressure you need.
Couplings: Heavy air use tools/equipment may need high ow couplings. Size maers.
PLEASE NOTE: Using oxygen in a plasma torch that is designed for air cung can cause a serious re and injury.
Be careful and always follow the manufacturer’s instrucons.
Plasma Machine Gas Supply - Compressed Air
Wilkinson Star Technical

16
Issue 2 November 2020
Jasic.co.uk Wilkinson Star Limited
Shield Drive
Wardley Industrial Estate
Worsley
Manchester
United Kingdom
M28 2WD
Telephone: [phone]
Email: [e-mail]