Jasic CUT80 (L205) User manual

Operator Manual
www.jasic.co.uk
Plasma Cut Series
|Plasma Cut 60 (JP-61) |Plasma Cut 80 (JP-81) |

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
Your new product
Thank you for selecng 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 informaon provided paying parcular aenon to the
safety precauons. The informaon will help protect yourself and others against the potenal 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 operaon.
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 informaon 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 top or underside of the
machine )
Disclaimer
Whilst every eort has been made to ensure that the informaon contained within this manual is
complete and accurate, no liability can be accepted for any errors or omissions. Please note products are
subject to connual development and may be subject to change without noce.
This manual should not be copied or reproduced without the wrien permission of Wilkinson Star
Limited

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SAFETY
These general safety norms cover both arc welding machines and plasma cung 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.
Prevenon against electric shock
The equipment should be installed by a qualied person and in accordance with current standards in
operaon. It is the users responsibility to ensure that the equipment is connected to a suitable power
supply. Consult with your ulity 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 o all equipment when not in use.
Cables (both primary supply and welding) should be
regularly checked for damage and overheang. Do not use worn, damaged, under sized, or poorly
jointed cables.
Ensure that you wear the correct protecve clothing, gloves, head and eye protecon.
Insulate yourself from work and ground using dry insulang 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
dierent machine.
Do not wrap cables over your body.
Ensure that you take addional safety precauons when you are welding in electrically hazardous
condions such as damp environments, wearing wet clothing, and metal structures. Try to avoid
welding in cramped or restricted posions.
Ensure that the equipment is well maintained. Repair or replace damaged or defecve parts
immediately. Carry out any regular maintenance in accordance with the manufacturers instrucons.
Safety against fumes and welding gases
Locate the equipment in a well-venlated posion.
Keep your head out of the fumes. Do not breathe the fumes.
Ensure the welding zone is in a well-venlated area. If this is not possible provision should be made for
suitable fume extracon.

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If venlaon is poor, wear an approved respirator.
Read and understand the Material Safety Data Sheets (MSDS’s) and the manufacturer’s instrucons for
metals, consumable, coangs, cleaners, and de-greasers.
Do not weld in locaons near any de-greasing, cleaning, or spraying operaons. Be aware that heat and
rays of the arc can react with vapours to form highly toxic and irritang gases.
Do not weld on coated metals, unless the coang is removed from the weld area, the area is well
venlated, and while wearing an air-supplied respirator. The coangs on many metals can give o toxic
fumes if welded.
Prevenon against burns and radiaon
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 ed with a proper shade of lter 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 protecve screens or barriers to protect others from ash, glare and
sparks from the welding area. Ensure that there are adequate warnings that welding or cung is taking
place.
Wear suitable protecve ame resistant clothing.
The sparks and spaer from welding, hot work pieces, and hot equipment can cause res 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, overheang, or re.
Check and be sure the area is safe and clear of inammable material before carrying out any welding.
Protecon against noise
Some welding and cung operaons may produce noise.
Wear safety ear protecon to protect your hearing.
Protecon from moving parts
When the machine is in operaon keep away from moving parts such as motors and fans. Moving parts,
such as the fan, may cut ngers and hands and snag garments.
Protecons and coverings may be removed for maintenance and controls only by qualied personnel,
aer rst disconnecng the power supply cable.
Replace the coverings and protecons and close all doors when the intervenon is nished, and before
starng the equipment.
Take care to avoid geng ngers trapped when loading and feeding wire during set up and operaon.
When feeding wire be careful to avoid poinng it at other people or toward your body.

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Always ensure machine covers and protecve devices are in operaon.
Precauons against re and explosion
Avoid causing res due to sparks and hot waste or molten metal
Ensure that appropriate re safety devices are available near the cung / welding area.
Remove all ammable and combusble materials from the cung / 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 combusble
or ammable material.
Do not work in atmospheres with high concentraons of combusble fumes, ammable gases and dust.
Always check the work area half an hour aer cung to make sure that no res have begun.
Risks due to magnec elds
The magnec elds created by high currents may aect the operaon of pacemakers or electronically
controlled medical equipment.
Wearers of vital electronic equipment should consult their physician before beginning any arc welding,
cung, gouging or spot welding operaons.
Do not go near welding equipment with any sensive electronic equipment as the magnec elds may
cause damage.
RF Declaraon
Equipment that complies with direcve 2004/108/EC concerning electromagnec compability (EMC)
and the technical requirements of EN60974-10 is designed for use in industrial buildings and not those for
domesc use where electricity is provided via the low voltage public distribuon system. Dicules may
arise in assuring class A electromagnec compability for systems installed in domesc locaons due to
conducted and radiated emissions.
In the case of electromagnec problems, it is the responsibility of the user to resolve the situaon. It may
be necessary to shield the equipment and t suitable lters on the mains supply.
LF Declaraon
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 aect the quality of power provided by the network. Consequently, connecon restricons or
maximum impedance requirements permied by the network at the public network connecon point
must be applied to these systems.
In this case the installer or the user is responsible for ensuring the equipment can be connected,
consulng the electricity provider if necessary.
Materials and their disposal
The equipment is manufactured with materials, which do not contain any toxic or poisonous materials

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dangerous to the operator.
When the equipment is scrapped, it should be dismantled separang components according to the
type of materials.
Do not dispose of the equipment with normal waste. The European Direcve 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 compable recycling facility.
Handling of Compressed gas cylinders and regulators
All cylinders and pressure regulators used in welding operaons 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
Funcons and characteriscs of the cung machine
Advanced digital control mode
The Plasma cung machines JP 61/81 MUC intelligent digital control technology, and all its major
funcons are performed using soware controls. The digital control plasma cung machine oers
many improvements in funcon and performance when compared with the tradional type plasma
cung machines.
With PWM technology and high power component IGBTs, it inverts the DC voltage, which is reced
from 50Hz/60Hz input AC voltage, to 30K~50KHz AC high voltage. The voltage is dropped and reced
to output the DC power supply for cung. This inverter technology provides a machine which is smaller
and much less weight than the tradional style machine. The technology provides a high eciency unit
and the switching frequency is outside the audible range.
Good consistency and stable performance
In tradional machines consistency and performance is oen governed by the tolerances of the
components used in manufacture and environmental such as temperature and humidity. In some cases
the same machine brand and type can vary in performance due to tolerance dierences. One of the
characteriscs of digital control is that it is not sensive to the change of these parameters. The
performance of cung machine will not be aected by the change of the parameters of individual
parts. Therefore, the consistency and stability of performance of the digital control cuer is beer than
that of tradional cuer.
Powerful cung performance
These machines provide economical cung of metals using compressed air as the plasma gas source.
The cung speed is 1.8 mes when compared with oxyacetylene cung. The machines can cut steel, s
stainless steel, copper, cast iron and aluminium easily and quickly. The arc is easy to ignite arc and uses
a non HF arc ignion mode. There is a post-ow funcon operates to cool the torch aer cung. The
simple operaon and high cung speed, smooth cung surface make the plasma process and
excellent cung method.

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Unpacking
Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging
unl the installaon is complete.
Locaon
The machine should be located in a suitable posion 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 airow.
Input connecon
Before connecng 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 qualied competent person. Always ensure the
equipment has a proper grounding. Never connect the machine to the mains supply with the panels
removed.
Output connecons
Insert the torch connector into the connecon socket and turn
clockwise unl it is ght taking care not to over ghten. No air
should leak from this connecon
Insert the work return cable into the socket and ghten by
turning clockwise
Check leads and connecons daily before use.
Connect the work clamp to the workpiece

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Air pressure seng
The machine should be connected to a suitable air supply, 4.5-5 Bar pressure.
The embedded lter reducer is preset prior to leaving the factory, and users should not need to set
it themselves. Please note this adjustment should be carried out by a competent person only.
If for any reason the reducer needs to be adjusted then it needs to be done as follows:
1Switch o the machine.
2Carefully remove the machine cover panel and handle.
3Switch on the machine taking care not to touch any electrical parts.
4Switch on the air purge switch to start the airow through the machine
5Li up the adjusng knob
6Adjust the pressure by rotang the knob in the “+” direcon to increase the air pressure . Turn the
knob in the “-” direcon to reduce the pressure.
7When the correct pressure is set push down the adjusng knob.
8Turn o the machine.
9Replace the panel and handle
Any water which has been collected by the air regulator will be drained by the auto drain of the
regulator. Air supplies should always be clean and dry.
Operaon
1Turn on the power switch of the machine, and the power indicator illuminates.
2Select proper working mode and proper funcon. There are two working modes available on
the machine panel: 2T and 4T. There are two funcons available: normal cung and metal mesh
cung. The electrode and nozzle are more easily to wear out in metal mesh cung.
3Push the torch trigger on the cung torch, the cung machine works.
4Set cung current according to the thickness of workpiece.
5Bring the copper nozzle of the cung torch into contact with the workpiece (For models with
pilot arc funcon, keep a distance of about 2mm between the copper nozzle of the torch and the

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workpiece.), and then push the torch trigger. Aer the arc is ignited and started, raise the cung
torch to the posion about 1mm above the workpiece, and start cung.
Controls
1Digital Ammeter
2Power indicator
3Warning indicator
4Pressure guage
5Current adjustment knob
62T / 4T selector
7Air purge / cut selector
8Torch connector
9Work return connector
10 Arc started signal
11 Arc voltage feedback
12 Air inlet
13 Mains Cable
14 Mains switch

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Panel Indicators
Symbol Funcon
1
Power indicator. It illuminates when the machine is powered on, and it ashes
aer arc is successfully ignited.
2
Overheang indicator. It illuminates when the working temperature of the IGBT
is overly high. When lit the machine stops working.
3
2T indicator: It illuminates when the machine is under 2T status.
4 4T indicator: It illuminates when the machine is under 4T status.
5
Gas-check indicator It illuminates when the machine is under gas-check status. When lit,
the machine cannot cut.
6
Metal mesh cung indicator The machine can cut metal mesh when this indicator illu-
minates.

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Maintenance and troubleshoong
The following operaon requires sucient 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 eciently and in safety, it must be maintained
regularly. Operators should understand the maintenance methods and means of arc welding machine
operaon. This guide should enable customers to carry on simple examinaon and safeguarding by
oneself, try to reduce the fault rate and repair mes of the arc welding machine, so as to lengthen service
life of arc welding machine.
Troubleshoong
Before cung 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 potenal 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 aer power
switch o before opening the case.
Period Maintenance item
Daily examinaon Check the condion of the machine, mains cables, welding cables and
connecons.
Check for any warnings LEDs and machine operaon.
Check the air intake is unobstructed.
Check the torch leads and components
Monthly examinaon Disconnect from the mains supply and wait for at least 5 minutes before
removing the cover. Check internal connecons and ghten if required.
Clean the inside of the machine with a so brush and vacuum cleaner. Take
care not to remove any cables or cause damage to components. Ensure that
venlaon grills are clear. Carefully replace the covers and test the unit.
This work should be carried out by a suitably qualied competent person.
Yearly examinaon Carry out an annual service to include safety check in accordance with the
manufacturers standard (EN 60974-4).
This work should be carried out by a suitably qualied competent person.

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TECHNICAL PARAMETERS
CUT 60 (JP-61) CUT 80 (JP-81)
RATED INPUT POWER SUPPLY 3 PHASE 400V 50/60 Hz 3 PHASE 400V 50/60 Hz
RATED INPUT CAPACITY (KVA) 10.8 14.4
POWER FACTOR 0.7 0.7
RATED OUTPUT (A/V) 60/104 80/112
RATED DUTY CYCLE (%) 40 40
NO LOAD VOLTAGE (V) 310 310
ARC IGNITION MODE |NON HF NON HF
POST AIR FLOW (S) 10 10
AIR PRESSURE (BAR) 4.5 4.5
INSULATION GRADE FF
PROTECTION CLASS IP 21S IP 21S
EFFICIENCY (%) 85 85
MACHINE DISPOSAL
Please do not dispose of electrical waste with normal waste products.
In accordance with the European direcve 2002/96/EC regarding waste electrical and electronic equip-
ment abnd its implementaon into naonal law any electrical or electronic which has reached its end
of life must be collected separately and disposed of via a suitable recycling facility.
The owner of the equipment is required to return the equipment to a suitable recycling facility or to
Wilkinson Star Limited for the correct recycling of the product.

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EXPOLDED PARTS LIST— JP-61
EXPOLDED PARTS LIST— JP-81

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PARTS LIST
JP-61 JP-81
No Descripon Part No Part No
1EMC Board 10043995
2Gas connector 10048726
32 Pin connector 10004691
4Torch connector 10004644
5Panel (middle) 10058211
6Bracket 10058273
7Jasic insert 10041712
84 pin connector 10035556
9Base panel 10058232
10 Insulang cover 10037078
11 Support 10037028
12 Support 10049912
13 Deector 10049881
14 Heatsink 10049894
15 Heatsink 10049893
16 Heatsink subplate 10049883
17 Display board 10060528
18 Gas inlet 10041723
19 Solenoid valve 10048389
20 Column 10049874
21 Connector 10049923
22 Handle bar 10058227
23 Quick connector 10004638
24 Power switch 10021935
25 Plasc bolt M3x6 10048737
26 Front support 10058240
27 Front scker 10060347 10060343
28 Rear support 10058238
29 Rear louver 10058230
30 Front panel 10058228
31 Rear panel 10058229
32 Handle socket 10058231
33 Arc striking board 10060523
34 Control board 10060526
35 Handle support 10058239
36 Recfying board 10052906 10053198
37 Recer 10006625 10006651
38 Display panel 10058233
39 Cover 10060287
40 Filter board 10052904 10053581
41 Power cable 10050677
42 Valve support 10057001
43 Cable clip 10004886
44 Inverng board 10052907
45 DC Fan 10043026 10056357
46 Knob 10040930
47 Pressure guage 10007295

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Notes on cung
Problems
The workpiece is not cut fully. This may be caused by:
 The cung current is too low.
 The cung speed is too high.
 The electrode and nozzle of the torch are burned.
 The workpiece is too thick.
Molten slag drops from the boom of workpiece. This may be caused by:
 The cung speed is too low.
 The electrode and nozzle of the torch are burned.
 The cung current is too high.
It is recommended not to ignite the arc in the air if not necessary. 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 workpiece, unless penetra-
on is needed.
Ensure spaer ies from the boom of workpiece while cung. If spaer comes up
from the top of workpiece, it indicates that the workpiece is not fully cut because the
cung torch is moved too fast or the cung current is too low.
Keep the nozzle slightly touching the workpiece or keep a short distance between the
nozzle and workpiece. If the torch is pressed against the workpiece, the nozzle may
sck to the workpiece, and smooth cung will be problemac.
For cung round workpieces or to meeng precise cung requirement, molding
boards or other tools are needed
It is recommended to pull the cung torch while cung.
Keep the nozzle of cung torch upright over the workpiece, and check if the arc is mov-
ing with the cung line. If the space is not enough, don’t bend the cable too much,
step on or press upon the cable to avoid suocang of gas ow. The cung torch may
be burned because the gas ow is too small. Keep the cung cable away from edge
tools.
Clean up the spaers on the nozzle mely, for it will aect the cooling eect of the noz-
zle. Clean up the dust and spaers on the torch head aer using everyday to ensure
good cooling eect.

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JP 61-81
CUT 61 Order code JP– 61
CUT 81 Order code JP– 81
© Wilkinson Star Limited