Jasic Plasma Cut Series User manual

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1

A WILKINSON STAR LIMITED PRODUCT 01-19 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. (It will begin with AA)
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.

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
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 manufacturer’s 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.
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

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
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 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 towards your body.
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 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

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which do not contain any toxic or poisonous
materials 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
FUNCTIONS AND CHARACTERISTICS OF THE
CUTTING MACHINE
This is a digital plasma cung machine with high
performance and using advanced technology. The
CUT45PWV is an ultra-portable plasma cung
system suitable for a variety of applicaon
requirements. It can be used in handheld cung or
with automated cung systems. The
CUT45PWV can cut conducve metal such as low
carbon steel, stainless steel and aluminium etc.
The modern design concept of this machine and the
applicaon of a large number of advanced and
mature technologies ensures the user’s investment
for the future.
Advanced digital control mode
The CUT45PWV uses intelligent digital control
technology and all its major funcons are
performed using this advanced soware. It is this
digital control which has led to improvements in
performance when compared with the tradional
plasma cung machines.
With PWM technology and high power IGBT
components it inverts the DC voltage which is
reced from 50Hz/60Hz input AC voltage to
30K~100KHz AC high voltage. Then, the voltage is
dropped and reced to output the high power DC
power supply for cung.
The machine adopts switching power supply
inverter technology, greatly reducing the volume
and weight of the plasma cuer and obviously
enhancing the power eciency. The switching
frequency is beyond audio range which almost
eliminates the noise polluon.
High consistency and stable performance
Generally speaking, for a cung machine with
analogue circuit control, the performance
characteriscs are determined by the parameters of
various components. Cung performance of the
machines dier as a result of the inconsistent
parameters of the components, so even for the
cung machines of the same brand, their
parameters oen dier from each other. In
addion, cung performance of the machine may
change since parameters of the components may
vary according to the environment such as
temperature and humidity etc. The consistency and
stability of this digitally controlled cuer is beer
than that of a tradional cuer.
Powerful cung performance
This machine is economical and praccal since it can
cut metals by using compressed air as the plasma
gas source.
The cung speed is increased by 1.8 mes when
compared with oxy-acetylene cung. It can cut
steel, stainless steel, copper, cast iron and
aluminium conveniently and quickly. It has an easy
start ignion mode and a post-ow cooling funcon
is available. Its simple operaon and high cung
speed gives excellent cut quality. Both contact and
non-contact mode is available for
successful arc ignion.
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

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
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 work piece.
Air pressure adjustment
The embedded lter regulator is correctly set when
leaving the factory and users do not need to set it
themselves in general.
If users need to reset the embedded lter reducer
the following steps are to be taken. Only suitably
qualied persons should make any adjustments.
1Switch o the machine at the mains supply.
2Remove the machine cover.
3Switch on the mains supply and the machine
taking care not to touch any electrical parts.
4Press the gas check buon on the front panel
and air will ow.
5Li the pressure control knob upwards.
6Adjust the gas pressure to the desired value
by rotang the knob (rotate to “+”
direcon to increase gas pressure; rotate to
“-” direcon to reduce gas pressure).
7Press down the pressure control knob to lock
it.
8Any water in the lter bowl will drain when
the air is o through the boom tube and
out of the machine.
PLEASE NOTE TO PROVIDE OPTIMUM
PERFORMANCE AIR SHOULD BE CLEAN AND DRY.
THE ADJUSTMENT REGULATOR IN THE MACHINE
IS NOT DESIGNED AS A DRYER/FILTER.
Operaon method
Turn on the power switch of the machine and the
power indicator illuminates.
Select correct working mode and 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 wear more quickly when
using the mesh cung mode.
Set cung current according to the thickness of
work piece to be cut.
Bring the copper nozzle of the cung torch to the
work piece keeping a distance of about 2mm
between the copper nozzle of the torch and the
work piece. Push the torch trigger on the cung
torch, the machine will start a pilot arc and cung

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
NOTES ON CUTTING
will start. Once the arc is completely through the
material start to move the torch along the required
cung path at the correct speed.
Travelling too fast will cause blow back of material
and failure to cut through. Travelling too slow will
cause an excessive build up of material under the
cut and give poor performance.
Maintain the torch at 900 to the work piece to
ensure a straight cut edge.
Typical issues when cung
The work piece 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 work piece is too thick.
Molten slag drops from the boom of work piece.
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.
Cung speed guide - Quality cut
12 mm at 500 mm/min
19 mm at 250 mm/min
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 work piece unless
penetraon is needed.
Ensure spaer ies from the boom of work piece while cung. If spaer ies from
the top of the work piece, it indicates that the work piece 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 work piece or keep a short distance between the
nozzle and work piece. If the torch is pressed against the work piece, the nozzle may
sck to the work piece, and smooth cung is dicult.
For cung shaped work pieces or to meet precise cung requirement a template may
aid accuracy.
It is recommended to pull the cung torch while cung.
Keep the nozzle of the cung torch upright over the work piece and check if the arc is
moving with the cung line.
Clean up the spaer on the nozzle regularly as this can aect the cooling of the nozzle.
Check the torch and consumable condion daily.

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PANEL LAYOUT
FRONT
1Pressure gauge
2Work return socket
3Torch connector socket
42T/4T selector
5Air purge/cut selector
6Current adjustment knob
REAR
7Mains switch
8Mains cable
9Air inlet

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CONTROL PANEL
POSITION DESCRIPTION
1POWER INDICATOR: THIS WILL BE LIT WHEN MAINS POWER IS ON.
2OVERHEAT INDICATOR: THIS WILL BE LIT WHEN THE MACHINE IS IN OVERHEAT CONDITION. THE MACHINE
WILL STOP WHEN THIS INDICATOR IS ON. LEAVE THE MACHINE ON UNTIL THE FAN COOLS IT DOWN AND
THE INDICATOR GOES OFF.
3TORCH PROTECTION INDICATOR: THIS WILL BE LIT IF TORCH CONSUMABLES ARE WORN OR DAMAGED.
THE MACHINE WILL BE OFF UNTIL THE FAULT IS CLEARED.
4AIR PRESSURE GUAGE.
52T/4T SELECTOR: THE LED WILL BE LIT TO INDICATE THE SWITCH MODE.
6GAS CHECK/MESH CUTTING INDICATOR: WHEN THE TOP POSITION IS LIT AIR WILL FLOW BUT THE
MACHINE WILL NOT CUT. WHEN THE MESH CUTTING IS SELECTED THE MACHINE CAN BE USED TO CUT
MESH/PERFORATED SHEET.
7CUTTING CURRENT ADJUSTER.

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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 arc 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 the 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. Replace where necessary.
Switch on the machine and check for any warning LEDs and general
operaon.
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. Check the security of output connecons
and plugs. Replace if signs of overheang. 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 a safety check in accordance with the
manufacturers standard (EN 60974-1).
This work should be carried out by a suitably qualied competent person.
Malfuncon Cause/Soluon
Turn on the machine, the power indicator illuminates,
the control PCB keys do not funcon and there is no
response when pushing the torch trigger.
The machine soware crashes: Shut down the
machine and restart it.

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TECHNICAL PARAMETERS
MODEL CUT 45PWV
Rated input voltage (V) AC95-265V±15% 50/60HZ
115V 230V
Rated input current Imax (A) 31 23
Rated input current Ie (A) 17 13.5
Rated input power (KW) 3.6 5.29
Cung current range (A) 20-30 20-45
No-load voltage (V) 290
Rated duty cycle 30A @ 30% 45A @35%
Cung capacity (Clean) mm 15
Cung capacity (Severance) mm 20
Compressed air requirement 170 L/min @ 4.5 Bar (65psi)
Eciency (%) 85
Power factor 0.99
Protecon class IP21S
Insulaon class F
Overall size (mm) 439 x 165 x 328
Weight (Kg) 9.2
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
equipment and 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.
Malfuncon Cause/Soluon
Turn on the machine, the power indicator illuminates,
the control PCB keys work normally but there is no
response when pushing the torch trigger.
1) The LED1 on the main board is on: The
control PCB is damaged.
2) The LED1 on the main board is o: Check the
torch trigger and torch trigger wire.
Turn on the machine, the power indicator illuminates
and the fan works. When pushing the torch trigger, the
solenoid valve funcons but there is no HF discharge.
The arc ignion part fails:
1) The inner electrode distance of the
discharge nozzle is too long.
2) There is leakage of the HF capacitor
102/10KV.
3) The relay is damaged.
4) The input voltage is too low.
Arc can not be ignited. The air pressure is too high or too low.

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Cut Series
JP-45PWV Order code JP-45PWV
© Wilkinson Star Limited