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Do  not  weld  on  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 o

 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 a

ect 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

Summary of Contents for Cut 45P

Page 1: ...wilkinsonstar com Cut 45P Air Plasma Cutting machine Order code JP 45P OPERATOR MANUAL ...

Page 2: ...upplier 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 __________________________________...

Page 3: ...ye 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 c...

Page 4: ... 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 durin...

Page 5: ...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 ...

Page 6: ...eyond audio range which almost eliminates the noise pollution High consistency and stable performance Generally speaking for a cutting machine with analogue circuit control the performance characteristics are determined by the parameters of various components Cutting performance of the machines differ as a result of the inconsistent parameters of the components so even for the cutting machines of t...

Page 7: ...0V AC 15 Rated input frequency Hz 50 60 Rated input capacity KVA 5 1 Recommended supply fuse A 20 Compressed air requirement 0 45Mpa 170L Min No load voltage 280V DC Cutting current A 20 45 Rated output voltage V 98 Rated duty cycle 45A 35 Efficiency 85 Power factor 0 99 Insulation class F Protection class IP21S Arc ignition Without HF Maximum cutting thickness mm 19 Weight kg 9 2 Overall size mm L ...

Page 8: ...Controls 4 PANEL LAYOUT FRONT REAR 7 1 AIR PRESSURE GUAGE 5 MAINS INPUT CABLE 2 WORK RETURN CONNECTOR 6 MAINS ON OFF SWITCH 3 TORCH CONNECTOR 7 AIR INLET CONNECTION 4 CURRENT CONTROL KNOB ...

Page 9: ...sumable parts of the machine are incorrectly fitted or the torch head is shorted When in this state the machine stops working 4 2T indicator It illuminates when the machine is in 2T status 5 4T indicator It illuminates when the machine is in 4T status 6 Gas check indicator It illuminates when the machine is in gas check status At this moment the machine cannot cut 7 Metal mesh cutting indicator Th...

Page 10: ...per 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 t...

Page 11: ...ust the gas pressure to the desired value by rotating the knob rotate to direction to increase gas pressure rotate to direction to reduce gas pressure Press down the pressure control knob to lock the adjusting knob Any water will be drained automatically via the auto drain function in the embedded filter reducer Ensure the mains supply is disconnected whilst replacing the cover Over current over v...

Page 12: ...d 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 unl...

Page 13: ... 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 o...

Page 14: ...Electrical schematic 7 13 ...

Page 15: ...Parts list 8 Cut 45P JP 45P 14 ...

Page 16: ...8681 Display panel 27 10037075 Insulating strip 9 10007295 Pressure guage 28 10050319 Main PCB 10 10041712 Jasic ident 29 10050326 Insulation 11 10037152 Quick connector socket 30 10037028 Support 12 10043926 Blanking plate 31 10048706 Base plate 13 10048633 Central connector 32 10006256 Rectifier 14 10050205 PFC inductance 33 10043394 Diode 15 10048682 Base panel 34 10050257 Heatsink 16 10048661 ...

Page 17: ...JP 45P AIR PLASMA CUTTING MACHINE Order code JP 45P Wilkinson Star Limited Issue 1 November 2014 Product is subject to change without notice xvi ...

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