Jasic JT-315PMWD User manual

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
Secon Title
1Your New Product
2Safety
3Product Overview
4Panel Layouts
5Control Panel Funcons
6Unpacking
7Input and Output Connecons
8Maintenance
9Error Codes
10 Technical Parameters
11 Electrical Schemac
Contents

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 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

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
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.
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
Check and be sure the area is safe and clear of
inammable material before carrying out any
welding.
Accidental contact of electrode to metal objects
can cause arcs, explosion, overheang or re.
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.
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.

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
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,
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
3PRODUCT OVERVIEW
This is a digital AC/DC inverter welder with a wide
range of funcons, high performance and advanced
technology. This mul-funcon welder with AC TIG
welding (square wave, triangular wave and sine
wave), AC pulsed TIG welding, DC TIG welding, DC

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
pulsed TIG welding, AC-DC hybrid TIG welding and
coated electrode MMA welding (DC, AC). It can be
used in a wide range of welding operaons with
various types of materials. The unique electrical
structure and air duct design inside the machine
can accelerate the dissipaon of the heat generated
by the power devices, thus increasing the
connuous load rang of the machine. Due to the
unique air duct heat dissipaon eciency, the
damage to the power devices and the control
circuit caused by the dust sucked by the fan can be
eecvely avoided, thus greatly improving the
reliability of the machine.
Excellent welding performance, rich funcon
integraon, high eciency, small size, lightweight,
and many other features make it very convenient
for both professional and non-professional welders
to put into use in both industrial applicaons and
outdoor applicaons and meet a wide range of
welding requirements.
Advanced IGBT inverter technology
The inverter frequency is 20 KHz which signicantly
reduces the loss of copper and iron, improves the
overall eciency and has a signicant energy saving
eect.
Leading control methods
Advanced control soluons have signicantly
improved the performance of the welder and have
met the welding process requirements to a greater
extent.
New secondary inverter topology patent
technology.
Using new control technology, the voltage spikes
generated by the secondary inverter are smaller,
the reliability is improved, the energy consumpon
is lower and the volume is smaller.
Controlled by world’s leading MCU intelligent digital
technology, the core funcons of the welder are
realized by soware. It is a digitally controlled
welder. Its funcon and performance are greatly
improved compared with the tradional welder.
New soware control can be upgraded according to
demand for easy maintenance.
Excellent welding performance
It can be widely used for welding all kinds of acid
and alkaline electrodes.
It has the characteriscs of easy arc striking, low
spaer, stable current and excellent weld bead
prole.
AC TIG welding can be widely used in welding with
non-ferrous metals such as various aluminum alloys
and magnesium alloys featuring a variety of
waveform opons and wider applicaon.
DC TIG welding can be applied to the welding of
various stainless steels and carbon steels.
Great shape and structure
Streamlined front and rear panel design.
High-strength engineering plascs are used on the
front and rear panels to eecvely ensure that the
machine can work eciently under harsh
condions such as high impact and dropping.
Excellent insulaon performance.
“Three proong” design, good an-stac
performance and corrosion resistance.

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
Automac protecon
The machine has excellent protecon funcons,
and there is a corresponding code when protecon
is enabled.
The machine integrates under-voltage and
overvoltage protecon. When the input mains
voltage is unstable and the voltage is too high or
too low, the welder protecon disables output and
prevents damage to the welder.
Overheang protecon: Due to high ambient
temperature or overloaded use, the temperature
of the internal components is too high the
protecon system prevents damage to the welder
due to high temperature.
Overcurrent protecon: When the welder exceeds
the design rated output, the welder enables
protecon to prevent damage to the welder.
Good product consistency and stable performance
This machine adopts intelligent digital control,
which is insensive to changes of component
parameters. The changes of component
parameters will not aect the performance of the
welder. It is insensive to changes in the
temperature and humidity of the environment.
Therefore, the consistency and stability of the
digital control welders are much beer than those
of the tradional welders.
Easy to use interface
Using the internaonally accepted graphical
language interface, the main human-machine
interface is simple, intuive and easy to
understand.
The operaon panel layout is convenient for
various user operaons.
High quality manual welding can be achieved
Excellent control algorithm signicantly improves
manual welding performance: Easier arc striking,
stable welding current, minimal spaer, non-sck,
good weld formaon, automac adaptaon to
changes in the length or cross-secon of the
welding cables, excellent quality in size
specicaons.
TIG welding of high requirements can be achieved
The improved digital constant current regulaon
technology ensures the low noise and high stability
of the arc in the full specicaon. In addion, the
sophiscated and mature control algorithm
provides a convenient and praccal method for the
user to freely control the current form. The
machine oers four classical TIG arc operaon
modes including 2 T, 4 T, cycle and spot welding
which provide a good way for users to realize the
special process requirements.
Remote control
Provides torch control and pedal switch opons
and users can select as needed.

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4PANEL LAYOUTS
Front
1Control panel
2“+” output socket
3“-” output socket
4Remote control socket
5Gas outlet
Rear
6Cooler unit connector
7Gas inlet
8Mains cable
9Cooler unit fuse
10 Mains switch

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
5CONTROL PANEL FUNCTIONS
1Digital display
2Digital display
3MMA control area
4Job selecon area
5Gas purge buon
6AC frequency and balance
7Parameter LEDs
8Tungsten selecon LED
9Warning LED
10 Job save buon
11 Job recall / delete buon
12 TIG Mode selector buon
13 AC wave type buon
14 Torch switch mode buon
15 Arc starng mode buon
16 Pulse / no pulse selecon buon
17 Rotary adjustment / push selector
18 VRD selecon LED
19 VRD on LED
20 MMA welding mode selecon
21 Remote control selecon
22 Cooling selecon

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The “A” indicator lights up when there
is current.
The “S” indicator lights up when a me
parameter is displayed.
The “Hz” indicator lights up when a
frequency parameter is displayed.
The “%” indicator lights up when a
percentage parameter is displayed.
DISPLAY FEATURES
DISPLAY 1
Displays voltage value
Displays “C+ storage
channel”
Display “Err”
The “V” indicator lights up when the
voltage is displayed.
The “JOB” indicator lights up when the
storage parameter channel is selected.
The “PRG” indicator lights up when the
parameter is saved to the channel or
the channel stores the last stored data.
The “GAS” indicator lights up when the
solenoid valve gas switch is turned on.
DISPLAY 2
Display current
Display me
Display frequency
Display percentage
Display error code
Display size of tungsten
electrode
Save and Recall Parameter Sengs
Press the job select buon to enter the job select mode. In job select mode,
select the corresponding job number by pressing the job select buon to scroll
up and the gas purge buon to scroll down to nd a free storage posion.
Any posion that has a job stored will light PRG in the display. There are 50 job
posions available.
Set parameters as needed, save to the selected channel by pressing the job select buon
to highlight the job number required and press “Save” buon to save the parameters.
The selected channel must be displayed in order to save the job.
If you do not operate in the job select / save mode for more than 5 seconds, the job select
mode will automacally be exited.
When recalling a job press the job select buon as above to nd the job number you
require and press the job recall buon. This will recall the stored parameters of that job.
To delete the data parameters / job press and hold the job recall delete buon unl a
beep is heard for 2 seconds. The PRG will then disappear from the deleted job number.

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MMA Parameter Sengs
MMA parameter zone
Press to select MMA mode. The
LED will be lit on the selecon,
either AC or DC.
VRD
The “on” LED will be LIT to show
the VRD opon is enabled and the
voltage at the output is below 24V.
The LED will be o when an arc is
established.
Hot start
To set the hot start or ignion amps, aer selecng
AC or DC welding mode turn the adjuster knob
unl the ignion amps LED is lit. Press the adjuster
unl the LED ashes. Turn the adjuster to increase
or decrease the value. The hot start current value
is between 0 and 80A added to the set welding
current value. When the seng is as required
press the adjuster again and the LED will be lit
solid.
To set the hot start / ignion me turn the
adjuster knob unl the ignion me LED is lit.
Press the adjuster unl the LED ashes. Turn the
adjuster to increase or decrease the me value.
When the seng is as required press the adjuster
again and the LED will be lit solid.
Welding current
To set the MMA welding current turn the adjuster
knob unl the “Amps set” LED is lit. Press the
adjuster unl the LED ashes. Turn the adjuster to
increase or decrease the current value. When the
seng is as required press the adjuster again and
the LED will be lit solid.
Arc force
To set the “Arc force” current turn the adjuster
knob unl the “Arc force” LED is lit. Press the
adjuster unl the LED ashes. Turn the adjuster to
increase or decrease the current value. This value
is between 0 and 100A added to the set welding
current. When the seng is as required press the
adjuster again and the LED will be lit solid.
TIG Parameter Sengs
TIG mode
Press the TIG buon to enter the
TIG mode welding selecon
interface.
Press the TIG buon to light the
mode required. This can be:
DC mode
AC mode
Hybrid mode (mix)
AC wave mode
Press the “AC WAVE” buon unl the
LED is lit next to the required wave
shape.
The selecons are square wave, triangle
wave or sine wave.
Torch control mode
Pres the torch mode buon to light the LED
corresponding to the switch mode required. The
opons are:
2T
4T
Cycle
Spot welding
2T mode
In the 2T mode, when the torch switch is pressed
down, it will start the pre ow gas and the arc
striking current rises to the set value over the
upslope me (if set). When the torch switch is

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
released, the current drops over the downslope
me (if set) and the arc will exnguish. The post gas
will ow for the me set.
4T mode
In 4T mode, when the torch switch is pressed down,
it will start the pre gas ow me (if set) and the arc
will start at the “start amps” value.
When the torch switch is released, the arc current
rises to the peak amp current.
When the torch switch is pressed down, the current
drops to the “nish amps” current over the
downslope me (if set).
When the torch switch is released again the arc is
exnguished and the post gas ow me will start .
Cycle mode
When the torch switch is pressed down, it will start
the pre gas ow me (if set) and the arc will start at
the “start amps” value.
When the torch switch is released, the arc current
rises to the peak amp current.
When the torch switch is pressed down, the current
drops to the “nish amps” current over the
downslope me (if set).
When the torch switch is released, the “nish
amps” will rise to the peak current as above. The
process will cycle unl the torch switch is pressed
and released within 500mSec. This will stop the
cycle and the post gas me will start.
Spot mode
In spot welding mode, when the torch switch is
pressed down, it will start the pre ow gas me and
the current will then go to the preset amps for the
set on me (up to 1 sec). The duraon between
spots is determined by the “o” me seng (up to
5 sec). At the end of the spot welding release the
torch switch and welding will end.
Striking mode
The opons for arc striking in the TIG
mode are HF start (non contact start)
or Li arc start (contact start). Press
the HF buon to light the LED next to
the required mode.
Pulse mode
Pressing the pulse buon will light the
LED for no pulse or pulse
For no pulse
For pulse
Remote mode
When torch indicator is lit the
torch controls the machine.
When the pedal LED is lit the
foot pedal controls the machine
striking and output.
NOTE
Using an analog torch with a remote control in the
handle you can only adjust the output current.
Using the digital torch, you can adjust mulple
parameters and output current. The machine can
detect analog or digital torch you use automacally.
Cooler control
Press the water buon to turn
on the water LED and the
cooler supply.
The water cooler will only start
when a welding arc is
established. Aer the arc is o the cooler will
connue to run for a short period. It will restart if
the arc is re-established.
When the coolant cannot ow an error will show
and the machine will stop unl the defect is cleared.
Tungsten electrode size
To set the tungsten electrode size use the
adjuster knob to select the electrode LED.
Press the adjuster and the LED will ash.
Rotate the adjuster unl the desired
electrode size is shown, then press the
adjuster and the LED will cease to ash.
When the selected tungsten does not
match the output current then the
warning LED will be lit. The machine will
connue to operate but there is possible
deterioraon of the tungsten (amps too
high) or diculty striking (amps to low).
NOTE
Note applicable in DC TIG mode.

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Tungsten chart
Gas purge
Press the panel and the gas will ow
through the machine and torch. In
addion “GAS” will be lit in the display.
Press again and gas will cease to ow and
the indicator in the display will go o. If the buon
is not pressed to exit the gas purge condion it will
exit automacally aer 30 seconds.
TIG parameter sengs
To adjust a parameter rotate the adjuster knob to
the selected parameter LED. Press the adjuster knob
and the LED will ash. Make the
adjustment and press the
adjustment knob and the LED will
cease ashing conrming the
parameter is saved.
1Preow gas me (secs). This
is the me gas will ow before
the arc starts.
2Start amperage seng (amps).
3Upslope me (secs). Time the current takes to
go from the start amperage to set welding
current.
4Peak amps (amps). This is normally the
selected welding current maximum.
5Base amps (amps). This is the background
current when pulse welding mode is used.
Cannot be selected unless pulse mode is
enabled.
6Downslope me (secs). Time the current takes
to go from the welding current to the nishing
amperage.
7Finish amps (amps). Oen referred to as the
crater ll amperage.
8Poslow gas me (secs). The me the gas
ows aer the welding has nished.
AC balance control
1AC Frequency (50-
200Hz)
The AC frequency is used to vary the arc on AC. The
higher the frequency the ser, narrower and more
penetrang the arc. Lower frequencies provide a
soer arc with less penetraon.
2AC Balance (cleaning) 20-60%
The AC balance controls the amount of the AC cycle
used for cleaning as opposed to heang. The more
me spent in the posive half cycle will result in
more cleaning of the base metal surface. More
posive half cycle results in a wider weld bead and
can reduce tungsten electrode life. Reducing the
amount of posive half cycle puts more heat into
the work piece increasing penetraon.
Pulse frequency
When welding in the pulse mode use the adjuster to
navigate to the Hz LED (1). Press the adjuster (the
LED will ash) and adjust to the desired frequency.
Press the adjuster to save the parameter. The LED
will stop ashing.
To set the rao of peak current to base current use
the adjuster to navigate the % LED (2). Press the
adjuster (the LED will ash) and adjust to the
desired rao percentage. Press the adjuster to save
the parameter. The LED will stop ashing.
This rao can be 5-95%.
Tungsten electrode
size (mm)
Recommended current
range (A)
0.5 6--15
1.0 16--55
1.6 56--90
2.0 91--140
2.4 141--190
3.2 191--240
4.0 241--315

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
Spot mode
When welding in the spot mode use the adjuster to
navigate the On LED (1). Press the adjuster (the LED
will ash) and adjust to the desired spot me. Press
the adjuster to save the parameter (the LED will
stop ashing).
Use the adjuster to navigate the O LED (2). Press
the adjuster (the LED will ash) and adjust to the
desired o me. Press the adjuster to save the
parameter (the LED will stop ashing).
Example:
The On me is set at 1 second and the O me at 5
seconds.
When the torch switch is operated the arc will be
on for 1 second and then o for 5 seconds and will
repeat unl the torch switch is released.
Hybrid (Mix) mode:
When operang in hybrid mode it is necessary to
set the hybrid frequency and me.
When in Mix mode TIG use the adjuster to navigate
the Hz LED (1). Press the adjuster (the LED will ash)
and adjust to the desired frequency. Press the
adjuster to save the parameter (the LED will stop
ashing).
Use the adjuster to navigate the DC duty % LED (2).
Press the adjuster (the LED will ash) and adjust to
the desired duty percentage. Press the adjuster to
save the parameter (the LED will stop ashing).

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
Welding mode Torch switch
mode
Manual arc
welding current
Hot start striking
current Arc force current Hot start striking me
MMA DC NO ●●●●
MMA AC NO ●●×●
Parameter funcon table
Welding
mode
Torch switch
mode
Advance gas feeding
Arc striking current
Up me
Peak current
Base current
Down me
Arc stopping current
Gas hysteresis
Spot welding me
AC frequency
Cleaning width
Pulse frequency Pulse duty cycle
Tungsten electrode selecon
DC TIG
2T ●●●●×●●●××××××
4T ●●●●×●●●××××××
Cycle ●●●●×●●●××××××
Spot welding ●××●×××●●×××××
DC Pulse
TIG
2T ●●●●●●●●×××●●×
4T ●●●●●●●●×××●●×
Cycle ●●●●●●●●×××●●×
Spot welding ××××××××××××××
AC TIG
2T ●●●●×●●●×●●××●
4T ●●●●×●●●×●●××●
Cycle ●●●●×●●●×●●××●
Spot welding ●××●×××●●●●××●
AC Pulse
TIG
2T ●●●●●●●●×●●●●●
4T ●●●●●●●●×●●●●●
Cycle ●●●●●●●●×●●●●●
Spot welding ××××××××××××××
Mix TIG
2T ●●●●×●●●×●●●●●
4T ●●●●×●●●×●●●●●
Cycle ●●●●×●●●×●●●●●
Spot welding ××××××××××××××

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
ACCESSORIES INFORMATION
Torch switch socket
1. Pin 1, Pin 2 and Pin 3 are for torch current regulaon.
2. Pin 4, Pin 5 and Pin 6 are for digital torch connecons. Pin 4 -, Pin 5 +,
Pin 6 2T/4T.
3. Pin 7 digital/analog torch idencaon pin. Connect pin 9 and 7 for
analog torch use.
4. Pin 8 and Pin 9 are torch switch connecons.
5. The torch switch socket can be connected to a digital torch, analog
torch or foot control switch.
6. Pin 2 is the common terminal of the potenometer. It uses the torch
control wheel 0 as the starng posion. When the current is the
minimum, the resistance of Pin 1 and Pin 2 is 10KΩ and the resistance of
Pin 2 and Pin 3 is 0Ω. When the wheel rotates to the maximum and the
current is the maximum, the resistance of Pin 1 and Pin 2 is 0Ω and the
resistance of Pin 2 and Pin 3 is 10KΩ.
Use of the foot control
1. The pedal remote control consists of a switch and a potenometer, as
shown in the gure.
2. Connect the pedal remote control to Pin 1, Pin 2, Pin 3, Pin 8 and Pin 9
of the torch switch socket on the front panel of the welder.
3. Under no load, press the remote buon to turn on
the indicator. The foot pedal enters the pedal remote
control mode.
4. Adjust the maximum welding current through the panel before
welding.
5. Step on the pedal control to start arc striking. Normally, HF non
contact arc striking is used. When the arc is struck, the welding
current is controlled by the foot pedal control. The maximum
output is the set current.
6. Pin 2 is the common terminal of the potenometer. It uses the
minimum pedal control current as the starng posion. When the
resistance of Pin 1 and Pin 2 is 10 KΩ, the resistance of Pin 2 and Pin 3 is
0Ω. When the pedal is pressed to the end and the current is the
maximum, the resistance of Pin 1 and Pin 2 is 0Ω and the resistance of Pin
2 and Pin 3 is 10KΩ.
TIG torch connecons
1. The wire control welding torch is divided into digital adjustable type and analog adjustable type, as
shown in the gure on the opposite page.
2. Connect the analog adjustable welding torch to Pin 1, Pin 2, Pin 3, Pin 8 and Pin 9 of the torch switch
socket on the front panel of the welder through a special cable. Pin 7 and Pin 9 must be short-circuited.

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
Pin 2 is the common terminal of the potenometer. It uses the torch
control wheel 0 as the starng posion. When the current is the
minimum, the resistance of Pin 1 and Pin 2 is 10KΩ and the
resistance of Pin 2 and Pin 3 is 0Ω. When the wheel rotates to the
maximum and the current is the maximum, the resistance of Pin 1
and Pin 2 is 0Ω and the resistance of Pin 2 and Pin 3 is 10KΩ.
3. Connect the digital adjustable welding torch to Pin 4, Pin 5,
Pin 6, Pin 7, Pin 8 and Pin 9 of the torch switch aviaon socket
on the front panel of the welder through a special cable. Pin 4
-, Pin 5 +, Pin 6 2T/4T. Pin 7 has no connecon.
4. Under no load, press the remote buon to
turn on the indicator. The welding torch
enters the torch control mode.
5. Set the maximum welding current through the panel before
welding. Adjust the current by adjusng the welding torch
potenometer in the welding process. The adjustable range is
the minimum value to the set value.
6. When using the digital adjustable control torch, the
adjustment parameter can be switched through the
“Parameter Selecon” buon on the welding torch, and the
parameters can be adjusted through the “Para+” and “Para-”
buon, the “Torch switch” of the welding torch controls the
output mode.
Para-
Parameter
selecon
Torch switch
Para+
Digital adjustable control torch
Torch switch
Current
regulating
potentiometer
Analog adjustable control torch
Analog torch plug Digital torch plug
Cooler connecons
1. Pin 1 and Pin 2 are the 230VAC output terminals of the water cooler. Pin 3 and
Pin 4 are the error signal input terminals of the water cooler.
2. Under no load, press the water buon to turn on the
indicator. The machine then enters water cooling cycle mode
during welding.
3. Aer welding has ceased, the cooler will work for 5
minutes. If there is no welding in 5 minutes, the water cooler switches o
automacally.

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
6UNPACKING
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.
7INPUT AND OUTPUT CONNECTIONS
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.
Operaon
When the installaon is correct, turn the power
switch to “ON” posion. At this me, the panel
indicator lights, the fan inside the machine starts to
rotate (fan is controlled by temperature and may
stop) and the welder starts to work normally.
MMA welding
Before manual welding, pay aenon to the
polarity of the cable connecons. There are two
connecon methods for DC welding, posive
electrode connecon and posive electrode
connecon. Check the electrode manufacturers
recommendaon for the correct conguraon.
Posive (DCEP) connecon method: Connect the
electrode holder cable to the posive output
connecon and the work piece to the negave
connecon on the machine.
Negave (DCEN) connecon method: Connect the
electrode holder cable to the negave output
connecon and the work piece to the posive
connecon on the machine.
When welding, it is selected according to the
process requirements of work piece. Improper
selecon may result in instable arc, splashing and
scking. In this case, swap the quick plug to change
the polarity.
TIG welding
Connect the TIG torch power lead into the negave
output connecon. Connect the torch gas
connecon into the quick t connector on the front
panel. Connect the torch switch or remote control
into the mul pin connector on the front panel.
Connect the work return cable into the posive

A WILKINSON STAR LIMITED PRODUCT 01-19 ISSUE 1
outlet connecon.
The gas inlet hose is connected at the rear of the
machine and the other end to a suitable
regulator / owmeter aached to the gas supply
cylinder.
8MAINTENANCE
ONLY SUITABLY QUALIFIED PERSONNEL SHOULD
CARRY OUT THESE CHECKS
WHEN REMOVING ANY COVERS SWITCH OFF AT
THE MAINS SUPPLY AND WAIT FOR 5 MINUTES
BEFORE REMOVING THE COVERS. COVERS
SHOULD ONLY BE REMOVED BY A SUITABLY
QUALIFIED PERSON
Check daily the condion of the machine, leads
and connecons and repair or replace items when
necessary.
Keep hands, hair and tools away from the moving
parts such as the fan to avoid personal injury or
machine damage.
Clean the dust periodically with dry and clean
compressed air. In welding environments with
heavy fume and dust polluon, the machine
should be cleaned daily. The pressure of
compressed air should be at a low level in order to
avoid the small parts inside the machine being
damaged.
Avoid rain, water and vapour entering the
machine. If this occurs, dry the machine and check
the insulaon of the equipment (including that
between the connecons and that between the
connecon and the enclosure). Only when there
are no abnormal phenomena anymore, can the
machine be used.
Check periodically whether the insulaon cover of
all cables is in good condion. If there is any
deterioraon they should be replaced.
When not in use the machine should be stored in a
clean dry place.