Jasic Power Arc 160 PFC User manual

Operator Manual
www.jasic.co.uk
Power Arc Series
|Power Arc 160 PFC (JPA-160PFC) |Power Arc 180 (JPA-180SE) |

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

A WILKINSON STAR LIMITED PRODUCT 12-16 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 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.

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
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.

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
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

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
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
PRODUCT OVERVIEW
The unique electronic structure and air channel design in this series of machines provides ecient
cooling of the power devices as well as improving the duty cycles of the machines. The design of the
forced air-cooling system channel can eecvely prevent the power devices and control circuits from
being damaged by the dust introduced into the machine by the fan. The reliability of the machine is
greatly improved as a result. The streamline design means front and rear panels are naturally
Integrated via large radian transion. The front and rear panels of the machine and the handle are
coated with rubber oil*, giving the machine a very tacle and comfortable grip with an excellent
appearance.
Product funcons
• Hot start arc ignion funcons: ensure the arc ignion in MMA welding easier and more reliable.
• Wide input voltage range on the PFC models
• An-scking funcon: Reduces the welding current if a short circuit occurs during welding.
• Self-adapve arc force technology: Maintains the opmum arc condions during welding even with
long cables.
• Advanced scratch start arc ignion: supports TIG welding without HF arc ignion circuit.
• Oponal VRD funcon: Provides addional safety keep the operator safe when the machine is idle.
Product performance characteriscs
• Advanced IGBT inverter technology
• Inverng frequency of 33~43 kHz greatly reduces the size and weight of the welder.
• Great reducon in magnec and resistance loss enhances the welding eciency and energy saving
eect.

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
• Working frequency is beyond the audio range, which almost eliminates noise polluon.
• Industry leading control system
• Advanced control technology meets the various welding applicaons and provides excellent welding
performance.
• It can be used with a wide range of welding electrodes.
• Easy arc starng, less spaer, stable current and good weld bead shaping.
• Modern high tech design
• Streamline design of front and rear panels.
• Front and rear panels made of high-intensity plascs suitable for working in severe condions.
• Excellent insulang property.
• Water-resistant, anstac and ancorrosion design.
CONTROLS
Front view
1. Overheang LED: Overheang LED on indicates that the
temperature inside the machine is too high and the machine is
under overheang protecon status.
2. Power LED: Power LED on indicates that the power switch of the
machine is on.
3. MMA/TIG switch: To toggle between MMA and TIG.
4. "+" Output terminal: To connect the electrode holder.
5. "-" Output terminal: To connect the work clamp.
6. Trademark
7. Welding current knob: To adjust the output current.
8. Handle
Rear view
9 Power switch
10 Warning label
11 Input cable gland
12 Cooling fan

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
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
Electrode polarity
In general when using manual arc welding electrodes the electrode holder is connected the posive
terminal and the work return to the negave terminal. Always consult the electrode manufacturer’s data
sheet if you have any doubts.
When using the machine for TIG welding the TIG torch should be connected to the negave terminal and
the work return to the posive terminal.
MMA welding
Insert the cable plug with electrode holder into the “+” socket on the front panel of the welding machine,
and ghten it clockwise. Insert the cable plug of the work return lead into the “-”ve socket on the front
panel of the welding machine, and ghten it clockwise

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
TIG Welding
Insert the cable plug with the work clamp into the “+” socket on the front panel of the welding machine,
and ghten it clockwise. Insert the cables plug of the TIG torch into the “-” socket on the front panel of
the machine and ghten clockwise.
Connect the gas hose to the regulator / owmeter located on the shield gas cylinder and connect the
other end to the machine.
OPERATION
Before starng any welding acvity ensure that you have suitable eye protecon and protecve
clothing. Also take the necessary steps to protect any persons within the area.
MMA
Aer connecng the welding leads as detailed you will need to switch the power switch on the back
panel to “ON” . Select MMA by switching to the MMA welding mode. There is voltage output at both
output terminals. Set the amperage on the machine suitable for the electrode being used. Please see
below a guide to amperages required. Ensure you check that you have the electrode polarity correct.
Electrode Diameter (mm) Recommended Welding Current (A)
1.0 20~60
1.6 44~84
2.0 60~100
2.5 80~120
3.2 108~148
4.0 140~180

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
TIG mode
Connect the TIG torch leads as detailed above. Ensure that a suitable inert gas supply is connected.
Switch the power switch on the back panel to “ON”. Select the TIG welding mode using the selector
switch. There is voltage output at both output terminals.
Aer the parameters are set appropriately, open the gas valve of the cylinder, the gas valve on the torch
and adjust the gas regulator to obtain the desired ow rate. The arc will start when the tungsten elec-
trode touches the work piece and is lied o aer touching by between 2-4mm The arc will cease when
the electrode (torch) is moved away from the work area.
TIG guides
The recommended size of tungsten to be used can be selected from the table below
Electrode types
Gas nozzle sizes
For welder training please contact our welding academy at
www.wilkinson-welding-academy.com
Electrode diameter /mm 1.0 1.6 2.4 3.2
Welding current /A 15-80 70-150 150-250 250-400
Type Material to be welded Colour
Thoriated 2% DC welding of steel, stainless
steel and copper
Red
Ceriated DC welding of steel, stainless
steel and copper
Grey
Lanthanated DC welding of steel, stainless
steel and copper
Black
Gas nozzle diameter/mm Electrode diameter/mm
81.0
9.5 1.6 / 2.4
11.1 3.2

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
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 welding 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.
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 60974-1).
This work should be carried out by a suitably qualied competent person.
Overheat LED lit Machine operated outside duty cycle. Allow the machine to cool and the unit will reset
automacally.
Fan not working—Contact the Jasic service centre
No power Mains LED lit —Contact the Jasic service centre
Mains LED not Lit—Check the mains supply

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
Technical Parameter Unit
Model
ARC160-PFC (JPA-160PFC) ARC180SE
(JPA-180)
Rated input voltage V230 +/- 15% 50/60 Hz95-230 +/- 15% 50/60HZ
AC110V AC2230V AC230V
Rated input power KVA 3.71 5.02 8
Welding current range A10~125 10~160 10~180
Rated duty cycle (400C) %35 35 35
No-load voltage V9/68 9/68 9/68
Overall eciency %85
Housing protecon grade IP 21S
Power factor cosφ0.998 0.7
Size without handle mm 365*135*235 313*130*206
Size with handle 365*135*277 313*130*250
Weight Kg 6.4 4.7
Applicable electrode sizes mm 1.0—3.2 1.0—4.0
Insulaon grade F
Standard IEC60974-1
Noise db ＜70
TECHNICAL PARAMETERS

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
PARTS LIST
JPA-160PFC
No. Part no. Part name No. Part no. Part name
110004949 Power switch 17 10006284
210042343 Back panel 18 10006282
310044009 Fan 19 10043392 Switching power transformer
410043476 Handle 20 10037147
510043689 Louver 21 10037146
610007251 IGBT 22 10059223 Control PCB
710059606 Base 23 10043393 Main transformer
810044032 Thermal switch 24 10005833 Electrolyc capacitor
910021853 Quick socket 25 10006248 Recer diode
10 10040930 Knob 26 10037078 Pin insulaon cover
11 10037135 Drive transformer 27 10037431 Recfying PCB
12 10006431 Thermal resistor 28 10044526 Power cord
13 10006474 Relay 29 10043331 Recfying PCB for PFC
14 10059115 Cover 30 10033180
15 10006650 Silicon bridge 1 31 10006545 Inductor
16 10043469 Front panel

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
PARTS LIST
JPA
No. Part no. Part name No. Part no. Part name
110047746 Power switch 15 10037859 Thermal switch
210037125 Back panel 16 10037135 Drive transformer
310044817 Fan 17 10006284
410043477 Handle 18 10006282
510043689 Louver 19 10037134 Switching power transformer
610059116 Cover 20 10006650 Bridge recer
710037113 Base 21 10037146
810043405 Front panel 22 10043914 Control PCB
910044030 Quick socket 23 10054243 Main transformer
10 10040930 Knob 24 10037138 Electrolyc capacitor
11 10037147 25 10006248 Recer diode
12 10006431 Thermal resistor 26 10037078 Pin insulaon cover
13 10006474 Relay 27 10037431 Recfying PCB
14 10007251 IGBT 28 10037858 Power cord

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
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 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.

A WILKINSON STAR LIMITED PRODUCT 12-16 ISSUE 1
JPA Series
Arc 160 PFC Order code JPA-160PFC
Arc 180 SE Order code JPA-180SE
© Wilkinson Star Limited