Wilkinson Star Jasic Arc Series User manual

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A WILKINSON STAR PRODUCT 2 08-18 ISSUE 1
Contents
Secon Title Page
1Your New Product 3
2Safety 4
3Product Overview 6
4Panel Layouts 7
5Unpacking 8
6Connecons 8
7Maintenance and Troubleshoong 9
8Technical Parameters 10

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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)
PLEASE REGISTER YOUR PRODUCT ONLINE AT WWW.JASIC.CO.UK/REGISTER
When all entry elds are complete the system will show a short message thanking you for a successful
registraon.
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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2SAFETY
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.
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.

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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 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
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

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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
Key features
 Advanced IGBT inverter technology
 Compact size, lightweight and modern design
 Digital meter
 An sck, arc force, hot start and DC li TIG
funcons
 Excellent weld characteriscs
 Wired remote control opon
 VRD - Oponal
 Auto compensaon for mains voltage
uctuaon
 Generator friendly
 Suitable for a wide range of electrodes

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4PANEL LAYOUTS
Front view
1Digital meter
2Current control
3Thermal overload indicator
4Mains problem indicator
5VRD indicator (lit when VRD on)
6Hot start control
7Arc force control
8Local / remote switch
9MMA / Li arc switch
10 "+" Output terminal
11 Remote control connector
12 "-" Output terminal
Rear view
14 Mains switch
15 Mains cable
16 Fan cover
17 Earth point

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5UNPACKING
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.
6CONNECTIONS
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 to 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
“+ve” 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.
Select the MMA mode with the selector switch.
Switch on the machine and adjust the MMA current
control to the required current. Fix the electrode
into the electrode holder and commence welding.
NOTE: If used with the VRD opon this will reduce
the no load voltage under 24V DC when in MMA
mode.
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 welding current guide
Li TIG Welding
Insert the welding torch into the negave torch
connector on the machine front and ghten it.
Connect the cylinder equipped with the gas
regulator to the gas inlet of the welding torch.
Insert the cable plug with work clamp into the
posive output terminal on the front panel of the
welding power source and ghten clockwise.
Select the li TIG opon using the selector switch
on the machine front panel. Adjust the current
control to set the desired welding current.
Lightly touch the tungsten electrode to the work
piece and then li it about 2-3mm clear. The arc
will be established at the set current.
Before starng any welding acvity ensure that
you have suitable eye protecon and protecve
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

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clothing. Also take the necessary steps to protect
any persons within the area. Ensure adequate re
prevenon assessments and equipment are in
place.
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.
7MAINTENANCE AND
TROUBLESHOOTING
The following operaon should only be carried out
by a suitably qualied, competent person. 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 out 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 may be a potenal danger to the user!
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.

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8TECHNICAL PARAMETERS
ARC400（JA 402）
Rated input voltage (V) AC400V±15% 50/60HZ
Rated input power (KW) 17.5
Rated input current Ieff (A) 19.6
Welding current range (A) 30~400
Arc force current range (A) 0~140
No-load voltage (V) 72
No-load voltage VRD on (V) 9
Rated duty cycle 400A @ 60%
Power factor 0.95
Protection class IP21S
Insulation class F
Overall size (mm) 618*330*441
Weight (Kg) 19

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Arc Series
Arc 400 Order code JA-402
© Wilkinson Star Limited